Electronic Header Flotation Control for Low-Friction Ground Following
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Solution Overview
Problem
Traditional hydraulic header flotation systems in crop machines suffer from high static friction in cylinder seals, leading to poor ground following capabilities and increased wear on ground-contacting components, especially when the mass supported by the ground is low, and they struggle to dynamically adjust lifting forces in response to terrain changes, resulting in either inadequate cutting height or harsh ride characteristics.
Innovation Solution
An electronically controlled hydraulic cylinder system that reduces static friction by applying an alternating wave pattern to the cylinder seals and dynamically adjusts lifting forces based on movement sensors' feedback, allowing for real-time changes in pressure to maintain optimal ground contact and reduce friction, thereby improving ground following and reducing wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional hydraulic float systems are used with low ground pressure (15% of header mass), then the header can be easily adjusted to different weights and full adjustability is achieved, but ground following capabilities deteriorate and wear on ground contacting components increases
Solution Approach 1:
The patent implements a dynamic control system that continuously adjusts the hydraulic cylinder forces in response to header movement. The system modifies the forces applied by the cylinder based on real-time feedback from movement sensors, allowing the flotation system to adapt dynamically to terrain changes while maintaining low ground pressure and improving ground following capabilities
Solution Approach 2:
The patent incorporates movement sensors that provide feedback signals to the electronic control system. This feedback mechanism enables the system to detect header position and movement, and automatically adjust the hydraulic forces to maintain optimal ground following, resolving the contradiction between low ground pressure and ground following performance
2Device complexity
If traditional hydraulic float systems are used with low ground pressure, then fewer moving parts and compact design are achieved, but static friction in cylinder seals increases resistance to motion
Solution Approach 1:
The patent applies an alternating wave pattern to the cylinder seals through the dynamic control system. This vibratory motion reduces static friction by preventing the seals from adhering to the cylinder walls, thereby reducing resistance to motion while maintaining the compact hydraulic system design
Solution Approach 2:
The electronic control system generates periodic alternating signals that create oscillating forces in the hydraulic cylinders. This periodic action keeps the cylinder seals in constant motion, reducing static friction and resistance to motion while maintaining system simplicity
3Ease of operation
If traditional float systems with preset flotation settings are used, then operator control is simplified, but the header cannot dynamically respond to terrain changes resulting in inadequate cutting height or harsh ride characteristics
Solution Approach 1:
The patent implements a self-adjusting flotation system where the electronic control system automatically modifies the hydraulic cylinder forces based on sensor feedback from header movement. This eliminates the need for manual operator adjustments while maintaining simple operation, as the system self-regulates to provide optimal ground following and smooth ride characteristics across varying terrain conditions
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 significantly reduces static friction, enhances ground following capabilities, and dynamically adjusts lifting forces to maintain optimal cutting height and reduce harsh ride characteristics, improving the overall performance and durability of crop machines.
Implementation Method 1
the effect of static friction provided by cylinder seals is significantly reduced so as to reduce resistance to motion of the cylinder in the floating action
Implementation Method 2
application of a hydraulic fluid under hydraulic pressure to said at least one float cylinder causes a lifting force to be applied to the crop harvesting component
Data Source
AI summary
A header is supported by a pair of hydraulic float cylinders, where a float pressure to the cylinders is directly controlled by an electronic control supplying a variable control signal to a PPRR valve arrangement to maintain the float pressure at a predetermined value. At the set pressure a predetermined lifting force is provided to the header. A position sensor is used to generate an indication of movement and/or acceleration and/or velocity. The electronic control is arranged, in response to changes in the sensor signal, to temporarily change the control signal to vary the lifting force and thus change the dynamic response of the hydraulic float cylinder. A lift force greater than that required to lift the header can be provided by a lift cylinder and can be opposed in a controlled manner to apply a controlled downforce by the back of the same cylinder or by a separate component.