Abstract:
Methods and systems are described for providing a local electrical power source at a header of a combine harvester. An alternator is mechanically coupled to a header backshaft. The header backshaft is mechanically coupled to a drive mechanism of the combine harvester to cause rotation of the header backshaft which, in turn, causes the alternator to generate electrical power. A power supply circuit transferred electrical power from the alternator to one or more electric devices mounted on the header. In some implementations, the header does not include any physical cables between the combine and the header.

Description:
BACKGROUND 
       [0001]    The present invention relates to electrical power systems for machines such as a combine harvester are coupled to a working element such as a header. 
       SUMMARY 
       [0002]    Combine harvesters are often coupled to a header that provides a working element. Mechanical power from the combine harvester is transferred to the header by rotating a backshaft. The rotation of the backshaft, in turn, drives the working element of the header. However, because the header is physically separate from the combine, any electrical power or data signals must be transferred to the header. In some implementations, this is done through a multi-pin coupling connector that may be secured by a harness. The harness, the connector, and the cable must be constructed to withstand the adverse operating environment of the combine harvester. As such, the connector cable might be manufactured of a high density material which, in turn, provides for a lower current capacity. Furthermore, the use of such a connector coupling limits customization, configuration, and growth of the combine header because the number of “pins” or data channels in the coupling cable is limited to a defined number (e.g., a 31-pin coupling). 
         [0003]    Various implementations described herein provide for increased intelligence, capability, and customizability of a header by providing an electrical power source on the header itself. In particular, an alternator mounted on the header converts mechanical power from the rotating backshaft into electrical power that can be used to power one or more electrical devices positions on the header. With a local power source on the header itself, a controller can be incorporated into the header that provides additional functions on the header itself that currently rely on power or control from the combine harvester. This electrical power source can be used, for example, to operate multiple lights positioned along the header, provide greater intelligence by powering microcontroller-based systems mounted on the header, and to operate electrical motors to control various functions of the header. A header controller that receives electrical power from the alternator can also be adapted to control the mechanical interface between the combine and the header and adjust a ground cutting height based on position feedback. 
         [0004]    In one embodiment, the invention provides an electrical power system for a header of a combine harvester. An alternator is mechanically coupled to a header backshaft. The header backshaft is mechanically coupled to a drive mechanism of the combine harvester to cause rotation of the header backshaft which, in turn, causes the alternator to generate electrical power. A power supply circuit transferred electrical power from the alternator to one or more electric devices mounted on the header. In some implementations, the header does not include any physical cables between the combine and the header. 
         [0005]    In another embodiment, the invention provides a method of providing power to an electric device mounted on a header of a combine harvester. A header backshaft, that is mechanically coupled to a drive mechanism of the combine harvester, is rotated by the drive mechanism. Electrical power is generated by an alternator positioned on the header and mechanically coupled to the header backshaft such that rotation of the header backshafter is converted to electrical power by the alternator. The electrical power generated by the alternator is then transferring to one or more electric devices mounted on the header using a power supply circuit. 
         [0006]    Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1A  is a side-view of a combine harvester equipped with a first header according to one embodiment. 
           [0008]      FIG. 1B  is a perspective view of a coupling between the header and the combine in the embodiment of  FIG. 1A . 
           [0009]      FIG. 2  is a block diagram of a power supply system for the header in the embodiment of  FIG. 1A . 
           [0010]      FIG. 3  is a front-view of a combine harvester equipped with a different header according to another embodiment. 
       
    
    
