Patent Description:
Combine harvesters implement various functions of crop gathering, threshing, separating, conveying and spreading residue back to the field. For example, the US patent applications published as <CIT> and <CIT> describe combine harvesters with residue spreaders that may be controlled to affect the distribution of the crop residue onto the soil or field. Many existing combines, however, are susceptible to non-uniform residue spread patterns.

An embodiment includes a combine having a feeder housing for receiving harvested crop, a separating system for threshing the harvested crop to separate grain from residue, a residue spreader wheel spinning for expelling the residue from the combine, and a controller that controls the combine. The controller is configured to control the residue spreader wheel to continuously oscillate between a first speed less than a nominal speed and a second speed greater than the nominal speed while spreading the residue.

Another embodiment includes a combine having a feeder housing for receiving harvested crop, a separating system for threshing the harvested crop to separate grain from residue, a residue spreader wheel spinning and having paddles extending at an angle for expelling the residue from the combine, and a controller that controls the combine. The controller is configured to control the paddles of residue spreader wheel to continuously oscillate between a first angle less than a nominal angle and a second angle greater than the nominal angle while spreading the residue.

Aspects of the disclosure provide methods and systems for controlling spreader wheel rotational speed and/or spreader wheel paddle angles to achieve a uniform residue spread pattern.

The terms "grain" and "residue" are used principally throughout this specification for convenience but it is to be understood that these terms are not intended to be limiting. "Grain" refers to that part of the crop material which is threshed and separated from the discardable part of the crop material, which is referred to as non-grain crop material, material other than grain (MOG). "Residue" refers to MOG that is to be discarded from the combine. Also the terms "fore", "aft", "left," and "right", when used in connection with the agricultural harvester (e.g. combine) and/or components thereof are usually determined with reference to the direction of forward operative travel of the combine, but again, they should not be construed as limiting.

Referring now to the drawings, and more particularly to <FIG>, there is shown one embodiment of an agricultural harvester in the form of a combine <NUM> (e.g. longitudinal rotary combine), which generally includes a chassis <NUM>, ground engaging wheels <NUM> and <NUM>, a header <NUM>, a feeder housing <NUM>, an operator cab <NUM>, a threshing and separating system <NUM>, a cleaning system <NUM>, a grain tank <NUM>, and an unloading auger <NUM>.

Front wheels <NUM> are larger flotation type wheels, and rear wheels <NUM> are smaller steerable wheels. Motive force is selectively applied to front wheels <NUM> through a power plant in the form of a diesel engine <NUM> and a transmission (not shown). Although combine <NUM> is shown as including wheels, is also to be understood that combine <NUM> may include tracks, such as full tracks or half-tracks.

Header <NUM> is mounted to the front of combine <NUM> and includes a cutter bar <NUM> for severing crops from a field during forward motion of combine <NUM>. A rotatable reel <NUM> feeds the crop into header <NUM>, and a double auger <NUM> feeds the severed crop laterally inwardly from each side toward feeder housing <NUM>. Feeder housing <NUM> conveys the cut crop to threshing and separating system <NUM>, and is selectively vertically movable using appropriate actuators, such as hydraulic cylinders (not shown).

Threshing and separating system <NUM> generally includes a rotor <NUM> at least partially enclosed by and rotatable within a corresponding perforated concave <NUM>. The cut crops are threshed and separated by the rotation of rotor <NUM> within concave <NUM>, and larger MOG elements, such as stalks, leaves and the like are discharged from residue system <NUM> of combine <NUM>. Smaller elements of crop material including grain and smaller MOG materials including particles lighter than grain, such as chaff, dust and straw, are discharged through perforations of concave <NUM>.

The combine controller may be a programmable logic controller, micro-controller, etc. The combine controller is programmable by the operator of the combine through a user (e.g. operator) interface, or through a remote computer. The operator, for example, enters commands through the user interface. In response to these commands, the controller sends control signals to the various actuators of combine <NUM>.

