Sugarcane Extractor Guide Vanes for Fan Efficiency and Billet Retention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sugarcane harvesters face inefficiencies in the primary extractor fan assemblies, leading to excessive power consumption and billet loss due to fixed inlet vanes that fail to adapt to varying field conditions, affecting fan performance and crop residue removal efficiency.
Innovation Solution
A sugarcane harvester with a primary extractor fan assembly featuring adjustable guide vanes controlled by a controller that adjusts the angle of incidence of fan blades and vanes based on real-time conditions, optimizing fan performance for efficient crop residue removal and reducing fuel consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If fixed inlet vanes are used in the primary extractor fan assembly, then the structure is simple, but the fan efficiency decreases under varying field conditions and crop loads
Solution Approach 1:
The patent applies the dynamics principle by transitioning from fixed inlet vanes to variable inlet vanes that can dynamically adjust their angle based on operating conditions. The controller receives input about fan speed and automatically positions the inlet vanes to optimize airflow angles, allowing the system to adapt to varying field conditions and crop loads, thereby improving fan efficiency and reducing power consumption.
Solution Approach 2:
The patent implements parameter changes by modifying the inlet vane angle parameter in response to changes in fan speed. The controller adjusts the vane position parameter to maintain optimal airflow angles across different operating conditions, transforming a static parameter system into a dynamic one that optimizes energy efficiency.
2Device complexity
If fixed inlet vanes are used in the primary extractor fan assembly, then the device complexity is low, but cleaning efficiency decreases under varying field conditions
Solution Approach 1:
The system dynamically adjusts inlet vane angles based on real-time fan speed measurements, enabling the cleaning assembly to maintain optimal performance across varying field conditions and crop loads, thereby improving productivity without excessive complexity.
Solution Approach 2:
The controller receives feedback about fan speed and automatically adjusts the inlet vane positions to optimize cleaning efficiency. This closed-loop control system ensures that the vanes are positioned correctly for current operating conditions, maintaining high productivity throughout the harvesting process.
3Loss of energy
If variable angle guide vanes with actuator system are implemented, then fan performance is optimized and power consumption is reduced, but device complexity increases
Solution Approach 1:
The system performs self-adjustment by automatically positioning the inlet vanes based on fan speed feedback without requiring manual intervention. The controller and actuator system work together to optimize performance autonomously, making the increased complexity worthwhile by significantly reducing power consumption.
4Productivity
If variable angle guide vanes with actuator system are implemented, then cleaning efficiency is improved across varying field conditions, but device complexity increases
Solution Approach 1:
The dynamic adjustment capability allows the cleaning assembly to maintain optimal efficiency across varying field conditions and crop loads, justifying the increased device complexity through significant productivity improvements.
Solution Approach 2:
The feedback-controlled system continuously optimizes vane positioning based on fan speed measurements, ensuring high cleaning efficiency throughout operation. This automated adjustment system makes the added complexity worthwhile by maintaining consistent productivity performance.
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 fan efficiency, reduces power consumption, and minimizes billet losses by dynamically adjusting the angle of vanes and blades to match changing field conditions, improving overall harvesting performance and reducing operational costs.
Implementation Method 1
A fan assembly includes a plurality of fan blades coupled to a spindle. A motor is configured to rotate the plurality of fan blades about a rotational axis of the spindle.
Implementation Method 2
A vane assembly includes an actuator system and a plurality of guide vanes operatively connected to the actuator system, wherein the actuator system is adapted to adjust an angle of each of the plurality of guide vanes.
Data Source
AI summary
A sugarcane harvester configured to cut sugarcane into a sugarcane mat having crop debris and billets. The harvester includes an extractor configured to receive the sugarcane mat at an inlet and to discharge crop debris from the sugarcane mat at an outlet. An extractor located between the inlet and the outlet includes an extractor fan having fan blades and a vane assembly including a plurality of guide vanes, wherein the angle of the guide vanes is adjustable. A selector includes a manual position to enable adjustment of a rotational speed of the fan blades and an automatic position which automatically adjusts the rotational speed of the fan blades. A controller identifies the position of the selector, and in response to the position of the selector adjusts the angle of the guide vanes to optimize fan performance for cleaning and fuel savings.