Hybrid Harvester Drive Control for Predicted Load Peaks
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Solution Overview
Problem
Agricultural machines face challenges in maintaining sufficient energy reserves for optimal electrical support of the internal combustion engine during phases of increased load, particularly in hybrid systems where an auxiliary electric machine is used.
Innovation Solution
A predictive control system adjusts the charge state of the electrical energy storage system based on pre-departure and inventory data, using sensor data from throughput and apron/laser sensors to forecast energy demand, optimizing the interaction between the internal combustion engine and electric auxiliary machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the auxiliary electric machine is used to compensate for load fluctuations, then the speed of the output shaft is kept constant, but the energy reserves in the electrical energy storage system may be depleted during phases of increased engine load
Solution Approach 1:
The control device proactively adjusts the charge level of the electrical energy storage system before high-load phases occur by predicting upcoming work phases using pre-departure data (field geometry, expected crop conditions) and inventory data (historical energy consumption). This preliminary charging ensures sufficient energy reserves are available before the auxiliary electric machine needs to compensate for load fluctuations, preventing energy depletion while maintaining constant speed.
Solution Approach 2:
The system continuously monitors the actual charge level of the electrical energy storage system and compares it with the predicted charge level. Based on this feedback, the control device dynamically adjusts the charging strategy during operation, modifying the state of charge to ensure sufficient energy reserves remain available for upcoming high-load phases while optimizing overall energy efficiency.
2Reliability
If the charge level is increased proactively before high-load phases, then energy reserves are sufficient, but the electrical energy storage system may be undercharged during low-load phases
Solution Approach 1:
The control device dynamically adjusts the target charge level based on the predicted work phase. During low-load phases, the system allows the charge level to decrease (improving productivity by reducing unnecessary charging). During predicted high-load phases, the system proactively increases the charge level (ensuring energy availability). This dynamic adaptation optimizes the balance between energy security and operational efficiency throughout the work order.
3Productivity
If pre-departure and inventory data are used for predictive control, then energy management is optimized, but the system complexity increases
Solution Approach 1:
The system performs complex predictive calculations using pre-departure data (field geometry, expected crop density from inventory systems) and historical data before the work order begins. This preliminary analysis creates a predicted work phase profile that guides subsequent real-time control decisions, allowing the system to optimize energy management without requiring complex real-time computations during operation.
Solution Approach 2:
The control device acts as an intermediary that integrates data from multiple sources (pre-departure information, inventory systems, real-time sensors) and translates it into simplified control commands for the auxiliary electric machine and energy storage system. This intermediary function consolidates complexity in a single control unit rather than distributing it across multiple systems.
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
Ensures efficient operation of the internal combustion engine by proactively managing energy reserves, reducing fuel consumption and maintaining performance during varying load conditions.
Implementation Method 1
an electrical auxiliary machine (12), in particular an electric motor, which can be coupled to an output shaft (16) of the internal combustion engine (11)
Implementation Method 2
an electrical energy storage device (15), in particular an accumulator, which is electrically connected to the auxiliary electric machine (12)
Data Source
Figure 1
Figure 2
AI summary
The invention relates to an agricultural machine, in particular a combine harvester, forage harvester or tractor, wherein the agricultural machine (1) has a drive arrangement (10) with an internal combustion engine (11) and with an electrical power supply system (14) comprising an electric auxiliary machine (12) and an energy storage device (15) for the electric auxiliary machine (12), and wherein the agricultural machine (1) has a driver assistance system (18) with a control device (19) which is configured to control the internal combustion engine (11), the electric auxiliary machine (12) and at least one power consumer (6, 8) which can be driven by the drive arrangement (10).It is proposed that the control device (19) of the driver assistance system (18) is configured to proactively control the charge level (21) of the electrical energy storage device (15) depending on the expected demand for electrical energy.