Abstract:
An apparatus and method for calibrating a PTO for driving a cutter of a header of an agricultural windrower, wherein a programmable control module in connection with at least signal operated device in operative control of a variable displacement pump operable for controlling operation of the PTO, is programmed as part of an automatic calibration routine for directing signals to the device having values which will increase over time from a first value toward a second value. At the same time, the control module determines when a first movement of the cutter occurs. If the first movement occurs before the second signal value is reached, information representative of an electrical signal corresponding to the first movement is stored. The routine is then repeated using a higher range of electrical signal values to calibrate where the cutter reaches max speed. In either instance, if the speed condition is not reached with the outputting of the signals within the range, the calibration fails.

Description:
This application claims the benefit of U.S. Provisional Application No. 60/699,492, filed Jul. 15, 2005. 

   TECHNICAL FIELD 
   The present invention relates to agricultural windrowers and, more particularly, to apparatus and a method for calibrating a PTO with the disk or sickle of an agricultural windrower. 
   BACKGROUND OF THE INVENTION 
   U.S. Pat. No. 6,901,729, is incorporated herein by reference in its entirety. This patent describes a header flotation system that is referred to as “non-independent”. U.S. Provisional Application No. 60/699,492, filed Jul. 15, 2005, is also incorporated herein by reference in its entirety. 
   A windrower typically consists of a self-propelled tractor or similar vehicle, and a cutting mechanism which is either towed by the tractor or carried thereby. The cutting mechanism carried by a windrower is typically referred to as a header, and is supported on the windrower by forwardly projecting arms. Briefly, the arms comprise elements of a lift and flotation mechanism or mechanisms operable for setting a height of the header above the ground or other surface over which the windrower moves, the flotation permitting the header to ride lightly up and over rises in the terrain during field operation. 
   Headers are typically available and a variety of configurations. Common elements of different headers include cutters operable for severing crops from the field. One typical cutting mechanism is a sickle cutter which includes a row of knives which extend across the width of the header and which are powered to move reciprocally sidewardly relative to a sidewardly extending array of fixed knives or bars, thereby effecting a cutting action. Another cutting mechanism is a disk cutter including a sidewardly extending array of rotatably driven disks having knives extending radially outwardly from the outer circumferential edges thereof, the rotation of which disks effects the cutting action. Both of these types of cutters may be provided in different overall sideward widths. A typical cutting speed for a sickle type cutter is about 1500 to 1800 strokes per minute, and the for a disk cutter, about 2200 to 3200 rpm. It is typically desirable for the cutters to operate at a constant speed, but, in operation, the cutting speed may vary as a result of changing conditions such as crop population, contact with the ground, or the like. Closed loop speed control is typically used to maintain a consistent cutting speed under varying loads and engine speed changes. 
   The cutters are powered using a fluid drive, such as a fluid power takeoff (PTO). A pump driven by the engine of the tractor provides pressurized fluid to the PTO system. The pump can be of a fixed displacement, or variable displacement, in the latter instance, the pressurization and direction of fluid flow, and thus the speed and direction of operation of the PTO, being controlled by solenoids. Varying electrical current signals would be utilized for operating the solenoids, for operating the cutters at the desired speed and in the desired direction. In order to achieve maximum response time from the closed loop speed control system, it is desired to eliminate the variations in offset and gain of the electrically controlled pump. 
   Therefore, it would be desirable to have an apparatus and method which enables calibrating PTO current values on the vehicle, taking into account associated system variances, and furthermore to do this with minimal operator intervention. 
   SUMMARY OF THE DISCLOSURE 
   What is disclosed is an apparatus and method which enables calibrating signals for operating a PTO for desired cutter operation using any standard header installed on a windrower, to facilitate optimized closed loop control of the cutter, by automatically deriving the offset and max speed signals. 
