Grain Cart Auger Control System Preventing Accidental Movement
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Solution Overview
Problem
Grain carts often suffer damage due to accidental movement of the discharge conveyor out of the unload position while full of grain, leading to grain spillage and potential damage to the auger system, which can cause downtime and repairs during harvesting operations.
Innovation Solution
A control system that includes a movement actuator and an auger feed gate position sensor to prevent the upper auger conveyor section from moving to the storage position when the auger feed gate is open, using a solenoid and check valve to lock out this movement and ensure the auger is clear of grain before folding, along with visual indicators to alert the operator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the upper auger housing is moved to the storage position while grain is still in the lower auger housing, then the grain cart can be quickly repositioned, but grain spills out of the top of the lower auger housing causing damage and downtime
Solution Approach 1:
The control system performs preliminary action by detecting when the auger feed gate is closed and preventing movement of the upper auger housing to the storage position until the auger is clear of grain. This ensures grain is emptied from the auger housing before repositioning, preventing spills and damage while maintaining quick operation when conditions are safe.
Solution Approach 2:
The control system uses feedback from the auger feed gate position sensor to monitor the state of the auger and dynamically control the movement actuator. When the feed gate is closed, the system receives feedback that grain flow is stopped and prevents premature movement, ensuring the auger is clear before repositioning, thus protecting the auger system while enabling efficient operation.
2Productivity
If the auger feed gate is kept open to maintain grain flow, then the harvesting operation continues efficiently, but the auger system is exposed to load pressure that can cause extensive damage
Solution Approach 1:
The control system requires preliminary action by preventing auger rotation when the feed gate is open and grain is present in the hopper. This forces the operator to close the feed gate before starting the auger, ensuring the auger is not exposed to damaging load pressure from full grain load, thereby protecting the auger system while maintaining harvesting efficiency.
Solution Approach 2:
The control system applies preliminary anti-action by blocking the auger rotation command when conditions indicate potential damage risk (feed gate open with grain in hopper). This counter-action prevents the harmful condition of loading the auger under excessive grain pressure before grain flow is controlled, protecting the auger system from extensive damage.
3Loss of time
If the upper auger housing is moved back to the unload position quickly after accidental separation, then operational downtime is reduced, but the moving upper auger slams into the rotating lower auger causing damage to bearings and springs
Solution Approach 1:
The control system performs preliminary action by detecting when the auger feed gate is closed and the auger is clear of grain before allowing movement of the upper auger housing. This ensures that when the operator needs to reposition the auger, the system is in a safe state, preventing slamming into the rotating lower auger and avoiding damage to bearings and springs while minimizing downtime.
4Loss of information
If grain flows from the top end of the lower auger housing during repositioning, then the operator can see the grain discharge, but grain occludes or blocks proper engagement of the upper and lower auger housings
Solution Approach 1:
The control system performs preliminary action by preventing movement of the upper auger housing until the auger feed gate is closed and the auger is clear of grain. This eliminates grain flow during repositioning operations, preventing grain from occluding or blocking proper engagement of the upper and lower auger housings, thereby ensuring accurate engagement while maintaining operator awareness through the control system's safety interlocks.
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
Prevents accidental damage to the auger system by ensuring the discharge conveyor is clear of grain before moving to the storage position, reducing downtime and repairs, and providing clear visual feedback to operators to avoid operational mistakes.
Implementation Method 1
A control system that includes a movement actuator and an auger feed gate position sensor to prevent the upper auger conveyor section from moving to the storage position when the auger feed gate is open, using a solenoid and check valve to lock out this movement
Implementation Method 2
using a solenoid and check valve to lock out this movement
Data Source
AI summary
A grain cart includes a lower auger conveyor section and an upper auger conveyor section pivotally movable relative to the lower auger conveyor section between a first position and a second position. The lower auger conveyor section further includes an auger feed gate movable between a closed position and an open position. The grain cart further includes a movement actuator adapted to move the upper auger conveyor section between the first position and the second position. The grain also includes a control system including an auger feed gate position sensor operatively coupled to the movement actuator and functioning to control the movement actuator based on input from the auger feed gate position sensor to provide a lock out function preventing the movement actuator from moving the upper auger conveyor section towards the first position only when the auger feed gate is in the open position.