AU2017101791A4 - Process Condition Monitoring Apparatus - Google Patents

Abstract

This invention provides an accessory for crop-harvesting machinery, such as a combined harvester and provides a method and means of detecting blockages to the flow of harvested crop matter being processed. The method comprises establishing a flow-monitoring zone through which a particulate stream such as chaff is discharged from the harvester, directing a beam of radiation across the zone when the stream is being discharged; monitoring the beam for disruption, and outputting a response to disruption detected, including an alert to an operator of the harvester. SHEET 1 OF 3 Conventional combine harvester (cut) 1: Reel 11) Top Adjustatle sieve 2) Cutter bar 12) Bottom sieve 3) Header auger 13) Tailings conveyor 4) Grain conveyor 14) Rethreshing of tailings 5) Stone trap 15) Grain auger 6) Threshing drum 16) Grain tank 7) Concave 17) Straw chopper 8) Straw walker 18) Dnvers cat 9: Grain pan 19) Engine 10) Fan 20) Unloading auger 21) Impeller FIGURE 1 (BACKGROUND)

Description

PROCESS CONDITION MONITORING APPARATUS AND METHOD Field of invention [01 ] This invention relates to crop-harvesting machinery, such as a combined harvester machine, and provides a method and means of detecting blockages to the flow of harvested crop matter being processed therein.

Background to the invention [02] Canadian patent 1113581 provides a general description of combine harvesters, stating “In general, the harvesting process of all combines is alike, that is, the material harvested enters the combine through a header portion and is elevated through the elevator housing into the threshing and separating units within the combine. The threshing and separating units receive the unthreshed crop material and generally separate the grain from the straw by means of a rubbing or beating motion. The grain and other unthreshed crop material separated from the straw falls from the threshing and separating units onto the grain handling and cleaning means while the straw is discharged from the rear of the threshing and separating units onto a beater element which expels the threshed straw through an opening in the hood of the combine.” [03] “The grain handling and cleaning means includes means to separate the light straw material or chaff from the grain and means to segregate the unthreshed material (known in the art as tailings) from the grain in order to collect the clean grain in a grain bin or tank located at the top of the combine.” [04] This patent proposes monitoring of airflow through the sieves, reduction of flow indicating a blockage.

[05] Conventional methods of detecting and notifying a harvester operator of blockages whilst harvesting, rely on a chain reaction of events, typically machinery rpm dropping, excessive engine loading or uneven flow of processed material. Excessive loading or strain on the engine components lead to premature failure and extensive downtime during the harvesting season, which is of short duration and operates on a critical timeline.

[06] An aftermarket device that is commonly installed on a harvester such as a New Holland combine harvester, may perform one or more chaff or seed disposal function, such as incineration, redirection or placement, or collection for offsite disposal. Excessive flow to such a device can frequently lead to unwanted build up or flow-stream material, causing blockages. However, it would take typically from 20s to 30s for the operator to become aware of the blockage, by which time considerably lengthy delays would ensue to unblock the process line, irrespective of the time and expense needed for repairing any damage.

[07] Apparatus is known from US patent 4311995 that indicates, to the operator of a combine harvester, that a sieve overload or blockage has developed. It makes use of wind sensors responsive to the fan air flow within the cleaning section of the harvester. The flow sensor signals are compensated for the ambient temperature within the combine such that they are independent thereof.

[08] US patent 7381130 discloses a method of detecting a condition indicative of the onset of plugging of a discharge of an agricultural combine, utilizing a pressure sensor installed at a location within the combine and upstream of the discharge and operable for sensing an air pressure condition relating to reduced crop residue flow toward the discharge.

[09] A disadvantage of this method is that it relies on a far downstream point, close to discharge. It would be advantageous to be able to detect signs of blockage in advance of this point, especially while remedial action can still be taken to keep the machine operating.

Objects of the invention [010] It is an object of this invention to address the shortcomings of the prior art and, in doing so, to provide means for early detection of blockage in harvesting machinery.

