Forage Harvester Kernel Processor Gap Control
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Solution Overview
Problem
Existing forage harvesters face challenges in optimally adjusting the gap between kernel processor rollers to match the physical parameters of the crop, leading to inefficiencies in kernel cracking and increased energy consumption due to manual adjustments or incomplete automation.
Innovation Solution
A forage harvester equipped with a camera and image processing system that detects the portion of uncracked kernels and adjusts the kernel processor gap and/or pressing force automatically to achieve optimal kernel cracking efficiency, while also considering crop throughput and moisture content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual adjustment of kernel processor gap is performed, then operator can control the gap size, but it is problematic to find an appropriate gap for all harvesting situations since optimal gap size depends on crop throughput and physical properties
Solution Approach 1:
The system automatically adjusts the kernel processor gap based on sensor measurements of crop properties (moisture content, kernel hardness) and throughput conditions. The control unit processes sensor signals and autonomously actuates the gap adjustment mechanism without operator intervention, enabling the system to adapt to varying crop conditions in real-time
Solution Approach 2:
The system dynamically changes the gap parameter based on measured crop properties. The control unit modifies the gap size according to sensor data about moisture content, kernel hardness, and throughput, optimizing the cracking process for different harvesting situations without manual intervention
2Use of energy by moving object
If the gap is defined too large, then energy consumption is reduced, but a relatively high portion of uncracked kernels results
Solution Approach 1:
The system uses sensors to detect the portion of uncracked kernels in the crop flow and feeds this information back to the control unit. Based on this feedback, the control unit automatically adjusts the gap size to optimize the balance between energy consumption and cracking effectiveness, ensuring reliable kernel processing while minimizing energy use
3Reliability
If the gap is defined to small, then kernel cracking effectiveness is improved, but unnecessary high energy consumption of the kernel processor results
Solution Approach 1:
The system dynamically adjusts the gap parameter based on real-time sensor data about crop properties and cracking effectiveness. By changing the gap size according to actual conditions rather than using a fixed small gap, the system achieves reliable kernel cracking while avoiding unnecessary energy consumption
4Extent of automation
If automatic adjustment based on sensed crop moisture is implemented, then gap adjustment is automated, but the ripeness of the crop and actual throughput are not taken into account
Solution Approach 1:
The sensor arrangement measures multiple crop parameters simultaneously (moisture content, kernel hardness, ripeness, throughput) rather than relying on a single parameter. This multi-functional measurement approach enables comprehensive automatic adjustment that accounts for all relevant crop conditions affecting optimal gap size
Data Source
AI summary
The invention refers to a forage harvester (10) comprising: a chopper means (22) for cutting harvested crop into short lengths, a kernel processor with at least two rotatively driven rollers (28) defining a gap arranged in the crop flow downstream the chopper means (22) for cracking kernels in the crop, a sensor arrangement (34) including a camera (42) viewing upon the crop flow downstream the kernel processor rollers (28) and an image processing system (46) for deriving the portion of uncracked kernels in the crop flow, and a control unit (48) coupled to the sensor arrangement (34) and to an actuator (50), the control unit (48) adjusting the kernel processor gap and/or pressing force of the kernel processor rollers (28) based upon the detected portion of uncracked kernels.