Pre-unloading Power Reduction for Harvesting Engines
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Solution Overview
Problem
Conventional agricultural machines face reduced efficiency during harvesting due to increased power demand from unloading systems, particularly when handling high-moisture crops, leading to insufficient engine speed and ground speed, which is not adequately addressed by existing power curve management systems.
Innovation Solution
A control system and method that includes a controller with multiple power curves stored in memory, allowing the engine to switch from a nominal power curve to a pre-unloading power curve with lower power output before unloading, and then to a boost power curve when unloading is activated, based on sensed factors such as crop amount, moisture, and type, to manage power demand and maintain efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the unloading system is activated to unload harvested crop from the tank, then the crop unloading function is achieved, but the power demand on the engine increases significantly
Solution Approach 1:
The controller switches the engine from nominal operation to pre-unloading operation before the unloading system is activated. This preliminary action reduces engine speed and power output in advance, reserving power capacity to handle the increased demand when the unloading auger starts operating, thereby preventing power deficiency during unloading
2Productivity
If the engine operates according to the nominal power curve during normal harvesting, then harvesting efficiency is maintained, but power reserve is insufficient when unloading is activated
Solution Approach 1:
The controller implements a pre-unloading power curve that reduces engine power output before unloading begins. This preliminary reduction in power consumption ensures that sufficient power is reserved to meet the increased demand when the unloading system activates, maintaining reliability during the transition
Solution Approach 2:
The system dynamically switches between three operational modes (nominal, pre-unloading, and boost) based on real-time conditions. The controller adjusts engine operation continuously, transitioning from nominal to pre-unloading mode before unloading starts, and to boost mode when unloading activates, optimizing both harvesting efficiency and power availability
3Power
If the engine operates in boost mode to satisfy increased power demand, then power availability is improved, but fuel consumption and emissions increase
Solution Approach 1:
By reducing engine power before unloading begins, the system prepares the engine to operate in a more efficient range during the high-power-demand unloading phase. This preliminary adjustment minimizes the need for excessive boost mode operation, reducing overall fuel consumption and emissions while still meeting power demands
Solution Approach 2:
The controller changes engine operating parameters by switching between different power curves (nominal, pre-unloading, and boost). This allows the engine to operate at optimal efficiency points during harvesting and only engage boost mode when absolutely necessary, minimizing energy losses
Data Source
AI summary
A work machine for harvesting crop includes a controller and an engine. The controller is configured to command operation of the engine in accordance with various power curves based on sensed factors associated with the harvested crop. The work machine stores the harvested crop in a tank to be unloaded by an unloading auger which is powered by the engine. Prior to activation of the unloading auger, the controller commands the engine to operate in accordance with a power curve associated with a reduced power level to reserve power for operation of the unloading auger.