Abstract:
A gauge wheel load sensor for an agricultural planter having a row unit that includes a pivotably mounted gauge wheel and a down pressure controller for controlling the down pressure on at least a portion of the row unit. The load sensor includes a mechanical element mounted for movement in response to the downward force applied to the row unit; a fluid-containing device containing a movable element coupled to the mechanical element for changing the fluid pressure in response to the movement of the mechanical element; and a transducer coupled to the fluid-containing device for producing an output signal in response to changes in the fluid pressure. An energy storage device, such as an accumulator, may be coupled to the fluid-containing device for receiving a limited amount of fluid in response to changes in the fluid pressure to damp pressure spikes in the output signal of the transducer.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Application No. 62/085,334, filed Nov. 28, 2014; and U.S. Provisional Application No. 62/076,767, filed Nov. 7, 2014, each of which is hereby incorporated by reference herein in its entirety. 
    
    
     FIELD OF THE INVENTION 
     This invention relates generally to agricultural planters and, more particularly, to gauge wheel load sensors and down pressure control systems for agricultural planters. 
     BRIEF SUMMARY 
     In accordance with one embodiment, a gauge wheel load sensor is provided for an agricultural planter having a row unit that includes a pivotably mounted gauge wheel and a down pressure controller for controlling the down pressure on at least a portion of the row unit. The load sensor includes a mechanical element mounted for movement in response to the downward force applied to the row unit; a fluid-containing device containing a movable element coupled to the mechanical element for changing the fluid pressure in response to the movement of the mechanical element; and a transducer coupled to the fluid-containing device for producing an output signal in response to changes in the fluid pressure. 
     A modified embodiment includes an energy storage device coupled to the fluid-containing device for receiving a limited amount of fluid in response to changes in the fluid pressure to damp pressure spikes in the output signal of the transducer. In one implementation, the fluid-containing device is a hydraulic cylinder, the movable element is a piston in the cylinder, and the energy storage device is an accumulator receiving pressurized fluid from the fluid-containing device and containing a movable element responsive to the pressure of the fluid received from the fluid-containing device. 
     In accordance with another embodiment, an agricultural planter row unit comprises a pivotably mounted gauge wheel and a down pressure controller for controlling the elevation of the row unit; a pair of gauge wheel support arms mounted for pivoting movement independently of each other; a gauge wheel equalizer arm extending transversely across the support arms and mounted for pivoting movement about an axis extending in the direction of travel of the row unit; a pair of contact rollers mounted on opposite ends of the equalizer arm, each of the contact rollers engaging different ones of the support arms for pivoting the equalizer arm in response to the independent vertical movements of the support arms. In one implementation, the a rocker arm is coupled to the center of the equalizer arm and mounted for pivoting movement in response to changes in the elevation of the center of the equalizer arm. 
     In accordance with another embodiment, a gauge wheel load sensor is provided for an agricultural planter having a row unit that includes a pivotably mounted gauge wheel and a down pressure controller for controlling the down pressure on at least a portion of the row unit. The load sensor comprises the load sensor comprises a mechanical element mounted for movement in response to the downward force applied to the gauge wheel; a fluid-containing device containing a movable element coupled to the mechanical element for changing the fluid pressure in response to the movement of the mechanical element, and a transducer coupled to the fluid-containing device for producing an output signal in response to changes in the fluid pressure. The mechanical element is preferably a ram in a hydraulic cylinder containing pressurized fluid, and the ram is coupled to the gauge wheel so that the ram is moved within the cylinder in response to vertical movement of the gauge wheel. The ram may be coupled to the gauge wheel so that the ram is advanced within the cylinder to increase the fluid pressure only in response to a change in the down force on the gauge wheel. The load sensor may also include an accumulator coupled to the portion of the fluid-containing device where the fluid pressure increases in response to the movement of the mechanical element. The ram may be coupled to the gauge wheel so that the ram is moved within the cylinder in response to vertical movement of the gauge wheel, and which includes an accumulator coupled to the hydraulic cylinder for receiving a portion of the pressurized fluid. The accumulator preferably includes a ram in a cavity that receives the pressurized fluid, so that the accumulator damps changes in the pressure of the fluid in response to vibratory movement of the ram. 