Grain which has been separated by the threshing and separating assembly <NUM> falls onto a grain pan <NUM> and is conveyed toward cleaning system <NUM>. Cleaning system <NUM> may include an optional pre-cleaning sieve <NUM>, an upper sieve <NUM> (also known as a chaffer sieve), a lower sieve <NUM> (also known as a cleaning sieve), and a cleaning fan <NUM>. Grain on sieves <NUM>, <NUM> and <NUM> is subjected to a cleaning action by fan <NUM> which provides an airflow through the sieves to remove chaff and other impurities such as dust from the grain by making this material airborne for discharge from straw hood <NUM> of combine <NUM>. Grain pan <NUM> and pre-cleaning sieve <NUM> oscillate in a fore-to-aft manner to transport the grain and finer non-grain crop material to the upper surface of upper sieve <NUM>. Upper sieve <NUM> and lower sieve <NUM> are vertically arranged relative to each other, and likewise oscillate in a fore-to-aft manner to spread the grain across sieves <NUM>, <NUM>, while permitting the passage of cleaned grain by gravity through the openings of sieves <NUM>, <NUM>.

The remaining non-grain crop material (i.e. residue) proceeds through a residue handling system <NUM>. Residue handling system <NUM> includes a chopper, a chopper pan, counter knives, a windrow door, a windrow chute and a residue spreader, which are not shown in <FIG>. When combine <NUM> is operating in the chopping and spreading mode, the chopper is set to a relatively high speed, and the counter knives may be engaged, the windrow door is closed and the residue spreader is running (e.g. rotating). This causes the non-grain crop material to be chopped in to pieces of approximately <NUM> inches (<NUM>) or less and spread on the ground in a uniform manner. In contrast, when combine <NUM> is operating in the windrow mode, the chopper is at a relatively low speed, the counter knives are disengaged and the windrow door is open. The residue spreader may continue operation to spread only the chaff, with the crop material passing through the passageway created by the open windrow door and guided by a windrow chute as it exits the combine.

The clean grain output by separating assembly <NUM> falls to a clean grain auger <NUM> positioned crosswise below and in front of lower sieve <NUM>. Clean grain auger <NUM> receives clean grain from each sieve <NUM>, <NUM> and from bottom pan <NUM> of cleaning system <NUM>. Tailings from cleaning system <NUM> fall to a tailings auger trough <NUM>. The tailings are transported via tailings auger <NUM> and return auger <NUM> to the upstream end of cleaning system <NUM> for repeated cleaning action. Clean grain auger <NUM> conveys the clean grain laterally to a generally vertically arranged grain elevator <NUM> for transport to grain tank <NUM>.

As shown in <FIG>, residue system <NUM> includes a windrow door <NUM>, a spreader chute <NUM>, a windrow chute <NUM>, spreader wheel system <NUM>, spreader deflectors (not shown), chopper wheel <NUM> and chopper pan <NUM>.

As shown in <FIG>, devices 115A-115D include actuators for operating windrow door <NUM>, spreader wheel system <NUM>, spreader deflectors, and chopper wheel <NUM>. These actuators are either electrical actuators that are electrically connected to a controller (e.g. programmable logic controller, micro-controller, etc.) located in the combine, or are hydraulic actuators that are driven by hydraulic devices such as valves and pumps that are electrically connected to the controller. Devices 115A-115D may also include sensors for monitoring the operational status of the actuators, and/or the operational status of windrow door <NUM>, spreader wheel system <NUM>, spreader deflectors, and chopper wheel <NUM>. The controller is programmable by the operator of the combine through a user (e.g. operator) interface, or through a remote computer (see <FIG> for further details). The operator, for example, enters commands through the user interface. In response to these commands, the controller sends control signals to the various actuators of residue handling system <NUM>.

As mentioned above, residue handling system <NUM> spreads the chopped up residue via path 112B as shown in <FIG>. Further details of the spreader wheel system and spreader deflectors are shown in <FIG>. Spreader wheel system <NUM> is shown to include driver-side spreader wheel <NUM>, passenger-side spreader wheel <NUM>, optional divider <NUM>, driver-side deflector <NUM>, and passenger-side deflector <NUM>. In general, spreader wheels <NUM> and <NUM> rotate paddles 120A-122D and 122A-122D (e.g. four paddles on each wheel) at a predetermined speed which contact and eject the residue from the combine via paths 118A and 118B respectively which are affected by both the speeds (RPM1, RPM2) of wheels <NUM> and <NUM>, the angles of the paddles, and the angles of deflectors <NUM> and <NUM>. This allows the combine to control the speed, angle and density at which the residue is ejected from the residue system. These variables (wheel rotational speeds and/or paddle angles) are controlled to produce a desirable (e.g. smooth/uniform) residue spread on the ground and avoid streaks and unevenness. It is noted that although the spreader wheels are shown in <FIG> to have four paddles, this is for explanatory purposes. In practice, the spreader wheels could have a different number of paddles.

