Forage Harvester CSPS Control With Variable Drum and Roller Gap
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Solution Overview
Problem
Existing forage harvesters face challenges in achieving nutritionally valuable chopped material with minimal time and energy input while efficiently chopping grains for easy digestion, and conventional methods for adjusting operating parameters are either too time-consuming or impractical due to high inertia and varying crop conditions.
Innovation Solution
A self-propelled forage harvester with a variable-speed chopping drum, adjustable cracker rollers, and an image processing unit to determine the Corn Silage Processing Score (CSPS) in real-time, using a control unit to adjust speed and gap width based on a characteristic map, and an optimization unit to adapt to changing crop conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the chopping drum speed is increased to chop grains finely for easy digestion, then the nutritional value of chopped material is improved, but the energy consumption and time input increase
Solution Approach 1:
The system changes operating parameters (chopping drum speed, cracker roller gap width) dynamically based on crop characteristics. The control unit adjusts these parameters to achieve optimal chopping fineness while minimizing energy consumption, resolving the contradiction between manufacturing precision and energy use.
Solution Approach 2:
The system transitions from fixed parameter settings to dynamic adjustment. The chopping drum speed and cracker roller gap width are no longer constant but are continuously adapted based on real-time crop conditions and target CSPS values, allowing optimal balance between chopping quality and energy efficiency.
2Measurement precision
If conventional sieving methods are used to measure CSPS, then measurement accuracy is improved, but the time consumption increases making real-time adjustment impractical
Solution Approach 1:
The patent replaces the mechanical sieving system with an optical/image processing system. Instead of physically sieving chopped material to determine particle size distribution, the system uses image processing to analyze particle dimensions, dramatically reducing measurement time while maintaining adequate accuracy for control purposes.
Solution Approach 2:
The system creates an optical copy (image) of the chopped material and analyzes this copy to determine particle size distribution. This allows CSPS measurement without physical manipulation of the material through sieves, enabling rapid assessment for real-time control adjustments.
3Use of energy by moving object
If the chopping drum speed is fixed to operate the motor at optimum speed-torque characteristic, then energy efficiency is improved, but the ability to adjust CSPS is reduced
Solution Approach 1:
The system makes the previously fixed parameters dynamic. The chopping drum speed and cracker roller gap width are continuously adjustable based on crop characteristics and target CSPS, allowing the system to adapt to varying conditions while the control unit optimizes motor operating points to maintain efficiency.
Solution Approach 2:
The control unit acts as an intermediary that coordinates between the motor's optimal operating range and the required CSPS adjustments. It selects parameter combinations that achieve target CSPS while keeping the motor operating efficiently, balancing adaptability with energy efficiency.
4Manufacturing precision
If the gap width is adjusted frequently to correct CSPS deviations, then the chopping quality is improved, but the system response time increases due to mechanical adjustment limitations
Solution Approach 1:
The system transitions from static to dynamic parameter adjustment. The gap width and chopping drum speed are continuously adapted based on measured CSPS values and target deviations, enabling the system to respond to changing crop conditions and maintain optimal chopping quality without excessive manual intervention.
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 enables efficient and energy-saving chopping with real-time adjustment of operating parameters to achieve optimal CSPS, ensuring high nutritional value and efficiency in crop processing.
Implementation Method 1
an image processing unit connected to a camera positioned along the crop's path behind the cracker roller pair to determine the actual CSPS value from images of the crop provided by the camera
Data Source
Figure 1~2
Figure 3~4
AI summary
A self-propelled forage harvester (1) comprises a chopping drum (5) driven at a variable speed (nHT) for chopping crop material, a pair of cracker rollers (7) with variable gap width (CC) arranged behind the chopping drum (5) along the crop path through the forage harvester (1) for crushing kernels in the chopped crop material, and a control unit (14) for controlling the speed and the gap width. The control unit (14) is part of an automatic setting system controlled by a characteristic map (CF), wherein the characteristic map (CF) describes a Corn Silage Processing Score, CSPS, as a function of at least the speed (nHT) and the gap width (CC).