IMPACT SENSING SYSTEMS AND METHODS FOR AN AGRICULTURAL HEADER

An impact sensor system for a header of an agricultural system includes a first sensor vibrationally connected to a deck plate of the header, wherein the first sensor is configured to generate first signals in response to detection of vibrations due to initial contact between a crop and the deck plate of the header. The impact sensor system also includes a second sensor vibrationally connected to the deck plate of the header and positioned forward of the first sensor, wherein the second sensor is configured to generate second signals in response to detection of the vibrations due to the initial contact between the crop and the deck plate of the header.

BACKGROUND

The present disclosure generally relates to impact sensing on an agricultural header, and more particularly, to impact sensing systems and methods that detect a location of initial contact between a crop and an agricultural header.

A harvester may be used to harvest crops, such as barley, beans, beets, carrots, corn, cotton, flax, oats, potatoes, rye, soybeans, wheat, or other plant crops. The harvester may include or be coupled to a header, which may be designed to efficiently harvest certain types of crops. For example, a corn header may be designed to efficiently harvest corn. In particular, the corn header may include row units that include components that operate to separate ears of corn from stalks as the harvester travel through a field. Conveyors (e.g., augers) carry the ears of corn toward processing machinery and/or storage compartments of the harvester, while the stalks are deposited back into the field.

BRIEF DESCRIPTION

In certain embodiments, an impact sensor system for a header of an agricultural system includes a first sensor vibrationally connected to a deck plate of the header, wherein the first sensor is configured to generate first signals in response to detection of vibrations due to initial contact between a crop and the deck plate of the header. The impact sensor system also includes a second sensor vibrationally connected to the deck plate of the header and positioned forward of the first sensor, wherein the second sensor is configured to generate second signals in response to detection of the vibrations due to the initial contact between the crop and the deck plate of the header.

In certain embodiments, a header for an agricultural system includes multiple row units distributed across a width of the header. The header also includes a first sensor coupled to a first location of a deck plate of a row unit of the multiple row units, wherein the first sensor is configured to generate first signals in response to detection of vibrations due to initial contact between a crop and the deck plate of the header. The header also includes a second sensor coupled to a second location of the deck plate of the row unit of the multiple row units, wherein the second sensor is configured to generate second signals in response to detection of the vibrations due to the initial contact between the crop and the deck plate of the header, and the first location is rearward of the second location along a longitudinal axis of the deck plate of the header.

In certain embodiments, a method includes operating a header to harvest crops as the header travels through a field. The method also includes generating, via a first sensor coupled to a first location of a deck plate of the header, first signals indicative of vibrations due to an initial contact between a portion of the crops and the deck plate of the header. The method further includes generating, via a second sensor coupled to a second location of the deck plate of the header that is separated from the first location by a distance along a longitudinal axis, second signals indicative of the vibrations due to the initial contact between the portion of the crops and the deck plate of the header. The method further includes processing, via one or more processors, the first signals and the second signals to determine a contact location of the initial contact between the portion of the crops and the deck plate of the header.

DETAILED DESCRIPTION

The process of farming typically begins with planting seeds within a field. Over time, the seeds grow and eventually become harvestable crops. Typically, only a portion of each crop is commercially valuable, so each crop is harvested to separate the usable material from the remainder of the crop. For example, a harvester may include or be coupled to a header to harvest crops within the field. The header may be a corn header that is designed to efficiently harvest corn within the field. The corn header may include multiple row units across a width of the corn header, each row unit may include deck plates, stalk rollers, and/or other components that operate to separate ears of corn from stalks as the harvester travel through the field. Conveyors (e.g., augers) carry the ears of corn toward processing machinery and/or storage compartments of the harvester, while the stalks are deposited back into the field.

It is presently recognized that it is desirable to determine a location (e.g., an impact location) of initial contact between the ears of corn and the deck plates relative to a longitudinal axis of the header. Generally, for good harvesting performance, the ears of corn should make initial contact with the deck plates toward a forward portion of the deck plates relative to the longitudinal axis of the header (e.g., a forward half; forward of a midpoint of the deck plates along the longitudinal axis). This may enable the stalks to be completely discharged from the header before reaching a rear portion of the deck plates, thereby reducing a likelihood of the stalks being fed into the processing machinery and/or storage compartments of the harvester (and thus, reducing an amount of material other than grain [MOG] among the ears of corn).

Accordingly, present embodiment relate generally to an impact sensor system. The impact sensor system may include one or more sensors (e.g., knock sensors; vibration sensors) positioned on the header, and the one or more sensors are configured to generate signals (e.g., data) indicative of the location of the initial contact between the ears of corn and the deck plates. In some embodiments, the one or more sensors are coupled, directly or indirectly, to the deck plates. For example, the one or more sensors may be coupled directly to protrusions (e.g., extensions) of the deck plates. As another example, the one or more sensors may be coupled indirectly to the deck plates via brackets (e.g., extensions).

