Patent Description:
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 be 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.

Document <CIT> discloses an impact sensor system for a header of an agricultural system according to the preamble of claim <NUM>.

These embodiments are not intended to limit the scope of the claimed subject matter, but rather these embodiments are intended only to provide a brief summary of possible forms of the disclosure. Indeed, the disclosure may encompass a variety of forms that may be similar to or different from the embodiments set forth below.

In one embodiment, an impact sensor system for a header of an agricultural system includes a damping feature configured to couple to the header to attenuate vibrations due to initial contact between a crop and the header to form attenuated vibrations. The impact sensor system also includes one or more sensors configured to couple to the header and to generate signals in response to detection of the attenuated vibrations. The impact sensor system further includes a controller configured to receive the signal and process the signals to determine a location of the initial contact between the crop and the header.

In one embodiment, a method includes operating a header to harvest crops as the header travels through a field and damping, via a damping feature coupled to the header, vibrations generated due to an initial contact between a portion of the crops and the header. The method also includes generating, via one or more sensors coupled to the header, signals indicative of the vibrations after the damping via the damping feature. The method further includes processing, via one or more processors, the signals to determine a location of the initial contact between the portion of the crop and the header.

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 header (e.g., 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 embodiments 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, damping features are utilized in combination with the one or more sensors to facilitate detection of the location of the initial contact between the ears of corn and the deck plates. For example, the damping features may include plastic or other non-metallic components of the row units, such as a hood between adjacent row units along the width of the header. As another example, the damping features may include a variable damping material incorporated into or added onto the row units, such as tapered foam or rubber pads coupled to the deck plates.

The damping features effect a variation in vibrations (e.g., variably alter the vibrations) measured by the one or more sensors as the location of the initial contact with the deck plates relative to the longitudinal axis of the header changes. In particular, the damping features cause greater variation in the vibrations, which results in greater variation in the signals generated by the sensors, as the location of the initial contact with the deck plates relative to the longitudinal axis of the header changes. In turn, this enables reliable and/or accurate assessment of the location of the initial contact with the deck plates (e.g., more reliable and/or accurate as compared to other techniques, such as the use of one or more sensors on metal components of the row units as the metal components provide little amplitude attenuation or delay).

With the foregoing in mind, <FIG> is a side view of an embodiment of an agricultural system <NUM>, which may be a harvester. The agricultural system <NUM> includes a chassis <NUM> configured to support a header <NUM> (e.g., a corn header) and an agricultural crop processing system <NUM>. The header <NUM> is configured to separate a portion of crops (e.g., ears of corn) from stalks and to transport the portion of the crops toward an inlet <NUM> of the agricultural crop processing system <NUM> for further processing of the portion of the crops. The header <NUM> may also return other portions of the crops (e.g., material other than grain [MOG], such as stalks) to a field.

The agricultural crop processing system <NUM> receives the portion of the crops from the header <NUM> and separates desired crop material from crop residue. For example, the agricultural crop processing system <NUM> may include a thresher <NUM> having a cylindrical threshing rotor that transports the crops in a helical flow path through the agricultural system <NUM>. In addition to transporting the crops, the thresher <NUM> may separate certain desired crop material (e.g., grain) from the crop residue, such as husks and pods, and may enable the desired crop material to flow into a cleaning system <NUM> (such as sieves) located beneath the thresher <NUM>. The cleaning system <NUM> may remove debris from the desired crop material and transport the desired crop material to a storage tank <NUM> within the agricultural system <NUM>. When the storage tank <NUM> is full, a tractor with a trailer may pull alongside the agricultural system <NUM>. The desired crop material collected in the storage tank <NUM> may be carried up by an elevator and dumped out of an unloader <NUM> into the trailer. The crop residue may be transported from the thresher <NUM> to a crop residue handling system <NUM>, which may process (e.g., chop/shred) and remove the crop residue from the agricultural system <NUM> via a crop residue spreading system <NUM> positioned at an aft end of the agricultural system <NUM>. To facilitate discussion, the header <NUM> may be described with reference to a lateral axis or direction <NUM>, a longitudinal axis or direction <NUM>, and a vertical axis or direction <NUM>. The agricultural system <NUM> and/or its components may also be described with reference to a direction of travel <NUM>.