In general, the combine controller can vary the rotational speed of spreader wheels <NUM>/<NUM> and/or the angles of paddles 120A/122A-120D/122D to control the distance of residue being ejected from the combine. <FIG> shows an example of varying the rotational speed of spreader wheels <NUM>/<NUM> and/or the angles of paddles 120A/122A-120D/122D in an oscillatory manner to produce a uniform residue spread.

For example, <FIG> shows data plot <NUM> of an oscillating spreader wheel rotational speed and/or paddle angle vs. time with respect to a nominal spreader wheel rotational speed and paddle angle. In this example, a nominal speed <NUM>, an oscillation period value and an oscillation range between a lower oscillation peak value and an upper oscillation peak value may be set either manually by the operator or automatically by the controller. These values may be determined based on various factors including but not limited to crop type, crop moisture, combine speed and environmental/terrain conditions.

In a first example, the a nominal wheel rotational speed may be set at <NUM> rpm, the oscillation range between a lower oscillation peak value of <NUM> rpm and an upper oscillation peak value of <NUM> rpm, while the oscillation period value may be set to <NUM> second. This would result in the controller oscillating the rotational speed the spreader wheels <NUM>/<NUM> between <NUM> rpm and <NUM> rpm every second. Although this oscillation is shown as a sinusoidal oscillation in <FIG>, it is noted that other types of oscillation are possible (e.g. square wave, saw tooth, etc.). In practice the oscillation behavior for varying rotational speed is achieved by motor control techniques such as pulse width modulation (PWM).

In a second example, the a nominal paddle angle may be set at <NUM>°, the oscillation angle range between a lower oscillation peak value of <NUM>° and an upper oscillation peak value of <NUM>°, while the oscillation period value may be set to <NUM> second. This would result in the controller oscillating the paddle angles of spreader wheels <NUM>/<NUM> between <NUM>° and <NUM>° every second. In practice the oscillation behavior is achieved by a combination of motor control techniques and mechanisms that convert rotational movement of the motor to linear movement.

In either case, when the rotational speed or paddle angle is decreased during the oscillation, the residue is thrown at a shorter distance from the combine, whereas when the rotational speed or paddle angle is increased during the oscillation, the residue is thrown at a further distance from the combine. This has the effect of producing a uniform residue spread on the ground.

Paddle angles can be varied in different manners. For example, the pitch angle or the radial angle can be varied in the oscillatory manner described above. These examples are now described below with respect to <FIG> and <FIG>.

For example, <FIG> shows a side view diagram of a residue spreading wheel of a combine showing varying paddle radial angles, according to an embodiment of the invention. As shown on the left side of <FIG>, paddles 120A/122A-120D/122D have radial angle (angle of paddle relative to the radial center of the wheel shown by the dashed line) of θ1=<NUM>°. This large radial angle may be beneficial for increasing friction between the paddles and the residue, thereby imparting increased energy on the residue which results in ejecting residue at a greater distance from the combine. In contrast, the as shown on the right side of <FIG>, paddles 120A/122A-120D/122D have radial angle (angle of paddle relative to the radial center of the wheel shown by the dashed line) of θ1<<NUM><NUM>. This smaller radial angle may be beneficial for decreasing friction between the paddles and the residue, thereby imparting decreased energy on the residue which results in ejecting the residue a shorter distance from the combine. Thus, the combine controller can vary (e.g. oscillate) the radial angle of paddles 120A/122A-120D/122D to control the distance of residue being ejected from the combine. In the example shown in <FIG>, the angle of rotation is shown by the arrow to be clockwise. However, it is noted that the angle of rotation in this example may be counter clockwise.