With the foregoing in mind,FIG.1is a side view of an embodiment of an agricultural system100, which may be a harvester. The agricultural system100includes a chassis102configured to support a header200(e.g., a corn header) and an agricultural crop processing system104. The header200is configured to separate a portion of crops (e.g., ears of corn) from stalks and to transport the portion of the crops toward an inlet106of the agricultural crop processing system104for further processing of the portion of the crops. The header200may also chop and/or return other portions of the crops (e.g., material other than grain [MOG], such as stalks) to a field.

The agricultural crop processing system104receives the portion of the crops from the header200and separates desired crop material from crop residue. For example, the agricultural crop processing system104may include a thresher108having a cylindrical threshing rotor that transports the portion of the crops in a helical flow path through the agricultural system100. In addition to transporting the portion of the crops, the thresher108may separate the desired crop material (e.g., grain) from the crop residue (e.g., husks), and may enable the desired crop material to flow into a cleaning system114(e.g., sieves) located beneath the thresher108. The cleaning system114may remove debris from the desired crop material and transport the desired crop material to a storage tank116within the agricultural system100. When the storage tank116is full, a tractor with a trailer may pull alongside the agricultural system100. The desired crop material collected in the storage tank116may be carried up by an elevator and dumped out of an unloader118into the trailer. The crop residue may be transported from the thresher108to a crop residue handling system110, which may process (e.g., chop/shred) and remove the crop residue from the agricultural system100via a crop residue spreading system112positioned at an aft end of the agricultural system100. To facilitate discussion, the header200may be described with reference to a lateral axis or direction140, a longitudinal axis or direction142, and a vertical axis or direction144. The agricultural system100and/or its components may also be described with reference to a direction of travel146.

In the illustrated embodiment, the agricultural system100may include one or more actuators configured to manipulate the spatial orientation and/or position of the header200with respect to the chassis102, and/or the spatial orientation of the header200with respect to the crop rows/ground/soil. A header height actuator226may drive the header200to move along the vertical direction144relative to the ground. The header200may be attached to the chassis102(e.g., via a linkage). The position of the header200may be manipulated by the header height actuator226to adjust the height of the header200. The agricultural system100may also include a header orientation actuator228. The header orientation actuator228may be configured to rotate the angular orientation of the header200(e.g., the entire header200or a portion thereof) relative to the ground. The actuators may be manipulated in response to one or more stimuli to adjust the agricultural system100to one or more environmental variables (e.g., soil condition, terrain, crop damage). As discussed herein, an impact sensor system may include one or more sensors (e.g., knock sensors; vibration sensors) on the header200, and the impact sensor system may receive and process signals generated by the one or more sensors to determine a location (e.g., impact location) of initial contact between the crop (e.g., ears of corn) and certain portions (e.g., deck plates) of the header200relative to the longitudinal axis142of the header200. In some embodiments, the actuators and/or other components of the header200may be manipulated based on the location of the initial contact.

FIG.2is a perspective view of an embodiment of the header200that may be employed within the agricultural system100ofFIG.1. In the illustrated embodiment, the header200is a corn header and includes multiple dividers202configured to separate rows of a crop (e.g., corn). The dividers202may be distributed across a width of the header200(e.g., along the lateral axis140). As the header200moves along a path, the dividers202may direct the crops from each row to one or more row units204. The row units204are configured to separate a portion of each crop (e.g., ear of corn) from a stalk of each crop, thereby separating the portion of each crop from the stalk and the soil. The portion of the crop may be directed toward one of a pair of conveyors206(e.g., augers) configured to convey the portion of the crop laterally inward to a center crop conveyor208at a center of the header200, and the center crop conveyor208directs the portion of the crop toward the inlet of the agricultural crop processing system. As illustrated, the conveyors206extend along a substantial portion of the width of the header200(e.g., along the lateral axis140). The conveyors206may be driven by a drive mechanism (e.g., electric motor, hydraulic motor). The row units204may also chop and/or return other portions of the crops (e.g., MOG, such as stalks) to the field.

