STRAW WALKER LOAD MONITORING

Abstract

A system and a method are provided for controlling a combine harvester. The method includes the steps of: receiving grain flow sensor signals from a plurality of grain flow sensors; based on the received grain flow sensor signals, determining a current load on a straw walker section; and based on the current load, adjusting an aggressiveness setting of a threshing and separation section of the combine harvester. The grain flow sensors are provided underneath and adjacent to a crop transfer surface of the straw walker section of the combine harvester and are distributed over a length of the straw walker section.

Claims

1. A method of controlling a combine harvester, the method comprising the steps of: receiving a plurality of grain flow sensor signals from a plurality of grain flow sensors provided immediately underneath and adjacent to a crop transfer surface of a straw walker section of the combine harvester, the plurality of grain flow sensors being distributed over a length of the straw walker section; determining, based on the plurality of grain flow sensor signals that have been received, a current load on the straw walker section; and adjusting, based on the current load, an aggressiveness setting of a threshing and separation section of the combine harvester.

2. The method of claim 1, wherein the step of determining the current load comprises determining a grain flow profile, which represents a variation of the plurality of grain flow sensor signals along the length of the straw walker section.

3. The method of claim 1, wherein the step of adjusting the aggressiveness setting comprises adjusting a rotational speed of at least one of a threshing drum, a beater, and a separation drum of the threshing and separation section.

4. The method of claim 1, wherein the step of adjusting the aggressiveness setting comprises adjusting at least one of (a) a threshing gap between a threshing drum and a cooperating threshing grate, and (h) a separation gap between a separation drum and a cooperating separation grate.

5. The method further of claim 1, further comprising the step of adjusting at least one of a speed of the straw walker section and a slope of the straw walker section based on the current load.

6. The method of claim 1, further comprising: receiving a straw quality sensor signal from a straw quality sensor provided at least one of above and adjacent to a rear end of the straw walker section; and adjusting the aggressiveness setting of the threshing and separation section based on a combination of the current load and the straw quality sensor signal.

7. The method of claim 1, further comprising: receiving an unthreshed grain sensor signal from an unthreshed grain sensor; and adjusting the aggressiveness setting of the threshing and separation section based on a combination of the current load and the unthreshed grain sensor signal.

8. The method of claim 1, further comprising: determining that the current load is above an upper threshold, wherein the step of adjusting the aggressiveness setting of the threshing and separation section of the combine harvester comprises at least one of: reducing a rotational speed of at least one of a threshing drum, a beater, and a separation drum, and increasing at least one of (a) a threshing gap between the threshing drum and a cooperating threshing grate, and (b) a separation gap between the separation drum and a cooperating separation grate.

9. The method of claim 1, further comprising: determining that the current load is below a lower threshold, wherein the step of adjusting the aggressiveness setting of the threshing and separation section of the combine harvester comprises at least one of: increasing at least one of a rotational speed of a threshing drum, a beater, and a separation drum, and reducing at least one of (a) threshing gap between the threshing drum and a cooperating threshing grate, and (b) a separation gap between the separation drum and a cooperating separation grate.

10. The method of claim 1, further comprising: determining a first current load level; reducing the aggressiveness setting of the threshing and separation section; determining a second current load level; comparing the second current load level to the first current load level, and further reducing the aggressiveness setting of the threshing and separation section if the second current load level is substantially lower than the first current load level, and maintaining the aggressiveness setting of the threshing and separation section if the second current load level is substantially equal to the first current load level.

11. A system for controlling a combine harvester, the system comprising: a plurality of grain flow sensors configured for befog provided immediately underneath and adjacent to a crop transfer surface of a straw walker section of the combine harvester and for being distributed over a length of the straw walker section; and a controller operatively coupled to the plurality of grain flow sensors and thereby configured for receiving a plurality of grain flow sensor signals therefrom, the controller being further configured: to determine a current load on the straw walker section based on the plurality of grain flow sensor signals that have been received, and to provide, based on the current load, a control signal for adjusting an aggressiveness setting of a threshing and separation section of the combine harvester.

12. The system of claim 11, wherein the plurality of grain flow sensors comprise at least one of an impact sensor, a pressure sensor, and a light based sensor.