In another example, <FIG> shows perspective view diagram of a residue spreading wheel of a combine showing varying paddle pitch angles, according to an embodiment of the invention. It is noted that although <FIG> only shows spreader paddle 120C/122C, this is for explanatory purposes.

As shown on the left side of <FIG>, paddle 120C/122C has pitch angle (angle of paddle relative to the rotational plane of the wheel shown by the dashed line) of θ2=<NUM>°. In contrast, the as shown on the right side of <FIG>, paddle 120C/122C has a pitch angle (angle of paddle relative to the rotational plane of the wheel shown by the dashed line) of θ2<<NUM><NUM>. The pitch angle relative to the rotational direction of wheels <NUM>/<NUM> has an effect of either increasing or decreasing the friction between the paddles and the residue, thereby imparting either an increased or decreased energy on the residue which results in ejecting the residue at either a greater or shorter distance from the combine. Thus, the combine controller can therefore vary (e.g. oscillate) the pitch angles of paddles 120A/122A-120D/122D to control the distance of the residue being ejected from the combine.

In either example, varying the radial and/or pitch angles of paddles 120A/122A-120D/122D is performed by actuators (not shown) within the spreader wheel connected to paddles 120A/122A-120D/122D. The actuators are controlled by the combine controller to vary the angles of paddles 120A/122A-120D/122D.

The pathways shown in <FIG> are typical for a plot of land <NUM> that is to be harvested. Typically, as harvesting is performed, the combine may employ residue system <NUM> to perform spreading and/or windrowing of the harvested crops at different locations of the field. For example, the combine may start performing spreading along path <NUM>. Once the combine reaches point <NUM>, a turn is made and spreading is performed along path <NUM>. Once the combine reaches point <NUM>, a turn is made and spreading is performed along path <NUM>. Finally, once the combine reaches point <NUM>, a turn is made and windrowing is performed in a zig-zag pattern along path <NUM>.

In the spreading zones (e.g. while traveling the pathways shown in <FIG>), the combine controls the speeds of wheels <NUM> and <NUM> and/or angles of the wheel paddles 120A/122A-120D/122D in the residue spreading system to achieve a desirable (e.g. uniform) residue spread. The speeds of wheels <NUM> and <NUM> and/or angles of the wheel paddles 120A/122A-120D/122D may initially be set manually by the combine operator, or they may initially be set by the combine controller. When setting these variables manually, the operator may use a number of factors including but not limited to their experience, combine heading, crop type, and weather forecasts (e.g. wind speed/direction). When setting these variables automatically, the combine controller may use a number of factors including but not limited to past results, combine heading, crop type, weather forecasts (e.g. wind speed/direction) and desired spread characteristics (e.g. density, uniformity, etc.).

Once the speeds of wheels <NUM> and <NUM> and/or angles of the wheel paddles 120A/122A-120D/122D are initially set, the combine may monitor an observable output such as images of the spread captured by a camera (not shown) mounted to the combine, and automatically adjust the speeds of wheels <NUM> and <NUM> and/or angles of the wheel paddles based on observable output of the spreader. In the manual adjustment scenario, the initial speeds of wheels <NUM> and <NUM> and/or angles of the wheel paddles 120A/122A-120D/122D are set either using predetermined values or based on operator experience. Once harvesting begins, the operator is able to visually observe the residue spread. If the residue spread is desirable, the operator can simply continue harvesting. If the residue spread is undesirable, the operator can make adjustments (e.g. oscillation peak range, oscillation frequency, nominal frequency, etc.).

<FIG> shows an example of a system for controlling the combine. The system includes an interconnection between a control system <NUM> of combine <NUM>, a remote PC <NUM> and a remote server <NUM> through network <NUM> (e.g. Internet). It should be noted that combine <NUM> does not have to be connected to other devices through a network. The controller of combine <NUM> can be a standalone system that receives operating instructions (e.g. speeds of wheels <NUM> and <NUM> and/or angles of the wheel paddles 120A/122A-120D/122D) through a user interface, or through a removable memory device (e.g. Flash Drive).

