Patent ID: 12225849

DETAILED DESCRIPTION OF THE INVENTION

Aspects of the disclosure provide methods and systems for determining grain loss based on frequency content of grain impacts. In various embodiments described throughout the specification, the system samples the frequency content of impacts for collected grain, and then adjusts the analysis of the frequency content of impacts for lost grain.

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 toFIG.1A, there is shown one embodiment of an agricultural harvester in the form of a combine10(e.g. longitudinal rotary combine), which generally includes a chassis12, ground engaging wheels14and16, a header18, a feeder housing20, an operator cab22, a threshing and separating system24, a cleaning system26, a grain tank28, and an unloading auger30.

Front wheels14are larger flotation type wheels, and rear wheels16are smaller steerable wheels. Motive force is selectively applied to front wheels14through a power plant in the form of a diesel engine32and a transmission (not shown). Although combine10is shown as including wheels, is also to be understood that combine10may include tracks, such as full tracks or half-tracks.

Header18is mounted to the front of combine10and includes a cutter bar34for severing crops from a field during forward motion of combine10. A rotatable reel36feeds the crop into header18, and a double auger38feeds the severed crop laterally inwardly from each side toward feeder housing20. Feeder housing20conveys the cut crop to threshing and separating system24, and is selectively vertically movable using appropriate actuators, such as hydraulic cylinders (not shown).

Threshing and separating system24generally includes a rotor40at least partially enclosed by and rotatable within a corresponding perforated concave42. The cut crops are threshed and separated by the rotation of rotor40within concave42, and larger MOG elements, such as stalks, leaves and the like are discharged from residue system70of combine10. 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 concave42. A grain loss sensor referred to as a rotor loss plate94may be positioned at or near the end of perforated cage42. Rotor loss plate94may be a metal plate for detecting impacts of grain and MOG by way of sensing electronics enclosed therein. For example, rotor loss plate94may include an accelerometer for measuring vibrations caused by grain and MOG impacts. The frequencies the plate vibrations due to the impact can then be used to determine how much grain is hitting rotor loss plate94(e.g. this may be the rate of grain impacts or the total number of grain impacts). This determination can be quantified as rotor grain loss (e.g. grain that separating assembly24did not properly separate from the MOG). Based on the rotor loss information, the combine controller (not shown) can adjust parameters (e.g. rotor speed, concave42positioning, etc.) of separating assembly24in an attempt to reduce future rotor grain loss.

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 combine10.

Grain which has been separated by the threshing and separating assembly24falls onto a grain pan44and is conveyed toward cleaning system26. Cleaning system26may include an optional pre-cleaning sieve46, an upper sieve48(also known as a chaffer sieve), a lower sieve50(also known as a cleaning sieve), and a cleaning fan52. Grain on sieves46,48and50is subjected to a cleaning action by fan52which 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 hood54of combine10. Grain pan44and pre-cleaning sieve46oscillate in a fore-to-aft manner to transport the grain and finer non-grain crop material to the upper surface of upper sieve48. Upper sieve48and lower sieve50are vertically arranged relative to each other, and likewise oscillate in a fore-to-aft manner to spread the grain across sieves48,50, while permitting the passage of cleaned grain by gravity through the openings of sieves48,50.

The remaining non-grain crop material (i.e. residue) proceeds through a residue handling system70. Residue handling system70includes a chopper, a chopper pan, counter knives, a windrow door, a windrow chute and a residue spreader, which are not shown inFIG.1A. When combine10is operating in the chopping and spreading mode, the chopper is set to a relatively high speed (e.g. 3,000 RPM), 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 6 inches or less and spread on the ground in a fairly uniform manner. In contrast, when combine10is operating in the windrow mode, the chopper is at a relatively low speed (e.g. 800 RPM), 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.

