Electronic Hydraulic Cylinder Flotation for Crop Headers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional hydraulic float systems for crop headers suffer from poor ground following capabilities due to internal friction in cylinder seals, leading to significant wear and undesirable ground pressure, especially when encountering obstacles or uneven terrain.
Innovation Solution
An electronically controlled hydraulic cylinder system with a proportional pressure reducing relieving (PPRR) valve, connected to sensors for real-time pressure and position feedback, dynamically adjusts the lift force to improve ground following and reduce friction, allowing for better terrain adaptation and reduced wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional hydraulic float systems are used, then the header is suspended with small ground pressure, but ground following capabilities deteriorate due to internal friction in cylinder seals
Solution Approach 1:
The patent replaces the traditional mechanical hydraulic float system with an electronically controlled system. Instead of relying solely on hydraulic pressure and mechanical linkages, the invention uses electronic sensors to detect header position and ground conditions, then uses electric motors or actuators to adjust the header height. This substitution eliminates the internal friction of hydraulic cylinder seals that plagues traditional systems, while maintaining the ability to suspend the header with controlled ground pressure.
Solution Approach 2:
The patent implements a feedback control system where sensors continuously monitor the header's position, orientation, and ground contact forces. This information is fed back to a control system that automatically adjusts the header height to maintain optimal ground following. The feedback mechanism allows the system to compensate for terrain variations dynamically, improving ground following capabilities without relying on high ground pressure that would increase friction wear.
2Reliability
If higher ground pressure is applied to improve ground following, then terrain contact improves, but wear on ground contacting components increases significantly
Solution Approach 1:
The patent employs a dynamic control system that continuously adjusts the header's ground contact force based on real-time terrain conditions. Rather than maintaining a constant high ground pressure, the system dynamically modulates the lift force to provide just enough contact pressure for effective ground following. This dynamic adjustment minimizes unnecessary wear on ground contacting components like cutter bars and skids while maintaining reliable terrain contact.
Solution Approach 2:
The system changes the parameter of ground contact force from a fixed high value to a variable value that adapts to terrain conditions. Sensors detect ground characteristics and the control system adjusts the header weight distribution and contact pressure accordingly. This parameter change allows the system to maintain good ground following on varied terrain while minimizing wear by reducing contact pressure when full pressure is not needed.
3Adaptability or versatility
If operator-selected flotation settings are used, then header contact force is adjusted, but the system cannot dynamically adapt to changing terrain conditions
Solution Approach 1:
The patent transforms the manual flotation adjustment system into an automated feedback-controlled system. Sensors continuously monitor terrain conditions, header position, and cutting performance, feeding this information to a control system that automatically adjusts flotation settings in real-time. This eliminates the need for manual operator intervention while providing continuous dynamic adaptation to changing terrain, significantly enhancing both adaptability and automation.
Solution Approach 2:
The system enables the header to self-adjust its flotation settings based on sensor feedback about terrain conditions and cutting performance. The control system automatically modifies lift forces and ground contact pressure without operator input, allowing the system to serve itself in adapting to varying field conditions. This self-service capability provides continuous dynamic adaptation while reducing operator workload.
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
The system enhances ground following capabilities, reduces friction-related wear, and dynamically adjusts lift forces to maintain optimal cutting height and reduce the impact of obstacles, improving the overall efficiency and durability of crop harvesting operations.
Implementation Method 1
a first hydraulic system containing a hydraulic fluid under pressure; a second hydraulic system containing a hydraulic fluid under pressure
Data Source
Figure 1
Figure 1A
Figure 2
AI summary
A crop machine having a first frame section pivotally connected to a second frame section, wherein each frame section is supported by hydraulic float cylinders directly controlled by an electronic control supplying a variable control signal to a PPRR valve arrangement to maintain a float pressure in each hydraulic cylinder at a predetennined value. The electronic control is arranged, in response to variation in a position sensor signal that provides an indication of movement and/or acceleration and/or velocity, to adjust the control signal to vary the lifting force of each hydraulic cylinder. A common accumulator is included, such that downward flexing of the second frame section forces additional fluid into a first hydraulic cylinder to apply additional lift pressure to the first frame section and upward flexing of the second frame section removes fluid from the first hydraulic cylinder to apply reduced lift pressure to the first frame section.