U.S. patent application number 09/775017 was filed with the patent office on 2001-08-30 for basket level indicator for cotton harvester.
Invention is credited to Lemke, Dwight D..
Application Number | 20010017589 09/775017 |
Document ID | / |
Family ID | 23008923 |
Filed Date | 2001-08-30 |
United States Patent
Application |
20010017589 |
Kind Code |
A1 |
Lemke, Dwight D. |
August 30, 2001 |
Basket level indicator for cotton harvester
Abstract
An apparatus for indicating the level of harvested cotton in a
basket assembly of a cotton harvester is provided. The apparatus
includes a transducer, a control circuit and an indicator. The
transducer is coupled to a motor of a compaction member of a
compaction assembly of the cotton harvester and measures the
pressure exerted by the harvested cotton upon the compaction
member. The transducer generates a pressure signal that is received
by the control circuit. The control circuit generates a basket
level indication signal a short time after the pressure signal
indicates a predetermined pressure has been measured.
Alternatively, the control circuit generates the basket level
indication signal when the pressure signal indicates the basket
assembly is approximately full. An indicator, such as a lamp or
buzzer, receives the basket level indication signal and provides an
indication to the operator of the level of harvested cotton in the
basket.
Inventors: |
Lemke, Dwight D.; (Geneseo,
IL) |
Correspondence
Address: |
J. William Stader
Case Corporation
700 State Street
Racine
WI
53404
US
|
Family ID: |
23008923 |
Appl. No.: |
09/775017 |
Filed: |
February 1, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09775017 |
Feb 1, 2001 |
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09265087 |
Mar 9, 1999 |
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6208259 |
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Current U.S.
Class: |
340/673 ;
340/541; 340/665; 340/684 |
Current CPC
Class: |
A01D 46/082
20130101 |
Class at
Publication: |
340/673 ;
340/665; 340/684; 340/541 |
International
Class: |
G08B 021/00 |
Claims
What is claimed is:
1. A basket level indicator apparatus for a cotton harvester, the
cotton harvester having a basket assembly into which the harvester
moves harvested cotton and a compacting assembly coupled to the
basket assembly having a motor and a compaction member, the motor
driving the compaction member to compress the harvested cotton, the
harvested cotton exerting a pressure on the motor, the apparatus
comprising: a transducer coupled to the motor to measure the
pressure exerted by the harvested cotton on the compaction member
and to generate a pressure signal representative of the exerted
pressure; a control circuit coupled to the transducer to receive
the pressure signal and to generate a basket level indication
signal a predetermined time after the pressure signal indicates a
predetermined pressure is measured; and an indicator coupled to the
control circuit, the indicator to receive the basket level
indication signal and provide an indication of the level of
harvested cotton in the basket assembly based on the basket level
indication signal.
2. The basket level indicator apparatus of claim 1, the motor being
a hydraulic motor having a hydraulic conduit and the transducer
being a pressure transducer, wherein the pressure signal is a
signal representative of hydraulic pressure.
3. The basket level indicator apparatus of claim 1, the motor being
an electric motor having a power source, wherein the transducer
monitors the electric power applied to the motor such that the
pressure signal is a signal representative of motor torque.
4. The basket level indicator apparatus of claim 1, further
comprising a timer input device coupled to the control circuit, the
input device to generate a control signal, the control circuit to
receive the control signal and adjust the predetermined time based
on the control signal.
5. The basket level indicator apparatus of claim 1, wherein the
transducer has a first predetermined threshold and a second
predetermined pressure threshold, the first predetermined threshold
being lower than the second predetermined pressure threshold, the
transducer generating the pressure signal at a first state when the
exerted pressure drops below the first predetermined pressure
threshold and at a second state when the exerted pressure rises
above the second predetermined pressure threshold.
6. The basket level indicator apparatus of claim 5, wherein the
control circuit generates the basket level indication signal when
the pressure signal is at the second state for the predetermined
time.
