Modular Electric Disc Cutterbar With Individual Motor Control

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Traditional disc cutterbars in agriculture are over-designed due to mechanical drivetrains, leading to increased weight, manufacturing costs, and complexity, with synchronized cutterhead rotation limiting flexibility and crop flow.

Innovation Solution

An electric motor-driven rotary disc cutter module system that allows individual cutterhead power and speed control, eliminating the need for a mechanical drivetrain, reducing weight, and enabling flexible repositioning and improved crop flow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a mechanical drivetrain is used to power cutterheads, then power can be transmitted to all cutterheads, but the cutterbar weight increases and complexity increases

Engineering Contradiction:

Improvepower transmission to cutterheadsVSAvoidcutterbar weight

Core Design Contradiction:

PowerVSWeight of moving object

Solution Approach 1:

The cutterbar is divided into modular cutterhead assemblies, each with its own electric motor. This segmentation eliminates the need for a centralized mechanical drivetrain, reducing overall weight while maintaining power delivery to each cutterhead independently.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mechanical drivetrain system is replaced with individual electric motors mounted on each cutterhead assembly. This substitution eliminates heavy mechanical power transmission components (gears, shafts, belts) while providing equivalent or superior power delivery to each cutterhead.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Stability of the object's composition

If a mechanical drivetrain is used to synchronize cutterhead rotation, then all cutterheads rotate at the same speed, but device complexity increases

Engineering Contradiction:

Improvesynchronized cutterhead rotationVSAvoiddrivetrain complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

Mechanical synchronization mechanisms (gear trains, timing belts, shafts) are replaced with electronic control systems. Each electric motor is equipped with a controller that receives signals from a central controller, enabling synchronized rotation through electronic communication rather than mechanical coupling.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The control system serves multiple functions: it synchronizes cutterhead rotation, monitors motor performance, and allows for speed adjustments. This multi-functionality reduces the need for separate mechanical synchronization mechanisms, simplifying the overall system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Power

If intermediate drive shafts are used to transfer power laterally along the cutterbar, then power can be distributed to all modules, but ease of repair deteriorates

Engineering Contradiction:

Improvepower distribution to modulesVSAvoidcutterhead replacement ease

Core Design Contradiction:

PowerVSEase of repair

Solution Approach 1:

The cutterbar is segmented into independent modular assemblies, each with its own power source. This segmentation allows any damaged module to be removed and replaced without affecting adjacent modules or requiring disassembly of the power transmission system, significantly improving ease of repair.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The power source (electric motor) is extracted from a centralized drivetrain and integrated directly into each cutterhead assembly. This extraction eliminates the need for intermediate drive shafts and complex lateral power transfer mechanisms, allowing individual modules to be serviced independently.

Inventive Principle:

Principle #2Taking out (Extraction)

4Reliability

If cutterheads are designed with over-engineered drivetrain parts, then reliability increases to handle shock loadings, but weight increases

Engineering Contradiction:

Improvedrivetrain reliability under shock loadingVSAvoidcutterbar weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

Heavy mechanical drivetrain components designed to withstand shock loadings are replaced with electric motors and electronic control systems. Electric motors provide high torque capability and can be controlled to handle shock loads without requiring over-engineered mechanical parts, significantly reducing weight while maintaining or improving reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS8931245B2Modular electric disc cutterbar and controller

Publication Date: 2015.01.13 CNH IND CANADA

AI summary

An electric motor-driven rotary disc cutter module for use in a cutterbar in an agricultural harvester. In one embodiment, each rotary disc module includes an electric motor driver for the rotary cutterhead. Individual cutterhead modules are staggered fore and aft along the cutterbar to provide continuous cutting across the lateral width of the cutterbar without requiring synchronized rotation of the cutterheads to prevent contact of the knives. This configuration allows for individual speed and/or rotational direction adjustment for each cutterhead to optimize crop cutting performance and/or crop movement within the header. A control system may be included to monitor performance and manage individual operation of the cutterhead modules.