FIG.3is a perspective front view of an embodiment of a portion of the header200. As shown, the portion of the header200includes the multiple dividers202that direct the crops to one or more row units204. Each row unit204includes various components that operate to separate desired crop material (e.g., the ears of corn) from the stalks, carry the desired crop material toward the conveyors206, and return the stalks to the field. For example, each row unit204may include a pair of stalk rollers210that are configured to grip the stalks and rotate in opposite directions to push the stalks toward the field (e.g., vertically downward; below the header200). Each row unit204also includes a pair of deck plates212that are positioned over the pair of stalk rollers210. Each deck plate212extends from a first end to a second end along the longitudinal axis142, and the pair of deck plates212are separated from one another along the lateral axis140to define a gap214. Further, each row unit204may include a pair of chains216(e.g., with lugs) that are configured to drive or push the desired crop material along the pair of deck plates212toward the conveyors206. The pair of deck plates212are spaced apart so that the gap214is sized to enable the stalks to pass through the gap214, but to block the desired crop material from falling through the gap214. Thus, the pair of stalk rollers210and the pair of deck plates212operate to separate the desired crop material from the stalks (e.g., the pair of stalk rollers210direct the stalks toward the field, while the desired crop material is blocked from falling through the gap214between the pair of deck plates212). As discussed in more detail herein, the pair of deck plates212are adjustable and may be driven (e.g., via an actuator) toward and away from one another along the lateral axis140to change a size of the gap214(e.g., a width of the gap214along the lateral axis140). A hood218is positioned rearward of each divider202and between adjacent row units204to cover various components, such as the actuator that drives the pair of deck plates212, linkages, sensors, and so forth.

As noted herein, for good harvesting performance, the crop (e.g., the desired crop material; the portion of the crop; ears of corn) should make initial contact with the pair of deck plates212toward a forward portion of the pair of deck plates212relative to the longitudinal axis142or the forward direction of travel146of the header200(e.g., a forward half; forward of a midpoint of the pair of deck plates212along the longitudinal axis142; a target impact region). This may enable the stalks to be completely discharged from the header200before reaching a rear portion of the pair of deck plates212, thereby reducing a likelihood of the stalks being fed into the conveyors206. Accordingly, an impact sensor system may include one or more sensors (e.g., knock sensors; vibration sensors) on the header200, and the impact sensor system may receive and process signals generated by the one or more sensors to determine the location of the initial contact between the crop and the pair of deck plates212(e.g., along a length of the pair of deck plates212; between the first end and the second end of the pair of deck plates212).

Further, the impact sensor system may include a controller (e.g., electronic controller) that receives and processes the signals, determines the location of the initial contact, and then generates an appropriate output. In some embodiments, the appropriate output may include a visual alarm (e.g., presented via a display screen in a cab of the agricultural system; text message with an explanation and/or a recommended adjustment to the header200) and/or an audible alarm (e.g., presented via a speaker in the cab of the agricultural system). In some embodiments, the appropriate output may include control signals, such as control signals to the actuators to adjust the position and/or the spatial orientation of the header200and/or a rotation rate of the pair of stalk rollers210. For example, in response to the location of the initial contact being rearward of the target impact region of the pair of deck plates (e.g., for some percentage of the crops over some period of time, such as more than 10, 20, 30, 40, or 50 percent over 10, 20, or 30 seconds), the controller may instruct output of the visual alarm and/or the audible alarm, raise the header200relative to the chassis of the agricultural system and the ground, and/or reduce an angle between the header and the ground (e.g., rotate the header relative to the chassis of the agricultural system to lift a front end of the header relative to a rear end of the header). In some embodiments, the controller may provide the control signals to manipulate the actuators based on the location of the initial contact, but also accounting for other operational features (e.g., detected loose or flying kernels, detected stalks at the rear end of the pair of deck plates212) to essentially optimize (e.g., aim to optimize; increase production rates and/or yield of the crop) the harvesting operations. Further, the controller may provide the control signals in response to the respective locations of a particular number (e.g., a threshold number, such as a threshold number or percentage over a period of time, such as more than 10, 20, 30 percent or more over the period of time) of the respective initial contacts being rearward of the target impact region of the pair of deck plates (or across all of the pairs of deck plates on the header200). Further, the controller may provide the control signals in response to a combined impact location (e.g., an average or median of the respective locations of the initial contacts over some period of time) being outside of the target impact region. In this way, the controller may provide the alarms and/or the control signals in response to the signals indicating undesirable impact locations (e.g., outside of the target impact region), and the control signals are intended to adjust the header200to provide or to cause desirable impact locations (e.g., within the target impact region).

FIG.4is a perspective front view of an embodiment of a portion of the header200, with components removed to show the pair of deck plates212and associated components of one row unit204. As shown, the row unit204includes a row unit frame400, which may be coupled to the frame201of the header200. The row unit frame400may support the pair of stalk rollers210and the pair of deck plates212. As noted herein, the pair of deck plates212may be adjustable to move toward and away from one another along the lateral axis140to change the size of the gap214. The gap214is defined by respective laterally-inner edges401of the pair of deck plates212.

The pair of deck plate212includes a first deck plate220and a second deck plate222. The first deck plate220is associated with a first deck plate linkage402, a first rearward coupler404, and a first forward coupler406. Similarly, the second deck plate222is associated with a second deck plate linkage412, a second rearward coupler414, and a second forward coupler416. As shown, the first deck plate220includes a first rearward protrusion420(e.g., extension), a first intermediate protrusion422(e.g., extension), and a first forward protrusion424(e.g., extension). Further, the second deck plate222includes a second rearward protrusion430(e.g., extension), a second intermediate protrusion432(e.g., extension), and a second forward protrusions434(e.g., extension).

