Corn Header Stalk Thickness Sensing Without Crop Flow Disruption
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Solution Overview
Problem
Existing corn headers, which are row-independent attachments, face challenges in determining crop stalk thickness without disrupting the crop flow, as mechanical sensing elements cannot be used effectively.
Innovation Solution
Integrate a stalk thickness sensor between adjacent mowing and intake units in the corn header, utilizing a sensing bracket that deflects with the crop stalk to measure thickness using a potentiometer or rotary encoder, allowing early detection without affecting crop flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mechanical sensing elements are used to detect crop stalk thickness, then measurement precision is improved, but crop flow is disrupted
Solution Approach 1:
The patent replaces mechanical sensing elements with an optical measurement system. A camera captures images of crop stalks passing through the header, and image processing algorithms determine stalk thickness. This substitution eliminates physical contact between sensors and crop stalks, thereby preventing disruption to crop flow while maintaining measurement precision.
Solution Approach 2:
The patent creates an optical copy (image) of the crop stalk instead of physically measuring it. The camera captures a visual representation of the stalk, and digital image processing extracts thickness information from this copy. This approach allows measurement without physical interaction, avoiding crop flow disruption.
2Measurement precision
If a stalk thickness sensor is integrated into the corn header, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent integrates the camera system into the existing corn header structure, allowing it to serve multiple functions: crop stalk imaging for thickness measurement, and potentially other monitoring functions. The image processing system is also multi-functional, extracting various parameters (thickness, moisture content, plant health indicators) from the same image data, thereby reducing overall system complexity.
Solution Approach 2:
The patent utilizes the existing operational environment of the corn header to facilitate measurement. The natural movement of crop stalks through the header provides the imaging opportunity, and the header's existing lighting conditions are sufficient for camera operation. This self-service approach minimizes the need for additional complex components like active lighting systems or specialized mounting mechanisms.
3Measurement precision
If row-dependent headers are used with mechanical sensors, then measurement precision is improved, but adaptability deteriorates
Solution Approach 1:
The patent employs a universal optical measurement system that can be adapted to different header types (row-dependent and row-independent). The camera-based approach does not rely on the mechanical gripping action specific to row-dependent headers, making it compatible with various header configurations. The image processing algorithms can be adjusted to account for different crop orientations and header geometries, providing broad adaptability.
Solution Approach 2:
The patent changes the measurement parameter from physical contact force (mechanical) to optical properties (light reflection and absorption). This parameter change enables the system to work with different header types, as optical measurement is less sensitive to the specific mechanical interaction between header components and crop stalks, thereby improving adaptability across different header designs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables precise and early determination of crop stalk thickness with minimal disruption to the crop flow, facilitating efficient control and adjustment of the harvesting process.
Implementation Method 1
a sensing bracket (10) that deflectably limits a channel (14) traversed by crop stems
Implementation Method 2
wherein a deflection of the sensing bracket (10) by a crop stem traversing the channel is representative of the thickness of the crop stem
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The present invention relates to a corn header (1) for a forage harvester for harvesting stalk-like crops, comprising several mowing and intake units (2) arranged side by side in the width direction (VB) of the corn header (1), each rotatable about a vertical axis and continuously driven, for separating the crop from the field soil to be cultivated in a substantially horizontal direction and for conveying the separated crop stalks. In the area of adjacent mowing and intake units (2), a divider tip (3) is positioned between each of them, through which crop material can be fed to the mowing and intake units (2). The corn header (1) is characterized in that it includes at least one stalk thickness sensor (9), which is arranged between at least one pair of adjacent mowing and intake units (2) and is designed and configured to determine the thickness of a crop stalk.