     In accordance with a further embodiment, a gauge wheel load sensor is provided for an agricultural planter having a row unit that includes a pivotably mounted gauge wheel and a down pressure controller for controlling the down pressure on at least a portion of the row unit. The load sensor comprises a mechanical element mounted for movement in response to the downward force applied to the gauge wheel; a fluid-containing device containing a movable element coupled to the mechanical element for changing the fluid pressure in the device in response to the movement of the mechanical element; a transducer coupled to the fluid-containing device for producing an output signal in response to changes in the fluid pressure; and an energy storage device coupled to the fluid-containing device for receiving a limited amount of fluid in response to changes in the fluid pressure to damp pressure spikes in the output signal of the transducer. The fluid-containing device is preferably a hydraulic cylinder, and the movable element is a piston in the cylinder, and the energy storage device is preferably an accumulator receiving pressurized fluid from the fluid-containing device, the accumulator containing a movable element responsive to the pressure of the fluid received from the fluid-containing device. 
     Yet another embodiment provides an agricultural planter row unit comprising a pivotably mounted gauge wheel and a down pressure controller for controlling the elevation of the row unit; a pair of gauge wheel support arms mounted for pivoting movement independently of each other; a gauge wheel equalizer arm extending transversely across the support arms and mounted for pivoting movement about an axis extending in the direction of travel of the row unit, and a pair of contact rollers mounted on opposite ends of the equalizer arm, each of the contact rollers engaging different ones of the support arms for pivoting the equalizer arm in response to the independent vertical movements of the support arms. The row unit preferably includes a rocker arm coupled to the center of the equalizer arm and mounted for pivoting movement in response to changes in the elevation of the center of the equalizer arm. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a vertical longitudinal section through a portion of an agricultural planter that includes a gauge wheel and an opener device. 
         FIG. 2  is an enlargement of the left side of  FIG. 1 . 
         FIG. 3  is a bottom perspective of the control portion of the equipment shown in  FIG. 1 . 
         FIG. 4  is an enlarged side elevation of the equipment shown in  FIG. 3 . 
         FIG. 5  is an enlarged top plan view of the equipment shown in  FIG. 3 . 
         FIG. 6  is an enlarged vertical longitudinal section through the equipment shown in  FIG. 3 . 
         FIG. 7  is a schematic diagram of a hydraulic control system for controlling the hydraulic system using a gauge wheel load sensor. 
         FIG. 8  is a schematic diagram of a modified hydraulic control system for controlling the hydraulic system using a gauge wheel load sensor. 
         FIG. 9  is a waveform diagram illustrating different modes of operation provided by the hydraulic control systems of  FIGS. 7 and 8 . 
         FIG. 10  is a plan view of a gauge wheel transducer system for an agricultural planter that includes a gauge wheel and an opener device. 
         FIG. 11  is a side elevation of the transducer system shown in  FIG. 10 . 
         FIG. 12  is a sectional view taken along line A-A in  FIG. 10 . 
         FIG. 13  is a side elevation, partially in section, of the transducer system of  FIGS. 10-12  mounted on a gauge wheel and its supporting structure. 
         FIG. 14  is a perspective view of portions of the devices shown in  FIG. 13 . 
         FIG. 15  is a plan view similar to  FIG. 10  but with portions removed to show the equalizer arm. 
         FIG. 16  is a plan view of a modified transducer system. 
         FIG. 17  is a longitudinal section taken along line  17 - 17  in  FIG. 16 . 
         FIG. 18A  is a side elevation of a modified sensing system for detecting the pressure exerted on a pair of gauge wheels. 
         FIG. 18B  is an end elevation of the system shown in  FIG. 18A . 
         FIG. 19  is a schematic diagram of a hydraulic and electrical control system for controlling a down pressure actuator. 
         FIG. 20  is a schematic diagram of a first modified hydraulic and electrical control system for controlling a down pressure actuator. 
         FIG. 21  is a schematic diagram of a second modified hydraulic and electrical control system for controlling a down pressure actuator. 