13. The system of claim 11, further comprising a straw quality sensor configured for being provided at least one of above and adjacent to a rear end of the straw walker section, the controller further being operatively coupled to the straw quality sensor for receiving a straw quality signal therefrom and being configured to adjust the aggressiveness setting of the threshing and separation section based on a combination of the current load and the straw quality sensor signal.

14. The system of claim 13, wherein the straw quality sensor comprises at least one of a camera, an ultrasound sensor, a laser sensor, and a radar sensor.

15. The system of claim 11, further comprising an unthreshed grain sensor, the controller further being operatively coupled to the unthreshed grain sensor and thereby being configured for receiving an unthreshed grain signal therefrom and being configured to adjust the aggressiveness setting of the threshing and separation section based on a combination of the current load and the unthreshed grain signal.

16. A combine harvester comprising: a threshing and separation section; a straw walker section including a crop transfer surface and a length; and a system for controlling the combine harvester, the system comprising: a plurality of grain flow sensors provided immediately underneath and adjacent to the crop transfer surface of the straw walker section of the combine harvester and being distributed over the length of the straw walker section; and a controller operatively coupled to the plurality of grain flow sensors and thereby configured for receiving a plurality of grain flow sensor signals therefrom, the controller being further configured: to determine a current load on the straw walker section based on the plurality of grain flow sensor signals that have been received, and to provide, based on the current load, a control signal for adjusting an aggressiveness netting of a threshing and separation section of the combine harvester.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] For the purpose of illustration, there are shown in the drawings certain embodiments of the present invention. It should be understood, however, that the invention is not limited to the precise arrangements, dimensions, and instruments shown. Like numerals indicate like elements throughout the drawings. In the drawings:

[0031] FIG. 1 shows a combine harvester in which the invention may be advantageously used;

[0032] FIG. 2 schematically shows a control scheme of the threshing and separation section of the combine harvester of FIG. 1;

[0033] FIG. 3 shows a top view of the straw walker section of the combine harvester of FIG. 1;

[0034] FIG. 4 shows a flow diagram of a possible control method according to the invention; and

[0035] FIG. 5 shows a flow diagram of a closed loop control process making use of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0036] FIG. 1 shows a combine harvester 10 in which the invention may be advantageously used. When harvesting crops, the harvester 10 travels in a forward direction indicated by the arrow A. Typically, a header 12 with a horizontal cutter bar for harvesting grain or a plurality of picking units for harvesting corn cuts the crop and moves it into the combine harvester 10 via an inlet opening of a feeder 14. The feeder 14 transports the harvested crop rearward to a threshing and separation section. In this exemplary combine harvester 10, the threshing and separation section includes a threshing drum 16, a beater 18 and a separation drum 20, all transversely placed on the combine harvester chassis. However, in other combine harvesters, the threshing and separation section may include more, less or different components.

[0037] The overall function of the threshing and separation section is to separate grain kernels from the ears of the harvested crop, to drop the separated grain kernels and part of the chaff onto a cleaning section 26 and to pass the remaining and large parts of the harvested crop, such as straw and threshed corn cobs, on to subsequent straw walker section 22. In relation to combine harvesters, all crop material other than grain is often referred to as MOG, i.e. material other than grain. Most of the MOG volume consists of straw and ears, but also chaff is considered MOG.

[0038] The reciprocating movement of the straw walker section 22 causes the crop material coming from the threshing and separation section to be moved further rearward. During the transport over the straw walker section 22, remaining grain kernels that have not been fully separated from the larger plant material yet, fall through openings in the crop transfer surface of the straw walker section 22 and are led to the cleaning section 26 too. All plant material reaching the rear end of the straw walker section 22 may be dropped on the floor in a swath behind the combine harvester 10 or is chopped by a straw chopper 30 before being spread over the field.

[0039] The cleaning section 26 typically includes one or more reciprocating sieves and a fan for blowing the chaff away while letting the grain kernels fall through openings in the sieves. After having made its way down through the sieves, the grain is collected and transported to a large grain tank 28 on top of the combine harvester 10. The chaff that is blown over the rear end of the sieves falls on the floor or is spread over that field by a chaff spreader (not shown). Any unthreshed ears that may have ended up on the sieve surfaces are heavier than the chaff and fall directly off the sieve end, allowing for them to be collected in and threshed by an unthreshed grain processor 24.