   According to a preferred aspect of the invention the method and apparatus utilizes a programmable control module in connection with at least one signal controlled device operable for controlling operation of the PTO, which signal controlled device is preferably a solenoid controlled pump. The displacement of the pump is variably controllable as a function of the signals, by varying a swash plate angle of the pump. The pump is preferably driven by an engine of the windrower and is thus subject to the effects of varying the engine speed, such as between a low idle speed and a higher operating or harvesting speed. More particularly in this regard, by increasing the engine speed, the pump speed will be increased, and if the swash plate angle is not correspondingly adjusted to decrease the displacement of the pump, the result will be greater pump output. The closed loop speed control will limit the impact of these changes, but its response time is adversely affected if the control loop does not account for offset and gain of the pump electrical control. 
   To avoid or limit these problems, the control module is programmed as part of an automatic calibration routine for directing control signals to the signal controlled device, here, the solenoid or solenoids controlling the pump, which signals have values which will increase over time from a first value toward a second value. At the same time, or, at an appropriate time during the routine, the control module will monitor a speed sensor of the header, to determine when a first movement of the header, e.g., the cutter, takes place. If the initial movement occurs before the second signal value is reached, the signal value for the first movement is stored. An additional routine is then used to calibrate the electrical current at which the cutter, will be maintained at its maximum speed. In the first instance, if the header speed condition falls outside predetermined limits, the calibration fails. 
   According to a preferred aspect of the invention, the signals comprise electrical current values within a range anticipated to encompass the current values required for initiating movement or operation of the cutter, and those required for operation of the cutter at maximum operating speed. 
   The apparatus and method of the invention are adapted for use with a wide variety of windrower header cutters, including disk cutters typically rotatable at speeds of between about 2200 rpm and 3200 rpm, and sickles typically reciprocally operable at speeds of between about 1500 and 1800 cycles per minute. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The advantages of this invention will be apparent upon consideration of the following detailed disclosure of the invention, especially when taken in conjunction with the accompanying drawings wherein: 
       FIG. 1  is a side elevational view of a crop harvesting machine of the type with which the invention may be used, showing a header including a sickle cutter in connection with apparatus of the instant invention; 
       FIG. 2  is another side view of the crop harvesting machine of  FIG. 1 , showing a header including a disk cutter in connection with apparatus of the instant invention; 
       FIG. 3  is a schematic of a PTO driveline of the machine of  FIG. 1 ; 
       FIG. 4  is a high level flow diagram of steps of a preferred embodiment of a computer program of the invention; 
       FIG. 5  is another high-level flow diagram of steps of a preferred embodiment of a computer program of the invention; 
       FIG. 5   a  is a continuation of the flow diagram of  FIG. 5 ; 
       FIG. 6  is a written listing of steps of the preferred program of the invention; 
       FIG. 7  is a written listing of further steps of the preferred program of the invention; 
       FIG. 8  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 9  is a written listing of still further steps of the preferred program of the invention; and 
       FIG. 10  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 11  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 12  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 13  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 14  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 15  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 16  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 17  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 18  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 19  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 20  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 21  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 22  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 23  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 24  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 25  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 26  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 27  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 28  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 29  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 30  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 31  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 32  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 33  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 34  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 35  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 36  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 37  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 38  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 39  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 40  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 41  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 42  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 43  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 44  is a written listing of still further steps of the preferred program of the invention; 
       FIG. 45  is a written listing of still further steps of the preferred program of the invention; and 
       FIG. 46  is a written listing of still further steps of the preferred program of the invention. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Many of the fastening, connection, processes and other means and components utilized in this invention are widely known and used in the field of the invention described, and their exact nature or type is not necessary for an understanding and use of the invention by a person skilled in the art, and they will not therefore be discussed in significant detail. Also, any reference herein to the terms “left” or “right” are used as a matter of mere convenience, and are determined by standing at the rear of the machine facing in its normal direction of travel. Furthermore, the various components shown or described herein for any specific application of this invention can be varied or altered as anticipated by this invention and the practice of a specific application of any element may already by widely known or used in the art by persons skilled in the art and each will likewise not therefore be discussed in significant detail. 
     FIGS. 1 and 2  show the present invention utilized in connection with a self-propelled windrower  10 ; however, it will be appreciated that the principles of the present invention are not limited to a self-propelled windrower, or to any specific type of harvesting machine. 
