Harvesting Machine Crop Flow Control via Density Sensors
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Solution Overview
Problem
Self-propelled harvesting machines face challenges in maintaining a constant crop flow to processing units due to fluctuations in crop density, leading to potential engine stalling or inefficient grain processing, as existing non-contact detection methods are costly and unreliable.
Innovation Solution
A self-propelled harvesting machine with a variable drive speed input unit and sensors to estimate crop throughput, allowing for timely adjustments in speed to maintain a stable crop flow, including reversing speed reductions after processing high-density areas to prevent engine stalling and ensure efficient processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the advance speed of the harvesting machine is controlled inversely proportional to crop density, then the crop flow rate can be maintained at constant strength, but the system cannot react quickly enough to sudden increases in crop density, causing the crop flow rate to exceed processing capacity
Solution Approach 1:
The system performs preliminary detection of crop density using sensors (optical, capacitive, or mechanical) positioned at the front of the harvesting machine, before the crop enters the input unit. This advance detection allows the control unit to predict upcoming high-density areas and pre-adjust the advance speed, preventing crop flow rate from exceeding processing capacity before the problem occurs.
Solution Approach 2:
The system continuously monitors crop density through sensors and feeds this information back to the control unit, which automatically adjusts the advance speed in real-time. This closed-loop feedback mechanism enables rapid response to changing crop density conditions, maintaining reliable processing unit operation by keeping crop flow rate within processing capacity.
2Loss of time
If non-contact detection methods are used to detect crop density fluctuations in advance, then early recognition of high-density areas is possible, but the cost of detection becomes considerable
Solution Approach 1:
The system employs relatively simple and cost-effective sensor options including optical sensors, capacitive sensors, or mechanical sensors instead of expensive sophisticated detection systems. These simpler sensors provide sufficient detection capability for crop density changes while keeping the overall system cost acceptable for widespread adoption in harvesting machines.
Solution Approach 2:
The system replaces complex electronic or optical detection systems with simpler mechanical sensing approaches where applicable, such as using mechanical sensors to detect crop density through direct physical interaction. This substitution reduces system complexity and cost while maintaining effective detection of crop density fluctuations.
3Reliability
If the drive speed of the input unit is reduced to prevent engine stalling in high-density areas, then the crop flow rate can be maintained within permissible range, but the layer thickness of the crop flow in the input unit increases
Solution Approach 1:
The system dynamically adjusts the drive speed of the input unit based on real-time crop density measurements and predicted crop flow conditions. Rather than maintaining a fixed speed reduction, the control unit continuously modulates the drive speed to maintain engine operation stability while minimizing the increase in crop flow layer thickness, adapting to changing conditions as the harvesting machine moves through the field.
Data Source
Figure 1~2
Figure 3~4
AI summary
The self-propelled harvesting machine has an input unit (4) with a unit for picking up crop material from a field and conveying the crop material, where a processing unit (5) is provided, to which the crop material is fed from the input unit. A unit is provided for estimating the crop throughput of the input unit. A traction drive is provided, whose forward speed is variable depending on the crop throughput. The drive speed of the input unit is variable depending on the crop material.