Patent Application
20220142048
The present invention relates to a combine harvester and a method of controlling a combine harvester.
Combine harvesters, also commonly called ‘combines’, harvest grain from the field and separate the grain kernels from all the other material in the harvested crop. This other material is commonly named ‘material other than grain’ or MOG and includes, e.g., straw, leaves, ears and chaff. This separation involves different process stages. In a threshing step, the grain kernels are separated from the chaff and the plant. A consecutive separation stage further separates the straw and other larger parts in the grain-MOG mixture from the smaller grain kernels and the chaff. Then, a cleaning stage, typically including a blower for blowing away the light-weight chaff and a set of reciprocating sieves for letting through the heavier grain kernels, separates the grains from the chaff.
Threshing and separation stages come in different mechanical setups. In a conventional combine, the threshing is done by a rotating, transversely placed threshing drum. Underneath the threshing drum, a threshing concave, also called threshing grate, is provided at a short distance (the threshing gap) from the rotor. The threshing drum typically includes a number of transversely placed threshing slats that cooperate with the threshing concave to release the grain kernels from the crop. Similarly, a separation concave, also called separation grate, extends under and about a transversely placed separation drum, leaving a separation gap in between. Usually, separation fingers or other separation elements on the surface of the separation drum cooperate with the separation grate to further separate the grain kernels from the straw. In advanced combines, the threshing and separation stages may include one or more additional drums positioned in parallel with the threshing and separation drums. In a very simple conventional combine harvester, the separation drum may be dispensed with. It is noted that although all drums and grates in the threshing and separation stages may be optimized for their respective specific functions, threshing drums will typically also provide for separation and vice versa.
From the threshing and separation drums, the straw is passed on to the straw walkers. The reciprocating back and forth movement of the straw walkers moves the straw to the rear of the combine where it may be dropped onto the field in a swath or cut and dispersed by a shredder-spreader combination. The reciprocating movement of the straw walkers further causes the heavier grain kernels to fall down through the straw volume that is carried to the rear of the combine. The straw carrying top surface of the straw walkers is also a grate and allows grain kernels that have not yet fallen through the threshing and separation grates to fall down and be led to the cleaning stage of the machine. Because of the grain separation function of the straw walkers, the straw walker section may be considered to be a part of the separation section.
When harvesting at high capacity, the threshing and separation drums and the straw walkers have to process large amounts of crop at high speeds. In order to minimize the amount of grain kernels that remain unthreshed, combine harvesters operating at high capacity will typically use a more aggressive threshing and separation process. Threshing aggressiveness may also be adjusted in dependence to crop type and/or crop conditions. For example, greener and moister grain is harder to thresh than less green and dryer grain. A disadvantage of aggressive threshing is that it does not only lead to increased threshing and separation, but also to damaged straw. While damaged straw may be a problem in itself, when the straw is to be collected in bales and used for feeding cattle, it also increases the load on the straw walkers. Undamaged straw leads to a more airy and voluminous mat of straw on the straw walkers, making it easier for the grain kernels to fall through the straw volume. Aggressive threshing leads to more straw breakage and shorter straws. The shorter straw forms a denser straw mat through which makes it more difficult for the straw walkers to effectively separate the grain kernels from the straw. As a result, grains may leave the combine at the rear end and fall on the field.
In order to avoid such grain loss, it is known to place grain loss sensors at the rear end of the straw walkers. Such grain loss sensors are typically impact sensors that can detect grain kernels falling off the rear end of the straw walkers. When such grain loss is detected or exceeds some lower threshold, the combine harvester may slow down or threshing and separations settings may be adjusted to bring the grain loss back to an acceptable level. A disadvantage of this method of detecting grain loss is that the combine control system can only react when it is already too late and grain is being lost.
What is needed in the art is a solution to at least some of the problems mentioned above and it is against this background that the present invention has been developed.
The present invention provides a method of controlling a combine harvester including 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.
With the method according to the invention, it becomes 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.
It is noted that in the US patent application published as US 2003 199291 A1, a combine harvester with so-called ‘separation sensors’ positioned along the length of the straw walkers is already disclosed. However, the monitoring system described therein is not configured for monitoring the straw walker load. In US 2003 199291 A1, the same separation sensors are also provided under the threshing and separation drums and are only used to monitor the total amount of grain that falls onto the sieves of the cleaning stage and to calculate the total grain loss with a higher accuracy than was possible before. Because this document only provides an improved way of calculating grain loss, it is only capable of adjusting threshing and separation settings after the increased grain loss has been detected and does not allow to pre-emptively adjust the threshing and separation process in order to avoid grain loss.