[0040] FIG. 2 schematically shows a control scheme of the threshing and separation section of the combine harvester of FIG. 1. It also shows the threshing and separation section, the straw walker section 22 and the unthreshed grain processor 24 in a slightly enlarged and more detailed view.

[0041] The threshing drum 16 typically consists of a rotating shaft or drum with a plurality of threshing slats at its outer circumferential surface. The threshing drum 16 operates in cooperation with a threshing grate 116 that is placed just under the threshing drum 16 to form a threshing gap therebetween. The harvested crop, coming from the feeder 14 is threshed between the threshing grate 116 and the rotating slats of the threshing drum 16. The aggressiveness of the threshing depends on the speed of rotation of the threshing drum 16, the size of the threshing gap and the shape, orientation and surface structure of the threshing slats and the threshing grate 116. All of these aspects may be controllable by suitable control mechanisms controlled by a central controller 110. For example, the aggressiveness of the threshing process can be increased by decreasing the threshing gap, increasing the rotational speed of the threshing drum 16 or increasing the aggressiveness of the threshing grate surface. The latter may be accompanied by a further opening of the threshing grate 116, thereby allowing more material to fall down through the threshing grate 116 onto the cleaning section 26.

[0042] The beater 18 is typically smaller than the threshing drum 16 and also rotates above a grate 118 that allows grain to fall through while pushing the general crop flow further in the direction of the separator 20. The beating elements at the outer circumference of the beater 18, may again be slats, but may take other forms. In addition to keeping the crop flowing, the beater 18 also functions to beat not yet completely threshed grain kernels out of their ears. Also the beater aggressiveness can be altered by adjusting its rotational speed, the gap towards the cooperating beater grate 118 and/or the shape and orientation of the beater grate 118 and the beating elements.

[0043] The separator drum 20 does typically not include slats, but uses separation fingers for raking through the grain-MOG mixture in order to separate the two and allow the grain to fall down through a separation grate 120, in the direction of the cleaning section 26. The aggressiveness of the separation section can also be adjusted by adjusting its rotational speed, the gap towards the cooperating separation grate 120 and/or the shape and orientation of the separation grate 120 and the separator fingers. The aggressiveness of the different parts of the threshing and separation section can be controlled separately or simultaneously and in mutual coordination.

[0044] FIG. 3 shows a top view of the straw walker section 22 of the combine harvester 10 of FIG. 1. The straw walker section 22 includes a number of straw walker modules 221-226 that are driven in a reciprocating motion in parallel with the driving direction and the longitudinal axis of the combine harvester 10. While the frequency of the reciprocating motion is usually the same for all modules 221-226, their phases may be different, which is visualized here by showing three of the modules 221, 223, 225 in a different longitudinal position than the other three modules 222, 224, 226. Each straw walker module 221-226 has a crop transfer surface 260 that carries the grain-MOG mixture that is received from the separator drum 20 and ‘walks’ it rearward to the back of the combine harvester 10. The reciprocating motion of the straw walker modules 221-226 causes the smaller heavier grain kernels to fall down through the grain-MOG mixture and through openings in the crop transfer surface 260. Gutters provided under the open crop transfer surface 260 collect the falling grain kernels and guide them back to the forward end of the straw walker section, where they are dropped onto the cleaning system 26.

[0045] According to the invention, a plurality of grain flow sensors 210 is provided underneath and adjacent to the crop transfer surface 260 of the straw walker modules 221-226. The grain flow sensors 210 are operatively coupled to the controller 110 for sending the grain flow sensor signals thereto. The grain flow sensors 210 are distributed over a length of the straw walker section 22 to enable obtaining a detailed grain flow pattern indicating how much grain is separated from the straw and other MOG at each location of the straw walker section 22.