The row unit204may include or be associated with a row unit linkage436(e.g., an actuator), which is coupled to the rearward couplers404,414and is configured to move relative to the row unit frame400along the lateral axis140. Together, the row unit linkage436, the deck plate linkages402,412, and the couplers404,406,414,416may form a deck plate linkage assembly that is coupled to the first deck plate220and the second deck plate222to drive the first deck plate220and the second deck plate222toward and away from one another along the lateral axis140to change the size of the gap214.

One or more couplings are provided between the first deck plate220and the row unit frame400, and one or more couplings are provided between the second deck plate222and the row unit frame400. For example, as shown, the rearward couplers404,414are coupled to the row unit linkage436and the row unit frame400(e.g., rotatably coupled via respective pins and/or bushings). Additionally, the first rearward coupler404is coupled to the first rearward protrusion420of the first deck plate220and the first deck plate linkage402(e.g., rotatably coupled via respective pins and/or bushings). Further, the second rearward coupler414is coupled to the second rearward protrusion430of the second deck plate222and the second deck plate linkage412(e.g., rotatably coupled via respective pins and/or bushings). The forward couplers406,416are coupled to the row unit frame400(e.g., rotatably coupled via respective pins and/or bushings). Additionally, the first forward coupler406is coupled to the first intermediate protrusion422of the first deck plate220and the first deck plate linkage402(e.g., rotatably coupled via respective pins and/or bushings). Further, the second forward coupler416is coupled to the second intermediate protrusion432of the second deck plate222and the second deck plate linkage412(e.g., rotatably coupled via respective pins and/or bushings).

As shown, the first rearward protrusion420of the first deck plate220and the second rearward protrusion430of the second deck plate222are complementary to one another and offset from one another along the longitudinal axis142. Additionally, the first intermediate protrusion422of the first deck plate220and the second intermediate protrusion432of the second deck plate222are complementary to one another and offset from one another along the longitudinal axis142. This configuration enables the first rearward protrusion420to couple to one portion of the first rearward coupler404, and the second rearward protrusion430to couple to another portion of the second rearward coupler414. Similarly, this configuration enables the first intermediate protrusion422to couple to one portion of the first forward coupler406, and the second intermediate protrusion432to couple to another portion of the second forward coupler416. Accordingly, this configuration enables movement of the row unit linkage436in one direction along the lateral axis140to drive the first deck plate220and the second deck plate222toward one another to decrease the size of the gap214, as well as movement of the row unit linkage436is another direction along the lateral axis140to drive the first deck plate220and the second deck plate222away from one another to increase the size of the gap214.

The header200may include an impact sensor system440with one or more sensors configured to generate signals indicative of the location of the initial contact between the crop (e.g., the desired crop material; the portion of the crop; ears of corn) and the pair of deck plates212. The one or more sensors may be vibrationally connected to the first deck plate220and the second deck plate222(e.g., directly or indirectly connected to the first deck plate220and the second deck plate222in a manner that enables the one or more sensors to detect vibrations due to the initial contact). For example, as shown, the impact sensor system440may include a first sensor442(e.g., knock sensor; vibration sensor; rearward sensor) and a second sensor444(e.g., knock sensor; vibration sensor; forward sensor) coupled to the first deck plate220. In particular, the first sensor442is coupled to the first deck plate220at a first location of the first deck plate220(e.g., proximate a rearward edge of the first deck plate220relative to the direction of travel146; at a rearward portion of the first deck plate220, such as a rearward quarter of the first deck plate220or a rearward half of the first deck plate220including or not including the midpoint; rearward of the second sensor444) and the second sensor444is coupled to the first deck plate220at a second location of the first deck plate (e.g., proximate a forward edge of the first deck plate220relative to the direction of travel146; at a forward portion of the first deck plate220, such as a forward quarter of the first deck plate220or a forward half of the first deck plate220including or not including the midpoint; forward of the first sensor442). Thus, the first sensor442and the second sensor444are separated from one another by a distance446(e.g., along the longitudinal axis142). It should be appreciated that the first location and the second location may be any suitable locations along the first deck plate220(e.g., forward, rearward, intermediate or midline) that enable the first sensor442and the second sensor444to be separated from one another by the distance446(e.g., along the longitudinal axis142).

