Patent Application
20240292780
The present disclosure generally relates to a harvesting machine, and more particularly to a system and method for adjusting the phasing of chopper blades for a sugarcane harvester.
Harvesters of various configurations, including sugarcane harvesters, have harvesting systems of various types. Harvesting systems for a sugarcane harvester, for example, include assemblies or devices for cutting, chopping, sorting, transporting, and otherwise gathering and processing sugarcane plants. Typical harvesting assemblies, in different implementations, include a base cutter assembly (or “base cutter”), feed rollers, and cutting drums, also known as choppers.
To actively harvest crops, the sugarcane harvester gathers and processes material from rows of sugarcane plants. In the case of one type of sugarcane harvester, the gathered sugarcane stalks are cut into billets that move through a loading elevator to an elevator discharge, where the cut sugarcane billets are expelled to a collector, such as the sugarcane wagon. Leaves, trash, and other debris are separated from the billets and ejected onto the field.
In various harvesters, harvesting assemblies are hydraulically powered by an engine-driven pump or electrically powered by a generator or other electrical power supply. The harvesting assemblies include feed rollers that move the cut stalks towards two rotating drums of a chopper system. The rotating drums each include a plurality of blades. As the rotating drums rotate in opposite directions, the blades interact to cut the harvested sugarcane stalks into longitudinal segments called “billets.”
Corresponding blades of the rotating drums cooperate to compressively cut the stalk into billets. The angular position of one drum may be adjusted relative to the other drum to adjust the timing of operation of the rotating drums (e.g., each drum can be manually angularly adjusted).
In one implementation, there is provided a chopping system for a crop harvester including a first chopper having a first axis of rotation, wherein the first chopper includes a plurality of first blades extending from the first axis of rotation. A second chopper includes a second axis of rotation, wherein the second chopper includes a plurality of second blades extending from a second axis of rotation. The first chopper and the second chopper rotate about their respective axes of rotation to cooperatively cut sugarcane stalk into billets. A motor is operatively connected to the first chopper and to the second chopper, wherein the motor rotates the first chopper and rotates the second chopper. A chopper timing actuator is configured to continuously adjust an interference between a first blade of the plurality of first blades with respect to a second blade of the plurality of second blades, wherein the continuous adjustment maintains the interference between the first blade and the second blade as the first chopper and the second chopper cut the sugarcane stalk into billets.
In some implementations the chopping system further includes a chopper speed sensor located at the first chopper, wherein the chopper speed sensor identifies a change in a rotational speed of the first chopper as the first chopper and the second chopper cut the sugarcane stalk into billets.
In some implementations the chopping system further includes a controller operatively connected to the chopper speed sensor and to the chopper timing actuator, wherein the controller transmits a chopper timing signal to adjust the chopper timing actuator in response to the identified rotational speed of the first chopper.
In some implementations the chopping system further includes an electric motor operatively connected to the controller and to the chopper timing actuator, wherein the chopper timing signal is transmitted to the electric motor to adjust the chopper timing actuator to maintain the interference between the first blade and the second blade.
In some implementations the chopping system further includes wherein the chopper speed sensor transmits a rotational speed signal of the identified rotational speed and wherein the rotational speed signal identifies a deceleration of the rotational speed of the first chopper during interference between the first blade and the second blade.
In some implementations the chopping system further includes wherein the deceleration identifies a time period during which the first blade contacts the second blade.
In some implementations the chopping system further includes wherein the controller compares the time period of deceleration with a threshold time period and in response to the comparison transmits the timing chopper signal to the electric motor.
In some implementations the chopping system further includes a crop feed flow sensor operatively connected to the controller, wherein the crop feed flow sensor identifies a flow of crop moving to the first and second chopper.
In some implementations the chopping system further includes wherein the controller adjusts the threshold time period based on the amount of flow of crop to adjust the timing chopper signal and based on the amount of crop flow and the deceleration.
In some implementations the chopping system further includes a hydraulic pressure supply sensor operatively connected to the controller, wherein the hydraulic pressure supply sensor identifies a hydraulic pressure of a hydraulic supply coupled to the motor.
In some implementations the chopping system further includes wherein the controller adjusts the threshold time period based on the hydraulic pressure to adjust the timing chopper signal based on the hydraulic pressure and the deceleration.
