Corn Header Deck Plate Gap Control for Variable Ear Size
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Solution Overview
Problem
The gap between deck plates in a corn header of a combine harvester is often set too wide or too narrow, leading to reduced harvesting yield, butt-shelling, and accumulation of debris, which affects efficiency and increases maintenance costs.
Innovation Solution
A system for automatically adjusting the gap between deck plates using an ear size sensor and controller, which measures ear and stalk diameters, and adjusts the actuator based on kernel depth and user inputs to maintain an optimal gap size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the gap between deck plates is set manually prior to harvesting, then the adjustment is simple and quick, but the gap size becomes fixed and cannot adapt to varying corn ear sizes, leading to reduced harvesting yield
Solution Approach 1:
The patent applies the dynamics principle by transforming the static, manually-adjusted gap into a dynamic, automatically-adjusting gap. The system uses sensors to detect corn ear characteristics in real-time and automatically modifies the gap size through actuators, allowing the deck plate gap to adapt dynamically to varying corn ear diameters during harvesting operations, thereby preventing both over-width and over-narrowness issues
Solution Approach 2:
The patent implements feedback by incorporating sensors that continuously monitor corn ear characteristics and feed this information back to a control system. The control system uses this feedback to automatically adjust the gap size, creating a closed-loop control system that adapts to real-time variations in corn ear size and maintains optimal gap dimensions throughout the harvesting process
2Adaptability or versatility
If the gap is set too wide to accommodate large ears, then all ear sizes can pass through, but small ears and debris are lost through the gap
Solution Approach 1:
The system dynamically adjusts the gap size based on real-time detection of corn ear characteristics. When larger ears are detected, the gap widens to accommodate them; when smaller ears are detected, the gap narrows to prevent loss. This dynamic adjustment allows the system to adapt to ear size variation while minimizing corn ear loss throughout the harvesting operation
Solution Approach 2:
The patent changes the physical parameter of gap size in response to detected corn ear characteristics. The control system modifies the gap dimension based on the relationship between corn ear diameter and kernel depth, transforming a fixed parameter into a variable parameter that optimizes performance for different ear sizes while preventing material loss
3Productivity
If the gap is set too narrow to prevent debris accumulation, then corn ears are retained, but the gap becomes clogged with stalk material and weeds
Solution Approach 1:
The system dynamically adjusts the gap size to maintain optimal dimensions that balance corn ear retention with debris prevention. By continuously monitoring corn ear characteristics and adjusting the gap accordingly, the system prevents both over-narrowness that causes clogging and over-width that causes debris accumulation, ensuring reliable operation throughout the harvesting season
Solution Approach 2:
The patent changes the gap parameter in response to detected corn characteristics to maintain optimal dimensions. The control system adjusts the gap size based on the relationship between ear diameter and kernel depth, ensuring the gap remains narrow enough to retain ears but wide enough to prevent clogging with stalk material and weeds
4Ease of operation
If the gap is set to accommodate stalk diameter, then stalks can pass through, but corn ears may not pass through if the gap is not large enough
Solution Approach 1:
The patent changes the gap parameter based on the relationship between stalk diameter and ear diameter. The control system adjusts the gap size according to detected corn characteristics, ensuring the gap is sufficiently large to accommodate both stalks and ears while maintaining optimal dimensions for efficient separation. This dynamic parameter adjustment resolves the conflict between stalk passage and ear passage requirements
Data Source
AI summary
A row unit of a corn header includes a first deck plate, a second deck plate, and a gap between the first and second deck plates. A position of one or both of the deck plates may be adjusted by a linkage assembly including at least one arm pivotably coupled, at a first end, to one or both of the deck plates and, at a second end, to an actuator. The actuator may be controlled by a controller to move one or both of the deck plates based on signals received from an ear size sensor such as a camera that measures various parameters of corn and also based on a kernel depth of the type of corn to be harvested.