7. The basket level indicator apparatus of claim 1, wherein the
control circuit generates the basket level indication signal when
the pressure signal indicates the basket assembly is approximately
full.
8. The basket level indicator apparatus of claim 1, wherein the
pressure signal represents a continuous indication of the exerted
pressure, the control circuit generates the basket level indication
signal to represent a continuous indication of the exerted
pressure, and the indicator displays a continuous indication of the
exerted pressure.
9. The basket level indicator apparatus of claim 1, the compacting
assembly having a second motor and a second compaction member, the
second motor driving the second compaction member to compress the
harvested cotton, the harvested cotton exerting a second pressure
on the second motor, further comprising: a second transducer
coupled to the second motor to measure the second pressure exerted
by the harvested cotton on the second compaction member and to
generate a second pressure signal representative of the second
exerted pressure, wherein the control circuit is coupled to the
second transducer to receive the second pressure signal and to
generate the basket level indication signal based on the pressure
signal and the second pressure signal.
10. A method of indicating the level of harvested cotton in a
basket assembly of a cotton harvester, the cotton harvester having
a basket assembly into which the harvester moves harvested cotton
and a compacting assembly coupled to the basket assembly having a
motor and a compaction member, the motor driving the compaction
member to compress the harvested cotton, the harvested cotton
exerting a pressure on the compaction motor, the method comprising:
measuring the pressure exerted by the harvested cotton on the
compaction member; generating a signal representative of the
exerted pressure; generating a basket level indication signal when
the pressure signal indicates the basket assembly is approximately
full; and providing an indication of the level of harvested cotton
in the basket assembly based on the basket level indication
signal.
11. The method of claim 10, wherein the step of generating a basket
level indication signal includes generating the basket level
indication signal a predetermined time after the pressure signal
indicates a predetermined pressure is measured.
12. The method of claim 11, further comprising adjusting the
predetermined time based on an operator-adjustable timer input
device.
13. The method of claim 10, the motor being a hydraulic motor
having a hydraulic conduit, wherein the step of measuring includes
measuring the pressure in the hydraulic conduit.
14. The method of claim 10, the motor being an electric motor
having a power source, wherein the step of measuring includes
measuring the electric power applied to the motor.
15. A basket level indicator apparatus for a cotton harvester, the
cotton harvester having a basket assembly into which the harvester
moves harvested cotton and a compacting assembly coupled to the
basket assembly having a motor and a compaction member, the motor
driving the compaction member to compress the harvested cotton, the
harvested cotton exerting a pressure on the motor, the apparatus
comprising: means for measuring the exerted pressure and for
generating a signal representative of the measured pressure; means
for generating a basket level indication signal when the pressure
signal indicates the basket assembly is approximately full; and
means for providing an indication of the level of harvested cotton
in the basket assembly based on the basket level indication
signal.
16. The basket level indicator apparatus of claim 15, wherein the
means for generating includes means for generating the basket level
indication signal a predetermined time after the pressure signal
indicates a predetermined pressure is measured.
17. The basket level indicator apparatus of claim 16, further
comprising means for adjusting the predetermined time based on
operator input.
18. The basket level indicator apparatus of claim 15, the means for
measuring including a pressure transducer.
19. The basket level indicator apparatus of claim 15, the means for
measuring including a power transducer.
20. The basket level indicator apparatus of claim 15 wherein the
means for generating includes a timer module.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to the field of
cotton harvesters and more specifically to the field of cotton
harvesters having an apparatus for indicating when harvested cotton
in a basket assembly associated with the cotton harvester has
reached a predetermined level.
BACKGROUND OF THE INVENTION
[0002] A cotton harvester is a vehicle driven across a field of
cotton that picks the cotton and stores it for baling. Cotton
harvesters generally include a header, a basket assembly and a cab.