The first sensor442and the second sensor444detect vibrations, the first sensor442outputs first signals indicative of the vibrations detected by the first sensor442, and the second sensor444outputs second signals indicative of the vibrations detected by the second sensor444. The first signals and the second signals, taken together, indicate the location of the initial contact with the first deck plate220(and thus, the pair of deck plates212and the row unit204) along the longitudinal axis142. In particular, a controller (e.g., electronic controller) may receive and process the first signals and the second signals to determine the location of the initial contact of the crop on the first deck plate220.

InFIG.4, the first sensor442is supported on a first bracket450(e.g., extension; rearward bracket) that is coupled (e.g., via a fastener, such as a bolt and/or a weld) to the first deck plate220, such as to the first rearward protrusion420of the first deck plate220. The second sensor444is supported on a second bracket452(e.g., extension; forward bracket) that is coupled (e.g., via a fastener, such as a bolt and/or a weld) to the first deck plate220, such as to the first forward protrusion424of the first deck plate220. The first bracket450and the second bracket452may extend laterally from the first deck plate220. In particular, respective plate-contacting ends (e.g., first ends) are coupled to the first deck plate220and respective sensor-supporting ends (e.g., second ends) are laterally offset from the first deck plate220(e.g., positioned on a laterally opposite side of the first deck plate220of the edge401that defines the gap214). As shown, the respective sensor-supporting ends may be laterally offset from the row unit frame400and may position the first sensor442and the second sensor444outside of the row unit frame400of the row unit204(e.g., to be under a respective hood between adjacent row units204; in a respective space defined between adjacent row unit frames400of adjacent row units204along the lateral axis140). This position may protect the first sensor442and the second sensor444from debris (e.g., via the hood), make the first sensor442and the second sensor444accessible for maintenance operations (e.g., inspection, repair, replacement), provide sufficient space for wiring (e.g., electrical wiring) and/or mounting the first sensor442and the second sensor444, provide sufficient space for the linkage assembly, enable retrofitting of the first sensor442and the second sensor444to a variety of headers, and/or provide any of a variety of other advantages. It should be appreciated that the first sensor442and the second sensor444may be positioned at any location that protects the first sensor442and the second sensor444from direct impact of the crop. For example, the first sensor442and the second sensor444may be positioned at any location under the hood218or other cover/structure (e.g., surrounded or at least partially covered by the hood218or other cover/structure; blocked from the direct impact or contact with the crop).

As shown, the first bracket450is mounted (e.g., rigidly coupled) to the first rearward protrusion of the first deck plate220via a respective fastener460(e.g., bolt, weld), and the first rearward protrusion420of the first deck plate220is coupled (e.g., rotatably coupled) to the row unit frame400via a respective fastener461(e.g., bushing). In some embodiments, to facilitate isolation of the first sensor442(and possibly to some extent, the second sensor444) from vibrations of the header200itself (e.g., due to travel over ground; engine vibrations), the respective fastener461may be formed from a nylon material (e.g., nylon or composite including nylon; instead of a metal material, like at least some other fasteners and/or the pair of deck plates212of the row unit204). Indeed, any of the couplings (e.g., fasteners, pins, bushings) disclosed herein may be formed from a nylon material (e.g., nylon or composite include nylon) and/or any suitable non-metal material (e.g., plastic material, composite material). However, it should be appreciated that any of the couplings disclosed herein may be formed from a metal (e.g., metal or metal alloy) material. Additionally, as shown, the first bracket450may extend laterally over (e.g., bend; across; above relative to the vertical axis144) the first rearward coupler404.

The second bracket452may be mounted (e.g., rigidly coupled) to the first forward protrusion424of the first deck plate220via a respective fastener462(e.g., bolt, weld). The first forward protrusion424may not be mounted to the first deck plate220, and instead, this portion of the first deck plate220may be positioned over or on the row unit frame400to slide over or along the row unit frame400. In some embodiments, to facilitate isolation of the second sensor444(and possibly to some extent, the first sensor442) from vibrations of the header200itself (e.g., due to travel over ground; engine vibrations), a non-metal (e.g., plastic material, including polymer or polymer composite material; nylon material, such as nylon or composite including nylon) sheet may be positioned between the first forward protrusion424and the row unit frame400. Indeed, a non-metal sheet may be positioned at any location between the first deck plate220and the row unit frame400(e.g., along some or any portion of the first deck plate220).

The first sensor442may include a first sensor element464and a first housing466, and the second sensor444may include a second sensor element468and a second housing470. It should be appreciated that the first housing466may couple to the first bracket450and the second housing470may couple to the second bracket452via any suitable fastener (e.g., bolt, weld, adhesive) or combination of fasteners. It should also be appreciated that certain components may be integrally formed (e.g., one-piece construction). For example, the first bracket450and/or the second bracket452may be integrally formed with the first deck plate220(e.g., be part of the first deck plate220). That is, the first deck plate220may include a first protrusion or extension that extends in a same or similar configuration/location as the first bracket450and a second protrusion or extension that extends in a same or similar configuration/location as the second bracket452.

