Grass Pickup Header Height Control via Real-Time Sensors
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Solution Overview
Problem
The existing pickup assemblies in agricultural harvesters face challenges in accurately controlling the height of the pickup unit over uneven terrain, leading to potential damage and reduced efficiency due to the inability to maintain optimal operating speed and height settings.
Innovation Solution
Incorporating at least one height sensor mounted close to the pickup unit, which provides real-time feedback to the controller for precise height adjustment, combined with a biasing member and optional additional sensors for enhanced accuracy, and a pickup unit adjuster for localized height adjustments without lifting the entire assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the pickup unit height is set low to avoid crop waste, then harvesting efficiency is improved, but the risk of damage to pickup tines and frame increases on uneven terrain
Solution Approach 1:
The pickup unit height is made dynamically adjustable through an actuator system that can rapidly change the height setting based on real-time terrain conditions detected by height sensors, allowing the system to maintain low height for efficiency on flat ground while automatically raising height to avoid damage on uneven terrain
Solution Approach 2:
Height sensors mounted on the pickup unit provide real-time feedback about the distance to the ground, which is fed to a controller that automatically adjusts the pickup unit height via an actuator, creating a closed-loop control system that maintains optimal height settings adaptively
2Productivity
If the harvester operates at high speed for optimal throughput, then productivity is improved, but the risk of damage to pickup components increases on uneven ground
Solution Approach 1:
Height sensors provide continuous feedback about pickup unit height relative to ground, enabling the control system to make real-time adjustments that allow high-speed operation while maintaining safe clearance over uneven terrain
Solution Approach 2:
The height control system enables dynamic adjustment of pickup unit height during high-speed operation, allowing the system to maintain optimal throughput while adaptively responding to terrain variations to prevent component damage
3Reliability
If the pickup unit height is set high to avoid damage on uneven terrain, then reliability is improved, but crop waste increases and harvesting efficiency decreases
Solution Approach 1:
The system dynamically adjusts pickup unit height based on real-time terrain conditions, maintaining high height settings only when uneven terrain is detected while keeping low height settings for optimal efficiency on flat ground, thus avoiding the continuous height elevation that would cause crop waste
4Device complexity
If the height sensor is mounted far from the pickup unit for structural reasons, then device complexity is reduced, but measurement accuracy decreases due to terrain variations
Solution Approach 1:
The height measurement function is segmented and distributed to multiple sensors mounted directly on the pickup unit rather than using a single sensor mounted on the main frame, providing localized accurate measurements at the critical pickup unit location
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 allows for accurate and rapid height control of the pickup unit, reducing the risk of damage and enabling operation at optimal speeds, thereby enhancing harvesting efficiency and profitability.
Implementation Method 1
the at least one height sensor may comprise a distance sensor that is configured to emit a wave signal towards and receive a reflection of the wave signal from the ground
Data Source
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AI summary
A pickup assembly 2 for an agricultural harvester 1 comprises a pickup assembly frame 200. A pickup unit 10 is carried by the pickup assembly frame 200 and configured to pick up a swath of crop from the ground. The pickup assembly 2 further comprises at least one height sensor 300, 310, 320 mounted to the pickup unit 10 and configured to generate a height signal representative of a distance between the pickup unit 10 and the ground.