In another implementation there is provided a method of harvesting sugarcane from a sugarcane field using a sugarcane harvester. The method includes: cutting sugarcane from the sugarcane field; moving the cut sugarcane to a chopping system; chopping the cut sugarcane into billets with the chopping system having a first chopper having first blades and a second chopper having second blades, wherein the first chopper and the second chopper are coupled together by a gear train driven by a motor; and adjusting an angular displacement between the first chopper and the second chopper to increase an interference between a first blade of the first blades and a second blade of the second blades, wherein the interference between the first blade and the second blade is adjusted continuously while harvesting sugarcane.
In some implementations the method further includes identifying a reduction in motor speed of the motor for determining an amount of the interference between the first blade and the second blade.
In some implementations the method further includes wherein the identifying the reduction in motor speed includes sensing motor speed with a sensor transmitting a signal to a controller.
In some implementations the method further includes wherein the signal identifies a time period of interference between the first blade and the second blade.
In some implementations the method further includes comparing, with the controller, the time period of interference with a threshold and adjusting the angular displacement based on the comparison.
In a further implementation there is provided a sugarcane harvester to cut sugarcane from a sugarcane field. The harvester includes a feed system to move the cut sugarcane to a chopping system, wherein the chopping system include a first chopper having first chopper blades and a second chopper having second chopper blades. A gearset is operatively connected to the first chopper and to the second chopper. A motor is operatively connected to the gearset. A sensor is operatively connected to the chopping system, wherein the sensor generates a speed signal to identify a rotational speed of one of the motor, the first chopper, or the second chopper. A controller is operatively connected to the sensor, wherein the controller receives the speed signal and compares the speed signal to a threshold. A chopper timing actuator is operatively coupled to the gearset, wherein the controller continuously controls the chopper timing actuator to adjust an angular displacement between the first chopper and the second chopper based on the comparison of the speed signal to the threshold.
In some implementations the sugarcane harvester further includes wherein the speed signal identifies a deceleration of the rotational speed of the first chopper during an interference between a first blade of the first chopper and a second blade of the second chopper.
In some implementations the sugarcane harvester further includes wherein the deceleration identifies a time period during which the first blade interferes with the second blade.
In some implementations the sugarcane harvester further includes wherein the controller compares the time period of deceleration with a threshold time period and in response to the comparison transmits a timing chopper signal to the electric motor.
The above-mentioned aspects of the present disclosure and the manner of obtaining them will become more apparent and the disclosure itself will be better understood by reference to the following description of the implementations of the disclosure, taken in conjunction with the accompanying drawings, wherein:
For the purposes of promoting an understanding of the principles of the novel disclosure, reference will now be made to the implementations described herein and illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the novel disclosure is thereby intended, such alterations and further modifications in the illustrated devices and methods, and such further applications of the principles of the novel disclosure as illustrated therein being contemplated as would normally occur to one skilled in the art to which the novel disclosure relates.
Referring to
The chopping system 20 is configured to receive the mat from the feed system 18 and to cut the crop stalk into billets. The primary extractor 22 is positioned downstream from the chopping system 20 and is configured to separate crop residue (e.g., leafy material) from the billets and expel the crop residue from the crop harvester 10. The elevator 24 is positioned at the rear of the machine to receive the cleaned flow of billets and is configured to convey the billets to an elevated position where they are discharged into a bin or container to be hauled away. The secondary extractor 26 is positioned near the top of the elevator 24 and is configured to further separate crop residue from the billets and to remove the crop residue from the crop harvester 10. Terms such as left and right are relative to a central fore-aft axis 30 of the harvester 10.
The harvester 10 comprises an operator's station 29, i.e. cab, and traction elements 31. A human operator can operate the harvester 10 from the operator's station 29. The traction elements 31 are positioned on the left and right sides of the harvester 10 for engaging the ground 33 and propelling the harvester 10. Each traction element 31 may be, for example, a track unit or a ground-engaging wheel (e.g., one track unit on each side of the harvester 10 as shown with respect to the right side in
Referring to
The first and second choppers 32 and 36 are configured to rotate about their respective axes of rotation 34, 38 to cooperatively cut crop stalk into billets. As the choppers 32 and 36 rotate, corresponding blades 42 of the choppers 32 blades 46 of chopper 36 cooperate to compressively cut the crop stalk into billets.