In some embodiments, the row unit204may include additional sensors, such as a third sensor472(e.g., knock sensor; vibration sensor; rearward sensor) and a fourth sensor474e.g., knock sensor; vibration sensor; forward sensor) coupled to the second deck plate222. The third sensor272is coupled to the second deck plate222at a first location of the second deck plate222(e.g., proximate a rearward edge of the second deck plate222relative to the direction of travel146; at a rearward portion of the second deck plate222, such as a rearward quarter of the second deck plate222or a rearward half of the second deck plate222including or not including the midpoint; rearward of the fourth sensor474) and the fourth sensor474is coupled to second deck plate222at a second location of the second deck plate222(e.g., proximate a forward edge of the second deck plate222relative to the direction of travel146; at a forward portion of the second deck plate222, such as a forward quarter of the second deck plate222or a forward half of the second deck plate222including or not including the midpoint; forward of the third sensor472). Thus, the third sensor472and the fourth sensor474are separated from one another by a distance476(e.g., along the longitudinal axis142). It should be appreciated that the first location and the second location may be any suitable locations along the second deck plate222(e.g., forward, rearward, intermediate or midline) that enable the third sensor472and the fourth sensor474to be separated from one another by the distance476(e.g., along the longitudinal axis142).

The third sensor472and the fourth sensor474detect vibrations, the third sensor472outputs third signals indicative of the vibrations detected by the third sensor472, and the fourth sensor474outputs fourth signals indicative of the vibrations detected by the fourth sensor474. The third signals and the fourth signals, taken together, indicate the location of the initial contact with the second deck plate222(and thus, the pair of deck plates212and the row unit204) along the longitudinal axis142. In particular, the controller may receive and process the third signals and the fourth signals to determine the location of the initial contact of the crop on the second deck plate222.

InFIG.4, the third sensor472is supported on a third bracket480(e.g., extension; rearward bracket) that is coupled (e.g., via a fastener, such as a bolt and/or a weld) to the second deck plate222, such as a position that is opposite the first bracket450(e.g., relative to the lateral axis140; aligned along the longitudinal axis142). The fourth sensor474is supported on a fourth bracket482(e.g., extension; forward bracket) that is coupled (e.g., via a fastener, such as a bolt and/or a weld) to the second deck plate222, such as to the second forward protrusion434of the second deck plate222. The fourth bracket482may be at a position that is opposite the second bracket452(e.g., relative to the lateral axis140; aligned along the longitudinal axis142). The third bracket480and the fourth bracket482may extend laterally from the second deck plate222. In particular, respective plate-contacting ends (e.g., first ends) are coupled to the second deck plate222and respective sensor-supporting ends (e.g., second ends) are laterally offset from the second deck plate222. As shown, the respective sensor-supporting ends may be laterally offset from the row unit frame400and may position the third sensor472and the fourth sensor474outside of the row unit frame400of the row unit204(e.g., to be under a respective hood between adjacent row units204; in a respective space defined between adjacent row unit frames400of adjacent row units204along the lateral axis140).

As shown, the third bracket480is mounted (e.g., rigidly coupled) to the second deck plate222via a respective fastener486(e.g., bolt, weld), and the second rearward protrusion430of the second deck plate222is coupled (e.g., rotatably coupled) to the row unit frame400via a respective fastener487(e.g., bushing). The third bracket480may extend laterally over (e.g., bend; across; above relative to the vertical axis144) the second rearward coupler414. In some embodiments, to facilitate isolation of the third sensor472(and possibly to some extent, the fourth sensor474) from vibrations of the header200itself (e.g., due to travel over ground; engine vibrations), the respective fastener487may be formed from a nylon material (e.g., nylon or composite including nylon). Indeed, any of the couplings (e.g., fasteners, pins, bushings) disclosed herein may be formed from a nylon material (e.g., nylon or composite including nylon) and/or any suitable non-metal material (e.g., plastic material, composite material). However, it should be appreciated that any of the couplings disclosed herein may be formed from a metal (e.g., metal or metal alloy) material. The fourth bracket482may be mounted to the second forward protrusion434of the second deck plate222via a respective fastener488(e.g., bolt, weld).

The second forward protrusion434may not be mounted to the row unit frame400, and instead, this portion of the second deck plate222may be positioned over or on the row unit frame400to slide over or along the row unit frame400. In some embodiments, to facilitate isolation of the fourth sensor474(and possibly to some extent, the third sensor472) from vibrations of the header200itself (e.g., due to travel over ground; engine vibrations), a non-metal (e.g., plastic material, including polymer or polymer composite material; nylon material, such as nylon or composite including nylon) sheet may be positioned between the second forward protrusion434and the row unit frame400. Indeed, a non-metal sheet may be positioned at any location between the second deck plate222and the row unit frame400(e.g., along some or any portion of the second deck plate222). As noted herein, it should be appreciated that any of the fasteners and/or contact points between the row unit frame400and the pair of deck plates212(e.g., including within the linkage assembly) may be formed from (e.g., include) a non-metal component (e.g., plastic material; nylon material). However, it should be appreciated that any of the couplings disclosed herein may be formed from a metal (e.g., metal or metal alloy) material.