         FIG. 22  is a schematic diagram of a third modified hydraulic and electrical control system for controlling a down pressure actuator. 
     
    
    
     DETAILED DESCRIPTION 
     An agricultural planter typically includes a number of individual row units, each of which includes its own row cleaner device, row opener device and row closing device. The down pressure is typically controlled separately for each row unit or each of several groups of row units, and is preferably controlled separately for one or more of the individual devices in each row unit, as described in more detail in pending U.S. application Ser. No. 14/146,822 filed Jan. 3, 2014, which is incorporated by reference herein in its entirety. 
       FIGS. 1-6  illustrate an improved gauge wheel load sensor that takes the upward force from a pivoting planter gauge wheel support, such as the pivoting support arms  10  in the row unit equipment shown in  FIGS. 1 and 2 , and translates that force into a fluid pressure in a fluid chamber  11 . The gauge wheel support arms push against an equalizer support  12 , which is connected via a pivot  13  with a rocker/cam  14 . The force on the gauge wheel due to the weight of the row unit and applied down force causes the rocker/cam  14  to pivot around a pivot bolt  15  and push against a hydraulic ram  16 . This force on the ram  16  causes the fluid in the chamber  11  to pressurize. The pressure is proportional to the amount of gauge wheel load. A pressure transducer  18  reads the amount of pressure and sends a signal to a row unit down pressure controller via signal line  19 . This signal allows the planter row unit down pressure to be controlled to a desired level. 
     Depth adjustment is accomplished in the conventional sense by pivoting the assembly around a pivot  20 , and locking a handle  21  into the desired position with a mechanism  22 . With this design it is preferred that that there is no air trapped in the fluid chamber  11 . For this reason the mechanism includes a bleed valve  23 . The process for removal of air is to extend the ram to the maximum extent with calibration/travel limiter plates  24  ( FIG. 4 ) removed. The system is then filled completely with fluid with the bleed valve  23  closed. Then the bleed valve  23  is opened, and the rocker arm  14  is pushed against the ram  16  to move the ram to the exact place where the calibration/travel limit plates  24  allow a calibration plate retaining screw  25  to fit into a hole. This ensures that each assembly is set the same so all the row units of the planter are at the same depth. At this point the bleed valve  23  is closed. With all air removed, the mechanical/fluid system will act as a rigid member against forces in compression. The travel limiter plate  24  keeps a cam pivot weldment from falling down when the planter is lifted off the ground. 
     Standard industry practice is to use a strain gauge to directly measure the planter gauge wheel load. The design shown in  FIGS. 1-6  is an improvement over the state of the art because it allows the sensor to measure only the down force on the gauge wheels. In typical designs using strain gauge type sensors, the mechanical linkage that allows the gauge wheels to oscillate causes the measured wheel force to have substantial noise due to changes in the force being applied. For this reason it can be difficult to determine which parts of the signal correspond to actual changes in down force on the gauge wheels, versus signal changes that are due to movement of components of the gauge wheel support mechanism. The reason for this is that strain gauge sensors will only measure the force that is being applied in a single plane. Because of the linkage and pivot assembly that is used on typical planters, the force being applied to the strain gauge type designs can change based on the depth setting or whether the planter gauge wheels are oscillating over terrain. In this way they will tend to falsely register changes in gauge wheel down force and make it difficult to have a closed loop down pressure response remain consistent. 
     The fluid seal of the pressure sensor described here creates friction in the system which has the effect of damping out high frequency noise. Agricultural fields have very small scale variations in the surface which cause noise to be produced in the typical down force sensor apparatus. By using fluid pressure this invention decouples the sensor from the mechanical linkage and allows the true gauge wheel force to be more accurately measured. Lowering the amount of systematic noise in the gauge wheel load output sensor makes it easier to produce an automatic control system that accurately responds to true changes in the hardness of the soil, as opposed to perceived changes in soil hardness due to noise induced on the sensor. 