In the illustrated embodiment, the agricultural system <NUM> may include one or more actuators configured to manipulate the spatial orientation and/or position of the header with respect to the agricultural system chassis, and/or the spatial orientation of the header with respect to the crop rows/ground/soil. A header height actuator <NUM> may drive the header <NUM> to move along the direction <NUM> relative to the ground. The header <NUM> may be attached to the chassis via a four bar linkage. The position of the four bar linkage may be manipulated by the header height actuator <NUM> to adjust the height of the header. The agricultural system <NUM> may also include a header orientation actuator <NUM>. The header orientation actuator <NUM> may be configured to rotate the angular orientation of the header <NUM> (e.g., the entire header <NUM> or a portion thereof) relative to the ground. The actuators may be manipulated in response to one or more stimuli to adjust the agricultural system <NUM> to 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 header <NUM>, 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 and certain portions (e.g., deck plates) of the header <NUM> relative to the longitudinal axis <NUM> of the header <NUM>. In some embodiments, the actuators may be manipulated based on the location of the initial contact.

<FIG> is a perspective view of an embodiment of the header <NUM> that may be employed within the agricultural system <NUM> of <FIG>. In the illustrated embodiment, the header <NUM> is a corn header and includes multiple dividers <NUM> configured to separate rows of a crop (e.g., corn). The dividers <NUM> may be distributed across a width of the header <NUM> (e.g., along the lateral axis <NUM>). As the header <NUM> moves along a path, the dividers <NUM> may direct the crops from each row to one or more row units <NUM>. The row units <NUM> are configured to separate a portion of each crop (e.g., an ear of corn from a stalk of each crop), thereby separating the portion of the crop from the soil. The portion of the crop may be directed toward one of a pair of conveyors <NUM> (e.g., augers) configured to convey the portion of the crop laterally inward to a center crop conveyor <NUM> at a center of the header <NUM>, and the center crop conveyor <NUM> directs the portion of the crop toward the inlet of the agricultural crop processing system. As illustrated, the conveyors <NUM> extend along a substantial portion of the width of the header <NUM> (e.g., along the lateral axis <NUM>). The conveyors <NUM> may be driven by a drive mechanism (e.g., electric motor, hydraulic motor). The row units <NUM> may also return other portions of the crops (e.g., MOG, such as stalks) to the field.

<FIG> is a perspective front view of an embodiment of a portion of the header <NUM>. As shown, the portion of the header <NUM> includes the multiple dividers <NUM> that direct the crops to one or more row units <NUM>. Each row unit <NUM> includes 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 conveyors <NUM>, and return the stalks to the field. For example, each row unit <NUM> may include a pair of stalk rollers <NUM> that are configured to grip the stalks and rotate in opposite directions to push the stalks toward the field (e.g., vertically downward; below the header <NUM>). Each row unit <NUM> also includes a pair of deck plates <NUM> that are positioned over the pair of stalk rollers <NUM>. Each deck plate <NUM> extends from a first end to a second end along the longitudinal axis <NUM>, and the pair of deck plates <NUM> are separated from one another along the lateral axis <NUM> to define a gap <NUM>. Further, each row unit <NUM> may include a pair of chains <NUM> (e.g., with lugs) that are configured to drive or push the desired crop material along the pair of deck plates <NUM> toward the conveyors <NUM>. The pair of deck plates <NUM> are spaced apart so that the gap <NUM> is sized to enable the stalks to fall through the gap <NUM>, but to block the desired crop material from falling through the gap <NUM>. Thus, the pair of stalk rollers <NUM> and the pair of deck plates <NUM> operate to separate the desired crop material from the stalks (e.g., the pair of stalk rollers <NUM> push the stalks toward the field, while the desired crop material is blocked from falling through the gap <NUM> between the pair of deck plates <NUM>). In some embodiments, the pair of deck plates <NUM> are adjustable and may be driven (e.g., via an actuator) toward and away from one another along the lateral axis <NUM> to change a size of the gap <NUM>. A hood <NUM> is positioned rearward of each divider <NUM> and between adjacent row units <NUM> to cover various components, such as the actuator that drives the pair of deck plates <NUM>, linkages, and so forth. It should be appreciated that certain hoods <NUM> (e.g., two hoods <NUM>) may be positioned adjacent to side walls of the header <NUM>, and thus, are positioned adjacent to one row unit <NUM> and one side wall of the header <NUM> (e.g., each hood <NUM> may be positioned adjacent to at least one row unit <NUM> or pair of deck plates <NUM>).