[0046] Optionally, the grain flow sensors 210 are provided inside the gutters of the individual straw walker modules 221-226, just below the crop transfer surface. Optionally, the grain flow sensors 210 are located such that they can provide reliable measurements, without disturbing the flow of grain towards the cleaning section 26. The grain flow sensors 210 may, e.g., include an impact sensor, a pressure sensor and/or a light based sensor. The impact sensors may, e.g., be a piezo-electric plate based sensor or a detection rod, coupled to a torque sensor. Detection rods have the advantage that they are smaller and do not affect the grain flow as much as the larger plate based sensors do. Pressure sensors generally measure pressure differences between two points, which pressure differences provide information about the amount of crop material present at the location of the sensors. In addition to the pressure sensors positioned just underneath the crop transfer surface 260 of the straw walker modules 221-226, light sensors may be provided at corresponding longitudinal and/or transverse positions above the straw walker section 22. Light sensors may, e.g., use LED or laser based light emitters and corresponding receivers. Light may be emitted from the left hand side and/or the right-hand side of a straw walker module 221-226 and received by a corresponding receiver at the other side. Alternatively, the emitter and receiver are provided as an integrated unit and the light is reflected at the other side of the straw walker module 221-226 before it is detected by the receiver. A ratio of the emitted and the received light can be used as a measure for the amount of grain flowing through the crop transfer surface 260.

[0047] In addition to the grain flow sensors 210, a straw quality sensor may be provided above and/or adjacent to a rear end of the straw walker section 22. The straw quality sensor may, e.g., include a camera 251, 252, an ultrasound sensor, a laser sensor and/or a radar sensor. The camera 251, 252 may use visible and/or infrared light. Depending on the technology that is used, the best results may be obtained by sensors that are provided inside the combine harvester 10, above the straw walkers, or by sensors monitoring the straw as it leaves the combine harvester 10 and is dropped onto the field. Of course, combinations of different types of sensors may be used for even more reliable measurements.

[0048] The controller 110 is operatively coupled to the straw quality sensor for receiving a straw quality signal therefrom and configured to adjust the aggressiveness setting of the threshing and separation section based on a combination of the current load and the straw quality sensor signal. Using information about the straw quality may be advantageous, because it allows the system to provide an optimal balance between aggressive threshing and separation to release all grain kernels from the crop and gentler threshing and separation to maintain straw quality.

[0049] In some embodiments, also an unthreshed grain sensor 240 may be provided and coupled to the controller 110. An unthreshed grain signal may then be used for adjusting the aggressiveness setting of the threshing and separation section based on a combination of the current load and the unthreshed grain signal. High amounts of unthreshed grain indicate that the threshing process may have to be more aggressive in order to make sure that no grain is unnecessarily lost. The unthreshed grain sensor 240 may, e.g., measure a volume or weight of the material going through the unthreshed grain processor directly. Alternatively, the amount of unthreshed grain is measured indirectly by measuring a physical load on the unthreshed grain processor 24.

[0050] FIG. 4 shows a flow diagram of a possible control method according to the invention. This method is controlled by the controller 110 of the control system 100 of FIG. 2. It uses sensor readings from the grain flow sensors 210, the straw quality sensors 251, 252 and the unthreshed grain sensor 240 as input and based thereon determines control signals for the threshing and separation section.

[0051] The control method starts with an input step 401 for receiving grain flow sensor signals from a plurality of grain flow sensors 210. Based on the received grain flow sensor signals, the controller 110 determines a current load on the straw walker section 22 in load determination step 402. The current load is then used as input for determining if the aggressiveness of the threshing and separation section is to be adjusted, and if so to what extent, in an aggressiveness calculation step 403. Then in actuation step 404, an aggressiveness setting of the threshing and separation section of the combine harvester 10 may be adjusted. When the adjustments have been made, the controller 110 optionally returns to the input step 401 and continues monitoring and processing the incoming grain flow sensor signals.

[0052] In addition to the grain flow sensor signals, the controller 110, in input step 401, may also receive straw quality signals. Although the straw walker load is already a good measure for straw quality, additional more direct measurements of straw quality may further improve the accuracy and reliability of the control method. When the optimal aggressiveness setting is determined in step 403, the additional straw quality signals may be used for finding an even better balance between preventing grain loss and maximizing straw quality.