       FIG. 7  is a schematic diagram of a hydraulic control system for any or all of the hydraulic actuators in a down pressure control system. The hydraulic cylinder  2600  is supplied with pressurized hydraulic fluid from a source  2601  via a first controllable two-position control valve  2602 , a restriction  2603  and a check valve  2604 . The pressurized hydraulic fluid supplied to the cylinder  2600  can be returned from the cylinder to a sump  2605  via a second controllable two-position control valve  2606 , a restriction  2607  and a check valve  2608 . Both the control valves  2602  and  2606  are normally closed, but can be opened by energizing respective actuators  2609  and  2610 , such as solenoids. Electrical signals for energizing the actuators  2609  and  2610  are supplied to the respective actuators via lines  2611  and  2612  from a controller  2613 , which in turn may be controlled by a central processor  2614 . The controller  2613  receives input signals from a plurality of sensors, which in the example of  FIG. 7  includes a pressure transducer  2615  coupled to the hydraulic cylinder  2600  via line  2616 , and a ground hardness sensor  2617 . An accumulator  2618  is also coupled to the hydraulic cylinder  2600 , and a relief valve  2619  connects the hydraulic cylinder  2600  to the sump  2605  in response to an increase in the pressure in the cylinder  2600  above a predetermined level. 
     To reduce the energy required from the limited energy source(s) available from the tractor or other propulsion device used to transport the row units over an agricultural field, the control valves  2602  and  2606  are preferably controlled with a pulse width modulation (PWM) control system implemented in the controller  2613 . The PWM control system supplies short-duration (e.g., in the range of 50 milliseconds to 2 seconds with orifice sizes in the range of 0.020 to 0.2 inch) pulses to the actuators  2609  and  2610  of the respective control valves  2602  and  2606  to open the respective valves for short intervals corresponding to the widths of the PWM pulses. This significantly reduces the energy required to increase or decrease the pressure in the hydraulic cylinder  2600 . The pressure on the exit side of the control valve is determined by the widths of the individual pulses and the number of pulses supplied to the control valves  2602  and  2606 . Thus, the pressure applied to the hydraulic cylinder  2622  may be controlled by separately adjusting the two control valves  2602  and  2606  by changing the width and/or the frequency of the electrical pulses supplied to the respective actuators  2609  and  2610 , by the controller  2613 . This avoids the need for a constant supply current, which is a significant advantage when the only available power source is located on the tractor or other vehicle that propels the soil-engaging implement(s) across a field. 
     The hydraulic control system of  FIG. 7  may be used to control multiple hydraulic cylinders on a single row unit or a group of row units, or may be replicated for each individual hydraulic cylinder on a row unit having multiple hydraulic cylinders. For example, in the system described above having a ground hardness sensor located out in front of the clearing wheels, it is desirable to have each hydraulic cylinder on any given row unit separately controlled so that the down pressure on each tool can be adjusted according to the location of that tool in the direction of travel. Thus, when the ground hardness sensor detects a region where the soil is softer because it is wet, the down pressure on each tool is preferably adjusted to accommodate the softer soil only during the time interval when that particular tool is traversing the wet area, and this time interval is different for each tool when the tools are spaced from each other in the direction of travel. In the case of a group of row units having multiple hydraulic cylinders on each row unit, the same hydraulic control system may control a group of valves having common functions on all the row units in a group. 
       FIG. 8  is a schematic diagram of a modified hydraulic control system that uses a single three-position control valve  2620  in place of the two two-position control valves and the two check valves used in the system of  FIG. 7 . The centered position of the valve  2620  is the closed position, which is the normal position of this valve. The valve  2620  has two actuators  2620   a  and  2620   b , one of which moves the valve to a first open position that connects a source  2621  of pressurized hydraulic fluid to a hydraulic cylinder  2622  via restriction  2620   c , and the other of which moves the valve to a second open position that connects the hydraulic cylinder  2622  to a sump  2623 . Electrical signals for energizing the actuators  2620   a  and  2620   b  are supplied to the respective actuators via lines  2624  and  2625  from a controller  2626 , which in turn may be controlled by a central processor  2627 . The controller  2626  receives input signals from a pressure transducer  2628  coupled to the hydraulic cylinder  2622  via line  2629 , and from an auxiliary sensor  2630 , such as a ground hardness sensor. An accumulator  2631  is coupled to the hydraulic cylinder  2622 , and a relief valve  2632  connects the hydraulic cylinder  2622  to the sump  2623  in response to an increase in the pressure in the cylinder  2622  above a predetermined level. 
