Sugar Cane Harvester Cutting Disc Activation via Lollipop Workload
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Solution Overview
Problem
Harvester machines for tall, stalky plants like sugarcane and sorghum face productivity and quality issues due to entanglement of plants, which leads to improper activation of cutting discs in row dividers, relying on operator judgment without technical support, resulting in potential damage and reduced harvest efficiency.
Innovation Solution
A method for controlled activation of cutting discs in row dividers, involving workload measurement and comparison with a threshold value to automatically activate the discs, with optional hydraulic or electric engine activation, and sensors for workload monitoring, along with adjustable threshold settings and timed disc operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the operator manually controls the activation of cutting discs based on empirical judgment, then the machine structure remains simple, but the reliability of plant separation deteriorates due to delayed or incorrect activation
Solution Approach 1:
The lollipop mechanism automatically detects when plants are entangled and activates the cutting disc without operator intervention. The sensor monitors the state of the lollipop and triggers the cutting disc activation when entanglement is detected, allowing the system to serve itself rather than requiring manual control.
Solution Approach 2:
A sensor is installed to monitor the workload or state of the lollipop in real-time and provide feedback to the control system. When the sensor detects that the lollipop is experiencing excessive load or plant entanglement, it sends a signal to activate the cutting disc, creating a closed-loop feedback control system that improves reliability.
2Productivity
If the cutting disc is activated manually when entanglement is detected, then energy consumption is reduced, but productivity deteriorates due to delayed activation and potential plant damage
Solution Approach 1:
The system continuously monitors the lollipop state in advance and activates the cutting disc before severe entanglement occurs. By detecting early signs of plant binding and triggering the cutting disc proactively, the system prevents damage before it happens, ensuring continuous harvesting operation and maintaining productivity.
Solution Approach 2:
The cutting disc is activated continuously or in rapid succession when entanglement is detected, ensuring uninterrupted plant separation. This continuous action prevents delays in harvesting and maintains the harvesting rhythm, thereby preserving productivity despite the additional energy consumption.
3Loss of time
If the operator monitors and controls cutting disc activation, then device complexity remains low, but loss of time increases due to operator distraction and delayed response
Solution Approach 1:
The system automatically monitors its own state and activates the cutting disc without requiring operator attention. The sensor continuously checks the lollipop condition and triggers the cutting disc activation autonomously, eliminating the time the operator would spend monitoring and responding to entanglement situations.
Solution Approach 2:
The manual mechanical control system is replaced with an automated sensor-based control system. Instead of relying on the operator's visual inspection and manual activation, an automated sensing and control mechanism takes over, significantly reducing the time required for plant separation and eliminating operator distraction.
4Manufacturing precision
If manual activation of cutting discs is used, then manufacturing cost is lower, but quality of harvest deteriorates due to improper cutting timing and potential root pulling
Solution Approach 1:
The sensor provides real-time feedback on the lollipop state, enabling precise timing of cutting disc activation. When the sensor detects specific conditions indicating plant entanglement, it triggers the cutting disc at the optimal moment, ensuring precise cutting timing that improves harvest quality while preventing root pulling damage.
Solution Approach 2:
The system performs preliminary detection of plant entanglement conditions and activates the cutting disc in advance of actual damage occurring. This preliminary action ensures that cutting occurs at the precise moment when plants are entangled but before root pulling or stem breaking can happen, significantly improving harvest quality.
Data Source
AI summary
A method for controlled activation of cutting discs of row dividers of a machine for harvesting tall, stalky plants, such as sugarcane and sorghum. The method is used in a harvester machine including an operating cabin, at least one row divider equipped with at least one lollipop activated rotationally, and at least one cutting disc activated rotationally. The method includes steps of measuring a workload of the lollipops, comparing the workload of the lollipops with a predefined workload threshold in order to, thus, determine whether to reinitiate the measurement of the workload or to activate the at least one cutting disk.