   In the illustrated embodiment, the self-propelled windrower  10  comprises a tractor  12  and a header  14  ( FIG. 1 ) or  16  ( FIG. 2 ), the header  14  or  16  being attached to the front end of a frame  18  or chassis of the tractor  12 . The header may be of generally any suitable construction and design, and will include crop-harvesting mechanisms, such as a sickle cutter  20  ( FIG. 1 ) or a plurality of disk cutters  22  ( FIG. 2 ). Header  14  additionally includes a reel  24  rotatable at a fixed or variable speed, as denoted by arrow A, for directing crops toward header  14  for harvesting by sickle cutter  20 . A draper  26  comprising endless belts is disposed and operable for directing the harvested crop toward the center of header  14 . Header  16  additionally includes an auger  28  operable for directing harvested crops toward a center of header  16 , and counter-rotating conditioner rolls  30  operable for conditioning the harvested crops prior to being deposited onto a field in a windrow. 
   Sickle cutter  20  of header  14  includes a row of knives extending sidewardly across the lower front of header  14  and reciprocally driven in the sideward direction, by at least one drive  34  which preferably includes a fluid motor  36 . Fluid motor  36  is connected in fluid communication with a PTO  38  of tractor  12 , by fluid lines  40  and  42 , for receiving pressurized fluid therefrom, for powering the reciprocating movement of the sickle knives, in the well known manner. Reel  24  and draper  26  can also be fluid driven, reel  24  by another fluid PTO, and draper  26  also by PTO  38 , or they can be separately driven utilizing any desired mechanical drive such as a belt, chain, gear, and/or shaft drive. 
   Disk cutter  22  of header  16  comprises a plurality of disks  44  arranged in a side-by-side array across the lower front of header  16 , each of the disks  44  carrying knives at spaced locations around an outer circumferential periphery thereof. Disks  44  are rotated by a drive  46  in the well known manner, drive  46  preferably including fluid motors  48  operable for driving one or more of disks  44 , fluid motors  48  being connected in fluid communication with PTO  38  of tractor  12 , by fluid lines  40  and  42 , for receiving pressurized fluid therefrom, also in the well known manner. 
   Headers  14  and  16  are interchangeably mountable on a pair of lower arms which extend forwardly from frame  18  of tractor  12 , and which are movable upwardly and downwardly for positioning the header at a desired cutting height, or at an elevated transport position, using one or more lift cylinders (not shown), also in the well known manner. The upper end of the header is connected to frame  18  by an upper or center link connected to a mechanism operable for tilting the header to a desired orientation, again, in the well known manner. 
   A typical operating speed for the sickle cutter  20  of header  14  will be within a range of from about 1500 cycles per minute to about 1800 strokes per minute, and a typical speed of rotation of disks  44  of disk cutters  22  is within a range of from about 2200 rpm to about 3200 rpm. It is desirable to have a capability to calibrate the output of PTO  38  for optimizing header closed loop speed control performance, hence providing a capability for improved performance, adjusting to changing conditions, particularly changing engine speed. 
   PTO  38  includes a PTO driveline  50  including a fluid valve arrangement  52  controllably operable for directing pressurized fluid through fluid lines  40  and  42  as desired or required for powering a header, such as header  14  or header  16 , connected to windrower  10 . 
   Referring also to  FIG. 3 , which is a schematic of PTO driveline  50 , the flow of pressurized fluid to valve arrangement  52  is generated by a variable displacement pump  66 , the displacement of which is determined by the angle of an internal swash plate, the angle being controlled by a header PTO forward/reverse solenoid  54 . In another embodiment, the pump can be a fixed displacement pump operated by a header PTO forward solenoid  56  and a header PTO reverse solenoid  58 . Solenoid  54  is controlled by an electrical signal, the electrical current value of which can be very precisely controllably varied through a range between zero and a greater amount. PTO driveline  50  includes a programmable control module  60  connected to header PTO forward/reverse solenoid  54  by suitable conductive paths  62 , which can be, for instance, wires of a wiring harness. Control module  60  is preferably a conventionally constructed and operable microprocessor based tractor control module, or the like, suitably located on tractor  12 , such as in an operator cab  64 . Pump  66  is driven by an engine  68  of tractor  12 , in the well known manner. Pump  66  is operable for providing fluid pressurized to predetermined system pressure by operation of engine  68  at least a low range speed, which is about 1300 rpm. 