     DETAILED DESCRIPTION 
       [0011]    Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. 
         [0012]      FIG. 1A  illustrates a combine harvester  10  including a vehicle chassis or frame  14 , a feeder throat or feederhouse  18 , and a harvester header  22  for cutting and gathering crop plants (not shown). The frame  14  includes an operator cab  26  and traction elements  30  (e.g., wheels) for supporting and moving the vehicle frame  14  with respect to the ground. The frame  14  includes a first or forward end  38  and a second or rear end  42 , and a chassis axis or frame axis  46  extends between the forward end  38  and the rear end  42 . The feederhouse  18  is supported on the forward end  38  of the frame  14  and may be pivoted relative to the vehicle frame  14  by an actuator  50  (e.g., a fluid cylinder). 
         [0013]    The header  22  is supported by the feederhouse  18  and extends transversely to the frame  14 . As used herein, “transverse” generally refers to an orientation that is perpendicular to the frame axis  14  of the harvester  10  and that extends laterally-between a first side of the harvester  10  and a second side of the harvester  10 . 
         [0014]    In the illustrated embodiment, the header  22  is a draper including a cutting bar  54  and rotating drum  58 ; in other embodiments, the header  22  may include another type of implement depending on the type of crop to be harvested. After the crop is cut by the cutting bar  54  and gathered on the header  22 , it is moved along the feederhouse  18  by an elevator  62  (e.g., a conveyor) toward a threshing mechanism  70  supported on the frame  14 . 
         [0015]      FIG. 1B  shows the feederhouse  18  of the combine harvester  10  with the header  22  removed. As shown in  FIG. 1B , the feederhouse  18  is couplable to the header  22  by a backshaft  101 . The backshaft  101  is rotated by a mechanical drive mechanism of the combine harvester  10 . For example, in various implementations, the backshaft  101  may be coupled by a belt or drive chain to a combustion engine, a transmission, or one of the rotating traction elements (e.g., wheels) of the combine harvester  10 . A coupler  103  is also positioned on the feederhouse  18  and is coupled to the header  22  by a cable to for data communication and, in some implementations, to provide electrical power from the combine harvester  10  to the header  22 . 
         [0016]    However, in some implementations, the backshaft  101  of the header is coupled to an alternator mounted on the header  22  to generate electrical power from the rotation of the backshaft  101  and to provide a source of electrical power on the header  22  itself. As further illustrated in  FIG. 2 , the combine harvester  10  includes a combine mechanical drive element  201  and a main combine controller  203 . The mechanical drive  201  of the combine harvester  10  is mechanically coupled to the header backshaft  101 . In some implementations, the resulting rotation of the backshaft  101  drives the rotation of a header working element  207  such as, for example, the rotating drum  58  in the example of  FIG. 1A . The rotation of the backshaft  101  also transfers mechanical power through a gear box  209  to an alternator  211  mounted on the header  22 . As such, the alternator  211  generates electrical power from the rotation of the backshaft  101 . 
         [0017]    In some implementations, the operation of the alternator  211  is controlled by an alternator controller  213  which may include a processor and a non-transitory computer-readable memory. Electrical power from the alternator  211  is provided to one or more inventers (e.g., inverter  215  and inverter  217 ) which convert the AC power from the alternator  211  to DC power that can be utilized by one or more electric devices mounted on the header  22 . The operation of each inverter  215 ,  217  is controlled by an inverter controller  219 ,  221 , respectively. In some implementations, electrical power from the inverter  215  (or inverter  217  or both) is stored to a battery  222  positioned on the header  22 . Electrical power from the battery  222  can then be used to power the electric devices of the header  22  when the backshaft  101  is not rotating and can be used to smooth the power supplied to the electric devices to account for variations in electric power provided by the alternator (for example, due to varying speeds of the backshaft). 
         [0018]    The type of electric device mounted on the header  22  may vary in implementations. However, the example of  FIG. 2  includes one or more lights  223  mounted on the header  22 , one or more rotational electric motors  225 , and one or more linear electric motors  227 . The electric lights  223  can be positioned along the housing of the header  22  to improve the operator&#39;s view of the fields particularly during nighttime harvesting. In some implementations, the rotating drum  58  can be powered by an electric motor  225  and, as such, the system illustrated in  FIG. 2  can be used to retrofit a new electrically-powered rotating drum header  22  on a combine harvester  10  that is still configured with a backshaft  101  to transfer mechanical power. 
         [0019]      FIG. 3  illustrates an example of another type of header. In this example, the combine harvester  301  is equipped with a corn header  303 . This header  301  is wider and, in order to facilitate improved mobility and easier storage, the outer arms  305 ,  307  of the header  303  can be raised by a lift element  309 ,  311 , respectively, until they are positioned at 90-degree angles relative to the center portion of the header  303 . In some implementations, the lift elements  309 ,  311  include an electric motor  227  that is powered by an alternator  211  coupled to the backshaft  101 . 
         [0020]    Returning now to  FIG. 2 , in some implementations, the operation of one or more of the electric devices of the header  22  are controlled by a header controller  229 . The header controller  229  can be communicatively linked to the main combine controller  203  through the data coupling  103  positioned on the feederhouse  18 . As such, an operator sitting in the cab  26  can operate a user interface control (not pictures) positioned in the cab to, for example, turn on the header lights  223  or adjust the speed/operation of the rotation motor  225  or the linear motor  227 . In such cases, a signal from the user interface control is provided to the main combine controller  203  which relays a control instruction through the data coupling  103  to the header controller  229 . The header controller  229  then operates the electric device based on the received control instruction. 
         [0021]    It is noted that, although  FIG. 2  illustrates multiple controllers positioned on the header (e.g., an alternator controller  213 , a first inverter controller  219 , a second inverter controller  221 , and a header controller  229 ), other implementations may include more, fewer, or different controllers. For example, a header  22  may be equipped with only a single header controller  229  which receives control instructions from the main combine controller  203  and operates the alternator  211 , all inverters  215 ,  217 , and any electrical devices. 
         [0022]    Furthermore, although the examples illustrated above show a data coupling  103  that is physically mounted on the feederhouse of the combine and uses a cable to transfer data signals from the combine controller  203  to the header controller  229 , other data couplings may be used in other implementations. For example, because the header controller  229  and the electrical devices on the header have a power source on the header itself, in some implementations it is not necessary to include a coupling that is capable of providing any electrical power from the combine harvester to the header. As such, the data coupling  103 , in some implementations, may include a wireless transceiver for wireless receiving data signals and commands from the main combine controller  203 . In some such implementations, no physical electrical cables are provided to couple the combine harvester to the header. 
         [0023]    Finally, although the example of  FIG. 2  illustrates a single alternator  211  with two inverters  215 ,  217 , other configurations are possible. For example, the alternator  211  can include a 12V automotive alternator that can be used to provide electrical power to relatively low-power devices such as light-emitting diode (LED)-type header lights  223  and the one or more controllers of the header. In other implementations, such as the one illustrated in  FIG. 2 , the alternator  211  can include a dual-voltage alternator that is capable of providing up to 60V of power. Devices such as LED header lights  223  are powered at the lower voltage level while the higher voltage level is used to drive higher-power electrical system such as an electrical motor  225 / 227  driving a rotating drum, lifting the header, or folding the arms of the header (see, e.g.,  FIG. 3 ). 
         [0024]    Thus, the invention provides, among other things, a header power system that includes an alternator mechanically coupled to a backshaft to provide an electrical power source for electrical devices mounted on the header. Various features and advantages of the invention are set forth in the following claims.