Prior to operating combine <NUM>, an operator may designate grain information (e.g. type of grain, moisture content of grain, etc.) as well as speeds of wheels <NUM> and <NUM> and/or angles of the wheel paddles 120A/122A-120D/122D. In one example, the operator uses interface <NUM> of the combine control system or PC <NUM> located at remote location <NUM>. Interface <NUM> and PC <NUM> allow the operator to view locally stored parameters from memory device <NUM> and/or download parameters from server <NUM> through network <NUM>. The operator may select (via Interface <NUM> or PC <NUM>) appropriate speeds of wheels <NUM> and <NUM> and/or angles of the wheel paddles 120A/122A-120D/122D based on various factors including, among others, the type of crop to be harvested by the combine, and the terrain. Once the speeds of wheels <NUM> and <NUM> and/or angles of the wheel paddles 120A/122A-120D/122D are selected, the operator can begin harvesting. Combine controller <NUM> then controls spreader wheel rotational motors <NUM> (e.g. electric motors, hydraulic motors, hydraulic valves, etc.) and/or valves and spreader wheel paddle angle actuators <NUM> based on the instructions. It is noted that harvesting may also be tracked and aided by GPS receiver <NUM>.

<FIG> is a view of the communication between the combine controller and the spreader wheel drive system, according to an embodiment of the invention. In this example, combine controller <NUM> controls left-side spreader wheel rotational motor(s) and/or valves 318A (e.g. electric motors for electrically driven wheels <NUM>/<NUM>, or hydraulic valves and/or hydraulic motors for hydraulically driven wheels <NUM>/<NUM>) for controlling rotational speed of wheels <NUM>/<NUM>, and left-side spreader wheel paddle actuators 326A for controlling radial/pitch angle of paddles 120A/122A-120D/122D. Combine controller <NUM> also controls right-side spreader wheel rotational motor(s) and/or valves 318B (e.g. electric motors for electrically driven wheels <NUM>/<NUM>, or hydraulic valves and/or hydraulic motors for hydraulically driven wheels <NUM>/<NUM>) for controlling rotational speed of wheels <NUM>/<NUM>, and right-side spreader wheel paddle actuators 326B for controlling radial/pitch angle of paddles 120A/122A-120D/122D.

Control of devices 318A/326A may be independent of control of devices 318B/326B. For example, devices 318A/326A may be controlled to vary wheel rotational speed and/or paddle angles of the left side spreader according to a first independent algorithm, while devices 318B/326B may be controlled to vary wheel rotational speed and/or paddle angles of the right side spreader according to a second independent algorithm. Conversely, control of devices 318B/326B may be dependent on control of devices 318B/326B and vice versa. In one example, 318A/326A and 318B/326B may be controlled increase rotational speed of left-side wheel <NUM> and the rotational speed of right-side wheel <NUM> in sync with one another. In another example, 318A/326A may be controlled to increase rotational speed of left-side wheel <NUM> while 318B/326B is controlled to decrease the rotational speed of right-side wheel <NUM>, and vice versa. This alternating type of controller allows peak power consumption of the spreader wheels to be reduced while also allowing power to be recycled in certain scenarios. For example, when the speed of wheel <NUM> is increased and <NUM> is decreased, peak power is reduced because only one motor is consuming power at a time. In addition, when the motors driving wheels <NUM>/<NUM> are electric motors, the braking of electric motor <NUM>, for example, will generate electrical power that can be recycled and fed to electric motor <NUM> (and vice versa) or stored in a battery (not shown) for later use.

In order to set the spreader wheel rotational speed and paddle angle parameters discussed above, the operator may use an interface <NUM> as shown in <FIG> where the various parameters and data are displayed to the operator and are modifiable through a graphical user interface (GUI) <NUM>. These may include a view of the map <NUM> with designated zones (e.g. spreading zones), land grade (not shown), current operational mode (spreading/windrow modes), and operational parameters/states for the spreader wheels, chopper, counter knives, windrow door, spreader wheels, spreader deflectors, etc. These parameters (e.g. nominal speed/angle values, oscillation period, and oscillation range) may be set or changed by the operator prior to harvesting or during harvesting. The operator can use a stylus or their finger on the touchscreen to set these parameters.