An operator in the cab operates the header to engage the cotton in
the field. As the vehicle is driven at a slow speed (e.g., less
than 4 miles per hour), the header picks the cotton, cleans the
cotton, lubricates the cotton if necessary and propels the cotton
up a duct into the basket assembly. The basket assembly holds the
cotton until the cotton can be unloaded into a separate storage
and/or packaging vehicle.
[0003] Frequent unloading of the basket assembly can waste valuable
harvest time during operation of the cotton harvester. Accordingly,
several modifications have been made to improve the amount of
cotton that can be stored in the basket assembly. For example, the
basket assembly has been made larger. The basket assembly also has
been equipped with a telescoping structure to allow the operator to
raise the basket assembly during harvesting to increase the total
basket assembly capacity and lower the basket assembly during
transportation. Also, compacting structures have been implemented
in the basket assembly to compress the cotton so that more cotton
can be held in the basket assembly.
[0004] Cotton is different than other harvested crops (e.g., corn,
wheat, soybeans) in that it can be compacted to significantly
increase the amount of cotton that can be stored in a defined
space. Thus, the amount of cotton that the basket assembly can
store is typically defined by the degree to which the cotton can be
compacted. In turn, the degree to which the cotton can be compacted
is typically defined by the upper limit of the force exerted by the
compacting structure on the harvested cotton (and, of course, the
equal and opposite force exerted by the harvested cotton on the
compacting structure).
[0005] The compactability of cotton provides unique challenges for
the operator when the operator attempts to determine if the basket
assembly needs to be emptied (i.e., is "full"). The operator cannot
determine from a simple glance at the basket assembly if the basket
assembly is full because the degree of compaction cannot be
accurately determined by looking at the basket assembly. Even to
the extent that the degree of compaction can be determined by
looking at the basket assembly, the operator is typically focused
on operating the vehicle and cannot be disturbed by continually
viewing the basket assembly. As a result, the operator must empty
the basket assembly before it has reached its full or desired
capacity, creating additional delays in harvesting time.
[0006] One proposed solution is an apparatus for compacting cotton
in a basket assembly having an alarm. This apparatus has a manual
mode of compaction and an automatic mode of compaction. During the
automatic mode, hydraulically-driven augers located at the top of
the basket assembly are continuously in motion, even when the
augers are clear of any harvested cotton. A transducer is located
in the hydraulic conduit of the augers to sense the hydraulic
pressure exerted by the augers on the harvested cotton. As the
level of harvested cotton increases, the cotton gathers around the
augers and exerts a force thereon, causing an increase in the
hydraulic pressure in the hydraulic conduit. When the pressure
reaches a predefined threshold, a detection circuit triggers an
alarm. This alarm indicates to the operator that the harvested
cotton has reached the height of the augers in the basket
assembly.
[0007] This solution merely indicates to the operator that the
cotton has reached the height of the augers. The operator receives
no indication of how compacted the harvested cotton is, and
therefore receives no indication of how full the basket assembly
is. Thus, what is needed is a cotton harvester with an improved
basket level indicator that provides a clear indication to the
operator when the harvested cotton in the basket assembly of the
cotton harvester has reached a predetermined level.
SUMMARY OF THE INVENTION
[0008] These and other needs are accomplished by the present
invention in which, according to one embodiment, an apparatus for
indicating the level of harvested cotton in a basket assembly of a
cotton harvester is provided. The apparatus includes a transducer,
a control circuit and an indicator. The transducer is coupled to a
motor of a compaction member of a compaction assembly of the cotton
harvester and measures the pressure exerted by the harvested cotton
upon the compaction member. The transducer generates a pressure
signal that is received by the control circuit. The control circuit
generates a basket level indication signal a short time after the
pressure signal indicates a predetermined pressure has been
measured. An indicator, such as a lamp or buzzer, receives the
basket level indication signal and provides an indication to the
operator of the level of harvested cotton in the basket
assembly.
[0009] According to one feature of the present invention, the
control circuit generates the basket level indication signal when
the pressure signal indicates the basket assembly is approximately
full.