   Other pertinent elements of PTO driveline  50  include a header PTO switch  70  selectably operable by an operator for selecting a forward or reverse direction of operation of the PTO; a header speed switch  72  selectably operable by an operator for increasing or decreasing the speed of operation of the header; a header PTO emergency stop switch  74 ; a seat switch  76 ; and a display device  78 , which can be, for instance, an interactive touch screen device or the like which can be automatically adapted or turned on for receiving operator inputs, each of switches  70 ,  72 ,  74  and  76 , and device  78 , being located in operator cab  64  and connected to the control module  60  via suitable conductive paths  62 . Electrical power is provided in the normal manner from an electrical system of the tractor, as represented by the +12 V connections in the schematic. 
   Other aspects of windrower  10  include a propulsion driveline including fluid motors in connection, respectively, with drive wheels, which are differentially operated for effecting steering movements. The differential operation of the fluid motors of the driveline, as well as the travel speed, is effected by varying the displacement of fluid pumps in connection with the respective fluid motors of the driveline. A typical range of operating speeds of engine  68  of windrower  10  will be from about 1300 rpm, which represents a low idle speed, to about 2200 or 2300 rpm, which represents a typical normal operating speed. 
   Because pump  66  of PTO driveline  50  is driven by engine  68 , operation of engine  68  at different speeds will result in operation of pump  66  at different speeds. This will cause pump  66  to generate different fluid flow outputs as the speed of the engine changes, if the displacement of the pump is not correspondingly adjusted for maintaining a particular fluid flow level. As noted above, as an alternative, a close loop speed control is applied to determine an optimal fluid flow for operating a header  14  or  16  installed on windrower  10 , then to maintain that optimal fluid flow, regardless of variations in engine speed, that is, to provide a capability to vary the displacement of pump  66  as the speed of engine  68  changes, in a manner for maintaining optimal or near optimal fluid flow conditions. However, the pump  66  has variations from unit to unit which must be taken into account if the closed loop speed control loop is to have an optimize response time. 
   Referring also to  FIGS. 4 ,  5  and  5   a , a flow diagram  80  illustrating steps of a method of the instant invention for calibrating PTO  38  for operation with a header, such as header  14  or header  16 , is shown, for determining the fluid flows needed for optimizing the operation of the closed loop speed control, particularly for use in adjusting the displacement of pump  66  responsive to changes in the speed of engine  68 . The steps of flow diagram  80  are preferably programmed in and executable by control module  60  at appropriate times, such as, but not limited to, when a pump  66  is first installed, or after a repair or service affecting stored register values. When the operator envokes a calibration, or re-calibration, control module  60  will output a message, denoted by  83 , on the screen of display device  78  that calibration is initiating, and request an action by the operator to enable the header  14  or header  16 , which will be to operate header PTO switch  70 . The calibration routine will then be automatically initiated when the operator has responsively taken the requested action. At block  82  control module  60  initiates an offset calibration routine. This is directed to the initial application of current to the PTO solenoid. Calibration is to be conducted with the fluid system in connection with PTO  38  operating at the normal fluid pressure, which is achieved when engine  68  is operating at least a low idle speed which, for tractor  12 , is about 900 rpm for a sickle header  14  or 1300 rpm for a disc header  16 . Accordingly, for a disc header  16 , control module  60  sets the engine speed equal to 1300 rpm, allows it to settle, and maintains it at that speed, as denoted at block  82 . Display device  78  may display a message that the system is in a calibration mode, and warn the operator not to attempt to operate the PTO, and will temporarily disable the PTO switches. Control module  60  then delivers an electrical current signal to the header PTO solenoid  54 . Control module  60  increasingly steps the value of the current signal from a first predetermined value of 0 ma, as denoted at block  84 , toward a value of 170 ma, as denoted at decision block  87 , in 1 ma increments, as denoted at block  85 . This range of signal values is used, as it is anticipated that a value within this range will be sufficient for initiating operation of the header cutter. This information can be displayed in a desired form on a screen of display device  78 . 
