Forage Harvester Feed Channel Slip Detection for Cut Length Control
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Solution Overview
Problem
Existing forage harvesters face challenges in controlling the cutting length of harvested crops due to slippage between the pre-compression rollers and the crop, leading to inconsistent chop quality and potential clogging of the feed channel, especially when crop density varies.
Innovation Solution
A forage harvester with a feeder unit that adjusts the opening width and applies a pressing force, using sensors to detect crop speed and conveyer speed differences to initiate countermeasures such as adjusting the pressing force, conveying speed, or travel speed to mitigate slippage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the compression force is increased to prevent slippage, then the crop conveying reliability is improved, but the risk of feed channel clogging increases due to excessive compression
Solution Approach 1:
The compression force is made dynamically adjustable through a control unit that receives signals from a crop flow sensor. The control unit automatically adjusts the compression force based on detected crop flow conditions, allowing the system to adapt to varying crop densities and prevent both slippage and clogging.
Solution Approach 2:
A feedback control system is implemented where a sensor detects crop flow conditions and sends signals to a control unit. The control unit continuously monitors the crop flow and adjusts the compression force accordingly, creating a closed-loop control system that prevents slippage while avoiding excessive compression that could cause clogging.
2Quantity of substance
If the opening width is decreased to increase compression, then the crop density is improved, but the conveying speed decreases causing slippage
Solution Approach 1:
Both the opening width and compression force are made dynamically adjustable. The control unit independently controls these parameters based on sensor feedback, allowing the system to optimize the balance between crop density and conveying speed according to actual crop flow conditions.
Solution Approach 2:
The system changes multiple parameters (opening width, compression force, conveying speed) in a coordinated manner based on detected crop flow conditions. This allows the system to maintain optimal crop density while preventing slippage by adjusting conveying speed to match the compressed crop flow.
3Manufacturing precision
If the conveying speed is increased to match crop speed, then the cut length control is improved, but the slippage increases when crop density is low
Solution Approach 1:
The control unit uses feedback from the crop flow sensor to continuously adjust the conveying speed. When crop density is low, the system reduces conveying speed to prevent slippage. When crop density is high, it increases conveying speed to maintain precise cut length control, optimizing both parameters based on real-time conditions.
Solution Approach 2:
The system dynamically adjusts multiple parameters including conveying speed, compression force, and opening width in coordination. This allows the system to maintain precise cut length control by matching conveying speed to crop flow conditions while preventing slippage through coordinated compression adjustments.
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
Ensures reliable control of cutting length and prevents feed channel clogging by accurately detecting and responding to slippage, maintaining consistent crop flow and improving silage quality.
Implementation Method 1
at least one sensor, in particular an active sensor, for detecting a speed of the harvested crop, in particular by means of a Doppler shift
Data Source
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AI summary
The invention relates to a forage harvester (1) with a feeder (10) designed to feed crop (50) picked up by the forage harvester (1) through a feed channel (11) to a chopping unit (30) and to pre-compress it by applying a pressing force, and which is adjustable to adapt the opening width of the feed channel (11). In order to enable improved control of the cutting length of the crop in a forage harvester, the invention provides that a crop velocity vG in the area of the feed channel (11) can be detected by at least one sensor (19, 20) and a control unit (4) is configured to detect a significant slip S between the crop (50) and the feeder (10) based on a difference Δv between a conveying velocity vF of the feeder (10) and the detected crop velocity vG, and then to initiate at least one countermeasure to counteract the slip S.