[0010] According to another feature of the present invention, a
timer input device is provided. The operator may adjust the timer
input device to adjust the short time between the measured pressure
reaching the predetermined pressure and the generation of the
basket level indicator signal. In one embodiment, this timer input
device allows the operator to select how much notice the operator
will have before the basket assembly is full.
[0011] According to another embodiment of the present invention, a
method of indicating the level of harvested cotton in a basket
assembly of a cotton harvester is provided. The method includes the
steps of: measuring a pressure exerted by the harvested cotton on a
compaction member; generating a signal representative of the
exerted pressure; generating a basket level indication signal when
the pressure signal indicates the basket assembly is approximately
full; and providing an indication of the level of harvested cotton
in the basket assembly based on the basket level indication
signal.
[0012] According to yet another embodiment of the present
invention, a basket level indicator apparatus for a cotton
harvester is provided. The apparatus includes means for measuring a
pressure exerted by harvested cotton in a basket assembly on a
compacting assembly coupled to the basket assembly, means for
generating a signal representative of the measured pressure, means
for generating a basket level indication signal when the pressure
signal indicates the basket assembly is approximately full, and
means for providing an indication of the level of harvested cotton
in the basket assembly based on the basket level indication
signal
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The features of the present invention which are believed to
be novel are set forth with particularity in the appended claims.
The invention itself, however, together with further advantages and
features thereof may best be understood by one skilled in the art
with reference to the following detailed description when taken in
conjunction with the accompanying drawings in which like reference
numerals refer to like elements, and in which:
[0014] FIG. 1 is a side view diagram of a cotton harvester;
[0015] FIG. 2 is a rear view diagram of the cotton harvester of
FIG. 1;
[0016] FIG. 3 is a top view diagram of the compacting assembly of
the cotton harvester of FIG. 1;
[0017] FIG. 4 is a side view diagram of the compacting assembly of
the cotton harvester of FIG. 1;
[0018] FIG. 5A is a block diagram of a basket level indicator
apparatus according to one embodiment of the present invention;
[0019] FIG. 5B is a timing diagram for the apparatus of FIG.
5A;
[0020] FIG. 6 is a block diagram of a basket level indicator
apparatus according to an alternate embodiment of the present
invention;
[0021] FIG. 7 is a side view diagram of a cotton harvester having a
basket level indicator apparatus according to another alternate
embodiment of the present invention;
[0022] FIG. 8A is a side view diagram of a cotton harvester having
a basket level indicator apparatus according to yet another
alternate embodiment of the present invention;
[0023] FIG. 8B is a block diagram of the cotton harvester of FIG.
8A;
[0024] FIG. 9A is a side view diagram of a cotton harvester having
a basket level indicator apparatus according to yet another
alternate embodiment of the present invention;
[0025] FIG. 9B is a partial rear view diagram of the cotton
harvester of FIG. 9A; and
[0026] FIG. 10 is a side view diagram of a cotton harvester having
a basket level indicator apparatus according to yet another
embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Referring first to FIG. 1, a cotton harvester 10 is shown.
Cotton harvester 10 is the 2555 Cotton Express.RTM. Picker
manufactured by Case Corporation, Racine, Wis., but may
alternatively be other cotton harvesters. Cotton harvester 10
includes a vehicle 12, front and rear wheels 14, 16, an engine 18,
a header 20, a cab 22, a basket assembly 24 and a duct structure
26. During cotton harvesting, cotton harvester 10 is propelled
along a cotton field by vehicle 12. Engine 18 drives front wheels
14 according to an operator-selected speed selected by an operator
in cab 22. Vehicle 12 is also steered by the operator by a suitable
steering device which operates rear wheels 16. The operator may
also raise or lower header 20, the operator lowering header 20 at
or near ground level during cotton harvesting.