The third sensor472may include a third sensor element490and a third housing492, and the fourth sensor474may include a fourth sensor element494and a fourth housing496. It should be appreciated that the third housing492may couple to the third bracket480and the fourth housing496may couple to the fourth bracket482via any suitable fastener (e.g., bolt, weld, adhesive) or combination of fasteners. It should also be appreciated that certain components may be integrally formed (e.g., one-piece construction). For example, the third bracket480and/or the fourth bracket482may be integrally formed with the second deck plate222(e.g., be part of the second deck plate222). That is, the second deck plate222may include a third protrusion or extension that extends in a same or similar configuration/location as the third bracket480and a fourth protrusion or extension that extends in a same or similar configuration/location as the fourth bracket482. As noted herein, the one or more sensors may be vibrationally connected to the pair of deck plates212, such as via the brackets or even through contact with the row unit frame400(e.g., the one or more sensors are coupled to or mounted on the row unit frame400, and the pair of deck plates212rest on the row unit frame400so that vibrations from the initial contact on the pair of deck plates212travel from the pair of deck plates212to the one or more sensors through the row unit frame400).

Any of a variety of shapes and/or types of deck plates may be adapted for use with the impact sensor system disclosed herein. For example,FIG.5is a perspective side view of a deck plate500that may be utilized in the header ofFIG.2, in accordance with an embodiment of the present disclosure. As shown, the deck plate500may include a rearward protrusion502that is sized to support a first sensor504(e.g., knock sensor; vibration sensor; rearward sensor; the first sensor504is mounted directly to the rearward protrusion502via a fastener, such as a bolt, weld, and/or adhesive). Further, the deck plate500may include a forward protrusion506that is sized to support a second sensor508(e.g., knock sensor; vibration sensor; the second sensor508is mounted directly to the forward protrusion506via a fastener, such as a bolt, weld, and/or adhesive). Indeed, the first sensor504and the second sensor508may be positioned at any of a variety of locations along the deck plate500. The deck plate500may be include any features of the first deck plate shown and described with reference toFIG.4. The first sensor504and the second sensor508may include any features of the first sensor442and the second sensor444, respectively, shown and described with reference toFIG.4.

FIG.6is a schematic diagram of a portion of the header200with sensors, as well as exemplary graphs of signals generated by the sensors. In one embodiment, the portion of the header200includes the first deck plate220, and the sensors include the first sensor442and the second sensor444coupled (directly or indirectly) to the first deck plate220. During harvesting operations, the crop may strike and make initial contact with the first deck plate220at a location600(e.g., impact location). In response to the initial contact, the first sensor442and the second sensor444detect vibrations and generate respective signals based on the vibrations. For example, the first sensor442may generate a first signal shown in a first exemplary graph602, and the second sensor444may generate a second signal shown in a second exemplary graph604. Because the first sensor442is closer to the location600, a respective amplitude of a first peak606of the first signal due to the initial contact is greater than a respective amplitude of a second peak608of the second signal due to the initial contact. It should be appreciated that one of both of the respective amplitude and/or a respective time of travel may be analyzed to determine the location600.

As shown, the impact sensor system includes a controller610(e.g., electronic controller) with a processor612and a memory device614. The controller610is communicatively coupled to the first and second sensors442,444. The controller610receives and processes the signals (e.g., using one or more algorithms; based on a comparison of the first peak606to the second peak608) to determine the location600of the initial contact, and then the controller610generates an appropriate output. As noted herein, the appropriate output may include the visual alarm and/or the audible alarm. In some embodiments, the appropriate output may include control signals, such as control signals to the actuators to adjust the position and/or the spatial orientation of the header200and/or a rotation rate of the pair of stalk rollers. In some embodiments, the controller610may not provide the alarm(s) and/or the control signals for each occurrence of the location600being outside of a target impact region630, but instead may record or track each occurrence and trigger the alarm(s) and/or the control signals in response to some percentage of the crops over some period of time striking outside of the target impact region630, such as more than 10, 20, 30, 40, or 50 percent over 10, 20, or 30 seconds. Further, it should be appreciated that the controller610may also receive and account for other inputs (e.g., detected loose or flying kernels, detected stalks at the rear end of the pair of deck plates) to provide the alarm(s) and/or to automatically, dynamically provide the control signals (e.g., with an aim to optimize; increase production rates and/or yield of the crop) the harvesting operations. For example, in some embodiments, the controller610may not provide the alarm(s) and/or the control signals if the initial contact of the crop occurs outside of the target impact region630, but the other inputs indicate that the harvesting operations are proceeding appropriately (e.g., minimal loose or flying kernels and minimal detected stalks at the rear end of the pair of deck plates).