As noted herein, for good harvesting performance, the crop should make initial contact with the pair of deck plates <NUM> toward a forward portion of the pair of deck plates <NUM> relative to the longitudinal axis <NUM> or the forward direction of travel <NUM> of the header <NUM> (e.g., a forward half; forward of a midpoint of the pair of deck plates <NUM> along the longitudinal axis <NUM>; a target impact region). This may enable the stalks to be completely discharged from the header <NUM> before reaching a rear portion of the pair of deck plates <NUM>, thereby reducing a likelihood of the stalks being fed into the conveyors <NUM>. Accordingly, an impact sensor system may include one or more sensors (e.g., knock sensors; vibration sensors) on the header <NUM>, 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 plates <NUM> (e.g., along a length of the pair of deck plates <NUM>; between the first end and the second end of the pair of deck plates <NUM>).

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 header <NUM>) 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 header <NUM> and/or a rotation rate of the pair of stalk rollers <NUM>. 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 <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> percent over <NUM>, <NUM>, or <NUM> seconds), the controller may instruct output of the visual alarm and/or the audible alarm, raise the header <NUM> relative 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 plates <NUM>) 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 <NUM>, <NUM>, <NUM> 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 header <NUM>). Further, the controller <NUM> 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 <NUM> 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 header <NUM> to provide or to cause desirable impact locations (e.g., within the target impact region).

<FIG> is a perspective front view of an embodiment of a portion of the header <NUM>, with one of the dividers of between adjacent row units <NUM> removed to show the hood <NUM> between the adjacent row units <NUM>. As noted herein, the impact sensor system may include one or more sensors positioned on the header, and the one or more sensors are configured to generate signals indicative of the location of the initial contact between the crop and the pair of deck plates. It is presently recognized that it may be advantageous to use damping features in combination with the one or more sensors to facilitate detection of the location of the initial contact.

