Residue Accelerator Chopping and Spreading System
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Solution Overview
Problem
Agricultural combines face challenges in efficiently distributing crop residue due to high power consumption and inability to vary chopper speed for optimal chopping and spreading, resulting in uneven distribution and reduced quality.
Innovation Solution
A system comprising a chopper with a rotational axis transverse to the harvesting direction, a residue accelerator with an elongate drum and radially extending vanes, and a spreader, where the accelerator operates at a higher speed than the chopper, allowing for efficient chopping and spreading while reducing power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the chopper operates at high speed (3000 RPM) to improve the velocity of chopped crop plants, then the distribution distance is improved, but the power consumption increases significantly
Solution Approach 1:
The system is divided into two independent functional components: a chopper that operates at lower speeds for efficient cutting, and a separate accelerator (fan assembly) that operates at high speeds to propel the chopped residue. This segmentation allows each component to optimize its operating parameters independently, reducing the overall power consumption while maintaining the required ejection velocity.
2Productivity
If the chopper speed is increased to ensure wide distribution of chopped crop plants, then the spreading effectiveness is improved, but the ability to vary speed for quality control is lost
Solution Approach 1:
By separating the chopping function from the acceleration function, the system allows independent control of each component's speed. The chopper can operate at optimized speeds for quality cutting, while the accelerator can be varied to control distribution width and effectiveness, providing both adaptability and productivity simultaneously.
Solution Approach 2:
The system enables dynamic speed control of the accelerator component while the chopper maintains its optimal operating speed. This dynamic adjustment capability allows the system to adapt to different crop types, moisture conditions, and field requirements without compromising chopping quality or distribution effectiveness.
3Speed
If fan blades are added to the chopper to increase air flow and blow chopped crop plants farther, then the distribution distance is improved, but the power consumption increases significantly
Solution Approach 1:
Instead of adding fan blades to the chopper assembly, the invention creates a separate accelerator component downstream of the chopper. This segmentation allows the chopper to maintain its simple, low-power design while the dedicated accelerator handles the high-power air flow generation, improving overall system efficiency and reducing total power consumption.
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 system enables efficient chopping and spreading of crop residue with reduced power consumption, improved distribution, and better quality control by allowing the chopper to operate at a slower, more efficient speed while the accelerator ensures wider dispersal.
Implementation Method 1
a residue accelerator disposed downstream of the chopper to receive chopped residue from the chopper and to accelerate the chopped residue
Implementation Method 2
the blades extending from the drum hit the stalks of the crop plant and cut them against a row of stationary blades
Implementation Method 3
a row of steering vanes are provided behind the chopper to spread the chopped plant stalks to the left and to the right of the combine
Data Source
Figure 1
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AI summary
A system of chopping and spreading residue for an agricultural combine comprises a chopper disposed in front of a residue accelerator at the rear of an agricultural combine. The chopper is disposed to receive crop residue from a threshing and separating section of the combine and to chop that residue into smaller portions, the residue accelerator is disposed behind the chopper to receive the chopped crop residue from the chopper, and to accelerate it.