Stalk Diameter Sensing System for Dynamic Deck Plate Adjustment
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Solution Overview
Problem
Agricultural harvesters face challenges in accurately sensing stalk diameters to adjust deck plate spacing, leading to inefficiencies in crop processing and potential damage to stalks during harvesting.
Innovation Solution
The implementation of a stalk-diameter sensing system with yieldably biased stalk feelers and dampers, which pivot to accurately measure stalk diameters and adjust deck plate spacing dynamically, ensuring proper crop handling and minimizing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If fixed deck plate spacing is used, then device complexity is reduced, but measurement precision of stalk diameter and processing efficiency deteriorate
Solution Approach 1:
The patent implements a dynamic adjustment system where deck plate spacing automatically changes based on real-time stalk diameter measurements. The sensing system detects stalk diameter variations and triggers corresponding adjustments to deck plate spacing, transforming a static system into a dynamic one that adapts to varying crop conditions, thereby improving measurement precision without requiring overly complex manual adjustment mechanisms
Solution Approach 2:
The system employs stalk feelers that automatically contact and measure passing stalks, triggering the adjustment mechanism without operator intervention. The deck plate spacing self-adjusts based on the measured stalk diameter, with the system serving itself by using the measurement data to automatically control the adjustment actuator, reducing the need for complex external control systems
2Productivity
If manual deck plate adjustment is used, then device complexity is reduced, but productivity and harvesting efficiency deteriorate
Solution Approach 1:
The system establishes a feedback loop where stalk diameter measurements are continuously taken by the sensing system and fed back to the control mechanism. This feedback triggers automatic adjustments to deck plate spacing, enabling real-time optimization of harvesting parameters without manual intervention, thereby improving productivity while managing system complexity through straightforward feedback control
Solution Approach 2:
The patent replaces manual mechanical adjustment with an automated system that uses sensing technology and actuator mechanisms. The mechanical system is supplemented with electronic sensing and control components that automatically adjust deck plate spacing, substituting human operation with automated mechanisms to enhance harvesting efficiency while keeping the overall system complexity manageable
3Reliability
If inaccurate stalk diameter sensing is used, then device complexity is reduced, but crop damage and processing inefficiency worsen
Solution Approach 1:
The system performs preliminary measurement of stalk diameter before the crop reaches the deck plates. The stalk feelers contact and measure the stalk diameter in advance, allowing the control system to pre-adjust deck plate spacing to the optimal setting before processing occurs, ensuring reliable crop handling without requiring complex real-time adjustment mechanisms during processing
Solution Approach 2:
The patent introduces stalk feelers as intermediary elements that physically contact the stalks to measure diameter. These feelers serve as mediators between the crop and the sensing system, translating physical stalk dimensions into measurable signals that trigger appropriate deck plate adjustments, thereby improving crop handling reliability while maintaining manageable sensing system complexity
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 enhances crop processing efficiency by accurately adjusting deck plate spacing based on real-time stalk diameter measurements, reducing mechanical stress on stalks and improving harvesting performance.
Implementation Method 1
a stalk feeler that is pivotally coupled to the row unit frame about a pivot axis
Implementation Method 2
a biasing member that is coupled to the row unit frame and the stalk sensing unit and that is configured to yieldably bias the stalk sensing unit into engagement with the stalk
Data Source
AI summary
An agricultural header for use with an agricultural harvester includes a frame, a row unit having a row unit frame, a first body and a second body. The first body is coupled to the row unit frame and includes a first post, a second post, and a third post defining a plurality of adjustment openings. The second body is pivotally coupled to the second post and selectively coupled to the third post via one of the plurality of adjustment openings. A first contact member and a second contact member are movably coupled to the second body. A sensing unit is disposed in contact with the first and second contact members. A stalk feeler is deflectably coupled to the sensing unit and is configured to being disposed within a plane. A movement of either contact member induces movement of the stalk feeler relative to the plane.