With the foregoing in mind, the damping features may include the hood <NUM>, which is formed from a plastic material or other non-metal material. Accordingly, as shown, the impact sensor system may include a first sensor <NUM> (e.g., knock sensor; vibration sensor) and a second sensor <NUM> (e.g., knock sensor; vibration sensor) coupled to the hood <NUM>. In particular, the first sensor <NUM> is coupled to the hood <NUM> at a first location of the hood <NUM> (e.g., proximate a rearward edge of the hood <NUM> relative to the direction of travel <NUM>) and the second sensor <NUM> is coupled to the hood <NUM> at a second location of the hood <NUM> (e.g., proximate a forward edge of the hood <NUM> relative to the direction of travel <NUM>). Thus, the first sensor <NUM> and the second sensor <NUM> are separated from one another by a distance <NUM> (e.g., along the longitudinal axis <NUM>). The hood <NUM>, which acts as the damping feature, affects a variation in vibrations measured by the first sensor <NUM> and the second sensor <NUM> as the location of the initial contact with the pair of deck plates relative to the longitudinal axis <NUM> of the header <NUM> changes. In particular, coupling the first and second sensors <NUM>, <NUM> to the hood <NUM> causes greater variation in the vibrations (e.g., as compared to coupling the first and second sensors to a metal component, such as the pair of deck plates), which results in greater variation in the signals generated by the first and second sensors <NUM>, <NUM>, as the location of the initial contact with the pair of deck plates relative to the longitudinal axis <NUM> of the header <NUM> changes. Because the hood <NUM> is coupled to the pair of deck plates, the first and second sensors <NUM>, <NUM> may detect vibrations due to the initial contact between the crop and the pair of deck plates. Further, because the hood <NUM> is also aligned (e.g., substantially aligned) with the pair of deck plates along the longitudinal axis <NUM>, the crop often strikes the hood <NUM> during (e.g., at the same, or substantially the same, time) the initial contact between the crop and the pair of deck plates. Indeed, the crop may strike the hood <NUM> first (e.g., prior to the deck plates <NUM>) to make the initial contact with the header <NUM>. Accordingly, while certain examples herein refer to the initial contact with the deck plates <NUM> to facilitate discussion, it should be appreciated that this is generally one example of the initial contact with the header <NUM> that may be measured by the impact sensor system. Further, the respective positions of the first and second sensors <NUM>, <NUM> relative to the pair of deck plates are known, and this may be taken into account during processing to determine the location of the initial contact. Additionally, placement of the first and second sensors <NUM>, <NUM> on the hood <NUM> may enable detection and monitoring of both of the adjacent row units <NUM> (e.g., instead of using one pair of sensors dedicated to each of the row units <NUM>), thereby providing relatively fewer signals for processing, cost savings, and so forth.

<FIG> is a schematic diagram of a portion of the header <NUM> with sensors, as well as exemplary graphs of signals generated by the sensors. In one embodiment, the portion of the header <NUM> includes the hood <NUM>, and the sensors include the first sensor <NUM> and the second sensor <NUM> coupled to the hood <NUM>. During harvesting operations, the crop may strike and make initial contact with the hood <NUM> (or some component coupled to the hood <NUM>, such as one of the deck plates) at a location <NUM> (e.g., impact location). In response to the initial contact, the first sensor <NUM> and the second sensor <NUM> detect vibrations and generate respective signals based on the vibrations. For example, the first sensor <NUM> may generate a first signal shown in a first exemplary graph <NUM>, and the second sensor <NUM> may generate a second signal shown in a second exemplary graph <NUM>. Because the first sensor <NUM> is closer to the location <NUM>, a respective amplitude of a first peak <NUM> of the first signal due to the initial contact is greater than a respective amplitude of a second peak <NUM> of the second signal due to the initial contact. Advantageously, the hood <NUM> may attenuate the vibrations (e.g., more attenuation than the metal components, such as the pair of deck plates; form attenuated vibrations), which may increase the variation in the respective amplitudes, which in turn facilitates analysis of the signals and determination of the location <NUM>. It should be appreciated that the hood <NUM> or other damping features disclosed herein may affect the amplitude and/or a time of travel (e.g., slow down or delay) of the vibrations, and one of both of these factors or characteristics (e.g., the amplitude and/or the time of travel) may be analyzed to determine the location <NUM>.

As shown, the impact sensor system includes a controller <NUM> (e.g., electronic controller) with a processor <NUM> and a memory device <NUM>. The controller <NUM> is communicatively coupled to the first and second sensors <NUM>, <NUM>. The controller <NUM> receives and processes the signals (e.g., using one or more algorithms; based on a comparison of the first peak <NUM> to the second peak <NUM>) to determine the location <NUM> of the initial contact, and then the controller <NUM> generates 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 header <NUM> and/or a rotation rate of the pair of stalk rollers. In some embodiments, the controller <NUM> may not provide the alarm(s) and/or the control signals for each occurrence of the location <NUM> being outside of a target impact region <NUM>, 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 region <NUM>, such as more than <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> percent over <NUM>, <NUM>, or <NUM> seconds. Further, it should be appreciated that the controller <NUM> may 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 controller <NUM> may not provide the alarm(s) and/or the control signals if the initial contact of the crop occurs outside of the target impact region <NUM>, 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). Additionally, it should be appreciated that the first and second sensors <NUM>, <NUM> may be positioned on any suitable portion of the header <NUM>, including other non-metal components (e.g., that provide damping) and/or metal components (e.g., the deck plates; with or without additional damping features applied to the metal components).

