Agricultural Harvester Header Control System for Uneven Terrain
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Solution Overview
Problem
Agricultural harvesters with narrow header height sensors are prone to inaccurately measuring ground profiles, leading to incorrect adjustments in header height and tilt angle, which can result in the header being driven into the ground, causing damage during operations in uneven terrain.
Innovation Solution
A control system that validates sensor measurements by comparing data from multiple sensors to identify and dismiss anomalous readings, ensuring accurate header positioning and preventing it from being driven into the ground by calculating and using the largest or smallest estimated header heights based on sensor data to generate control signals for actuator control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If narrow header height sensors are used on forage harvesters, then the header can be positioned closer to the ground to improve harvesting effectiveness, but the sensors become sensitive to furrows and ditches causing incorrect height measurements that lead to the header being driven into the ground
Solution Approach 1:
The patent combines multiple header height sensors (first sensor at left edge, second sensor at right edge, and third sensor in center) to work together as a unified measurement system. The controller integrates readings from all three sensors and uses validation logic to identify and dismiss anomalous readings from any single sensor, thereby resolving the contradiction between using narrow sensors for close-ground positioning and maintaining measurement reliability in uneven terrain
Solution Approach 2:
The system implements feedback by continuously monitoring header height measurements from multiple sensors, comparing these measurements against expected ground plane profiles, and automatically adjusting header position based on validated sensor data. The controller uses feedback from the sensor array to detect when a sensor reading is anomalous (such as when a narrow sensor measures a furrow or ditch) and compensates by relying on readings from other sensors, thus maintaining both close-ground operation and measurement accuracy
2Ease of operation
If header height is adjusted based on sensor readings from extreme edges, then the header tilt angle can be optimized for flat terrain, but the header may be driven into the ground when sensors detect furrows or ditches at field edges
Solution Approach 1:
The system performs preliminary validation of sensor readings before using them to control header positioning. The controller预先 compares measurements from all three sensors to identify anomalies and establishes a validated ground plane profile before executing header adjustment commands. This preliminary action prevents incorrect tilt angle adjustments that would drive the header into the ground when sensors detect furrows or ditches
Solution Approach 2:
The patent applies different functions to different parts of the sensor array: the center sensor provides a reference measurement for the middle of the header, while the edge sensors detect ground conditions at the extremes. The controller selectively weights and validates readings from each sensor location based on its local measurement quality, using the center sensor as a stable reference point that is less likely to be affected by edge conditions such as furrows or ditches
Data Source
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AI summary
Aspects of the present invention relate to a control system (50) for controlling pivoting of a header (20) of an agricultural harvester (10). The control system (50) comprises: first, second, and third header height sensors (52, 54, 56), each for mounting to a respective point on the header (20), each configured to provide a respective header height signal representing a respective measured header height of their respective point on the header (20) above a ground plane (32); a header angle sensor (60) configured to provide a header angle signal indicative of a pivot angle of the header (10) about an axis; and a processor (58) configured to: receive (102) the signals; calculate (104) an estimated first header height based on the pivot angle and the second and third header heights; determine (106) a replacement first header height by selecting the smallest of the estimated and the measured first header height; and generate (112) a control signal based at least on the replacement first header height.