Harvester Power Allocation for Predictive Unloading Demand
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Solution Overview
Problem
Agricultural harvesters face inefficiencies in power management during crop harvesting and unloading operations, leading to reduced productivity and potential hardware failures due to insufficient power reserves and inefficient power distribution between harvesting and unloading processes.
Innovation Solution
A predictive power management system that adjusts engine power and vehicle speed based on anticipated unloading needs, using sensors and map data to optimize power allocation between harvesting and unloading, ensuring continuous maximum power availability for both operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the engine operates at maximum power during harvesting, then harvesting productivity is improved, but power availability for unloading operations becomes insufficient
Solution Approach 1:
The system performs preliminary actions by reducing engine power and vehicle speed before unloading operations begin. The controller monitors grain tank fill level and anticipates upcoming unloading events, proactively adjusting power allocation to ensure sufficient power reserves are available when unloading equipment activates, thereby preventing power deficits during critical unloading operations
Solution Approach 2:
The system dynamically adjusts engine power and vehicle speed based on real-time operating conditions and predicted future states. The controller continuously monitors harvesting rate, grain tank fill level, and unloading queue status to optimize power distribution between harvesting and unloading functions, allowing the system to adapt power allocation flexibly throughout the harvesting operation
2Power
If the engine power is reduced to ensure power availability for unloading, then power availability for unloading is improved, but harvesting productivity deteriorates
Solution Approach 1:
Power reduction is performed in advance based on predicted unloading events rather than reactively. The controller uses grain tank fill level sensors and unloading queue monitors to anticipate when unloading will be needed, reducing power only when and where it will be needed, thereby minimizing the impact on harvesting productivity while ensuring power availability for unloading
Solution Approach 2:
The system changes operating parameters (engine power, vehicle speed) based on the operational phase. During normal harvesting, the system operates at maximum productivity. When unloading is anticipated or occurring, the system adjusts power and speed parameters to appropriate levels, optimizing the balance between harvesting productivity and unloading power availability
3Power
If the vehicle speed is reduced to maintain power for unloading, then power availability for unloading is improved, but harvesting efficiency deteriorates
Solution Approach 1:
The system reduces vehicle speed in advance of unloading events based on grain tank fill level monitoring. By anticipating when the tank will be full and unloading will be needed, the system proactively adjusts speed to maintain power reserves, avoiding the need for abrupt speed reductions during unloading operations that would disrupt harvesting efficiency
4Loss of energy
If the engine operates without power reserves, then fuel efficiency is improved, but reliability deteriorates due to insufficient power during unloading
Solution Approach 1:
The system maintains power reserves by performing preliminary power reduction when unloading is anticipated. This proactive approach ensures sufficient power is available for unloading operations without requiring the engine to continuously operate with large power reserves, thereby maintaining reliability during unloading while improving overall fuel efficiency
Solution Approach 2:
The system uses feedback from grain tank fill level sensors, unloading queue monitors, and power demand sensors to continuously adjust engine power output. This closed-loop control ensures power reserves are maintained only when and where needed, optimizing the balance between fuel efficiency and reliability during unloading operations
Data Source
AI summary
A harvesting machine is provided for harvesting a crop and discharging the harvested crop to an offboard container, such as a wagon or a truck, or the ground. The harvesting machine includes a power system to provide power, a crop harvester powered by the power system, and a crop discharging system to discharge crop from an onboard storage container to the offboard location, typically a container. During a harvesting operation, the harvesting machine operates at a nominal maximum power, typically a current power consumption. The nominal maximum power is reduced in anticipation of a predicted power used for discharging the harvested crop from the onboard storage container. The current power consumption for harvesting is adjusted and allocated by the predicted power to make available power for the crop discharging system. Once crop is discharged using the discharging power, the harvesting machine returns to the nominal maximum power.