Harvester Crop Discharge System Flow Control
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Solution Overview
Problem
Agricultural harvesters face difficulties in efficiently unloading harvested crops due to the need to halt unloading prematurely to prevent spilling, leading to leftover crops in the discharge system that are difficult to resume, resulting in waste if not properly managed.
Innovation Solution
A method and system utilizing a flow control device monitored by a computing device with sensors to halt crop transfer when a first quantity is discharged, allowing any remaining crop in the discharge system to be conveyed to the discharge location, ensuring the total quantity matches the desired amount before shutting down, thereby preventing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the crop discharge system unloads harvested crop at a high rate, then productivity is improved, but the risk of spillage increases requiring premature shutdown
Solution Approach 1:
The system employs sensors to detect the volume of harvested crop in the crop discharge system and provides feedback to the controller. The controller adjusts the operation of the flow control device and crop discharge system based on this feedback to maintain optimal unloading rates while preventing spillage, thereby resolving the contradiction between high productivity and spillage prevention.
Solution Approach 2:
The controller proactively controls the flow control device to regulate crop flow into the discharge system before spillage occurs. By monitoring crop volume in advance and adjusting flow rates preemptively, the system maintains high unloading rates while preventing the conditions that lead to spillage and premature shutdown.
2Reliability
If the operator halts unloading when the crop cart is full, then spillage is prevented, but harvested crop remains in the discharge system causing waste
Solution Approach 1:
Sensors continuously monitor the volume of harvested crop in the discharge system and provide real-time feedback to the controller. This enables the controller to determine precisely when to halt unloading - when the crop cart is full but before crop waste occurs in the discharge system - thereby preventing both spillage and waste.
Solution Approach 2:
The system uses its own sensors and control mechanisms to automatically manage the unloading process, eliminating the need for operator intervention. The controller autonomously halts unloading at the optimal moment based on sensor data, preventing both spillage and crop waste without requiring the operator to estimate crop volume.
3Productivity
If a small volume of harvested crop is conveyed at high velocity, then productivity is improved, but the system has difficulty accelerating stationary crop upon resumption
Solution Approach 1:
The system dynamically adjusts the velocity of crop conveyance based on operational conditions. The controller modulates the speed of the crop discharge system components, allowing high velocity during active unloading for productivity while reducing velocity before shutdown to facilitate easier resumption. This dynamic adjustment resolves the contradiction between high conveyance velocity and ease of resumption.
4Reliability
If a large volume of harvested crop is conveyed at low velocity, then spillage risk is reduced, but the system lacks sufficient torque to accelerate crop upon resumption
Solution Approach 1:
The controller dynamically adjusts conveyance velocity and flow rate based on system state. During operation, it maintains optimal velocity for spillage prevention while ensuring sufficient power is available for acceleration. Before shutdown, it reduces velocity to manageable levels, ensuring that when resumption is needed, the system has the torque required to accelerate the crop without difficulty.
Solution Approach 2:
The system maintains continuous monitoring and control of crop flow velocity and volume. By keeping the crop discharge system in a controlled state with continuous feedback, it ensures that velocity is always at an optimal level that prevents spillage while maintaining the system's ability to accelerate crop when needed, avoiding both extremes of too high or too low velocity.
Data Source
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AI summary
A method (200) for unloading harvested crop (12) from an agricultural harvester (10) includes monitoring a quantity of the harvested crop (12) discharged from the harvester (10) based on sensor data indicative of the quantity of the harvested crop (12) discharged from the harvester (10). The method further includes controlling an operation of a flow control device (90) of the harvester (10) to halt transfer of the harvested crop (12) from a crop tank (20) of the harvester (10) to a crop discharge system (22) of the harvester (10) when a first quantity of the harvested crop (12) has been discharged from the harvester (10). Additionally, the method includes continuing to control an operation of the crop discharge system (22) after halting further transfer of the harvested crop (12) from the crop tank (20) to the crop discharge system (22) to convey any remaining harvested crop (12) contained within the crop discharge system (22) to the discharge location.