   Control module  60  will then monitor the output of a speed sensor of the header  14  or  16  for an indication that an initial movement of the cutter has occurred, as denoted by decision block  86 . 
   As the current is stepped, module  60  will monitor the current value of the electrical signal, hold the engine speed steady, and if the speed sensor signal is not received, and the current exceeds the second predetermined value of 170 ma, as determined at decision block  87 , module  60  will determine that the calibration has failed, as denoted at block  89 . If, at decision block  87 , the signal current has not exceeded 170 ma, module  60  will continue stepping the current value upwardly. If, before the current reaches or exceeds 170 ma, the speed signal indicating initial movement of the header is received, module  60  will determine that the offset calibration is successful, as denoted at block  88 . Module  60  will then proceed to store the current value corresponding to the initial operation, as denoted at block  90 , and proceed to a maximum speed calibration routine, as denoted at block  91 . 
   The maximum speed calibration routine is set forth in  FIG. 5 , as denoted by block  100 . This is directed to determining the electrical current value necessary for operation of the solenoid that produces maximum operating speed thereof. The engine speed is again set or maintained at a speed near low idle, to provide normal fluid system pressure, as denoted at block  101 . Module  60  first applies a current sufficient to assure the pump is producing maximum flow, 130 ma as denoted by block  102 . The maximum header RPM is measured and stored for further reference, as denoted by block  103 . Module  60  will then step the current signal delivered to the header PTO solenoid  54  or  56  with which the PTO is equipped. In this routine, control module  60  steps the value of the current signal using a binary tree algorithm. Control module  60  must first initialize two variables associated with the binary tree algorithm. The first variable being the electrical current range, initialized to  32  ma as denoted by block  104 . The second being the electrical current value, initialized to 103 ma, as denoted by block  105 . The electrical current range is then divided in half, as denoted by block  106 . The electrical current range is compared to the minimum electrical current resolution required, 0.5 ma as denoted by block  107 . The header speed is allowed to settle and an average measurement of header speed is compared to the maximum header speed measured, less 25 RPM, as denoted by decision block  110 . If the latest average measurement of header speed, corresponding to the applied current, exceeds the stored maximum header speed, the current will be reduced by the value of the electrical current range, as denoted by block  111 . If the latest average measurement of header speed, corresponding to the applied current, is less than or equal to the stored maximum header speed less 25 RPM, the current will be increased by the value of the electrical current range, as denoted by block  111 . The process then repeats, starting at block  106  until the electrical current range is less than the minimum electrical current range resolution, 0.5 ma, as denoted by block  107 . When the minimum electrical current range resolution requirement is met, the electrical current value, corresponding to maximum header speed less 25 RPM, is stored as denoted by block  108 . 
   Control module  60  can additionally be programmed for calibrating header PTO forward/reverse solenoid  54  in the reverse operating mode, using the above routines for offset and/or maximum speed calibration. 
   As a result of execution of the calibration routines of the instant invention, registers of control module  60  will contain information representative of the electrical current value required to be directed to solenoid  54  for providing fluid flow for effecting initial operation of the cutter of the presently mounted header  14  or  16 , and for providing the fluid flow for operation of the cutter at the target normal or maximum operating speed thereof. These values can then be used by control module  60 , for determining new current values for achieving pump swash plate angles required for providing the optimal fluid flow to the header for a variety of engine speeds, using well know closed loop speed control algorithms. If, after calibration the pump is changed, the calibration routine will be repeated. In this instance, the previous calibration values can be discarded by the control module. 
   Referring also to  FIGS. 6-46 , lines of code of an actual computer program embodying the above described steps of the method of the invention is disclosed. The notes accompanying the lines of code describe many features of the method of the invention. 
   It will be understood that changes in the details, materials, steps and arrangements of parts which have been described and illustrated to explain the nature of the invention will occur to and may be made by those skilled in the art upon a reading of this disclosure within the principles and scope of the invention. The foregoing description illustrates the preferred embodiment of the invention; however, concepts, as based upon the description, may be employed in other embodiments without departing from the scope of the inventions. Accordingly, the following claims are intended to protect the invention broadly as well as in the specific form shown.