Header Backshaft Alternator for Cable-Free Combine Power
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Solution Overview
Problem
Existing electrical power systems for combine harvesters, which rely on a multi-pin coupling connector, face limitations in customization, configuration, and current capacity due to the need for physical cables to transfer power and data to the header, restricting the integration of advanced features and intelligence.
Innovation Solution
An alternator is mechanically coupled to the header backshaft, converting mechanical power into electrical power, providing a local power source for the header, which includes a power supply circuit to power devices such as lights and motors, and a controller to manage mechanical interfaces and functions, potentially eliminating the need for physical cables between the combine and header.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a multi-pin coupling connector with physical cables is used to transfer electrical power from the combine to the header, then electrical power can be transmitted to the header, but the current capacity is limited and customization is restricted
Solution Approach 1:
The patent extracts the electrical power generation function from the combine and relocates it to the header by installing an alternator on the header that is driven by the backshaft. This eliminates the need for physical cable connections for power transmission and removes the limitations of multi-pin connectors, enabling unlimited customization and higher current capacity for electrical devices on the header.
2Power
If a multi-pin coupling connector is used to transfer electrical power, then power can be delivered to the header, but the number of available power channels is limited to a defined number of pins
Solution Approach 1:
The patent removes the complex multi-pin coupling connector system entirely by extracting power generation to the header itself. The alternator mounted on the header provides direct local power generation, eliminating the need for multiple pinned connections and associated harness complexity.
3Power
If physical cables and connectors are used between the combine and header, then electrical connection is established, but the system reliability is reduced due to potential connection failures
Solution Approach 1:
The patent eliminates physical cable connections between the combine and header for power transmission by moving the alternator to the header. This removes the failure points associated with connectors, harnesses, and cable joints, significantly improving system reliability.
4Adaptability or versatility
If an alternator is mounted on the header to generate electrical power locally, then current capacity and customization are improved, but the mechanical interface complexity increases
Solution Approach 1:
The patent combines the power generation function with the existing mechanical drive system by mounting the alternator on the header and driving it through the backshaft. This merges the electrical power generation need with the existing mechanical rotation already present in the header system, avoiding the need for separate drive mechanisms.
Solution Approach 2:
The backshaft serves multiple functions: it transmits mechanical power for header operation and simultaneously drives the alternator for electrical power generation. This multi-functionality reduces the need for additional mechanical components and simplifies the overall system architecture.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances the intelligence and customizability of the header by providing a reliable and flexible electrical power source, enabling advanced features like position-based cutting height adjustment and reduced dependency on the combine harvester for power, while eliminating the limitations of traditional connector-based systems.
Implementation Method 1
An alternator mounted on the header converts mechanical power from the rotating backshaft into electrical power
Data Source
AI summary
Methods and systems are described for providing a local electrical power source at a header of a combine harvester. An alternator is mechanically coupled to a header backshaft. The header backshaft is mechanically coupled to a drive mechanism of the combine harvester to cause rotation of the header backshaft which, in turn, causes the alternator to generate electrical power. A power supply circuit transferred electrical power from the alternator to one or more electric devices mounted on the header. In some implementations, the header does not include any physical cables between the combine and the header.