[011] The objective is further to provide a device that can be integrated with new machinery or installed as an aftermarket item.

[012] The preceding discussion of the background to the invention is intended to facilitate an understanding of the present invention. However, it should be appreciated that the discussion is not an acknowledgement or admission that any of the material referred to was part of the common general knowledge in Australia or elsewhere as at the priority date of the present application.

[013] Further, and unless the context clearly requires otherwise, throughout the description and the claims, the words ‘comprise’, ‘comprising’, and the like are to be construed in an inclusive sense - that is meaning “including, but not being limited to” - as opposed to an exclusive or exhaustive sense - meaning “including this and nothing else”.

Summary of invention [014] According to a first aspect of the invention, there is provided a method of operational condition monitoring in a combine harvester, the method comprising steps of a. providing a monitoring zone through which a particulate stream is discharged in use from the harvester b. operating the harvester to discharge the stream through the zone c. directing a beam of radiation across the zone; d. monitoring the beam for disruption, and e. outputting a response to disruption detected.

[015] In a preferred form of the invention, the response comprises an operating fault alert.

[016] In a preferred embodiment, the method comprises directing the beam at a photoelectric sensor and monitoring the output of the sensor, a disruption of output representing disruption of the beam incident on the sensor.

[017] In a further preferred form of the invention, the step of monitoring the beam includes measuring attenuation of the beam by the particulate stream.

[018] In a further preferred form of the invention, the method includes using the attenuation measurement as an indication of the operational condition of the harvester.

[019] According to a still further preferred form of the invention, the method comprises comparing the attenuation measurement with a set standard.

[020] According to the invention, complete attenuation indicates a build-up of material in the zone, which may signal a downstream blockage.

[021] According to the invention, zero attenuation indicates a lack of material in the zone, which may signal an upstream blockage.

[022] According to a further preferred form of the invention, the method comprises taking measurements at intervals and comparing a latest measurement with a previous measurement.

[023] In an embodiment, the method includes comparing successive measurements.

[024] In a still further preferred form of the invention, the method includes issuing an alert to the operator if the latest measurement differs from the most recent previous measurement by more than a set amount.

[025] In a preferred embodiment, an alert is issued to an operator if substantially complete attenuation has been measured for a predetermined length of time.

[026] According to the invention, the beam may comprise electromagnetic radiation or ultrasound waves. In the case of electromagnetic radiation, the beam is preferably capable of inducing a photoelectric response in receiver comprising a sensor device.

[027] According to a second aspect of the invention there is provided an operational condition monitoring kit for a mobile harvesting plant, the kit comprising: a. a beam emitter and a beam receiver, i. said emitter and receiver being operatively mountable adjacent a particulate matter discharge stream from the harvester, to define a detection zone, through which the steam passes in use, ii. the receiver being operable to output a signal responsive to receiving the beam; b. electrical circuitry configured for operatively connecting the emitter, receiver and a power source; c. the circuitry comprising operatively connected components including: i. a power supply switch, ii. alerting means responsive to the signal emanating from the receiver and, in the absence of the signal, configured to issue an alert to a plant operator.

[028] In a preferred form of the invention, attenuation of the beam causes interruption of signal from receiver) [029] Preferably, the attenuation responsive means comprises a microprocessor programmed to measure beam attenuation using data received from the emitter and receiver, and [030] Preferably, the alert issuing means is connected to the processor for issuing an alert responsive to a measurement of attenuation indicative of an unsatisfactory operating condition within a harvester to which the kit is operatively mounted.

[031] In a preferred form of the invention, the attenuation responsive means comprises a relay configured to activate the alert issuing means on interruption of the signal from the receiver.

[032] According to a third aspect of the invention there is provided operational condition monitoring apparatus for use with a mobile harvesting plant, the apparatus comprising: a. a beam emitter and a beam receiver operatively mountable adjacent a particulate matter discharge stream from the plant, to define a detection zone, through which the stream passes in use, the receiver configured to output a signal responsive to receiving at least a portion of a beam emitted by the emitter; b. electrical circuitry for connecting the emitter and receiver to a power source; and comprising: i. a power supply switch, ii. alerting means configured for receiving the signal outputted by the receiver and, in the absence of the signal, configured to issue an alert.

