Agricultural Load Sensor Calibration via Actuator Force Correlation
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Solution Overview
Problem
Agricultural implement load sensors require calibration to maintain accuracy, as factory calibration degrades over time due to creep, leading to under or over estimation of load applied to ground engaging tools.
Innovation Solution
A system and method for calibrating load sensors using a down force actuator and a controller to determine load values at different actuator positions, correlating load data with corresponding force values through regression analysis to update calibration tables or formulas, ensuring accurate load measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If load sensors are used to measure load applied to ground engaging tools, then load measurement capability is provided, but measurement precision degrades over time due to creep
Solution Approach 1:
The system performs preliminary calibration actions by applying known down forces through the actuator to the ground engaging tool and correlating these with load sensor readings. This establishes a baseline relationship before field use, allowing the system to proactively identify and correct calibration drift before it significantly impacts measurement accuracy.
Solution Approach 2:
The system implements continuous feedback by regularly comparing actuator-applied down forces with load sensor measurements during operation. When discrepancies exceed thresholds indicating creep degradation, the system automatically triggers recalibration routines, creating a closed-loop feedback mechanism that maintains measurement precision over extended periods.
2Measurement precision
If factory calibration is applied to load sensors, then initial measurement accuracy is achieved, but calibration effectiveness reduces over time
Solution Approach 1:
The system transitions from static factory calibration to dynamic field calibration. The actuator continuously adjusts down forces during operation, and the system adapts calibration parameters in real-time based on actual performance data, allowing the calibration to evolve and maintain accuracy despite sensor degradation from creep.
Solution Approach 2:
The system changes calibration parameters by applying multiple known down force levels through the actuator and correlating these with load sensor readings. This multi-point calibration approach adjusts the relationship between actuator force and sensor output, compensating for non-linear creep effects and maintaining reliability under varying load conditions.
3Loss of information
If load cells are installed on ground engaging tools, then load communication capability is provided, but device complexity increases
Solution Approach 1:
The actuator serves multiple functions: it applies down forces to the ground engaging tool during normal operation and simultaneously serves as a calibration apparatus by applying known reference forces for correlation with load sensor readings. This eliminates the need for separate calibration equipment, reducing overall system complexity while maintaining full load measurement capability.
Solution Approach 2:
The system merges the calibration function with the existing actuator and control system. Rather than adding independent calibration hardware, the load sensor calibration is integrated into the existing actuator control architecture, allowing single-point access for both operational control and calibration activities, thereby minimizing added complexity.
Data Source
AI summary
A system for calibrating load sensors installed on an agricultural implement. The system includes a load sensor provided in operative association with a ground engaging tool and configured to capture load data indicative of a load applied to the ground-engaging tool. The system also includes a controller communicatively coupled to the load sensor configured to determine first and second load values based on the load data received from the load sensor when the down force actuator is disposed at first and second actuator positions so as to apply first and second down forces, respectively, against the ground engaging tool. The controller is also configured to determine a relationship between the first and second load values and corresponding force values associated with the first down force and the second down force.