Electric Corn Head Row Control With Plug Detection and Yield Sensing
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Solution Overview
Problem
Existing corn heads require significant manual operation and lack efficiency and accuracy in controlling row units, such as engaging and disengaging, speed adjustment, and gap management, leading to inefficiencies and potential crop damage.
Innovation Solution
A corn head system with individually driven row units, featuring a power supply, motor driver, and motor on each row unit, along with a controller for automated control, allowing for row-by-row operation and data collection, including real-time detection of plugged units and dynamic power adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single drive shaft mechanism is used for the entire swath of the corn head, then the device complexity is reduced, but the ease of operation and control precision deteriorate due to significant manual operation requirements
Solution Approach 1:
The corn head is divided into multiple independently controlled row units, each with its own motor and controller. This segmentation allows individual row units to be controlled separately, eliminating the need for manual operation while maintaining manageable system complexity through modular architecture
Solution Approach 2:
The traditional mechanical single drive shaft system is replaced with an electrical distributed motor system. Each row unit has its own electric motor controlled by a controller receiving signals from the combine, substituting centralized mechanical power transmission with decentralized electrical control
2Extent of automation
If individually driven row units with motors and controllers are implemented, then the ease of operation and automation are improved, but the device complexity increases
Solution Approach 1:
Each row unit is designed as a universal module that can perform multiple functions (harvesting, data collection, self-diagnosis) through integrated sensors and controllers. This multi-functionality reduces the need for separate specialized components, managing overall system complexity while enhancing automation
Solution Approach 2:
Sensors in each row unit provide real-time feedback on harvest conditions, crop presence, and operational status to the combine's control system. This feedback enables automated adjustment and monitoring, improving automation extent while using standardized feedback mechanisms across all row units
3Measurement precision
If row-by-row data collection is implemented, then the measurement precision and yield mapping resolution are improved, but the loss of time for data processing increases
Solution Approach 1:
Data from individual row units is collected, organized, and pre-processed during the harvest operation itself rather than after. This preliminary action includes timestamping and spatial mapping of data as it's generated, reducing the time required for post-harvest processing while maintaining high measurement precision
Data Source
AI summary
The disclosed apparatus, systems and methods relate to an electrically driven corn head and/or a corn head retrofitted with individual electric motor assemblies on each corn head. In various implementations, the corn head is configured for row-by-row control of harvesting operations. In certain implementations, the corn head and associated systems can count and estimate size of stalks and ears. Further the system is configured to measure yield.