     As depicted in  FIG. 9 , a PWM control system supplies short-duration pulses P to the actuators  2620   a  and  2620   b  of the control valve  2620  to move the valve to either of its two open positions for short intervals corresponding to the widths of the PWM pulses. This significantly reduces the energy required to increase or decrease the pressure in the hydraulic cylinder  2622 . In  FIG. 9 , pulses P 1 -P 3 , having a voltage level V 1 , are supplied to the actuator  2620   b  when it is desired to increase the hydraulic pressure supplied to the hydraulic cylinder  2622 . The first pulse P 1  has a width T 1  which is shorter than the width of pulses P 2  and P 3 , so that the pressure increase is smaller than the increase that would be produced if P 1  had the same width as pulses P 2  and P 3 . Pulses P 4 -P 6 , which have a voltage level V 2 , are supplied to the actuator  2620   a  when it is desired to decrease the hydraulic pressure supplied to the hydraulic cylinder  2622 . The first pulse P 4  has a width that is shorter than the width T 2  of pulses P 2  and P 3 , so that the pressure decrease is smaller than the decrease that would be produced if P 4  had the same width as pulses P 5  and P 6 . When no pulses are supplied to either of the two actuators  2620   a  and  2620   b , as in the “no change” interval in  FIG. 9 , the hydraulic pressure remains substantially constant in the hydraulic cylinder  2622 . 
       FIGS. 10-15  illustrate a modified gauge wheel load sensor that includes an integrated accumulator  122 . The purpose of the accumulator  122  is to damp pressure spikes in the sensor when the planter is operating at low gauge wheel loads. When the forces that the gauge wheel support arms  110  are exerting on the hydraulic ram  117  are near zero, it is more common for the surface of the soil or plant residue to create pressure spikes that are large in relation to the desired system sensor pressure. These pressure spikes produce corresponding changes in the vertical position (elevation) of the gauge wheels. As the target gauge wheel down force increases, and consequently the pressure in the fluid chamber  111  and the transducer output voltage from sensor  118 , the small spikes of pressure due to variations in the soil surface or plant residue decrease proportionally. 
     In the present system, rather than have a perfectly rigid fluid coupling between the ram  117  and the pressure transducer  118 , as load increases on the ram  117 , the fluid first pushes against a piston  125  of the accumulator  122  that is threaded into a side cavity  123  in the same housing that forms the main cavity for the ram  117 . The increased pressure compresses an accumulator spring  126  until the piston  125  rests fully against a shoulder on the interior wall of the accumulator housing  127 , thus limiting the retracting movement of the accumulator piston  125 . At this point, the system becomes perfectly rigid. The amount of motion permitted for the accumulator piston  125  must be very small so that it does not allow the depth of the gauge wheel setting to fluctuate substantially. The piston accumulator (or other energy storage device) allows the amount of high frequency noise in the system to be reduced at low gauge-wheel loads. Ideally an automatic down pressure control system for an agricultural planter should maintain a down pressure that is as low as possible to avoid over compaction of soil around the area of the seed, which can inhibit plant growth. However, the performance of most systems degrades as the gauge wheel load becomes close to zero, because the amount of latent noise produced from variation in the field surface is large in relation to the desired gauge wheel load. 
     Planter row units typically have a gauge wheel equalizer arm  130  that is a single unitary piece. It has been observed that the friction between the equalizer arm  130  and the gauge wheel support arms  110 , as the gauge wheel  115  oscillates up and down, can generate a substantial amount of noise in the sensor. At different adjustment positions, the edges of the equalizer arm  130  contact the support arms  10  at different orientations and can bite into the surface and prevent forces from being smoothly transferred as they increase and decrease. When the equalizer arm  130  is a single unitary piece, there is necessarily a high amount of friction that manifests itself as signal noise in the sensor. This signal noise makes it difficult to control the down pressure system, especially at low levels of gauge wheel load. 