<FIG> is a flowchart showing a method <NUM> for controlling the rotational speed of the spreader wheels for achieving a uniform residue spread pattern. In step <NUM>, the controller or operator sets the oscillation parameters (e.g. nominal speed, oscillation period, oscillation speed range) of the spreader wheels. In step <NUM>, the controller controls the electric motors and/or hydraulic valves of the spreader wheels <NUM>/<NUM> to oscillate rational speed of spreader wheels <NUM>/<NUM> based on these parameters. Either the operator observes the output spread or the combine, via a camera (not shown), monitors the output spread in step <NUM>. If the output spread is determined to be desirable (e.g. uniform) in step <NUM>, then the spreading continues using the same parameters. However, if the output spread is determined to be undesirable (e.g. non-uniform) in step <NUM>, then the operator or the controller adjusts one or more of the parameters in step <NUM> with the goal of achieving a desirable output spread.

<FIG> is a flowchart showing a method <NUM> for controlling the angles of the spreader wheel paddles for achieving a uniform residue spread pattern. In step <NUM>, the controller or operator sets the oscillation parameters (e.g. nominal paddle angle, oscillation period, oscillation angle range) of the spreader wheel paddles. In step <NUM>, the controller controls the actuators of the paddles to oscillate the angles (e.g. pitch/radial angles) of the paddles based on these parameters. Either the operator observes the output spread or the combine, via a camera (not shown) monitors the output spread in step <NUM>. If the output spread is determined to be desirable (e.g. uniform) in step <NUM>, then the spreading continues using the same parameters. However, if the output spread is determined to be undesirable (e.g. non-uniform) in step <NUM>, then the operator or the controller adjusts one or more of the parameters in step <NUM> with the goal of achieving a desirable output spread.

Although <FIG> and <FIG> are described with respect to achieving a uniform spread, there could be scenarios where a non-uniform spread is desirable. In such a scenario, the operator or the controller adjusts sets/adjusts the parameters with the goal of achieving a non-uniform spread. This may include an oscillation behavior that is not symmetrical like the sinusoidal behavior shown in <FIG>.

In addition, although <FIG> and <FIG> are described as separately controlling the rotational speed of the spreader wheels and the angles of the paddles, these control methods could be combined. In such a scenario, the operator or controller could set both oscillation rotational speed parameters and oscillation paddle angle parameters. The controller could then oscillate both the rotational speed and the paddle angles in a manner that produces a uniform output spread (e.g. rational speed and paddle angle can decrease/ increase at the same time).

Steps <NUM>-<NUM> of <FIG> and <FIG> are performed by controller <NUM> upon loading and executing software code or instructions which are tangibly stored on a tangible computer readable medium <NUM>, such as on a magnetic medium, e.g., a computer hard drive, an optical medium, e.g., an optical disc, solid-state memory, e.g., flash memory, or other storage media known in the art. Thus, any of the functionality performed by the controller <NUM> described herein, such as the steps shown in <FIG> and <FIG>, are implemented in software code or instructions which are tangibly stored on a tangible computer readable medium. Upon loading and executing such software code or instructions by the controller <NUM>, the controller <NUM> may perform any of the functionality of the controller <NUM> described herein, including the steps shown in <FIG> and <FIG> described herein.

It is to be understood that the operational steps are performed by the controller <NUM> upon loading and executing software code or instructions which are tangibly stored on a tangible computer readable medium, such as on a magnetic medium, e.g., a computer hard drive, an optical medium, e.g., an optical disc, solid-state memory, e.g., flash memory, or other storage media known in the art. Thus, any of the functionality performed by the controller <NUM> described herein is implemented in software code or instructions which are tangibly stored on a tangible computer readable medium. Upon loading and executing such software code or instructions by the controller <NUM>, the controller <NUM> may perform any of the functionality of the controller <NUM> described herein, including any steps of the methods described herein.

Claim 1:
A combine (<NUM>) comprising:
a feeder housing (<NUM>) for receiving harvested crop;
a separating system (<NUM>) for threshing the harvested crop to separate grain from residue;
a residue spreader wheel (<NUM>, <NUM>) spinning for expelling the residue from the combine (<NUM>); and
a controller (<NUM>) that controls the combine (<NUM>),
characterized in that,
the controller (<NUM>) is configured to control the residue spreader wheel (<NUM>, <NUM>) to continuously oscillate between a first speed less than a nominal speed and a second speed greater than the nominal speed while spreading the residue.