The processor612may be used to execute software, such as software for processing signals, controlling the agricultural system, and/or controlling the header200. Moreover, the processor612may include multiple microprocessors, one or more “general-purpose” microprocessors, one or more special-purpose microprocessors, and/or one or more application specific integrated circuits (ASICS), or some combination thereof. For example, the processor612may include one or more reduced instruction set (RISC) or complex instruction set (CISC) processors. The memory device614may include a volatile memory, such as random access memory (RAM), and/or a nonvolatile memory, such as read-only memory (ROM). The memory device614may store a variety of information and may be used for various purposes. For example, the memory device614may store processor-executable instructions (e.g., firmware or software) for the processor612to execute, such as instructions for processing signals, controlling the agricultural system, and/or controlling the header200. The processor612may include multiple processors and/or the memory device614may include multiple memory devices. The processor612and/or the memory device614, or the multiple processors and/or the multiple memory devices, may be located in any suitable portion of the agricultural system (e.g., a cab of the agricultural system and/or on the header200). Further, the controller610may be a distributed controller with the multiple processors and/or the multiple memory devices in separate housings or locations (e.g., in the agricultural system, in the header200, remote, in the cloud).

FIG.7is a flowchart of an embodiment of a method700for determining an impact location on a header, such as the header ofFIG.2. The method700may be performed via the controller disclosed herein, or another suitable device. Further, the method700may be performed differently in additional or alternative embodiments. For instance, additional steps may be performed with respect to the method700, and/or certain steps of the method700may be modified, removed, performed in a different order, or a combination thereof. The method700may be performed based on data received from the sensors ofFIGS.4-6and/or based on other types of data (e.g., detected loose or flying kernels, detected stalks at the rear end of the pair of deck plates212).

At block702, the controller may receive signals from one or more sensors coupled to (e.g., directly or indirectly) one or more deck plates of a row unit of a header. In some embodiments, the one or more sensors may include a first sensor (e.g., knock sensor; vibration sensor; rearward sensor) and a second sensor (e.g., knock sensor; vibration sensor; forward sensor) positioned at separate locations along a longitudinal axis of the header. During harvesting operations, the crop (e.g., the portion of the crop; the desirable crop material; ears of corn) may strike and make initial contact with the one or more deck plates at a location (e.g., impact location) along the one or more deck plates. In response to the initial contact, the first sensor and the second sensor detect vibrations and generate respective signals based on the vibrations.

At block704, the controller may process the signals to determine the location of initial contact between the crop and the one or more deck plates of the row unit of the header. If the first sensor is closer to the location, a respective amplitude of a first peak of a first signal generated by the first sensor due to the initial contact is greater than a respective amplitude of a second peak of a second signal generated by the second sensor due to the initial contact. The controller may process (e.g., using one or more algorithms) the first signal and the second signal (e.g., analyze respective amplitudes of the first peak and the second peak and/or respective time delays) to determine the location of the initial contact.

At block706, the controller may generate an appropriate output. In some embodiments, the appropriate output may include a visual alarm and/or an audible alarm. In some embodiments, the appropriate output may include control signals, such as control signals to the actuators to adjust the position and/or the spatial orientation of the header and/or a rotation rate of the pair of stalk rollers. For example, in response to the location of the initial contact being rearward of a target impact region of the one or more deck plates, the controller may instruct output of the visual alarm and/or the audible alarm, raise the header relative to the chassis of the agricultural system and the ground, and/or reduce an angle between the header and the ground. In some embodiments, the controller may provide the control signals to manipulate the actuators based on the location of the initial contact, but also accounting for other operational features (e.g., detected loose or flying kernels, detected stalks at the rear end of the one or more deck plates) to essentially optimize (e.g., aim to optimize; increase production rates and/or yield of the crop) the harvesting operations. The controller may repeat the method700as the agricultural system harvests crops in a field.

While only certain features of the disclosure have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the disclosure. It should be appreciated that features shown and described with reference toFIGS.1-7may be combined in any suitable manner. Additionally, while certain examples refer to sensors placed at rearward and forward locations, it should be appreciated that the rearward and forward locations may be general locations relative to a deck plate, relative to another sensor, or any other suitable placement that facilitates or enables techniques disclosed herein. Further, it should be appreciated that multiple additional sensors may be provided along the deck plate(s) (e.g., 3, 4, 5, 6 or more total sensors along the deck plate(s); distributed along the longitudinal axis142) to generate additional signals that may be processed and utilized to determine the location of the initial contact, as described herein.