Reel-Mounted Contact Sensing for Precise Crop Canopy Height
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Solution Overview
Problem
Existing crop height detection systems in agricultural machines, such as lidar, ultrasonic, and radar sensors, struggle to accurately detect crop height immediately in front of the harvester or in specific areas, leading to imprecise harvester control due to variable crop canopy heights across a field.
Innovation Solution
A crop canopy height detection system utilizing contact sensors mounted on rotating tines of a combine harvester's reel, combined with position sensors, to detect physical contact and calculate precise crop height in real-time, enabling independent control of reel sections based on local crop height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If lidar, ultrasonic, or radar sensors are used to detect crop height, then detection coverage area is increased, but measurement precision of crop height immediately in front of the harvester deteriorates
Solution Approach 1:
The patent divides the detection task into multiple segments by placing multiple contact sensors at different positions on the reel (front, center, rear sections). Each sensor independently measures crop height in its specific zone, providing precise localized measurements rather than a single averaged value. This segmentation allows the system to maintain high measurement precision across the entire detection area.
Solution Approach 2:
The patent transitions from distance-based detection (lidar/radar measuring at a distance) to contact-based detection (sensors mounted on rotating tines that physically contact the crop). By mounting sensors on the rotating reel tines that directly engage with the crop, the system achieves precise measurements of crop height immediately in front of the header, eliminating the distance-related precision loss of optical sensors.
2Measurement precision
If contact sensors are mounted on rotating tines to detect crop contact, then crop height measurement precision is improved, but device complexity increases
Solution Approach 1:
The rotating reel serves multiple functions: it guides crop to the cutter, aggregates crop material, and now also serves as the mounting structure for height detection sensors. The reel's rotation brings sensors into contact with the crop at different positions, allowing a single mechanical component to fulfill both its traditional function and the new sensing function, thereby reducing overall system complexity.
Solution Approach 2:
The system incorporates position sensors that track the angular position of each contact sensor on the rotating reel. This feedback mechanism provides the controller with real-time information about sensor position and crop contact status, enabling accurate calculation of crop height despite the dynamic rotating configuration. The feedback loop compensates for the complexity of rotating sensor mounting.
3Adaptability or versatility
If multiple contact sensors are placed on different reel sections for independent height control, then adaptability to variable crop height is improved, but manufacturing complexity increases
Solution Approach 1:
The reel is divided into multiple independently controllable sections (front, center, rear), with contact sensors mounted on each section. This segmentation allows each reel section to be independently adjusted based on local crop height conditions, providing adaptability to variable crop heights across the field width. Each section can be controlled independently to optimize harvesting performance.
Solution Approach 2:
The system implements local quality control by measuring and controlling crop height independently at different locations across the reel width. Each contact sensor on a specific reel section provides localized height information, allowing the control system to adjust that specific section's cutting height to match local crop conditions, rather than applying a uniform height setting across the entire header.
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
Accurately detects crop height immediately in front of the harvester and in specific areas, allowing for precise adjustment of the header and reel positions, enhancing crop yield and reducing equipment malfunctions.
Implementation Method 1
the contact sensors are mounted to some of the rotatable tines of the reel and detect deflection of the tines caused by contact with crop being directed into the header of the combine
Implementation Method 2
at least one position sensor mounted on a non-rotating portion of the header that senses angular positions of the contact sensors when they detect physical contact with the crop
Data Source
AI summary
A crop canopy height detection system for an agricultural machine includes a plurality of contact sensors and a processing unit. The contact sensors are spaced apart across the front of the machine and are each operable to detect physical contact with a crop being harvested by the machine and to generate a corresponding crop contact signal. The processing unit receives the crop contact signals from the contact sensors and determines a canopy height of the crop based on the crop contact signals.