Similar to rotor loss sensor94, another grain loss sensor referred to as a residue loss plate92may be positioned in residue system70. Residue loss plate92may also include an accelerometer for measuring vibrations caused by grain and MOG impacts. The frequencies of these vibrations can then be used to determine how much grain being thrown by the chopper is hitting residue loss plate92. This determination can be quantified as residue grain loss (e.g. grain that residue handling system70is ejecting from the combine). Based on the residue loss information, the combine controller (not shown) can adjust parameters (e.g. chopper speed/positioning, etc.) of residue handling system70in an attempt to reduce future residue grain loss.

The clean grain output by separating assembly24falls to a clean grain auger56positioned crosswise below and in front of lower sieve50. Clean grain auger56receives clean grain from each sieve48,50and from bottom pan58of cleaning system26. Tailings from cleaning system26fall to a tailings auger trough62. The tailings are transported via tailings auger64and return auger66to the upstream end of cleaning system26for repeated cleaning action. Clean grain auger56conveys the clean grain laterally to conveyor system including a generally vertically arranged grain elevator60for transport to grain tank28.

Similar to loss sensors92/94, another impact sensor referred to as sampling plate90may be positioned in grain tank28. Sampling plate90may include an accelerometer for measuring vibrations caused by grain impacts as the clean grain is conveyed from grain elevator60into the grain tank. The frequencies of these vibrations can then be used to determine the impact frequencies of the grain hitting sampling plate90. This determination can be quantified as clean grain frequency information (e.g. the vibrational frequency of the plate due to the impact of the grain free of any MOG). Based on the clean grain frequency information, the combine controller (not shown) can filter the frequencies of the vibrations determined by loss sensors92/94in order to specifically look for frequencies that coincide with grain impacts (not MOG impacts). This can be accomplished by band bass filtering the frequencies detected loss sensors92/94, where the parameters of the band bass filter are set based on the clean grain frequency information. More details of this process is discussed below with reference to other figures.

A pair of grain tank augers68at the bottom of grain tank28convey the clean grain laterally within grain tank28to unloading auger30for discharge from combine10. The clean grain sent to unloading auger30may be discharged from combine10to an adjacent grain cart110(seeFIG.1B) for storing the harvested grain. More specifically, as shown atFIG.1B, combine10includes grain bin102for storing grain and unload tube108for carrying grain from grain bin102to grain cart110when a fill level sensor112detects that the grain has reached a certain level. Combine10includes a controller104in cab106, and a transceiver (not shown). Grain cart110may also include a transceiver114for communicating with combine transceiver116, bin level sensor112and a grain impact sensor such as sampling plate90(e.g. sampling plate90can be located in grain tank28or in grain cart110. In some embodiments, exemplary controllers may be placed at different locations within the cab or other locations on the combine. In the example ofFIG.1B, the level of grain in grain bin102is detected by a bin level sensor116, while the level of grain in grain cart110is detected by bin level sensor112. The controller may control the combine to send grain from grain bin102to grain cart110, and measure both levels to ensure that grain does not spill either from grain bin102or grain cart110.

FIG.2Ashows details of clean grain collection within grain tank28. As described above, grain elevator60transports the clean grain vertically along path202A. Upon reaching the top of the elevator, the clean grain falls onto sampling plate90and then falls into grain tank28along path202B. Sampling plate90detects the frequencies of the clean grain impacts. This clean grain frequency information is then sent to the combine controller for processing (e.g. to determine band bass filter parameters for filtering the frequency information from loss plates92/94).

FIG.2Bshows details of residue handling system70. For example, as shown inFIG.2B, residue handling system70includes windrow door104, windrow chute108, chaff pan106, spreader impeller110, spreader deflectors (not shown), chopper114and chopper pan116. Although not shown inFIG.2B, windrow door actuator, windrow chute actuator, spreader wheel system, spreader deflectors, and chopper114are electrically connected to combine controller10. As described above, chopper114rotates and propels MOG (and any grain that was not properly separated from the MOG) towards the back of residue system70along path204A. The MOG and grain then impacts residue loss plate94and is ejected from the combine via path204B. Residue loss plate94detects the frequencies of the grain and MOG impacts and sends this residue loss frequency information to the combine controller for processing (e.g. determine residue system grain loss).