[0053] With the method illustrated by the flow diagram of FIG. 4, it is possible to monitor the straw walker load continuously and to adjust the threshing and separation settings before actual grain losses occur. It is further possible to strike an optimal balance between lowering straw walker load, improving straw quality and avoiding grain loss. The load determination step 402 may include determining a grain flow profile, representing a variation of the grain flow sensor signals along the length of the straw walker section 22. Alternatively, control decisions are made based on, e.g., absolute grain flow values at different locations along the length of the straw walkers and/or based on ratios of grain flow values at different locations. Control decisions may also be based on detected sudden and/or undesired changes in any such values.

[0054] When the straw walker load level is low, the grain flow sensors 210 at the front of the straw walker section record a significant flow of grain through the crop transfer surface 260 of the straw walker modules 221-226. Most separation occurs in the front area of the straw walker section 22. While the straw is moved to the rear of the straw walker section 22, fewer and fewer grain kernels remain. Consequently, grain flow sensor signals from the rear grain flow sensors 210 will be significantly lower than those from the front of the straw walker section 22.

[0055] When straw walker load increases because the straw mat becomes denser, the grain flow sensor signals from the sensors 210 at the front go down. Since more grain kernels are carried further rearward, grain flow sensor signals at the rear may increase and the overall front-to-rear grain flow profile flattens. Because this flattening of the grain flow profile already occurs before the actual grain loss starts increasing, it is now possible to adapt the threshing and separation settings at an earlier stage, before it is too late. With the method according to the invention, it may even be possible to completely prevent the increase in grain loss.

[0056] As already described above, adjusting the aggressiveness setting may, e.g., include adjusting a rotational speed of a threshing drum 16, a beater 18 and/or a separation drum 20. Generally, faster drum rotation leads to more aggressive threshing and separation. Usually, the rotational speeds of the different drums are directly linked and controlled together. When the combine harvester allows for it, the rotational speeds of the different drums may be controlled independently. Alternatively or additionally, adjusting the aggressiveness setting may include adjusting a threshing gap between a threshing drum 16 and a cooperating threshing grate 116 and/or a separation gap between a separation drum 20 and a cooperating separation grate 120. The smaller the gaps, the more aggressive the threshing and/or separation process.

[0057] In addition to adjusting the aggressiveness setting of the threshing and separation section, also the separation performance of the straw walker section 22 can be adjusted, e.g. by adjusting the speed or the slope of the straw walkers. Such adjustments have already been used for compensating for variation in slope on hilly terrain, but can also be useful for adjusting to straw walker load variations that are not exclusively caused by changes in slope.

[0058] An advanced method for controlling a combine harvester 10 is schematically shown in FIG. 5. This method can be used for finding the right aggressiveness settings for optimizing straw quality without causing unnecessary grain loss. The closed loop control process shown there includes determining a first current straw walker load level (step 501), reducing the aggressiveness setting of the threshing and separation section 22 (step 502), determining a second current straw walker load level (step 503), and then comparing the second current load level to the first current load level (504). If the second current load level is substantially lower than the first current load level, the aggressiveness setting of the threshing and separation section is further reduced (back to step 502) and the monitoring is resumed or continued. If the second current load level is substantially equal to the first current load level, the optimal aggressiveness setting of the threshing and separation section is found and no further adaptations of the threshing and separation section are needed.

[0059] This way, it is possible to find the most aggressive threshing and separation settings that still lead to a relatively low straw walker load and optimal straw quality. Since a further reduction of the threshing and separation aggressiveness will not further lower the straw walker load or increase the straw quality, there is no need to further adapt the threshing and separation process and run the risk of increased grain losses.

[0060] The method of FIG. 5 thus aims for minimal grain loss, without compromising on straw quality. In a similar way, the control method may be adapted to find the least aggressive threshing and separation setting that does not lead to an increase of grain loss. Such a method will lead to optimal straw quality, without compromising on grain loss.

[0061] These and other advantages of the present invention will be apparent to those skilled in the art from the foregoing specification. Accordingly, it is to be recognized by those skilled in the art that changes or modifications may be made to the above-described embodiments without departing from the broad inventive concepts of the invention. It is to be understood that this invention is not limited to the particular embodiments described herein, but is intended to include all changes and modifications that are within the scope and spirit of the invention.