As seen in
The chopping system 20 includes the following two purposes: 1) chopping stalk into billets; and 2) aiding in cleaning and feeding of the billets for later use. The chopper system functions with rotating drums 40 and 44 each having an equal number of blades 42, 46 affixed to the respective drums and extending from the drum's axis of rotation. One blade tip of one blade from a first drum hits a flat part of another blade on a second drum as the choppers rotate. In one implementation, one chopper is provided with motive power by the motor 52 and the motive power is transferred to the second chopper by gears resulting in identical rotational speed that is phased relative to the other. In one implementation, a pair of gears of the same diameter are used. The phase between the rotating drums 40 and 44 controls how much interference each blade on one drum has with a blade on the other drum. The degree of interference when opposed blades make contact is described as the chopper timing.
The rotation of chopper 32 is timed with respect to the rotation of chopper 36 to ensure that the blades of chopper 32 contact the blades of chopper 36 and to provide an interference between opposing blades of different drums. To reach a predetermined interference for acceptable billet production, an angular displacement between chopper 32 and chopper 36 is adjusted, if necessary, to establish the phase between drums and to achieve the predetermined interference. By adjusting the interference between blades, the cutting of billets by the chopping system 20 is improved. Chopper timing between chopper 32 and chopper 36 is determined, in one implementation, by monitoring the rotational speed of the chopper motor 52, which in turn determines the rotational speed of both chopper 32 and chopper 36. The chopper motor 52 is selected to have sufficient power to drive each of the chopper drums 40 and 44 to cut billets. As is understood by one skilled in the art, the chopper motor 52 is selected to meet the power requirements of the system. By selection of the proper motor, interference of the chopper blades primarily affects rotational speed of the drums 40 and 44 more than any other factors, such as crop characteristics or the flow of crop.
In one implementation, to identify an occurrence blade interference, the rotational speed of one of or both of the choppers 32 and 36 is monitored in real time by a chopper controller 60 of
As the chopper blades interfere, the rotational speeds of the choppers 32 and 36 decrease in response to the interference of each pair of opposed blades. The interference also reduces the rotational speed of the motor 52 experienced under the increased load. In one implementation, a time period identified during the reduction in rotational speed, the time of interference is quantified. Using the measured time period, an angular displacement, i.e. the phase, between choppers 32 and 36 is adjusted, if necessary.
In another implementation, the rate of change for transitions between blade contact and no blade contact are used to identify the chopper blade interference. As the blades begin to interfere, i.e., swiping, the rotational speed of the drums sharply decelerates during blade contact, and then accelerate once swiping has ended. Every time the blades initially contact each other, i.e., a swipe, the rotational speed of the drums slows and the intensity of the signal identifying contact, i.e. signal pulses, suddenly increases. As blade contact diminishes, the intensity of the signal identifying contact is reduced. Since the load on the motor is reduced as blades become disengaged, the rotational speed of the drums speeds up. During this transition from blade contact to no blade contact, the intensity of the signal pulses, which initially increase, now decrease at a rate of change that is less than a rate of change for the increase. The rate of change of the signal, therefore, is used to identify duration of blade contact.
An identification of the rate of change in the signal at the point of blade contact and after is monitored and is used to adjust the angular displacement of the drums. Consequently, not only does the “time period” of each blade contact exceed some time period of blade noncontact, the intensity of blade contact and its rate of change exceeds a known intensity of level of blade noncontact every time a blade swipes. In one or more implementations, identification of time periods is used to adjust angular displacement, identification of rates of change is used to adjust angular displacements, or both are used in combination to adjust angular displacements. In other implementations, the system identifies one of a duration of a change in rotational speed of the drums, an acceleration in the rotational speed of the drums, or a deceleration in the rotational speed of the drums.
