Header Reel Height Control Using Crop Canopy Sensing

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Solution Overview

Problem

Current reel height control systems in combine harvesters are often set based on a predetermined distance above the header, failing to optimize reel position relative to crop canopy height, leading to inefficiencies in crop guidance and potential losses.

Innovation Solution

A reel height control system that utilizes sensors, such as ultrasound, lidar, or contact sensors, to detect crop canopy height and adjust the reel's position independently of the header, ensuring it follows the crop height for optimal harvesting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the reel height is set to a predetermined distance above the header, then the reel position is easy to control and maintain, but the reel fails to optimize its position relative to crop canopy height leading to reduced harvesting efficiency

Engineering Contradiction:

Improvereel height controlVSAvoidcrop yield

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The system continuously monitors crop canopy height using sensors and automatically adjusts reel position based on real-time feedback. The control system receives data from height sensors, processes this information, and actuates the reel positioning mechanism to maintain optimal reel-to-crop distance, thereby resolving the contradiction between ease of operation and productivity.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The reel height control transitions from a static predetermined offset to a dynamic adjustment system. The reel position is continuously varied based on actual crop conditions, allowing the system to adapt to varying crop canopy heights while maintaining ease of operation through automated control.

Inventive Principle:

Principle #15Dynamics

2Reliability

If the reel is raised or lowered the same amount as the header to follow ground contours, then the header height control is properly maintained, but the reel height does not optimize for crop canopy height variations

Engineering Contradiction:

Improveheader height controlVSAvoidcrop guidance efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The height control system is segmented into independent control loops: one for header height following ground contours and another for reel height following crop canopy. This allows each component to be optimized independently - the header maintains reliable ground-following control while the reel independently tracks crop height for optimal guidance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different quality characteristics are applied to different parts of the system. The header control prioritizes ground contour following for reliable cutting, while the reel control prioritizes crop height tracking for effective guidance. Each component has specialized control parameters tailored to its specific function.

Inventive Principle:

Principle #3Local quality

3Device complexity

If the reel height is fixed relative to the header, then the device complexity is reduced, but the system cannot adapt to variable crop canopy heights across the field

Engineering Contradiction:

Improvereel height control systemVSAvoidreel height adaptation

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The system performs self-adjustment through automated sensors and control mechanisms. The reel height control system monitors crop conditions and automatically positions the reel without requiring manual intervention or complex operator input, thereby achieving adaptability while keeping operational complexity manageable.

Inventive Principle:

Principle #25Self-service

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

Enhances crop yield by effectively guiding the crop into the header, minimizing losses and optimizing the reel's position relative to the crop canopy.

Implementation Method 1

The sensors may employ any sensor technologies that can sense crop canopy height in front of the combine harvester and may include ultrasound sensors, lidar sensors, radar sensors, contact sensors, or combinations of these sensors

Methodology Applied

Scientific EffectUltrasound: Ultrasound

Implementation Method 2

Methodology Applied

Scientific EffectLIDAR: LIDAR

Data Source

PatentUS20260000024A1System and Method for Controlling Height of a Harvesting Machine Header Reel

Publication Date: 2026.01.01 AGCO CORP

AI summary

A reel height control system implemented on a combine harvester or other agricultural machine having a rotatable reel includes one or more sensors for sensing a crop to be harvested and generating corresponding sensor signals; machine controls for raising or lowering the reel; and a processing unit for receiving the sensor signals from the sensors, determining a height of the crop based on the sensor signals, and controlling the machine controls to position the reel to follow the height of the crop.