Harvester Accumulator Load Detection via Metering Roller

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Solution Overview

Problem

Existing accumulator contents detection systems in harvesters face inaccuracies due to uneven filling and voids in crop material, leading to false detection of low or empty conditions, which can reduce wrapping time for bales and result in unnecessary energy waste.

Innovation Solution

A system comprising a controller, sensors, and metering rollers that detect the load transmitted to a drive metering roller, comparing it to a predetermined range to accurately determine the accumulator's content level, optimizing the operation of the harvester by ensuring efficient bale formation and energy use.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional detection methods are used to determine accumulator content level, then the system can detect low or empty conditions, but the detection accuracy deteriorates due to uneven filling and voids in crop material

Engineering Contradiction:

Improveaccumulator content level detection accuracyVSAvoiddetection reliability under uneven filling conditions

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent replaces traditional mechanical or level-based detection methods with a load-based detection system. Sensors measure the load transmitted to the drive metering roller, which correlates to the actual crop material being metered, rather than relying on accumulator fill level. This substitution eliminates detection errors caused by uneven filling and voids, as the load measurement directly reflects the material actually available for baling.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces load measurement as an intermediary parameter between the accumulator content and the detection system. Instead of directly measuring crop material volume or level, the system measures the load on the drive roller, which serves as a reliable mediator that accurately reflects the actual metered material quantity regardless of accumulator fill uniformity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Loss of energy

If the system stops operation when accumulator is detected as low or empty, then energy waste is reduced, but wrapping time for bales is reduced due to false detection

Engineering Contradiction:

Improveenergy waste from unnecessary operationVSAvoidbale wrapping time

Core Design Contradiction:

Loss of energyVSLoss of time

Solution Approach 1:

The patent replaces inaccurate level-based detection with load-based detection to prevent false low/empty conditions. This ensures the system continues operation during valid wrapping cycles while only stopping when actual material depletion occurs, thereby preserving wrapping time while avoiding energy waste from unnecessary operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system uses continuous load measurement feedback from the drive metering roller to make accurate stop/go decisions. This feedback mechanism ensures operation continues as long as sufficient material is being metered, preventing premature shutdown during wrapping while enabling timely cessation when material is truly depleted, optimizing both energy efficiency and productivity.

Inventive Principle:

Principle #23Feedback

3Productivity

If the system operates continuously without accurate detection, then productivity is maintained, but energy waste increases due to unnecessary operation

Engineering Contradiction:

Improveharvesting productivityVSAvoidenergy waste from unnecessary operation

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The system implements continuous load measurement feedback to enable real-time decisions about operation continuation. This allows the system to maintain productivity by operating during all valid material availability periods while automatically ceasing operation when material is truly depleted, eliminating energy waste without compromising productivity.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces unreliable content level detection with accurate load measurement on the drive roller. This substitution enables precise determination of actual material availability, allowing the system to maximize productive operation time while minimizing energy waste from unnecessary operation, thereby optimizing the productivity-energy efficiency balance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 provides accurate detection of the accumulator's content level, optimizing the harvester's operation by ensuring sufficient time for bale wrapping and reducing energy waste, thereby improving the efficiency and productivity of the harvesting process.

Implementation Method 1

The at least one sensor detects a load transmitted to the drive metering roller

Methodology Applied

Scientific EffectLoad detection:

Data Source

PatentUS11744179B2Accumulator contents detection system for harvester

Publication Date: 2023.09.05 DEERE & CO

AI summary

An accumulator contents detection system for a harvester includes an accumulator, a plurality of metering rollers, and at least one sensor. The accumulator accumulates crop material. The plurality of metering rollers receives crop material from the accumulator. The plurality of metering rollers includes a drive metering roller. The at least one sensor detects a load transmitted to the drive metering roller.