FIG.3shows an example of a system for controlling the combine. The system includes an interconnection between a control system320of combine10, a remote PC306and a remote server302through network300(e.g. Internet). It should be noted that combine10does not have to be connected to other devices through a network. The controller of combine10can be a standalone system that receives operating instructions (e.g. grain loss alerts, etc.) through a user interface, or through a removable memory device (e.g. Flash Drive).

Prior to operating combine10, an operator may designate grain information (e.g. type of grain, moisture content of grain, etc.) as well as grain loss alert levels. This grain information may also be determined by analyzing images of the grain captured by a camera (not shown). In one example, the operator uses interface304of the combine control system or PC306located at remote location308. Interface304and PC306allow the operator to view locally stored parameters from memory device316and/or download parameters from server302through network300. The operator may select (via Interface304or PC306) appropriate grain loss alert levels based on various factors including, among others, the type of crop to be harvested by the combine, and the terrain. Once the grain loss alert levels are selected, the operator can begin harvesting. Combine controller310then controls actuators314(e.g. thresher, chopper, etc.) based on the instructions. For example, the loss plate324may be used during harvesting to compare the detected grain loss to alert levels set by the operator. When a specified grain loss level is reached, the alert output to the operator. Harvesting may also be tracked and aided by GPS receiver312.

During harvesting, controller310, in conjunction with sample plate318determines optimal grain impact frequency filtering parameters which are used to filter the frequency information from loss plates324to determine accurate grain loss information. A detailed example of this operation is now described with reference toFIG.4Awhich shows the communication between the combine controller310, sample plate90and loss plates92/94.

In general sample plate90and loss plates92/94have a similar structure that includes an impact sensors400A/402A and optional filters400B/402B. Impact sensors400A/402A may be any type of transducer that is able to determine impact frequency. For example, impact sensors400A/402A may include an accelerometer mounted to the plate that detects physical vibrations of the plate, or a microphone mounted in proximity to the plate that detects sound caused by the physical vibrations of the plate. Optional filters400B/402B may be band pass filters having a band that is set by the manufacturer to detect vibrations in a given range that coincides with known grain impact frequencies, while suppressing non-grain vibrations such as vibrations caused by the combine engine and other combine actuators. This band may be fairly large given the wide range of possible grains that are to be detected.

In order to accurately filter the frequency information output from sample plate90and loss plates92/94, an adaptive filter310A is employed. Although shown as being part of combine controller310, it is noted that adaptive filter310A may be separate from combine controller310(e.g. adaptive filter310A may be an intermediary between combine controller310and impact plates90/92/94. In either case, combine controller310A is able to adjust parameters (e.g. center frequency of the pass band, cutoff frequencies, etc.) of adaptive filter310A.

During operation, as clean grain404hits sample plate90, impact sensor400A detects and passes the impact frequencies to combine controller310for further processing. Also, during operation, as residue406(e.g. grain and/or MOG) hits loss plates92/94, impact sensor402A detects and passes the impact frequencies to combine controller310A for further processing. Knowing that the impact frequencies of the clean grain can be used as a frequency signature, combine controller310uses the impact frequencies of the clean grain to adjust parameters of adaptive filter310A. Combine controller310then uses adaptive filter310A to filter the impact frequencies received from impact sensor402A. This effectively passes the frequencies that coincide with the clean grain, while suppressing the unwanted frequencies of the MOG. The combine controller310is then able compute accurate grain loss data based on these filtered frequencies (e.g. grain hits are used, while MOG hits are ignored). This ensures that MOG hits are not accidentally counted as part of the grain loss analysis.