[0028] As vehicle 12 drives harvester 10 along the cotton field,
header 20 engages the cotton plants, picks the cotton from the
cotton plants, cleans the cotton and moisturizes the cotton if
necessary. This harvesting process can be controlled by the
operator in cab 22 through use of suitable harvesting controls (not
shown). The harvested cotton is then blown by a fan (not shown) up
duct structure 26 into basket assembly 24 for storage.
[0029] Basket assembly 24 comprises several structures to improve
the amount of harvested cotton that may be stored therein. For
example, basket assembly 24 includes a top portion 30 and a bottom
portion 32 coupled in a telescoping arrangement, top portion 30
having a front wall 34 and a rear wall 38. Thus, top portion 30 is
extended either manually or automatically (operator control from
cab 22) during or prior to cotton harvesting to increase the volume
of basket assembly 24, and top portion 30 is retracted into bottom
portion 32 prior to transportation of harvester 10 from one
location to another (e.g., from one field to another). Top portion
30 further includes a top panel 40 providing a cover on basket
assembly 24 and a floor 42. Also, basket assembly 24 comprises a
compacting assembly 60 (FIG. 3) to compact the harvested cotton in
basket assembly 24, thereby increasing the harvested cotton
capacity of basket assembly 24. The compacting assembly will be
described hereinbelow with reference to FIGS. 3-4.
[0030] Referring still to FIG. 1, basket assembly 24 includes a
door 46 hingedly coupled to floor 42 of basket assembly 24. Door 46
may be opened by rotating door 46 about a door axis 48 to remove
the harvested cotton from basket assembly 24. Alternatively or
additionally, a hydraulic actuator assembly could by coupled
between basket assembly 24 and vehicle 12 for elevating the entire
basket assembly relative to the vehicle to facilitate removing the
harvested cotton from basket assembly 24.
[0031] As shown in FIG. 2, a conveyor assembly 50 may be provided
to assist in removing the harvested cotton from basket assembly 24.
In this embodiment, floor 42 of basket assembly 24 is a conveyor
belt rotatable about conveyor wheels 52, 54 and 56, one or more of
which wheels is a driving wheel driven in a counter-clockwise
direction from the rear view as depicted in FIG. 2. Thus, when door
46 is opened, the operator may engage the conveyor belt to assist
in shifting the harvested cotton from basket assembly 24 out door
46.
[0032] Referring now to FIGS. 3-4, these figures show a compacting
assembly 60 according to one embodiment of the present invention.
Harvested cotton is unlike other harvested crops in that it is
highly compactable in a given storage volume. Thus, to maximize the
amount of harvested cotton that may be stored in basket assembly
24, it is advantageous to include a compacting assembly 60 or
similar assembly to compress the harvested cotton. While an
exemplary compacting assembly 60 is shown and will now be
described, the present invention has applications with other
compacting assemblies as well.
[0033] FIG. 3 is a top view of basket assembly 24 with top panel 40
removed. Compacting assembly 60 includes a frame 61 and one or more
compaction members 62, each compaction member 62 coupled to rear
wall 38 of basket assembly 24 by motors 64. Motors 64 are hydraulic
motors, but may also be electrostatic motors, electric motors, DC
motors, servo motors, etc. Compaction members 62 in this embodiment
are augers or other helical-shaped members having fin portions 66
and shaft portions 68, shaft portions 68 extending from motors 64
across basket assembly 24 to front wall 44 along compaction member
axes 70. Motors 64 engage shaft portions 68 in counterclockwise
rotational motion causing fin portions 66 to exert forces away from
motors 64 on any harvested cotton that may come in contact with fin
portions 66.
[0034] Referring to FIG. 4, compacting assembly 60 further includes
an actuator assembly 72 coupling top panel 40 to frame 61. Actuator
assembly 72 extends compacting assembly 60 downward while
compacting assembly 60 remains hingedly coupled to rear wall 38.
