Windrow Merger Pickup Head Pressure Control on Uneven Terrain
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Solution Overview
Problem
Windrow mergers face challenges in uneven terrain, where the pickup head may hover above ground or drag on the ground, leading to incomplete crop collection and damage to the field due to varying downward forces as it moves up and down to follow contours, resulting in inefficiencies and field scarring.
Innovation Solution
The implementation of a windrow merger design featuring a hydraulic actuator system with a control system that maintains a substantially constant force or pressure between the pickup head and the terrain, using a hydraulic pump driven by a tractor's PTO to adjust the height of the pickup head and ensure consistent contact, reducing friction and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the pickup head is allowed to move up and down to follow terrain contours, then the merger can operate on uneven terrain, but the downward force on the ground varies causing field damage and incomplete crop collection
Solution Approach 1:
The patent employs a feedback control system where sensors detect the actual downward force exerted by the pickup head on the terrain, and this information is fed back to the hydraulic actuator control. The controller adjusts the hydraulic pressure in real-time to maintain a predetermined constant downward force, ensuring consistent crop collection while preventing field damage regardless of terrain variations.
Solution Approach 2:
The patent utilizes a hydraulic actuator system to control the vertical position and downward force of the pickup head. By regulating hydraulic pressure, the system can precisely control the force applied to the terrain, maintaining constant contact pressure on uneven ground without causing excessive damage or incomplete crop pickup.
2Productivity
If the pickup head maintains constant contact with the ground to collect all crop, then complete crop collection is achieved, but excessive friction and wear on skid shoes occurs
Solution Approach 1:
The feedback control system continuously monitors the downward force and adjusts hydraulic pressure to maintain exactly the predetermined optimal force level. This ensures sufficient contact for complete crop collection while preventing excessive force that would cause unnecessary friction and wear on the skid shoes.
Solution Approach 2:
The system dynamically adjusts the hydraulic pressure parameter to maintain constant downward force despite changes in terrain conditions. This parameter control ensures optimal balance between maintaining sufficient contact for complete crop collection and minimizing friction and wear on the skid shoes.
3Ease of operation
If hydraulic pressure is allowed to vary with head height, then the system responds naturally to terrain changes, but inconsistent force application causes operational problems
Solution Approach 1:
The feedback control system eliminates the inconsistency by continuously measuring the actual downward force and comparing it to the predetermined target force. The hydraulic actuator is controlled to maintain this constant force regardless of head height or terrain variations, ensuring reliable and consistent operation.
Solution Approach 2:
The patent replaces the passive mechanical suspension system with an active hydraulic control system. Instead of relying on natural mechanical response to terrain changes, the hydraulic system with feedback control actively maintains constant downward force, providing more reliable and consistent 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
This design allows for efficient crop collection across uneven terrain by maintaining consistent force and pressure, minimizing field damage and operational wear, while ensuring optimal performance and reducing the risk of leaving crops behind or causing scarring.
Implementation Method 1
hydraulic actuator that connects the pickup head to a frame assembly of the merger... maintain a substantially constant hydraulic pressure in the hydraulic actuator
Implementation Method 2
hydraulic pump driven by a power takeoff (PTO) of the tractor to charge and discharge a hydraulic actuator
Data Source
AI summary
Windrow mergers employ one or more design features as described herein in connection with a suspension assembly that allows the pickup head to rise or fall relative to a frame of the merger. One feature maintains a substantially constant force or pressure between a pickup head of the merger and the terrain regardless of a height of the head. Another feature maintains a substantially constant hydraulic pressure in a hydraulic actuator that connects the pickup head to a frame assembly of the merger. Still another feature employs a hydraulic pump driven by a power takeoff (PTO) of the tractor to charge and discharge a hydraulic actuator arranged to raise and lower the pickup head of the merger between an upper limit and a lower limit.