An example frequency plot of a clean grain hit on sample plate90is shown in the data plot ofFIG.4B. In this example, a clean grain hit causes a large spike408in intensity at frequency F1which is larger than an intensity threshold, while surrounding noise410is less than the intensity threshold due to the absence of MOG. The intensity threshold may be set by combine controller310in order to distinguish between hits and other vibrational noise. It is noted that F1is not stationary and may vary due to various factors. These factors including but are not limited to type of grain and grain moisture level which both affect grain density, and therefore how hard or soft a piece of grain is when it hits plates90/92/94. In general, as moisture content increases, impact frequency decreases and vice versa. Thus, hit frequency F1can increase or decrease according to these factors.

Applicant's system accounts for these variations in F1by periodically sampling the impact frequencies of the clean grain in order to adjust the parameters of the adaptive filter. For example, if impact frequencies of the clean grain decrease due to moisture, combine controller310adjusts the parameters of adaptive filter310A to pass lower impact frequencies received from impact sensor402A. This effectively passes the frequencies that coincide with the wet grain, while suppressing the frequencies of the MOG, thereby leading to more accurate loss data.

FIG.5is a flowchart for determining the frequency of the clean grain and then filtering the frequencies output by loss plates92/94to determine an accurate accounting of grain loss. In step500, combine controller310controls sample plate90to sample the impact frequencies of clean grain. This sampling may occur over a given amount of time over numerous impacts to determine an accurate reading of impact frequencies of clean grain (e.g. the vibrational frequencies caused by impacts of clean grain). In step502, combine controller310then determines a frequency signature (e.g. center frequency and bandwidth) based on the impact frequencies of clean grain (e.g. average center frequency, average bandwidth, etc.) on sample plate90. A frequency band of a set range at a set center frequency may be set as the frequency signature to be used to adjusting the adaptive filter. In step504, combine controller310then sets the parameters of the adaptive filter to pass this frequency signature. Combine controller310then compares the filtered frequencies detected by loss plates92/94to an intensity threshold to determine if a grain impact is detected or not. In step506, combine controller310then computes grain loss (e.g. grain lost per unit time, percentage of grain lost to grain collected, total weight of grain lost, etc.) based on this information. In one example, combine controller310can display the grain loss to the combine operator. The combine operator may then manually adjust combine operational parameters (e.g. harvesting speed, rotor speed, etc.) in an attempt to reduce grain loss. In another example, combine controller310may use the grain loss to automatically adjust combine operational parameters (e.g. harvesting speed, rotor speed, etc.) in an attempt to automatically reduce grain loss. In step508, combine controller310determines if and when the process should be repeated. This decision may be based on a predetermined time schedule (e.g. periodic sampling of clean grain) or based on a trigger. The trigger may be manually provided by the operator, or may be automatic based on varying conditions (e.g. increase/decrease in grain loss, terrain changes, moisture detections, weather conditions, etc.). These varying conditions may be detected by sensors such as moisture sensors, cameras or the like.

The steps of sampling grain, determining the frequency of the sampled grain, setting the filter frequency, computing the grain loss and controlling the combine based on the grain loss shown in steps500-508ofFIG.5are performed by controller310upon loading and executing software code or instructions which are tangibly stored on a tangible computer readable medium316, 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 controller310described herein, such as the steps shown inFIG.5, 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 controller310, the controller310may perform any of the functionality of the controller310described herein, including the steps shown inFIG.5described herein.

It is to be understood that the operational steps are performed by the controller310upon 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 controller310described 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 controller310, the controller310may perform any of the functionality of the controller310described herein, including any steps of the methods described herein.

The term “software code” or “code” used herein refers to any instructions or set of instructions that influence the operation of a computer or controller. They may exist in a computer-executable form, such as machine code, which is the set of instructions and data directly executed by a computer's central processing unit or by a controller, a human-understandable form, such as source code, which may be compiled in order to be executed by a computer's central processing unit or by a controller, or an intermediate form, such as object code, which is produced by a compiler. As used herein, the term “software code” or “code” also includes any human-understandable computer instructions or set of instructions, e.g., a script, that may be executed on the fly with the aid of an interpreter executed by a computer's central processing unit or by a controller.

Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather various modifications may be made in the details within the scope and range of equivalence of the claims and without departing from the invention.