Crop Conditioner Roll Gap Calibration With Displacement Feedback

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Solution Overview

Problem

Existing agricultural conditioning systems require manual and time-consuming adjustments of roll gaps for different crop conditions, which fail to account for changing field conditions and cannot monitor the maintenance of set conditions during harvesting.

Innovation Solution

A control system that utilizes sensors to measure and compare actual displacements of conditioning system components with expected displacements, adjusting the component positioning system to maintain accurate conditioning levels by accounting for factors like slack and wear, and generating control signals to drive the system to a target displacement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual adjustment of roll gap is made prior to harvesting operation, then conditioning level can be set for a given crop, but the adjustment is time-consuming and cannot account for changing field conditions

Engineering Contradiction:

Improvemanual adjustment operationVSAvoidtime for adjustment

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The system performs self-calibration automatically by comparing sensor-measured displacement with expected displacement values stored in memory, eliminating the need for manual operator intervention. The controller autonomously adjusts the component positioning system to maintain accurate conditioning levels throughout the harvesting operation.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Expected displacement values for various conditioning levels are pre-calculated and stored in memory during system setup. This preliminary action allows the system to quickly reference and achieve target conditioning levels without time-consuming manual adjustments during field operations.

Inventive Principle:

Principle #10Preliminary action

2Ease of operation

If manual adjustment of roll gap is made prior to harvesting operation, then conditioning level can be set, but it is not possible to monitor whether the set roll gap is maintained over the whole harvesting process

Engineering Contradiction:

Improvemanual adjustment operationVSAvoidroll gap monitoring

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

A sensor continuously measures the actual displacement of conditioning system components and provides real-time feedback to the controller. The controller compares this measured displacement with expected displacement values and automatically adjusts the positioning system to maintain accurate conditioning levels throughout the harvesting process.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The manual mechanical adjustment system is replaced with an automated electro-mechanical positioning system controlled by electronic signals. The sensor and controller work together to continuously monitor and adjust component positions, replacing the need for manual mechanical adjustment and enabling continuous monitoring of roll gap maintenance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If different conditioning settings are required for changing field conditions, then crop conditioning accuracy can be improved, but manual re-adjustment is not feasible during harvesting

Engineering Contradiction:

Improveconditioning level accuracyVSAvoidharvesting efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The system transitions from static manual adjustment to dynamic automated control. The component positioning system can continuously adjust conditioning levels in real-time based on actual displacement measurements, allowing the system to adapt to changing field conditions without stopping or slowing the harvesting operation.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

Continuous sensor feedback enables the controller to detect deviations from target conditioning levels and automatically adjust the positioning system accordingly. This closed-loop control maintains precise conditioning accuracy throughout the harvesting process without requiring manual intervention or reducing productivity.

Inventive Principle:

Principle #23Feedback

4Manufacturing precision

If automatic control system with sensor feedback is implemented, then conditioning accuracy and adaptability are improved, but system complexity increases

Engineering Contradiction:

Improveconditioning level consistencyVSAvoidcontrol system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The controller serves multiple functions: it stores expected displacement values in memory, processes sensor feedback signals, compares measured versus expected values, and controls the component positioning system. This multi-functionality reduces the need for separate dedicated components for each control function, thereby managing system complexity while maintaining high conditioning accuracy.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20250374859A1Crop Conditioning

Publication Date: 2025.12.11 AGCO CORP

AI summary

Systems and methods are provided for monitoring operation of a conditioning system of or otherwise associated with an agricultural machine. This includes driving the conditioning system to a control condition associated with an expected displacement associated with one or more components of the conditioning system and determining a determining a measured displacement for those components. The measured displacement is compared with the expected displacement to determine a calibration for a component positioning system of the conditioning system. Operation of the component positioning system can then be controlled in accordance with the determined calibration.