[033] In a preferred embodiment of the invention, the alerting means comprises a relay connected to a buzzer, the relay configured to power the buzzer in the absence of the signal from the receiver.

[034] In a further embodiment, the alerting means comprises: i. a microprocessor programmed to measure beam attenuation using data received from the receiver, and ii. alert issuing means connected to the processor for issuing an alert responsive to a measurement of attenuation indicative of an unsatisfactory operating condition within a harvester to which the apparatus is operatively mounted.

Brief description of drawings [035] In order that the invention may be readily understood, and put into practical effect, reference will now be made to the accompanying figures. Thus:

Figure 1 shows in schematic form a diagram of a known form of combine harvester, provided for background and to provide context to the invention. (The drawing is adapted from an illustration obtainable from the website https://garethbarlow.wordpress.com/2014/08/12/video-how-do-they-combine-harvesters-work/.

Figure 2 is a schematic diagram of the harvester of Figure 1, to which apparatus according to a preferred embodiment of the invention has been retrofitted.

Figure 3 is a schematic plan view of the apparatus of the invention retrofitted in Figure 2.

Figure 4 is a schematic circuit diagram of apparatus of the invention according to the preferred embodiment of Figure 2.

Detailed description of an embodiment of the invention [036] The invention is concerned with the flow of process material that is established in a mobile harvester plant, for example a combine harvester or other harvesting machinery. In this embodiment, the stream of interest to be monitored is the chaff that is ejected, falling from the back of the sieves, but is not to be considered as being limited to this stream only. The stream to be monitored could also encompass the straw flow or any by-product produced as a result of harvesting a crop.

[037] With reference to Figure 1 for context, a chaff stream passes from the header on a combine harvester to the monitoring zone of the apparatus of the present invention via gravity. A beam is directed into the zone to be intercepted by the falling stream and is monitored for continuity or disruption. Complete continuity or complete disruption are signs of an operating fault in the harvester or in an addon implement located downstream. The beam may be emitted from a single emitter to a single receiver or from an array of emitters to an array of receivers. The beam may be monochromatic, in the form of a laser beam.

[038] The type of emitter/receiver and beam combination is preferably photoelectric - i.e. one in which the emitted beam will induce a photoelectric response in the sensor of the receiver, but is not necessarily so limited: [039] Alternatively, the beam may be ultrasonic, or may make use of radar frequency waves.

[040] Whatever the choice, in the event of a blockage in the process stream being monitored, the beam is reflected, attenuated or blocked, so that it fails to reach the receiver. An output is then generated to activate an audible or visual warning- or alarm-giving device, such as a buzzer or flashing display of light.

[041] The process of the harvester is illustrated in Figure 1, using a schematic diagram of the functional elements of a conventional combine harvester, obtained from the website https://garethbarlow.wordpress.com/2014/Q8/12/video-how-do-thev-combine-harvesters-work/ [042] Of interest for the purposes of describing the present invention in its preferred embodiment, reference is made to the chaff stream, marked by the broken lined directional arrow, and flowing from left to right in the drawing, across forwardly inclined top adjustable sieve, labelled 11. Threshed grain passes through the sieve and on to lower sieve 12, leaving the chaff on upper side of sieve 11 to be ejected from a discharge outlet located just fore of straw chopper 17. The chaff may possibly be collected and used for animal feed.

[043] The apparatus of the invention is configured to be an after-market accessory, and may be mounted to an add-on implement, for example a device that sees to chaff destruction, collection, burial or incineration. Devices that perform these functions are well known as down-stream processing add-ons to the main harvester plant.

[044] As there is no system associated with devices of this nature - whether below or within - that monitors a blockage condition, it is only when the header stalls because of a backlog of chaff that has accumulated on the sieve, or in the add-on implement, that the operator of the combine harvester is alerted. By then, damage may have already been caused upstream in the harvester, in addition to damage associated with the blockage in the add-on implement.