Optionally, the determining of the current load includes determining a grain flow profile, representing a variation of the grain flow sensor signals along the length of the straw walker section. 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.
When the straw walker load level is low, the grain flow sensors at the front of the straw walker section will record a significant flow of grain through the crop transfer surface of the straw walkers. Most separation occurs in the front area of the straw walkers. While the straw is moved to the rear of the straw walkers, fewer and fewer grain kernels remain. Consequently, grain flow sensor signals from the rear grain flow sensors will be significantly lower than those from the front of the straw walker section.
When straw walker load increases because the straw mat becomes denser, the grain flow sensor signals from the sensors 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.
In the event that the grain flow profile indicates that the threshing and separating system is approaching its limits and grain loss can be expected to occur soon, additional measures may be taken to prevent grain loss. For example, the ground speed of the combine harvester may be reduced in order to lower the throughput and allow the threshing and separating system to process all incoming crop at a less than maximum aggressiveness level. Similar measures may be taken in the event of a sudden and large change to the grain flow profile.
Adjusting the aggressiveness setting may, e.g., include adjusting a rotational speed of a threshing drum, a beater and/or a separation drum. 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 and a cooperating threshing grate and/or a separation gap between a separation drum and a cooperating separation grate. The smaller the gaps, the more aggressive the threshing and/or separation process.
In addition to adjusting the aggressiveness setting of the threshing and separation section, also the separation performance of the straw walker section 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, according to the current invention, also be useful for adjusting to straw walker load variations that are not exclusively caused by changes in slope.
In an embodiment of the method for controlling a combine harvester according to the invention, a closed loop control process is used. The control process includes determining a first current load level, reducing the aggressiveness setting of the threshing and separation section, determining a second current load level, and then comparing the second current load level to the first current load level. 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 and the monitoring is resumed or continued. If the second current load level is substantially equal to the first current load level, the aggressiveness setting of the threshing and separation section is maintained. 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.
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.
According to another aspect of the invention, a system is provided for controlling a combine harvester. The system includes grain flow sensors provided underneath and adjacent to a crop transfer surface of a straw walker section of the combine harvester and a controller, operatively coupled to the grain flow sensors for receiving grain flow sensor signals therefrom. The grain flow sensors are distributed over a length of the straw walker section. The controller is configured perform the methods according to the invention.
Straw walkers usually include about five or six parallel straw walker modules, the reciprocating movement of neighboring modules being out of phase. Each module includes a grate-like crop transfer surface below which a gutter is provided for leading the grains back to the front of the combine harvester where it can be dropped onto the front portion of the cleaning section. Optionally, the grain flow sensors are provided inside the gutters and over the whole width of the straw walker section, i.e. in each one of the straw walker modules.
The grain flow sensors 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 don't 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 of the straw walkers, light sensors may be provided at corresponding longitudinal and/or transverse positions above the straw walker section.
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 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 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.
In addition to the grain flow sensors, a straw quality sensor may be provided above and/or 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. 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.
The straw quality sensor may, e.g., include a camera, an ultrasound sensor, a laser sensor and/or a radar sensor. The camera 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, above the straw walkers, or by sensors monitoring the straw as it leaves the combine and is dropped onto the field. Of course, combinations of different types of sensors may be used for even more reliable measurements.
In some embodiments, also an unthreshed grain sensor may be provided, the controller further being operatively coupled to the unthreshed grain sensor 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. 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.
According to a further aspect of the invention, a combine harvester is provided including a threshing and separation section, a straw walker section and one of the systems for controlling a combine harvester as described above.
It will be appreciated that optional features of the first aspect of the invention may be combined with the other aspects of the invention.
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:
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
With the method illustrated by the flow diagram of
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.
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.
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.
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.
An advanced method for controlling a combine harvester 10 is schematically shown in
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.
The method of
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.
| Number | Date | Country | Kind |
|---|---|---|---|
| 19165986.1 | Mar 2019 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2020/058110 | 3/24/2020 | WO | 00 |
