Agricultural Header Float Control for Uneven Terrain
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Solution Overview
Problem
Conventional hydraulic float systems in crop harvesting headers face challenges in maintaining optimal ground following and weight distribution, especially on uneven terrain, leading to force imbalances and reduced effectiveness in cutting crops close to the ground.
Innovation Solution
A crop harvesting header with a mounting assembly featuring left and right float elements that apply controlled lift forces, equipped with sensors to detect tilt angles and adjust lift forces accordingly, allowing the header to tilt relative to the propulsion vehicle, and a control system that modifies lift forces to maintain balance and extend the flex range by rotating the combine faceplate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional hydraulic float systems are used to support the header, then the header can be easily adjusted to different weights and types with full adjustability from the cab, but the ground following capability deteriorates and force imbalances occur on uneven terrain
Solution Approach 1:
The header support system is divided into multiple independent float cylinders (left and right sides) that can operate independently. Each float cylinder is controlled by separate pressure control valves, allowing independent adjustment of lift forces on each side to maintain balance on uneven terrain while preserving overall system adjustability.
Solution Approach 2:
Pressure sensors are installed in the float cylinder circuits to detect pressure changes and tilt conditions. The controller receives feedback from these sensors and automatically adjusts the pressure control valves to maintain proper header attitude and ground following capability, resolving the force imbalances that occur on uneven terrain.
2Device complexity
If the header is fixedly mounted to the feeder house, then the structure is simplified, but the header cannot float on the ground and ground following capability is lost
Solution Approach 1:
The mounting structure transitions from a fixed rigid connection to a dynamic floating connection using spring-based float elements. These float elements allow the header to move vertically and tilt relative to the propulsion vehicle, enabling ground following while maintaining a relatively simple overall mounting structure without complex hydraulic systems.
3Reliability
If spring flotation systems are used to improve ground following capability, then ground pressure is reduced to 10% of header mass, but the system lacks the adjustability and compactness of hydraulic systems
Solution Approach 1:
The system merges the advantages of spring flotation (ground following capability and compactness) with hydraulic control (adjustability). Spring elements provide the floating action and ground following, while integrated hydraulic pressure control valves and sensors enable automatic and manual adjustment of lift forces, combining both approaches into a single unified system.
4Manufacturing precision
If the header tilts on uneven terrain, then the cutter bar cannot cut close to the ground, but preventing tilt reduces the flex range needed to navigate obstacles
Solution Approach 1:
The float control system applies different lift forces to different parts of the header (left and right sides independently). This allows localized adjustment of header attitude, maintaining cutting height precision at the cutter bar while permitting controlled tilting and flexing at other parts of the header to navigate obstacles and uneven terrain.
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
The system ensures improved ground following and weight distribution, maintaining efficient cutting close to the ground by balancing lift forces and extending the flex range, thereby enhancing the harvesting process on uneven terrain.
Implementation Method 1
each for applying controlled left and right lift forces to the header... each float element can comprise a cylinder where a lift force of the cylinder is controlled by changing a hydraulic pressure to a chamber of the cylinder
Implementation Method 2
each float element can comprise a spring, which can be formed by a plurality of springs, where a lift force of the spring is controlled by changing an effective length of the spring
Implementation Method 3
at least one sensor for detecting the angle of tilt of the header so as to detect when the left end is raised relative to the right end and when the right end is raised relative to the left end
Implementation Method 4
a control system for decreasing the left lift force when said at least one sensor indicates that the left end is raised relative to the right end and for decreasing the right lift force when said at least one sensor indicates that the right end is raised relative to the left end
Implementation Method 5
a lift force of the spring is controlled by changing an effective length of the spring. That is typically an upper end of the spring connected to the vehicle is raised and lowered by a control system to extend and release the spring to change the lift force
Data Source
AI summary
A harvesting header on a vehicle such as a combine harvester includes a mounting assembly comprising left and right float elements each for applying controlled left and right lift forces and arranged to allow upward floating of each end of the header in response to ground contact. Left and right sensors detect the angle of tilt of the header and a control system operates to reduce the left lift force when the left end is raised and to reduce the right lift force when the right end is raised. On a combine harvester this can be done by rotating the face plate of the feeder house in the required direction. In other systems the force generated by the left and right float elements can be directly modified. The changes to the lift force are applied only when the propulsion vehicle is tilted beyond a predetermined angle.