Sugarcane Harvester Extractor with NIR Detection for Small Billet Loss

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Solution Overview

Problem

Sugarcane harvesters face challenges in detecting small or shredded sugarcane billets that do not generate sufficient impact force for conventional impact sensors, leading to undetected sugar loss during the extraction process.

Innovation Solution

A sugarcane harvester equipped with a constituent sensor, such as a Near InfraRed (NIR) sensor, to measure the sugar content of extracted material, and a controller to analyze this data and adjust operations based on a trash sugar content threshold, detecting billet loss by identifying elevated sugar content levels.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If an impact sensor is used to detect billet loss, then impact events with sufficient force can be detected, but small or shredded billets that do not generate enough impact force cannot be detected

Engineering Contradiction:

Improvebillet loss detection capabilityVSAvoiddetection coverage across different billet sizes

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The patent replaces the mechanical impact sensor system with an optical/NIR sensor system. Instead of detecting billets through mechanical impact force, the system uses Near Infrared sensors to detect sugar content in the extracted material, enabling detection of small or shredded billets that lack sufficient mass to trigger impact sensors.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the detection parameter from mechanical impact force to sugar content concentration. By monitoring the sugar content in the extracted material using NIR sensors, the system can identify when small or shredded billets are being lost, providing a different physical basis for detection that is sensitive to billet size and integrity.

Inventive Principle:

Principle #35Parameter changes

2Measurement precision

If a constituent sensor and controller are added to detect sugar content, then small or shredded billets can be detected, but the device complexity increases

Engineering Contradiction:

Improvedetection of small or shredded billetsVSAvoidsensor and control system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The NIR sensor system serves multiple functions: it detects sugar content to identify billet loss, monitors extracted material composition, and provides data for harvest quality assessment. This multi-functionality justifies the added complexity by providing comprehensive monitoring capabilities beyond simple billet detection.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system uses the extracted material that is already being removed by the fan assembly as the detection target. Instead of requiring separate sampling systems, the constituent sensor analyzes the material that is naturally present in the extraction airflow, eliminating the need for additional complex sampling infrastructure.

Inventive Principle:

Principle #25Self-service

3Productivity

If the fan assembly extracts material continuously, then leaf residue is effectively removed, but small billets may pass through undetected

Engineering Contradiction:

Improveextraction efficiencyVSAvoidbillet retention accuracy

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system implements feedback by continuously monitoring sugar content in the extracted material and using this information to detect billet loss events. When the sensor detects elevated sugar content indicating billet presence, the system can alert operators or adjust operations to prevent further loss, creating a closed-loop monitoring system that enhances reliability without reducing extraction efficiency.

Inventive Principle:

Principle #23Feedback

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

Effectively detects and alerts for sugarcane billet loss, reducing harvest loss by adjusting operational parameters to prevent further billet extraction, thereby improving harvest efficiency.

Implementation Method 1

a fan assembly positioned within the interior passage of the housing and configured for inducing a flow of air across a flow of sugarcane billets and through the interior passage for extracting leaf residue

Methodology Applied

Scientific EffectAir flow: Convection

Implementation Method 2

A constituent sensor, such as a Near InfraRed (NIR) sensor, to measure the sugar content of extracted material

Methodology Applied

Scientific EffectNear InfraRed detection: Absorption Spectroscopy

Data Source

PatentUS20250228160A1Extractor for a sugarcane harvester

Publication Date: 2025.07.17 DEERE & CO

AI summary

A sugarcane harvester includes an extractor system having a housing defining an interior passage leading to an exhaust outlet. A fan assembly is positioned within the interior passage for inducing a flow of air across a flow of sugarcane billets and through the interior passage for extracting leaf residue. A constituent sensor is positioned to detect data related to a sugar content of the extracted material, including the leaf residue, moving through the interior passage of the housing. A controller may determine a current sugar content of the extracted material passing through the interior passage of the housing from data sensed by the constituent sensor, and determine that the extracted material passing through the housing includes sugarcane billets when the current sugar content is greater than a trash sugar content threshold.