Forage Harvester Swath Sensor Using Crossed Distance Axes
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Solution Overview
Problem
Conventional forage harvester systems rely on complex and unreliable camera-based methods for swath detection, which are affected by outdoor light conditions and color similarities between the swath and the ground, leading to inconsistent performance in assisting operators or automating the harvesting process.
Innovation Solution
The implementation of a forage harvester equipped with two distance sensors mounted at lateral ends of the header, positioned to intersect before reaching the ground surface, allowing for reliable swath detection independent of light conditions and colors, using time-of-flight sensors that measure sensor-to-target distances and provide proportional offset information for steering adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a camera is used for swath detection, then the system can detect the position of the swath, but the processing becomes complex and time-consuming
Solution Approach 1:
The patent extracts only the essential measurement function from the camera system by using distance sensors that directly measure sensor-to-target distance along specific axes. This eliminates the need for complex image processing while retaining the ability to detect swath position, thereby resolving the contradiction between measurement precision and device complexity.
Solution Approach 2:
The patent replaces the optical-mechanical camera system with a simpler distance sensing system that directly measures distance along sensor axes. This substitution eliminates the need for image processing hardware and software, reducing device complexity while maintaining detection capability.
2Measurement precision
If a camera is used for swath detection, then the system can detect the position of the swath, but the detection is unreliable under varying light conditions and similar colors
Solution Approach 1:
The patent replaces the optical camera system with distance sensors that measure physical distance along sensor axes. This substitution eliminates dependence on optical properties such as color and light conditions, thereby improving detection reliability while maintaining measurement precision.
Solution Approach 2:
The patent changes the detection parameter from optical properties (color, brightness) to physical distance measurement. By measuring sensor-to-target distance along crossed sensor axes, the system achieves reliable detection independent of lighting conditions and color similarities.
3Measurement precision
If distance sensors are mounted on the header, then the sensor-to-target distance can be measured, but the sensors must be positioned to ensure the sensor axes cross before reaching the ground surface
Solution Approach 1:
The patent employs asymmetric positioning of the two distance sensors on the header, with each sensor oriented at a different angle so that their sensor axes cross before reaching the ground surface. This asymmetric configuration ensures that the sensor axes intersect in space, creating a geometric relationship that enables reliable distance measurement and swath detection while avoiding the need for complex positioning 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
This solution enables more reliable and cost-effective swath detection and steering, reducing processing complexity and hardware requirements, while being less susceptible to environmental factors, allowing for improved automation and operator assistance in forage harvesting.
Implementation Method 1
the first and second distance sensors are time-of-flight sensors
Data Source
AI summary
A forage harvester including a header for picking up a swath from a ground surface. The header includes a first and a second distance sensor adapted to measure a sensor-to-target distance respectively along a first and second sensor axis. The first distance sensor is mounted at a first lateral end of the header, and the second distance sensor is mounted at a second lateral end of the header. The first and second distance sensors are positioned such that, when the forage harvester is placed on an even ground surface, the first sensor axis crosses the second sensor axis before reaching the even ground surface in front of the harvester.