Harvesting Header Hydraulic Loop for Cavitation-Resistant Tool Drive
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Solution Overview
Problem
There is a need for simple and robust solutions to drive and control tools for headers in agricultural harvesting machines, particularly in combine harvesters, as existing systems are complex and prone to cavitation due to inconsistent hydraulic fluid pressure.
Innovation Solution
A hydraulic fluid loop system is integrated into the header frame, featuring a hydraulic pump driven by a mechanical input shaft, a clutch that engages at a pressure threshold, and a fluid loop that circulates hydraulic fluid to tools, enhancing flow rate and pressure, while preventing cavitation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hydraulic fluid is circulated from the crop-harvesting machine to the header tools, then the tools can be operated, but the flow rate is insufficient and pressure is inconsistent causing cavitation
Solution Approach 1:
The patent combines the crop-harvesting machine's hydraulic system with the header's hydraulic system by integrating a fluid loop that connects both systems. This allows the header to receive hydraulic fluid from the machine while also having access to its own pump, creating a merged system that ensures sufficient flow rate and pressure consistency to prevent cavitation.
Solution Approach 2:
The clutch is configured to engage the header's hydraulic pump before the fluid pressure drops to cavitation levels. This preliminary engagement ensures that the pump is already operating and maintaining adequate pressure and flow rate before conditions become problematic, preventing cavitation damage before it occurs.
2Productivity
If a hydraulic pump is added to the header, then flow rate and pressure are improved, but the device complexity increases
Solution Approach 1:
The header's hydraulic pump serves multiple functions: it can operate independently to provide sufficient flow rate and pressure to the tools, and it can also work in conjunction with the crop-harvesting machine's hydraulic system. This multi-functionality allows the system to maintain simplicity while achieving improved productivity, as the same pump handles different operational scenarios.
Solution Approach 2:
The clutch acts as an intermediary component that simplifies the control of the hydraulic pump. Instead of requiring complex control systems to manage when the pump should engage or disengage, the clutch automatically responds to fluid pressure conditions, engaging when pressure drops and disengaging when pressure is sufficient. This intermediary mechanism reduces overall system complexity while maintaining improved flow rate and pressure.
3Reliability
If the hydraulic pump is engaged continuously, then sufficient pressure is maintained, but energy consumption increases
Solution Approach 1:
The hydraulic pump operates periodically rather than continuously, engaging when fluid pressure drops below a threshold and disengaging when pressure is sufficient. This periodic operation maintains reliable pressure consistency while significantly reducing energy consumption compared to continuous operation, as the pump only runs when needed to restore and maintain adequate pressure levels.
Solution Approach 2:
The system uses fluid pressure as feedback to control the clutch engagement. When the fluid pressure in the loop exceeds a threshold pressure (10-30 psig), the clutch disengages the pump; when pressure drops, the clutch engages the pump. This feedback mechanism ensures pressure consistency while optimizing energy consumption by preventing unnecessary pump operation.
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 allows for efficient operation of hydraulic tools with increased flow rates, reduces cavitation damage, and lowers operational costs by optimizing hydraulic fluid management, enabling more tools to be operated and improving combine harvester efficiency.
Implementation Method 1
a clutch structured to engage the hydraulic pump with the input shaft when a pressure in the hydraulic fluid loop exceeds a threshold pressure of between 10 psig (69 kPa) and 30 psig (207 kPa)
Implementation Method 2
a hydraulic fluid loop carried by the header frame and structured to circulate hydraulic fluid within the header from the hydraulic pump to the at least one tool and back to the hydraulic pump
Implementation Method 3
preventing cavitation
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A harvesting header (100) includes a header frame (102, 104, 106, 108) structured to be coupled to the crop-harvesting machine (1), a hydraulic pump (160) carried by the header frame, at least one tool (204) carried by the header frame, a hydraulic fluid loop (200) carried by the header frame, a fluid inlet (216) structured to receive hydraulic fluid from the crop-harvesting machine, and a fluid outlet (222) structured to deliver hydraulic fluid to the crop-harvesting machine. The hydraulic fluid loop is structured to circulate hydraulic fluid within the header from the hydraulic pump to the tool(s) and back to the hydraulic pump. Related methods of operating a harvesting header and a non-transitory computer-readable media (1402) are also disclosed.