Grain Unloader Control System for Startup Torque Reduction
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Solution Overview
Problem
Grain unloading systems in agricultural devices face issues such as grain settlement causing damage, increased startup torque, and structural stress due to uneven loading, particularly when the grain tank and unloader augers are started simultaneously or when the unloader conveyor is pivoted with grain, leading to potential damage and mechanical issues.
Innovation Solution
A control system for the unloader conveyor that includes a load sensing device to selectively disengage the vertical segment of the conveyor when cumulative loading exceeds a predetermined value, reducing startup torque and preventing grain compaction by allowing the horizontal segment to operate initially, followed by the vertical segment once the grain is cleared.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the grain tank auger and unloader auger are started simultaneously, then the unloading process is more efficient, but the startup torque and power requirements increase significantly
Solution Approach 1:
The control system initiates the unloader auger operation before the grain tank auger begins operation. This preliminary action clears settled grain from the unloader conveyor, reducing the torque required when the grain tank auger subsequently feeds grain into the unloader, thereby resolving the high startup power requirement while maintaining efficient unloading
2Productivity
If the grain tank auger starts first and forces grain into the unloader, then the unloading process continues, but grain becomes compacted and damaged in the lower unloader housing
Solution Approach 1:
The system performs preliminary clearing of the unloader conveyor by operating the unloader auger alone before the grain tank auger begins feeding grain. This prevents grain compaction and damage by ensuring the unloader path is clear before grain is forced into the conveyor, eliminating the harmful compaction effect while maintaining continuous unloading capability
3Ease of operation
If the unloader conveyor is pivoted while loaded with grain, then the unloader remains in position for unloading, but greater loads and stress are placed on the supporting structure
Solution Approach 1:
The control system automatically reverses the unloader auger operation when the unloader reaches the unloading position to clear any grain from the conveyor before the operator pivots it. This preliminary clearing action removes the grain load that would otherwise create excessive stress on the supporting structure during pivoting, while still allowing easy repositioning of the unloader
4Productivity
If the unloader auger stalls and the grain tank auger continues to operate, then the grain tank auger keeps conveying grain, but the inlet of the unloader becomes packed with grain
Solution Approach 1:
The control system continuously monitors the operational status of the unloader auger and automatically responds to stall conditions by reversing the grain tank auger operation. This feedback mechanism detects when the unloader auger has stalled and immediately corrects the condition by reversing the grain tank auger to clear the packed inlet, maintaining system reliability while allowing continuous grain conveyance capability
Data Source
AI summary
An agricultural device for controlled unloading of grain including an unloader conveyor including an enclosed housing having an inlet end including an opening for receiving grain, and an opposite outlet end including a discharge opening through which the grain can be discharged. An unloader conveyor element extends through the housing between the ends and operable for conveying the grain through the housing from the inlet end and discharging the grain through the discharge opening. The unloader conveyor element includes a substantially vertical unloader conveyor segment connected to a substantially horizontal unloader conveyor segment. An unloader drive selectably operates a portion of the conveyor element associated with the substantially vertical unloader conveyor segment in a disengaged mode in response to a sensed cumulative loading condition of the substantially vertical unloader conveyor segment and the substantially horizontal unloader conveyor segment exceeding a predetermined value.