Disk Gang Load Normalization for Tillage Plugging Detection
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Solution Overview
Problem
Existing systems struggle to accurately detect disk gang plugging in tillage implements, which occurs when field materials accumulate and impede the rotation of disks, making it difficult for operators to determine when corrective action is needed.
Innovation Solution
A system and method using load sensors and a computing system to determine total and average loads on disk gangs, applying correction factors based on disk size and number, and calculating plug status values to detect plugging and initiate appropriate control actions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If load sensors are used to detect disk gang plugging, then detection capability is improved, but measurement precision deteriorates due to variations in disk size and number across different gangs
Solution Approach 1:
The system applies local quality by customizing the detection approach for each disk gang based on its specific characteristics. The controller calculates a normalized load value for each gang by dividing the total load by the number of disks in that gang, accounting for the fact that different gangs have different numbers of disks. This localized normalization ensures that each gang is evaluated according to its own configuration, improving measurement precision across diverse gang structures.
Solution Approach 2:
The system changes the parameter being monitored from raw load force to normalized load per disk. By transforming the measurement parameter from total load to load divided by number of disks, the system creates a standardized metric that allows accurate comparison across disk gangs with different configurations. This parameter transformation resolves the precision issue while maintaining the ability to detect plugging conditions.
2Difficulty of detecting and measuring
If multiple load sensors are deployed on different disk gangs, then detection coverage is improved, but device complexity increases
Solution Approach 1:
The system merges the data from multiple load sensors into a unified detection framework. The controller receives load sensor data from multiple disk gangs, normalizes each gang's load by its disk count, and compares all gangs using this standardized metric. This merging approach maintains comprehensive detection coverage while simplifying the overall system architecture through centralized processing and a unified evaluation method.
Solution Approach 2:
The controller serves multiple functions: it receives data from multiple sensors, normalizes loads for different gang configurations, detects plugging conditions, and can trigger alerts or control actions. This multi-functionality reduces device complexity by consolidating detection, processing, and response capabilities into a single intelligent controller rather than requiring separate systems for each function.
Data Source
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AI summary
A tillage implement (10) includes a plurality of disk gangs (44), with each disk gang (44) including a shaft and a plurality of disks (46) spaced apart from each other along the shaft. Furthermore, the tillage implement (10) includes a plurality of load sensors (108) configured to generate data indicative of loads being applied to the plurality of disk gangs (44) and a computing system (112) communicatively coupled to the plurality of load sensors (108). In this respect, the computing system (112) is configured to determine a total load being applied to each disk gang (44) based on the data generated by the plurality of load sensors (108). Additionally, the computing system (112) is configured to determine an average load per disk (46) being applied to each disk gang (44) based on the determined total loads. Moreover, the computing system (112) is configured to determine a plug status value for each disk gang (44) based on the determined average loads per disk (46).