The processor <NUM> may be used to execute software, such as software for processing signals, controlling the agricultural system, and/or controlling the header <NUM>. Moreover, the processor <NUM> may 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 processor <NUM> may include one or more reduced instruction set (RISC) or complex instruction set (CISC) processors. The memory device <NUM> may include a volatile memory, such as random access memory (RAM), and/or a nonvolatile memory, such as read-only memory (ROM). The memory device <NUM> may store a variety of information and may be used for various purposes. For example, the memory device <NUM> may store processor-executable instructions (e.g., firmware or software) for the processor <NUM> to execute, such as instructions for processing signals, controlling the agricultural system, and/or controlling the header <NUM>. The processor <NUM> may include multiple processors and/or the memory device <NUM> may include multiple memory devices. The processor <NUM> and/or the memory device <NUM>, 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 header <NUM>). Further, the controller <NUM> may 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 header <NUM>, remote, in the cloud).

<FIG> is a schematic diagram of an embodiment of a portion of the header <NUM> with a variable damping element <NUM> and sensors, as well as exemplary graphs of signals generated by the sensors. In one embodiment, the portion of the header <NUM> includes the pair of deck plates <NUM> that define the gap <NUM>, and the sensors include a first sensor <NUM> (e.g., measurement sensor; knock sensor; vibration sensor) and a second sensor <NUM> (e.g., reference sensor; knock sensor; vibration sensor). As shown, the first sensor <NUM> may be coupled to one of the deck plates <NUM>, and the second sensor <NUM> may be coupled to the other one of the deck plates <NUM>. Further, the first sensor <NUM> and the second sensor <NUM> may be coupled at corresponding (e.g., matching) locations of their respective deck plates <NUM> (e.g., along the lateral axis <NUM> and the longitudinal axis <NUM>; both proximate to the first end or both proximate to the second end; both proximate to a laterally inner edge or both proximate to a laterally outer edge).

The variable damping element <NUM> may be applied to the deck plate <NUM> (e.g., under the deck plate <NUM> relative to the vertical axis <NUM>; between the deck plate <NUM> and the ground relative to the vertical axis <NUM>). For example, the variable damping element <NUM> may be a foam or rubber pad (e.g., tapered foam or rubber pad) that is adhered to a bottom surface (e.g., ground-facing surface) of the deck plate <NUM>. The variable damping element <NUM> may be formed from any of a variety of materials that have a higher damping coefficient than steel, for example. It may also be desirable for the variable damping element <NUM> to be formed from a material that is durable and that does not absorb water. As shown, the variable damping element <NUM> may extend from a first end to a second end along the longitudinal axis <NUM>. In some embodiments, the first end of the variable damping element <NUM> is proximate to the first end of the deck plate <NUM> and the second end of the variable damping element is proximate to the second end of the deck plate <NUM>. A thickness of the variable damping element <NUM> varies between the first end and the second end of the variable damping element <NUM>. For example, the variable damping element <NUM> may have a first, greater thickness at the first end, and a second, lesser thickness at the second end (or vice versa with the first, greater thickness at the second end, and the second, lesser thickness at the first end; variable width along the lateral axis <NUM>). Further, the thickness may change gradually and/or linearly between the first end and the second end of the variable damping element <NUM>.

During harvesting operations, the crop may strike and make initial contact with the deck plates <NUM> (e.g., both of the deck plates <NUM>), such as at a first location <NUM> (e.g., impact location). In response to the initial contact, the first sensor <NUM> and the second sensor <NUM> detect vibrations and generate respective signals based on the vibrations. For example, the first sensor <NUM> may generate a first signal with a first peak <NUM> shown in a first exemplary graph <NUM>. However, the second sensor <NUM> may generate a second signal with a second peak <NUM> shown in the first exemplary graph <NUM>.