[045] Referring to figure 2, apparatus of a preferred embodiment of this invention is generally denoted by the number 100 and shown in schematic form superimposed on the diagram of Figure 1. A more detailed exposition is provided with reference to Figure 3 and Figure 4.

[046] In Figure 2 there is also shown the relative location of a downstream chaff-processing implement, in the form of a conveyor 22. Chaff 24, which has been moved along sieve 11 as shown by directional arrow D1, drops from the end of the sieve into and through detection zone 26 to fall on to conveyor 22. The conveyor takes it away in the direction of directional arrow D2. The implement having conveyor 22 does not form part of the invention, but is included to illustrate the role that can be played by the apparatus 100 of the invention as an intermediate tool between upstream and downstream processing units.

[047] With reference to Figure 3, apparatus 100 is shown in schematic plan view installed to monitor flow to a downstream implement receiving chaff from the harvester. Chaff 24 is shown moving on the harvester plant in direction D1, approaching end 28 of sieve 11, from which it falls in an arc-like trajectory on to a receptacle 38 of a downstream processing implement, in this example an iHSD device. An electromagnetic beam of light 30 in the infrared range, emitted from emitting lamp 32 at a wavelength of 875nm, impinges on a photoelectric sensor receiver 34 set to receive at the emission frequency.

[048] An example of an emitter/ sensor pairing that is suitable for use in this invention is a high power, opposed-mode sensor model in the QS30 Series, available from Banner Engineering (www.bannerenqineering.com) under the trade mark WORLD-BEAM® sensors.

[049] The emitter/ receiver units are supported by rackets 36, 36’ connected by a frame (not shown) to the chassis of the harvester. The emitter 32 and receiver 34 define between them a monitoring zone 40 (shown in broken lines), through which the beam and the falling chaff pass in substantially orthogonal directions, the chaff in a downward trajectory and the beam substantially transverse to the direction of fall, but in a plane defined by a tangent to the trajectory.

[050] The speed of discharge of the chaff is such that in the case of the sieve and other components of the harvester functioning correctly, it passes substantially in a falling sheet through zone 40 and is so detected by virtue of causing a degree of attenuation of the beam. The beam is not completely attenuated, as an amount of infrared light passes through the falling curtain of chaff to reach the receiver.

[051] While receiver 34 receives incoming radiation emitted by emitter 32, it outputs an electronic signal via a wired connection 42 to a time delay relay 44 of conventional design, shown in Figure 4. Relay 44 is connected by wiring 46 to a buzzer 48. The buzzer is located in the control cab of the harvester and is capable of emitting a loud audible alarm to attract the attention of an operator of the harvester. The buzzer may also be connected to a visual alarm such as a flashing red lamp. The relay may be connected to other instrumentation for event logging, as it known in the art.

[052] If infrared radiation of sufficient intensity fails to reach the receiver, so that the receiver is not activated to issue an output 50, and this condition continues for a period equal to the time delay setting of the relay, the relay, being of the normally open type, closes its output circuit to energise the buzzer.

[053] The invention is configured to detect both flow and zero-flow conditions, both of which indicate the presence of chaff build-up at a particular location. The build-up may have deleterious knock-on effects, whether upstream or downstream.

[054] The condition of chaff flow is signalled by the intensity of the received beam. The following circumstances are contemplated: a. Maximum beam intensity indicates a lack of chaff passing. This suggests a blockage or failure upstream, preventing chaff arriving at the monitoring station/zone. b. A complete lack of a beam being detected indicates that an accumulation of chaff has likely blocked the beam completely from reaching the receiving sensor. This could be an accumulation of chaff resulting from a build-up or blockage downstream.

[055] An intermediate intensity beam would suggest that chaff is flowing, causing only a limited degree of attenuation or beam scattering. This is addressed in the alternative embodiment below. A gradual increase in intensity indicates a decline in flow density, suggesting the development of an upstream issue.

