Combine Header Reel Force Feedback for Lodged Crop Height Control
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Solution Overview
Problem
Existing combine harvesters face challenges in efficiently harvesting lodged crops without damaging the harvester components due to inadequate control of the reel height, which can result in ineffective reaping or reel penetration into the ground.
Innovation Solution
A header system with a reel actuator and sensor system that adjusts the reel position based on force measurements, allowing precise control to maintain optimal height above the ground, minimizing contact with the ground while effectively lifting lodged crops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the reel height is lowered to harvest lodged crop, then the harvesting effectiveness is improved, but the risk of reel contact with ground increases causing damage
Solution Approach 1:
The system uses force sensors mounted on the reel to continuously monitor the force exerted on the reel during operation. When the sensed force exceeds a predetermined threshold indicating potential ground contact, the control system automatically adjusts the reel height to prevent damage. This closed-loop feedback mechanism enables the reel to operate at optimally low heights for lodged crop harvesting while maintaining reliability through real-time monitoring and automatic protection.
2Reliability
If the reel height is increased to prevent ground contact, then the harvester reliability is improved, but the crop reaping effectiveness deteriorates
Solution Approach 1:
The force sensors provide continuous feedback on the force applied to the reel, allowing the control system to maintain the reel at the lowest possible height that does not cause ground contact. This enables maximized crop reaping effectiveness while preserving harvester reliability through real-time force monitoring and dynamic height adjustment.
Solution Approach 2:
The system dynamically adjusts the reel height based on real-time force measurements rather than using a fixed height setting. This dynamic adaptation allows the reel to operate optimally close to the ground for lodged crop harvesting while automatically raising when ground contact is detected, thus resolving the contradiction between reliability and productivity.
3Manufacturing precision
If force sensing is added to the reel system, then the reel position control precision is improved, but the device complexity increases
Solution Approach 1:
The system replaces complex mechanical position measurement systems with force sensing. Instead of using mechanical encoders or position sensors on the reel, the invention uses force sensors that measure the load on the reel to infer position and ground contact status. This substitution simplifies the overall system while achieving precise control through force-based feedback.
Solution Approach 2:
The force sensors act as an intermediary between the reel and the control system, providing indirect measurement of reel position and ground contact conditions. Rather than directly measuring position, the system uses force as a mediator to infer positional information, simplifying the sensing requirements while maintaining control precision.
Data Source
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AI summary
A header (18) for a combine harvester (10) is provided. The header (18) comprises a header frame (82) and a reel (36) rotatably mounted to the header frame (18). At least one actuator (86) is mounted to the reel (36) and is configured for adjusting a position of the reel (36) relative to the header frame (82). At least one actuator sensor (88) is coupled to the at least one actuator (86) and is configured to generate an actuator signal representative of a force on the reel (36). A controller (100) is operably coupled to the at least one actuator sensor (88) and is configured to receive the actuator signal from the at least one actuator sensor (88) and to operate the at least one actuator (86) to adjust the position of the reel (36) relative to the header frame (82) in dependence of the actuator signal.