As the harvesting operations continue, the crop may strike and make initial contact with the deck plates <NUM> (e.g., both of the deck plates <NUM>), such as at a second location <NUM> (e.g., impact location). In response to the initial contact, the first sensor <NUM> and the second sensor <NUM> detect vibrations and generate respective signals based on the vibrations. For example, the first sensor <NUM> may generate a third signal with a third peak <NUM> shown in a second exemplary graph <NUM>. However, the second sensor <NUM> may generate a fourth signal with a fourth peak <NUM> shown in the second exemplary graph <NUM>.

The signals generated by the second sensor <NUM> (e.g., on the deck plate <NUM> that is devoid of the variable damping element <NUM>) act as reference signals to enable the controller <NUM> to account for variations that might occur due to changes in size of the crop, stalk roll speed, and so on. As shown to facilitate discussion, for similar impacts (e.g., force) at the first and second locations <NUM>, <NUM>, the signals generated by the second sensor <NUM> generates the second signal with the second peak <NUM> and the fourth signal with the fourth peak <NUM>, respectively. Further, the second peak <NUM> and the fourth peak <NUM> may have substantially similar amplitudes. However, for the similar impacts (e.g., force) at the first and second locations <NUM>, <NUM>, the first sensor <NUM> generates the first signal with the first peak <NUM> and the third signal with the third peak <NUM>, respectively. Further, the first peak <NUM> and the third peak <NUM> have substantially different amplitudes due to the variable damping element <NUM> (e.g., due to the difference in the thickness of the variable damping element <NUM> between the first location <NUM> and the second location <NUM>; a level of damping varies with position along the deck plates <NUM>; variably attenuate vibrations). As noted herein, the reference signal may be used to scale, adjust, or otherwise account for the changes in size of the crop, stalk roll, speed, and so on so that the peaks in the signals generated by the first sensor <NUM> can be analyzed to accurately determine the location of the initial contact between the crop and the deck plates <NUM>. It should be appreciated that the variable damping element <NUM> disclosed herein may variably alter the amplitude and/or a time of travel (e.g., slow down or delay) of the vibrations, and one of both of these factors or characteristics (e.g., the amplitude and/or the time of travel) may be analyzed to determine the first location <NUM> and the second location <NUM>.

The controller <NUM> receives and processes the signals (e.g., using one or more algorithms) to determines the locations of the respective initial contacts, and then the controller <NUM> generates an appropriate output as described herein (e.g., with reference to <FIG>). It should be appreciated that the first and second sensors <NUM>, <NUM> may be positioned proximate to either the first end or the second end of the deck plates <NUM>, and thus, either the first end or the second end of the variable damping element <NUM>. Further, the variable damping element <NUM> may be incorporated into and/or coupled to any suitable component of the header <NUM>, including the hood. For example, the hood may be molded to have a gradually changing thickness between the first end and the second end of the hood to thereby provide the variable damping element, or the foam or rubber pad may be coupled to the hood to provide the variable damping element.

The variable damping element <NUM> may have other forms and/or configurations. For example, the variable damping element <NUM> may be formed from multiple different materials distributed along the longitudinal axis <NUM>, such that the vibrations (e.g., wavelength; acoustic frequency) generated by the initial contacts vary based on the locations of the initial contacts. Similar effects and variation in the vibrations may be achieved in other ways. For example, the deck plates <NUM> and/or the hoods <NUM> may be formed from multiple different materials and/or have varying dimensions along the longitudinal axis <NUM> (e.g., the deck plates <NUM> may have a variable width relative to the lateral axis <NUM> between the first end and the second end of the deck plates <NUM>), such that the vibrations (e.g., wavelength; acoustic frequency) generated by the initial contacts vary based on the locations of the initial contacts. As another example, the deck plates <NUM> and/or the hoods <NUM> may be split into multiple sections (e.g., segmented), and each section of the multiple sections may be coupled to a respective sensor (e.g., knock sensor, vibration sensor).