[056] In an alternative embodiment, the relay is replaced by a microprocessor. The receiver provides a transduced signal to the microprocessor, proportional to the incident beam intensity. The processor computes the degree of attenuation of the beam that the incoming signal represents and compares it with a standard. The comparison could be absolute or relative.

[057] Should the speed of discharge vary from expected or preset parameters, the sheet of falling chaff will not pass through the zone, but may pass to the fore of it, or behind it, or not at all. In each of these cases, attenuation of the beam will cease, signalling an alarm condition and causing an alert to be issued into the cab or other operating location.

[058] In a further embodiment a relay is used, receiving an output from a receiver capable of detecting the intensity of the incoming beam and emitting an output only when the intensity exceeds a minimum threshold, representative of a material stream failing to each the monitoring zone. On receiving the output, the relay triggers a buzzer connected to its output circuit.

[059] In another example, if excessive flow results in scattering or attenuation which causes the intensity of the incident beam received to fall below a threshold value at which the receiver ceases to generate an output, such as a threshold detection value for the receiver, the receiver ceases to emit its signal to the relay, triggering in the relay an output representing an alarm condition associated with a excessive flow to the downstream implement or an accumulation of material at the intake of such implement.

[060] These embodiments merely illustrate selected examples of the method, kit and apparatus of the invention providing means for the monitoring of a flow stream in a harvesting plant and indicating the condition of operation of the plant. With the insight gained from this disclosure, the person skilled in the art is well placed to discern further embodiments by means of which to put the claimed invention into practice.

Claims (7)

1. Claims

   1. A method of operational condition monitoring in a combine harvester, the method comprising steps of a. providing a monitoring zone through which a particulate stream is discharged in use from the harvester, b. operating the harvester to discharge the stream through the zone, c. directing a beam of radiation across the zone, d. monitoring the beam for disruption, and e. outputting a response to disruption detected.
2. 2. The method of claim 1 comprising directing the beam at a photoelectric sensor and monitoring the output of the sensor, a disruption of output representing disruption of the beam incident on the sensor.
3. 3. The method of claim 1 wherein the step of monitoring the beam includes measuring attenuation of the beam by the particulate stream. 4. the method of claim 3 comprising taking measurements at intervals and comparing a latest measurement with a previous measurement.
4. 5. An operational condition monitoring kit for a mobile harvesting plant, the kit comprising: a. a beam emitter and a beam receiver, i. said emitter and receiver being operatively mountable adjacent a particulate matter discharge stream from the harvester, to define a detection zone, through which the steam passes in use, ii. the receiver being operable to output a signal responsive to receiving the beam or a portion thereof; b. electrical circuitry configured for operatively connecting the emitter, receiver and a power source; c. the circuitry comprising operatively connected components including: i. a power supply switch, ii. alerting means responsive to the signal emanating from the receiver and, in the absence of the signal, configured to issue an alert to a plant operator.
5. 6. Operational condition monitoring apparatus for use with a mobile harvesting plant, the apparatus comprising: a. a beam emitter and a beam receiver operatively mountable adjacent a particulate matter discharge stream from the plant, to define a detection zone, through which the stream passes in use, the receiver configured to output a signal responsive to receiving at least a portion of a beam emitted by the emitter; b. electrical circuitry for connecting the emitter and receiver to a power source; and comprising: i. a power supply switch, ii. alerting means configured for receiving the signal outputted by the receiver and, in the absence of the signal, configured to issue an alert.
6. 7. Apparatus according to claim 6 wherein the alerting means comprises a relay connected to a buzzer, the relay configured to power the buzzer in the absence of the signal from the receiver.
7. 8. Apparatus according to claim 6 wherein the alerting means comprises: i. a microprocessor programmed to measure beam attenuation using data received from the receiver, and ii. alert issuing means connected to the processor for issuing an alert responsive to a measurement of attenuation indicative of an unsatisfactory operating condition within a harvester to which the apparatus is operatively mounted.