Mower Deck Automatic Leveling via Ultrasonic Sensors
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Solution Overview
Problem
Existing mower deck leveling systems are inaccurate and require manual operation, failing to ensure the mower deck is properly aligned and level relative to the ground surface, which affects cut quality and efficiency.
Innovation Solution
A mower deck automatic leveling system equipped with sensors and actuators that measure and adjust the deck's position relative to the ground surface, allowing for precise leveling from the operator seat, using ultrasonic sensors to determine distance and electric actuators to make adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual leveling process is used with measuring instruments, then the operator can check the height of rotary blades, but the operator must get off the seat and manually adjust threaded nuts and bolts, which reduces ease of operation
Solution Approach 1:
The patent replaces manual mechanical leveling operations with an automated electronic system. Sensors detect blade height positions, microprocessors calculate leveling adjustments, and electric actuators automatically adjust the mower deck, eliminating the need for operators to manually measure and adjust threaded nuts and bolts while maintaining or improving leveling accuracy
Solution Approach 2:
The system enables self-service leveling by automatically detecting blade heights through sensors, computing the required adjustments, and executing the leveling process without operator intervention. The microprocessor controls the entire process, allowing operators to perform leveling from the operator seat rather than manually getting off to adjust components
2Extent of automation
If electrical lifting mechanism is used to indicate when mower deck reaches the ground, then the system can detect ground contact, but it does not level the mower deck after reaching height of cut position and may not be accurate
Solution Approach 1:
The system continuously monitors blade height positions using sensors and provides feedback to the microprocessor. The microprocessor compares detected positions with target positions and automatically adjusts the mower deck to achieve precise leveling at the height of cut position, ensuring both automation and accuracy through closed-loop control
Solution Approach 2:
The patent replaces the simple electrical lifting mechanism with a sophisticated sensor-based detection system. Multiple sensors measure blade height positions with high precision, and the microprocessor processes this data to determine accurate leveling adjustments, significantly improving measurement precision over basic electrical contact detection
3Extent of automation
If sensors are used to detect and adjust deck position relative to the frame, then automatic adjustment is achieved, but the system may not accurately detect if the mower deck is level with respect to the ground surface and the vehicle frame may not always be completely straight and level
Solution Approach 1:
The patent replaces frame-relative sensor detection with ground-relative laser measurement. The laser distance meter measures the actual distance from the mower deck to the ground surface, providing accurate ground level detection that is independent of vehicle frame alignment, thereby improving measurement precision while maintaining automatic adjustment capability
Solution Approach 2:
The system introduces a laser distance meter as an intermediary measurement tool between the mower deck and the ground. This intermediary device provides accurate ground level information that is not affected by vehicle frame imperfections, enabling precise leveling detection relative to the actual ground surface rather than the vehicle frame
4Adaptability or versatility
If active height control is used to move or flex mower deck when sensor detects ground contour changes, then response to ground contour is improved, but the mower deck is not actually leveled, which does not address the fundamental leveling need
Solution Approach 1:
The system performs preliminary leveling by first establishing the correct height of cut position and ensuring the mower deck is properly leveled at this position before operation. The microprocessor calculates and executes the adjustments needed to achieve accurate leveling at the height of cut position, creating a stable baseline for consistent cutting performance
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
The system ensures accurate and automatic leveling of the mower deck at various heights, improving cut quality, reducing operator effort, and maintaining optimal blade alignment, thereby enhancing grass cutting performance and reducing engine power requirements.
Implementation Method 1
A plurality of sensors (e.g., ultrasonic sensors) mounted to the mower deck at different locations measure the distance to the ground surface
Data Source
AI summary
A mower deck automatic leveling system includes actuators that adjust the position of the mower deck at a plurality of different locations between the mower deck and vehicle frame at the selected cutting height, and sensors that calibrate the actuators by measuring the distance to a ground surface at a plurality of different locations on a mower deck at the selected cutting height.