Automatic Driveline Calibration for Agricultural Sprayers
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Solution Overview
Problem
Modern agricultural machines, such as self-propelled sprayers, face calibration challenges due to excessive wear in components, leading to reduced responsiveness and requiring time-consuming and labor-intensive manual recalibration processes, which can be inaccurate and costly.
Innovation Solution
An onboard logic controller uses feedback data like engine speed, wheel speed, temperatures, and pressures to automatically calibrate the hydrostatic drivetrain system, determining the magnitude of electrical signals for hydraulic power through a processor and touchscreen Human Machine Interface, allowing for precise calibration without human error.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual calibration methods are used by service personnel or operators, then calibration can be performed, but the process is time-consuming, labor-intensive, and prone to human error
Solution Approach 1:
The system performs automatic calibration of the hydrostatic drivetrain without requiring external service personnel or operator intervention. The processor autonomously controls the hydrostatic pump, monitors sensor data, and adjusts calibration parameters based on feedback from speed sensors and pressure transducers, eliminating manual labor and reducing time consumption.
Solution Approach 2:
The calibration process utilizes real-time feedback from sensors monitoring wheel speed, engine speed, and hydraulic pressure. The processor continuously compares actual system performance against target calibration values and automatically adjusts electrical signal magnitudes to minimize deviations, ensuring high calibration accuracy while reducing manual intervention.
2Ease of operation
If manual calibration is performed by observing machine characteristics and selecting input markings, then calibration can be adjusted, but the process is labor intensive and leads to inaccurate results due to human error
Solution Approach 1:
The manual observation and selection process is replaced with an automated electronic calibration system. The processor automatically monitors machine characteristics through sensors and electronically adjusts calibration parameters without requiring operator observation or manual input selection, eliminating human error while maintaining ease of operation through simple initiation via touchscreen interface.
Solution Approach 2:
The system autonomously performs the entire calibration process including monitoring wheel speed, engine speed, and hydraulic pressure, then automatically determines the appropriate calibration adjustments. This self-calibration capability eliminates the need for operators to manually observe characteristics and select markings, thereby improving accuracy while keeping the operation simple through automated initiation.
3Reliability
If factory calibration is performed initially, then the system is configured for operation, but excessive wear on components causes loss of responsiveness over time requiring recalibration
Solution Approach 1:
The system performs automatic calibration to restore responsiveness before significant performance degradation occurs. By detecting changes in system characteristics through sensor feedback and automatically adjusting calibration parameters, the system maintains optimal responsiveness throughout the component service life, extending the effective calibration validity period without requiring frequent manual interventions.
Solution Approach 2:
The continuous monitoring of wheel speed, engine speed, and hydraulic pressure provides feedback that detects gradual changes in system performance due to component wear. The processor uses this feedback to automatically adjust calibration parameters, maintaining system responsiveness over extended periods and reducing the frequency of recalibration operations.
Data Source
AI summary
By using various feedback data on a sprayer system, such as engine speed, wheel speed, sensed temperatures and/or sensed pressures, an onboard logic controller can be used to fine tune parameters of the driveline system in an automatic calibration process. In one aspect, a controller can drive up engine speed and manipulate electrical current being sent to coils of propel pumps and/or wheel motors as current reaches a point where there is no more change in wheel speed as detected by the system, thereby achieving a. calibration setpoint. Additionally, during the automatic calibration process, the machine as a whole can be monitored with respect to several sensors, such as pressures, temperatures, and the like, so that if any parameter being monitored is out of a predetermined range, the calibration can be stopped and not set.