Ultrasonic Height Control for Sugar Cane Harvester Base Cutter
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Solution Overview
Problem
Current automatic cutter height control systems for sugar cane harvesters are ineffective in maintaining consistent cutting heights due to difficulties in distinguishing between cutting in dirt and high-yield cane, leading to inefficiencies and reduced sugar production, as they rely on hydraulic pressure which is not reliable in modern, powerful machines.
Innovation Solution
The implementation of ultrasonic height sensors to measure the base cutter height relative to the furrow and machine body, combined with optional pitch sensors to differentiate between sink and lift in changing terrain, ensures consistent cutting height across varying field conditions, while a camera-based system maintains top cutter height relative to plant features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If hydraulic pressure-based control systems are used to detect cutting height, then the system can sense cutting resistance changes, but it cannot reliably distinguish between cutting in dirt and cutting high-yield cane
Solution Approach 1:
The patent introduces ultrasonic sensors as an intermediary measurement device that directly measures the position of the base cutter relative to the ground surface, rather than inferring position from hydraulic pressure. This intermediary measurement system resolves the ambiguity of whether high pressure indicates dirt cutting or thick cane cutting, as the ultrasonic sensor provides direct positional data independent of cutting resistance
Solution Approach 2:
The patent replaces the mechanical hydraulic pressure-based detection system with an ultrasonic sensing system. The ultrasonic sensors emit sound waves and measure the time for echoes to return, providing a non-contact, non-mechanical method for measuring cutter-to-ground distance that is not affected by cutting resistance variations
2Productivity
If modern powerful harvesters are used to increase productivity, then harvesting speed increases, but the hydraulic pressure signal becomes less reliable for height control
Solution Approach 1:
The patent replaces the hydraulic pressure measurement system with ultrasonic sensing that is independent of the harvester's power and cutting force. The ultrasonic sensors measure distance through sound wave propagation, which is unaffected by the mechanical power of the harvester, thus maintaining measurement precision even as harvesting speed and power increase
3Productivity
If the base cutter cuts at varying heights above or below optimum, then harvesting can continue without interruption, but sugar production efficiency is reduced
Solution Approach 1:
The patent implements a feedback control system where ultrasonic sensors continuously measure the distance between the base cutter and the ground surface, and this measurement is fed back to a control system that automatically adjusts the cutter height. This closed-loop feedback ensures the cutter maintains the optimal cutting height, maximizing sugar yield while allowing continuous harvesting operation
Solution Approach 2:
The system enables the harvester to automatically maintain optimal cutting height through self-adjustment based on ultrasonic sensor feedback, without requiring constant operator intervention. The machine serves itself by automatically correcting cutter position to maintain optimal sugar harvesting conditions
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 ensures consistent cutter heights are maintained even in changing field conditions, optimizing sugar cane harvesting by preventing over- or under-cutting, thereby improving efficiency and reducing contamination, ultimately enhancing sugar production quality and quantity.
Implementation Method 1
a first ultrasonic sensor mounted inside the row separator unit and configured to measure a first height of the row separator unit above a rut in which tracks of the harvester travel
Implementation Method 2
The controller is further configured to receive a pitch angle of the harvester from a pitch sensor
Implementation Method 3
a camera-based system maintains top cutter height relative to plant features
Data Source
Figure 1A~1D
Figure 2
Figure 3
AI summary
Sugar cane harvester automatic cutter height control systems maintain consistent cutter heights even as a harvesting machine traverses changing field conditions. After an operator chooses an initial cutting height the automatic systems maintain that height even as ground conditions change.