     To alleviate this situation, the equalizer arm  130  illustrated in  FIG. 16  has a pair of contact rollers  131  and  132  are mounted on opposite ends of the equalizer arm. These rollers  131  and  132  become the interface between the equalizer arm and the support arms  110 , allowing forces to be smoothly transferred between the support arms  110  and the equalizer arm  130 . The roller system allows the gauge wheel support arms  110  to oscillate relative to each other without producing any sliding friction between the support arms  110  and the equalizer arm  130 . This significantly reduces the friction that manifests itself as signal noise in the sensor output, which makes it difficult to control the down pressure control system, especially at low levels of gauge wheel load. 
       FIG. 17  is a longitudinal section through the device of  FIG. 16 , with the addition of a rocker arm  150  that engages a ram  151  that controls the fluid pressure within a cylinder  152 . A fluid chamber  153  adjacent the inner end of the ram  151  opens into a lateral cavity that contains a pressure transducer  154  that produces an electrical output signal representing the magnitude of the fluid pressure in the fluid chamber  153 . The opposite end of the cylinder  152  includes an accumulator  155  similar to the accumulator  125  included in the device of  FIG. 9  described above. Between the fluid chamber  153  and the accumulator  155 , a pair of valves  156  and  157  are provided in parallel passages  158  and  159  extending between the chamber  153  and the accumulator  155 . The valve  156  is a relief valve that allows the pressurized fluid to flow from the chamber  153  to the accumulator  155  when the ram  151  advances farther into the chamber  153 . The valve  157  is a check valve that allows pressurized fluid to flow from the accumulator  155  to the chamber  153  when the ram  151  moves outwardly to enlarge the chamber  153 . The valves  156  and  157  provide overload protection (e.g., when one of the gauge wheels hits a rock) and to ensure that the gauge wheels retain their elevation setting. 
       FIGS. 18A and 18B  illustrate a modified sensor arrangement for a pair of gauge wheels  160  and  161  rolling on opposite sides of a furrow  162 . The two gauge wheels are independently mounted on support arms  163  and  164  connected to respective rams  165  and  166  that control the fluid pressure in a pair of cylinders  167  and  168 . A hydraulic hose  169  connects the fluid chambers of the respective cylinders  167  and  168  to each other and to a common pressure transducer  170 , which produces an electrical output signal corresponding to the fluid pressure in the hose  169 . The output signal is supplied to an electrical controller that uses that signal to control the down forces applied to the two gauge wheels  160  and  161 . It will be noted that the two gauge wheels can move up and down independently of each other, so the fluid pressure sensed by the transducer  170  will be changed by vertical movement of either or both of the gauge wheels  160  and  161 . 
       FIGS. 19-22  illustrate electrical/hydraulic control systems that can be used to control a down-pressure actuator  180  in response to the electrical signal provided to a controller  181  by a pressure transducer  182 . In each system the transducer  182  produces an output signal that changes in proportion to changes in the fluid pressure in a cylinder  183  as the position of a ram  184  changes inside the cylinder  183 . In  FIG. 19 , the pressurized fluid chamber in the cylinder  183  is coupled to an accumulator by a relief valve  186  to allow pressurized fluid to flow to the accumulator, and by a check valve  187  to allow return flow of pressurized fluid from the accumulator to the cylinder  183 . In  FIG. 20 , the accumulator  185  is replaced with a pressurized fluid source  188  connected to the check valve  187 , and a sump  189  connected to the relief valve  186 . In  FIG. 21 , the accumulator  185  is connected directly to the pressurized fluid chamber in the cylinder  183 , without any intervening valves. In the system of  FIG. 22 , the pressure sensor  182  is connected directly to the pressurized fluid chamber in the cylinder  183 . 
     While particular embodiments and applications of the present invention have been illustrated and described, it is to be understood that the invention is not limited to the precise construction and compositions disclosed herein and that various modifications, changes, and variations can be apparent from the foregoing descriptions without departing from the spirit and scope of the invention as defined in the appended claims.