Agricultural Header Torque Sensor for Clutch Slip Detection

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

In agricultural harvesters with separate drive systems for feed/snapping and chopping units, operators cannot visually detect safety clutch slips in the chopping units, leading to potential damage due to continued operation with a slipping clutch, which is costly and time-consuming to repair.

Innovation Solution

A torque sensor is installed on the power transmission shaft or drivetrain, connected to a torque fluctuation monitor that signals a safety clutch slip to the operator via a user interface, allowing for early detection and prevention of clutch damage without the need for sensors at each individual clutch.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If the drive system for feed/snapping unit and chopping unit is separated to enable independent speed control, then energy consumption is reduced, but safety clutch slip cannot be visually detected by operator

Engineering Contradiction:

Improveenergy consumptionVSAvoidsafety clutch slip detection

Core Design Contradiction:

Use of energy by moving objectVSLoss of information

Solution Approach 1:

The patent implements a feedback mechanism where a sensor detects clutch slip and sends a signal to the control unit, which then provides visual feedback to the operator through the display. This allows the operator to be informed of clutch slip conditions even though the chopping unit is no longer directly visible, resolving the information loss while maintaining separate drive systems for energy efficiency

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent introduces an intermediary detection system (sensor and control unit) that mediates between the clutch mechanism and the operator. Instead of requiring direct visual observation, the intermediary system detects clutch slip and communicates it to the operator, enabling separate drive systems while maintaining safety monitoring

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If safety clutch is placed between chopper unit and drive shaft for protection, then chopper unit is protected from damage, but clutch slip cannot be detected when drive systems are separated

Engineering Contradiction:

Improvechopper unit protectionVSAvoidclutch slip detection

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The sensor provides feedback about clutch slip conditions to the control unit, which then informs the operator. This maintains the protective function of the safety clutch while solving the detection problem by creating an information feedback loop that works independently of direct visual observation

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces the mechanical visual detection method (operator seeing feed/snapping unit motion) with an electronic sensing system. The sensor electronically detects clutch slip and communicates it to the operator, substituting mechanical observation with electronic detection to maintain both protection and detectability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Loss of information

If sensor is placed at each individual safety clutch for detection, then clutch slip can be detected, but device complexity and cost increase

Engineering Contradiction:

Improveclutch slip detectionVSAvoidsensor quantity

Core Design Contradiction:

Loss of informationVSDevice complexity

Solution Approach 1:

The patent merges the detection function into a single sensor that monitors the clutch system, rather than requiring separate sensors at each clutch location. The control unit processes this single sensor's data to detect clutch slip, combining multiple detection needs into one sensing point to reduce complexity

Inventive Principle:

Principle #5Merging (Combining)

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

This solution enables early detection and prevention of safety clutch slips, reducing the risk of damage and maintenance costs by signaling clutch issues through a user interface, while maintaining efficient energy use by allowing independent speed control of feed/snapping and chopping units.

Implementation Method 1

at least one torque sensor is provided at one of the second power transmission shaft, drivetrain and drive, which torque sensor is operationally connected to a torque fluctuation monitor

Methodology Applied

Scientific EffectTorque: Torque

Data Source

PatentUS10694671B2Header with multiple row elements

Publication Date: 2020.06.30 BLUE LEAF I P INC

AI summary

An agricultural vehicle with a header including multiple row units each include a feed/snapping unit and a chopping unit. The header further includes a first power transmission shaft for driving the feed/snapping units, and a second power transmission shaft connected via a drivetrain to a drive at the agricultural vehicle. Each chopper unit includes a safety clutch and is connected via the safety clutch to the second power transmission shaft. At least one torque sensor is provided for the second power transmission shaft, drivetrain, or drive, which torque sensor is operationally connected to a torque fluctuation monitor configured to recognize a predetermined change in torque fluctuation indicating a safety clutch slip. The torque fluctuation monitor is operationally connected to a user interface for signaling the safety clutch slip.