Movable Auger Cover Grain Unload Control
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Solution Overview
Problem
Conventional combine harvester unload systems face challenges such as torque demand spikes during startup, grain dribble, and non-free flowing grains due to suboptimal orifice sizes, leading to inefficiencies and potential shear bolt failures, especially when handling large grain loads.
Innovation Solution
A control system with multiple auger covers and cutouts that adjust to change the grain pathway size, controlled by sensors and a controller to manage grain flow based on operating conditions, allowing for variable unload rates and torque management without the need for dual or variable speed drives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single drive system is used to manage grain tank unloading, then device complexity is reduced and cost is lowered, but torque demand spikes during startup when the system is full or partially full of grain
Solution Approach 1:
The patent applies the Dynamics principle by making the auger cover movable rather than fixed. The auger cover can be positioned at different locations along the auger, allowing the system to dynamically adjust the grain pathway size. This dynamic adjustment enables a single drive system to handle varying torque demands during startup and operation, eliminating the need for complex dual or variable speed drive systems while managing torque spikes effectively.
2Device complexity
If fixed auger cover design is used, then device complexity is minimized, but grain flow control is insufficient leading to grain dribble and non-free flowing grains
Solution Approach 1:
The patent transforms the fixed auger cover into a movable one that can be positioned at different locations along the auger. This dynamic positioning capability allows precise control of the grain pathway size, ensuring optimal grain flow characteristics. The movable cover prevents grain dribble and promotes free-flowing grain by adjusting the pathway according to operating conditions, significantly improving productivity without adding excessive complexity.
Solution Approach 2:
The patent applies Parameter changes by varying the grain pathway size through movable auger cover positioning. By changing the physical parameter of pathway dimensions, the system optimizes grain flow characteristics under different operating conditions. This parameter adjustment enables control over grain flow rate and prevents issues like grain bridging and dribble, enhancing overall system performance.
3Device complexity
If suboptimal orifice sizes are used in conventional unload systems, then device complexity is reduced, but grain flow efficiency decreases causing grain dribble and potential shear bolt failures
Solution Approach 1:
The patent uses a movable auger cover that can be positioned at different locations to dynamically adjust the grain pathway size. This dynamic adjustment optimizes grain flow through the unload system, preventing grain dribble and reducing stress on system components. By controlling the pathway size, the system maintains reliable operation and prevents shear bolt failures that occur with suboptimal fixed orifice designs.
4Productivity
If higher unload rates are implemented to increase productivity, then grain unloading speed improves, but torque requirements exceed capabilities of single drive systems
Solution Approach 1:
The patent applies Dynamics by implementing a movable auger cover that enables dynamic control of grain pathway size. This allows the system to achieve higher unload rates when needed by optimizing the pathway configuration, while managing torque requirements within the capabilities of a single drive system. The dynamic adjustment capability provides flexibility to match unload rate with available torque, avoiding the need for complex dual or variable speed drive systems.
Data Source
AI summary
A combine unload control system having a grain tank for storing grain and at least one auger for unloading grain from the grain tank. The control system also includes a first auger cover proximate to the at least one auger, having one or more first auger cutouts disposed on a portion of the first auger cover and a second auger cover proximate to the at least one auger and having one or more second auger cutouts disposed on a portion of the second auger cover. The control system further includes a controller configured to control amounts of grain to pass through the one or more first auger cutouts and the one or more second auger cutouts and flow to the at least one auger by causing the first auger cover and the second auger cover to move relative to each other.