Electronically Controlled Hydraulic Cylinder Flotation System
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Solution Overview
Problem
Traditional hydraulic header flotation systems in crop machines suffer from high static friction in cylinder seals, leading to increased resistance and poor ground following capabilities, especially when the mass supported by the ground is low, resulting in wear and potential damage from harsh terrain interactions.
Innovation Solution
The implementation of an electronically controlled hydraulic cylinder system with a dynamic control system that reduces static friction by applying an alternating wave pattern to the cylinder seals and adjusts lifting forces based on movement sensors, allowing for real-time modification of pressure to enhance ground following and reduce wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional hydraulic float systems are used with low ground pressure (small percentage of header mass supported by ground), then the system is compact with few moving parts and full adjustability, but the ground following capabilities deteriorate due to high static friction in cylinder seals
Solution Approach 1:
The patent applies vibratory motion to the cylinder seals to reduce static friction. The vibration causes the seals to oscillate, preventing them from sticking and reducing the static friction force that hinders header movement. This allows the compact hydraulic system to maintain good ground following capabilities even with low ground pressure.
Solution Approach 2:
The patent implements periodic vibratory action on the cylinder seals through controlled oscillations. This periodic motion continuously breaks the static friction bond between the seals and cylinder walls, enabling smooth header movement and improving ground following performance without increasing system complexity.
2Reliability
If higher ground pressure (15% of header mass) is applied to overcome static friction and improve ground following, then the ground following capabilities improve, but wear on ground contacting components increases significantly
Solution Approach 1:
By applying vibratory motion to reduce static friction, the system can achieve good ground following with lower ground pressure, thereby reducing wear on ground contacting components. The vibration prevents seal sticking, allowing smooth operation at reduced pressure levels.
Solution Approach 2:
The patent changes the operational parameters by introducing vibratory motion and dynamically adjusting the lifting forces. This allows the system to operate at lower ground pressures while maintaining ground following capabilities, thus reducing wear on components without sacrificing performance.
3Ease of operation
If traditional hydraulic float systems with preset flotation settings are used, then the system is simple to operate with rocker switches, but the header response to terrain changes is delayed and ground following is poor
Solution Approach 1:
The patent incorporates feedback mechanisms including movement sensors that detect header position and terrain changes in real-time. This feedback is used by the electronic control system to dynamically adjust lifting forces, enabling the header to respond immediately to terrain variations and improve ground following performance.
Solution Approach 2:
The patent transitions from static preset flotation settings to dynamic control where lifting forces are continuously adjusted based on real-time sensor data. This dynamic adaptation allows the header to respond rapidly to changing terrain conditions while maintaining ease of operation through automated control.
4Speed
If the header is allowed to fall rapidly to terrain contact position, then the ground following responsiveness improves, but the header impacts the ground harshly causing damage and rough ride
Solution Approach 1:
The patent applies cushioning forces before the header contacts the ground by detecting upcoming terrain features through sensors. The electronic control system reduces lifting forces in advance to control the descent speed, preventing harsh impacts while maintaining rapid response to terrain changes.
Solution Approach 2:
The patent uses dynamic control to continuously adjust lifting forces during header movement. By modulating the forces in real-time based on sensor feedback, the system optimizes the balance between fall speed for responsiveness and force reduction to prevent impact damage and ensure smooth 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
This solution significantly reduces static friction, improves ground following capabilities, and minimizes wear by dynamically adjusting lifting forces in response to terrain changes, ensuring smoother operation and reduced risk of damage.
Implementation Method 1
a hydraulic system containing a hydraulic fluid under pressure; an electronically controlled hydraulic cylinder system with a dynamic control system that reduces static friction by applying an alternating wave pattern to the cylinder seals and adjusts lifting forces based on movement sensors
Implementation Method 2
reduces static friction by applying an alternating wave pattern to the cylinder seals
Data Source
AI summary
A header is supported by a pair of hydraulic float cylinders, where a float pressure to the cylinders is directly controlled by an electronic control supplying a variable control signal to a PPRR valve arrangement to maintain the float pressure at a predetermined value. At the set pressure a predetermined lifting force is provided to the header. A position sensor is used to generate an indication of movement and/or acceleration and/or velocity. The electronic control is arranged, in response to changes in the sensor signal, to temporarily change the control signal to vary the lifting force and thus change the dynamic response of the hydraulic float cylinder. A lift force greater than that required to lift the header can be provided by a lift cylinder and can be opposed in a controlled manner to apply a controlled downforce by the back of the same cylinder or by a separate component.