Header Height Control Using Dual Sensor Feedback
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Solution Overview
Problem
Existing header height control systems in agricultural combines struggle to accurately adjust the height and tilt angle of the header over uneven terrain, leading to potential damage from the header digging into the ground due to insufficient terrain feedback and rigid connections.
Innovation Solution
Incorporating a wheel sensor associated with a gauge wheel to provide additional terrain information, allowing the controller to compare cutter height and wheel position signals to adjust the header's height and tilt angle, and using an actuator system to prevent the header from contacting the ground excessively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single cutter sensor is used to detect ground height, then the system structure is simple, but the measurement precision deteriorates when the cutter sensor is off the ground
Solution Approach 1:
The patent combines multiple sensors (cutter sensor and gauge wheel sensor) to detect ground height. The controller integrates signals from both sensors to determine actual ground contour, allowing accurate measurement even when the cutter sensor is off the ground, thus resolving the contradiction between simple structure and precise measurement.
Solution Approach 2:
The gauge wheel sensor acts as an intermediary to detect ground height when the cutter sensor cannot make contact. The controller uses the gauge wheel sensor's position signal as a substitute measurement source, enabling continuous ground contour detection without requiring the cutter sensor to remain in constant contact.
2Device complexity
If the header is rigidly connected to the combine, then the header height control system is simple to control, but the reliability deteriorates when the header contacts ground objects
Solution Approach 1:
The patent introduces a decoupling mechanism that allows the header to be dynamically disconnected from the combine's height control. When the gauge wheel sensor detects ground contact or abnormal terrain, the controller can decouple the header, allowing it to move independently and follow ground contour, thus preventing damage from rigid connection while maintaining simple control architecture.
3Stability of the object's composition
If the gauge wheel spring is made strong to keep the header level, then the header stability is improved, but the object-generated harmful factors worsen when the spring fully compresses on terrain irregularities
Solution Approach 1:
The patent implements feedback control where the gauge wheel sensor continuously monitors ground contact conditions. When the spring approaches full compression or the header begins to dig into the ground, the controller receives feedback signals and adjusts the header position or decouples it, preventing the harmful effect while maintaining header stability during normal operation.
Data Source
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AI summary
An agricultural vehicle includes a chassis and a header system carried by the chassis. The header system includes a frame; a cutter carried by the frame; a cutter sensor associated with the cutter which outputs a cutter height signal; a gauge wheel carried by the frame behind the cutter; a wheel sensor associated with the gauge wheel which outputs a wheel position signal; an actuator system including actuators which can adjust a height and/or a tilt angle of the frame; and a controller electrically coupled to the cutter height sensor, the wheel sensor and the actuator system. The controller is configured to: receive the cutter height signal; receive the wheel position signal; compare the cutter height signal and the wheel position signal to determine a terrain irregularity is present; and activate one or more actuators to adjust the frame in response to determining the terrain irregularity is present.