Disc Implement Plugging Detection Using Accelerometer Comparison

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Solution Overview

Problem

Agricultural implements such as disc harrows and planters face plugging issues due to residue getting stuck between disc scrapers and blades, leading to reduced efficiency and potential soil compaction, which can impact planting conditions and increase production costs.

Innovation Solution

Incorporation of a plugging detection system with accelerometers mounted on ground-engaging elements to detect deviations in acceleration, alerting operators to plugged conditions, allowing for timely intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If disc harrow implements are used to cut and incorporate residue into soil, then crop residue management is improved, but plugging occurs between disc scraper and blade reducing efficiency

Engineering Contradiction:

Improvecrop residue management efficiencyVSAvoidoperational reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The accelerometer detects plugging conditions before they cause significant operational problems by monitoring acceleration changes in real-time. This preliminary detection allows operators to take corrective action early, preventing the plugging from worsening and maintaining reliable operation throughout the field work cycle.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors acceleration data from the accelerometer and provides real-time feedback to the operator through visual or audible alerts. This feedback loop enables operators to respond immediately to plugging conditions, adjusting the implement or clearing blockages before they compromise productivity or cause damage.

Inventive Principle:

Principle #23Feedback

2Productivity

If multiple passes are reduced to minimize soil erosion and production costs, then productivity is improved, but plugging problems become more severe

Engineering Contradiction:

Improvenumber of field passesVSAvoidplugging severity

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

By detecting plugging conditions early through acceleration monitoring, the system enables operators to address issues during a single pass rather than requiring multiple passes to complete the same work. This preliminary detection prevents plugging from escalating to a point where field work must be stopped and resumed later.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Real-time acceleration feedback allows operators to maintain optimal operation throughout the field, responding to plugging conditions as they develop. This continuous monitoring ensures that each pass completes the intended work without interruption, maximizing productivity while minimizing the harmful effects of plugging.

Inventive Principle:

Principle #23Feedback

3Difficulty of detecting and measuring

If plugging detection system with accelerometers is added to ground-engaging elements, then plugging detection capability is improved, but device complexity increases

Engineering Contradiction:

Improveplugging detection capabilityVSAvoidsystem complexity

Core Design Contradiction:

Difficulty of detecting and measuringVSDevice complexity

Solution Approach 1:

The system replaces complex mechanical monitoring mechanisms with electronic accelerometers and digital signal processing. Instead of using mechanical sensors that require physical contact and complex linkages, the accelerometer wirelessly detects acceleration changes caused by plugging, significantly reducing mechanical complexity while improving detection accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system monitors acceleration parameters that naturally change when plugging occurs, rather than requiring direct mechanical measurement of plugging conditions. By detecting changes in acceleration patterns, the system transforms an otherwise difficult-to-measure condition into a simple electronic signal that can be processed and analyzed with minimal additional complexity.

Inventive Principle:

Principle #35Parameter changes

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

Prevents plugging by enabling early detection and corrective action, thereby maintaining implement efficiency and reducing soil compaction, thus optimizing farming operations.

Implementation Method 1

The plugging detection system has an accelerometer for each of the plurality of ground-engaging elements and a control module that compares accelerometer data of each ground-engaging element to accelerometer data of the remaining ground-engaging elements

Methodology Applied

Scientific EffectAcceleration detection: Accelerometer

Data Source

PatentUS20250366387A1Agricultural Implements Comprising Plugging Detection Systems and Related Methods

Publication Date: 2025.12.04 AGCO CORP

AI summary

An agricultural implement includes a main frame having a support bar oriented in a direction generally transverse to a direction of travel when the implement is used to work a field, a plurality of rotating ground-engaging elements aligned along a length of the support bar, and a plugging detection system configured to alert an operator if one or more of the ground-engaging elements have an acceleration different from an acceleration of remaining ground-engaging elements by at least a threshold amount. The plugging detection system has an accelerometer for each of the plurality of ground-engaging elements and a control module that compares accelerometer data of each ground-engaging element to accelerometer data of the remaining ground-engaging elements. Related methods are also disclosed.