Harvesting Machine Granulometric Sensor for Cutting Length Control
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Solution Overview
Problem
Current forage harvesters face challenges in accurately adjusting the cutting length due to slippage caused by high moisture in crops, leading to undesired long fodder particles that can result in mouldiness and digestion issues, as the real cutting length does not consistently match theoretical calculations.
Innovation Solution
A harvesting machine equipped with a chopper, crop feed arrangement, and a drive system featuring a granulometric sensor using a camera and image processing system to automatically adjust the cutting length by applying a virtual grid to image data from chopped crop particles, allowing for rapid detection and adjustment of particle sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If theoretical cutting length calculations are used based on feed speed and chopper speed, then the control system is simple, but the real cutting length does not match due to slippage causing long fodder particles
Solution Approach 1:
The patent replaces mechanical measurement methods (speed sensors, encoders) with an optical measurement system. A camera captures images of chopped crop particles, and image processing algorithms automatically determine particle lengths by analyzing the images. This optical substitution eliminates slippage errors inherent in mechanical speed-based calculations and provides direct visual measurement of actual cutting length.
Solution Approach 2:
The patent creates a visual copy (image) of the chopped crop particles and processes this copy to determine particle dimensions. Instead of measuring the physical particles directly or calculating from mechanical parameters, the system captures optical copies via camera and derives cutting length from image analysis, enabling non-contact, high-precision measurement.
2Speed
If a camera with high speed shutter and flash is used to capture moving particles at 100 km/h, then particle images can be obtained, but the system cost and complexity increase
Solution Approach 1:
The patent introduces a light-tight enclosure as an intermediary structure that creates a controlled measurement environment. Inside this enclosure, the camera can use longer exposure times without ambient light interference, eliminating the need for high-speed shutters and complex flash synchronization systems. The enclosure mediates between the fast-moving particles and the camera's exposure requirements.
Solution Approach 2:
The system uses periodic flashing lights positioned inside the light-tight enclosure to illuminate the particles during their passage. This periodic illumination provides sufficient light for the camera sensor without requiring high-speed mechanical shutters, simplifying the overall camera system while still capturing clear images of particles moving at 100 km/h.
3Loss of time
If the image processing system works fast enough to derive particle size data in sufficient time, then prompt reaction to cutting length changes is achieved, but processing complexity increases
Solution Approach 1:
The image processing system segments the image into individual particle regions and applies simplified geometric analysis to each segment. By dividing the complex task of analyzing entire images into smaller, independent particle measurements, the system achieves fast processing times. Each particle's dimensions are determined by analyzing its segmented region separately, enabling parallel processing and reducing overall computation time.
Solution Approach 2:
The patent uses disposable, pre-defined geometric templates (virtual grids with predetermined size and shape) for particle measurement. Instead of implementing complex real-time geometric fitting algorithms, the system compares particle images against a library of simple geometric shapes. This approach uses computationally inexpensive, pre-calculated templates that can be quickly matched against particle images, achieving fast processing without complex algorithms.
4Productivity
If virtual grids with predetermined size and shape are applied to image data, then particle length derivation is simplified and fast, but measurement flexibility is reduced
Solution Approach 1:
The system dynamically selects from multiple virtual grid templates with different sizes and shapes based on the specific crop type and desired measurement parameters. Rather than using a single fixed grid, the control system can switch between different grid configurations adaptively. This dynamic selection maintains measurement speed by using pre-defined templates while providing flexibility to accommodate different crop varieties and cutting requirements.
Data Source
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AI summary
The invention refers to a harvesting machine (10) including a chopper means (22), a crop feed arrangement, a drive arrangement for driving the crop feed arrangement and the chopper means (22), a control device (88) connected to the adjustable component and to a granulometric sensor (38), said control device (88) automatically controlling the adjustable component such that the length of the chopped crop detected by the granulometric sensor corresponds to a desired length. The granulometric sensor (38) comprises a camera (44) viewing upon the chopped crop downstream the chopper means (22) and provides image data to an image processing system (92) that derives the length of the chopped crop particles (50).The image processing system (92) is investigating for each particle (50) in an image whether it falls through a grid (96) of a predetermined size and shape in order to derive the length of the chopped crop particles (50).