<FIG> is a flowchart of an embodiment of a method <NUM> for determining an impact location on a header, such as the header of <FIG>. The method <NUM> may be performed via the controller disclosed herein, or another suitable device. Further, the method <NUM> may be performed differently in additional or alternative embodiments. For instance, additional steps may be performed with respect to the method <NUM>, and/or certain steps of the method <NUM> may be modified, removed, performed in a different order, or a combination thereof. The method <NUM> may be performed based on data received from the sensors of <FIG> and <FIG>, and/or based on data received from the sensors of <FIG>, and/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 plates <NUM>).

At block <NUM>, the controller may receive signals from one or more sensors coupled to (e.g., directly or indirectly) a damping feature on a header. In some embodiments, the one or more sensors may include a first sensor (e.g., knock sensor; vibration sensor) and a second sensor (e.g., knock sensor; vibration sensor) coupled to a plastic or non-metal component of the header, such as a hood of the header. For example, the first sensor may be coupled to the hood at a first location of the hood (e.g., proximate a rearward edge of the hood relative to the direction of travel) and the second sensor may be coupled to the hood at a second location of the hood (e.g., proximate a forward edge of the hood relative to the direction of travel). Thus, the first sensor and the second sensor are separated from one another by a distance (e.g., along the longitudinal axis). The hood, which acts as the damping feature, effects a variation in vibrations measured by the first sensor and the second sensor as the location of the initial contact with the pair of deck plates relative to the longitudinal axis of the header changes. During harvesting operations, the crop may strike and make initial contact with the hood (or some component coupled to the hood, such as one of the deck plates) at a location (e.g., impact location). In response to the initial contact, the first sensor and the second sensor detect vibrations and generate respective signals based on the vibrations.

In some embodiments, the one or more sensors may include a first sensor (e.g., measurement sensor; knock sensor; vibration sensor) and a second sensor (e.g., reference sensor; knock sensor; vibration sensor) each coupled to a respective deck plate of the pair of deck plates of a row unit of the header. A variable damping element may be applied to the respective deck plate with the first sensor. For example, the variable damping element <NUM> may be a foam or rubber pad (e.g., tapered foam or rubber pad) that is adhered to the deck plate. A thickness of the variable damping element varies between a first end and a second end of the variable damping element. During harvesting operations, the crop may strike and make initial contact with the deck plates at a location (e.g., impact location). In response to the initial contact, the first sensor and the second sensor detect vibrations and generate respective signals based on the vibrations.

At block <NUM>, the controller may process the signals to determine the location of initial contact between the crop and the header (e.g., the deck plates of a row unit of the header). For example, the controller may process the signals from the first and second sensors on the hood of the header. In such cases, 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) to determine the location of the initial contact.

As another example, the controller may process the signals from the first and second sensors on the pair of deck plates with the variable damping element. Due to the variable damping element, the first sensor generates signals with peaks of substantially different amplitudes for different locations of initial contact (e.g., due to the difference in the thickness of the variable damping element, a level of damping varies with position along the deck plates). As noted herein, the reference signal may be used to scale, adjust, or otherwise account for the changes in size of the crop, stalk roll, speed, and so on so that the peaks in the signals generated by the first sensor can be analyzed to accurately determine the location of the initial contact between the crop and the header. 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, with consideration of the second peak for reference) to determine the location of the initial contact.

Claim 1:
An impact sensor system for a header (<NUM>) of an agricultural system (<NUM>), wherein the impact sensor system comprises:
a damping feature (<NUM>, <NUM>) configured to couple to the header (<NUM>) to attenuate vibrations due to initial contact between a crop and the header (<NUM>) to form attenuated vibrations;
one or more sensors (<NUM>, <NUM>, <NUM>, <NUM>) configured to couple to the header (<NUM>) and to generate signals in response to detection of the attenuated vibrations; and
a controller (<NUM>) configured to:
receive the signals;
characterized in that the controller is further configured to
process the signals to determine a location of the initial contact between the crop and the header (<NUM>).