As seen in
While a motor sensor 66 is described to identify a slowing of the rotational speed of the motor 52 and to identify blade interference, other implementations include the use of other types of sensors to determine blade interference. For instance, in one implementation, a speed sensor is located at the gearset 54 to identify a rotational speed of a gear in the gearset, whose rotational speed is reduced during blade interference. In another implementation, a speed sensor is coupled to one or both of the drums 40 or 44 to identify drum rotational speed. In this implementation, a hall effect sensor is used to identity drum speed which correlates to a reduction in motor speed, and therefore the period of time of interference. In another implementation, an optical sensor is used to identify rotational speeds of the chopper 32 or chopper 36 or to identify a rotational speed of a gear in the gearset 54. In a further implementation, the motor 52 is a hydraulic motor driven by a hydraulic fluid supply 84. In this implementation, the hydraulic pressure supply sensor 70 identifies a change in the pressure of hydraulic fluid. The hydraulic pressure supply sensor 70 transmit a signal to the controller 60 which is used to identify blade interference.
Once the chopper timing intensity is known in real time, the controller 60 transmits a signal to an electronic motor 86 that drives a chopper timing actuator 88. The actuator 88 mechanically adjusts the timing, if necessary, continuously over a selected period of time, such as during a harvesting operation, by adjusting the angular displacement between the chopper 32 and the chopper 36.
Other onboard sensors are used in these and other implementations for sensor fusion to prevent false detection of timing in instances where the identification of blade interference is affected and results in an overload of the chopper. For instance, under some circumstances the crop mat being fed to the chopper system 20 becomes larger than average and affects the rotation of the chopper 32 or the chopper 36. The larger crop mat is detected by the crop feed flow sensor 27. In this implementation, the signal 76 is affected by the larger crop mat due to the increase of load experience by the motor 52. Other events can also affect the load experienced by the motor. In these instances, the motor sensor 60 indicates a slowing down of the rotational speed of the motor not resulting from blade interference. To identify, the actual blade interference, the crop feed flow sensor 27 transmits a signal to the controller 60 indicating that a larger amount of crop is being fed to the chopper system 20. Such a slowing down of the motor in this case, however, would be more continuous over a longer period of time during complete rotations of the choppers and would be identified at time other the times of blade interference. In this implementation, the controller 60 compares the slowing down of the motor to a predetermined or known reduction in motor speed, e.g. revolutions per minute (RPM) resulting from crop flow to identify the time of blade interference.
In one or more implementations, the controller 60 adjusts the timing between opposing blades using different control methods such as a closed loop control based on the measured timing as well as feed forward control based on influencers of the chopper timing, such as the crop feed flow sensor 27.
Once the comparison is made by the controller 60, the controller 60 determines whether the identified chopper timing is greater than or less than the threshold at block 104. If the chopper timing is greater than the threshold, the blade interference is insufficiently short to effectively cut the sugarcane stock into billets. If the controller determines that the chopper timing is greater than the threshold, then the chopper timing actuator is actuated at block 106 to adjust the angular displacement of the choppers. If however, the controller determines that the chopper timing is not greater than the threshold, the process returns to start block 92 to continue the process of determining whether the angular displacement of the choppers requires adjustment through the harvest.
In one implementation, the adjustment of the angular displacement between blades is made while the drums are not rotating by using a clutch which disengages the drums. In this case, an actuator is used to make the adjustment. In other implementations, the angular displacement is adjusted continuously as the drum rotate using a continuously variable transmission arrangement.
While the disclosure has been illustrated and described in detail in the drawings and foregoing description, such illustration and description is to be considered as an example and not restrictive in character, it being understood that an illustrative implementation has been shown and described and that all changes and modifications that come within the spirit of the disclosure are desired to be protected. It will be noted that alternative implementations of the present disclosure may not include all of the features described yet still benefit from at least some of the advantages of such features. Those of ordinary skill in the art may readily devise their own implementations that incorporate one or more of the features of the present disclosure and fall within the spirit and scope of the appended claims.
While exemplary implementations incorporating the principles of the present disclosure have been described hereinabove, the present disclosure is not limited to the described implementations. Instead, this application is intended to cover any variations, uses, or adaptations of the disclosure using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this disclosure pertains and which fall within the limits of the appended claims.
This application claims priority to Provisional Patent Application Ser. No. 63/449,077, having the title “System to Adjust the Phasing of Chopper Blades for a Sugarcane Harvester” filed Mar. 1, 2023, the disclosure of which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63449077 | Mar 2023 | US |