Thus, compacting assembly 60 rotates about a compacting assembly
axis 76 (FIG. 3). As compaction members 62 extend downward into
basket assembly 24 and as motors 64 rotate compaction members 62,
harvested cotton in basket assembly 24 is compressed downward
toward floor 42 of basket assembly 24. This compression exerts a
force against fin portions 66 which is transferred as rotational
torque via shaft portions 68 to motors 64. This rotational torque
causes a measurable pressure change in motors 64. As basket
assembly 24 is filled with more harvested cotton, the pressure
change will increase, providing an indication of the level of
harvested cotton in basket assembly 24 (e.g., how "full" basket
assembly 24 is).
[0035] Referring now to FIG. 5A, a basket level indicator apparatus
80 according to one embodiment of the present invention is shown.
In this embodiment, basket level indicator apparatus is shown
coupled to one of motors 64. Apparatus 80 includes a control
circuit 82, a transducer 84, a timer input device 86 and an
indicator 88. Transducer 84 (e.g., a transducer such as Case
Corporation Part No. 194407A2, manufactured by Sigma-netics) is
coupled to motor 64 such that transducer 84 measures the
above-described pressure change in motor 64 caused by harvested
cotton impinging on fin portions 66 of compaction members 62 and
generates a pressure signal 83 (see FIG. 5B) having an electrical
signal representative of the measured pressure. For example, if
motor 64 is a hydraulic motor, transducer 84 is located in the
hydraulic conduit of the hydraulic motor to sense the hydraulic
pressure in the conduit. This hydraulic pressure represents the
force exerted by the hydraulic motor on compaction members 62 and
on the harvested cotton (and, of course, the equal and opposite
force exerted by the harvested cotton on compaction members 62 and
on the hydraulic motor.) In another embodiment, motor 64 is an
electric motor having a power source, transducer 84 is a power
transducer to monitor the power applied to the motor (e.g.,
current, voltage, energy, etc.) such that the pressure signal is a
signal representative of motor torque. An example of a suitable
power transducer is Case Part No. 194407A2 manufactured by
Sigma-netics.
[0036] Transducer 84 includes a grounded pressure-activated contact
switch coupled to a voltage source having a predetermined voltage
(e.g., +12 Volts DC), such that transducer 84 generates a signal of
a first state (e.g., zero VDC) when the measured pressure drops
below a first predetermined pressure threshold (e.g., about 850
pounds per square inch or "PSI") and a signal of a second state
(e.g., +12 VDC) when the measured pressure rises above a second
predetermined threshold (e.g., about 1100 PSI). Thus, transducer 84
has hysteresis characteristics. Alternatively, transducer 84 could
generate a pulse-width modulated signal, a frequency modulated
signal, an amplitude modulated signal, or any other type of signal
representative of the actual pressure measured by transducer 84.
Transducer 84, in one embodiment, is coupled to a hydraulic fluid
conduit supplying fluid to a plurality of motors 64, all of motors
64 coupled in series to the same conduit. An alternative to
transducer 84 is two or more sensors, each coupled to one of motors
64, each of sensors 84 providing a pressure signal to control
circuit 82, whereby control circuit 82 could assess more accurately
whether basket assembly 24 is full by combining pressure signals
received from motors 64 (e.g., averaging) or by waiting until all
pressure signals have reached the predetermined pressure threshold
before changing or generating pressure signal 83.
[0037] A suitable sensor must be selected for transducer 84 having
a pressure threshold such that the pressure exerted by the
harvested cotton on compaction members 62 triggers transducer 84 to
the second state sometime before a maximum pressure of motors 64 is
reached or basket assembly 24 is full. This time will provide the
operator with an opportunity to empty basket assembly 24 before the
maximum pressure of motors 64 is reached or basket assembly 24 is
overpacked. According to the present invention, this time also
provides the operator with sufficient time to finish harvesting a
row or simply to know in advance how long until motors 64 reach
their maximum rotating power (i.e., when basket assembly 24 is
full). Alternatively, transducer 84 could generate pressure signal
83 to provide a continuous indication of the measured pressure to
control circuit 82 and control circuit 82 could either determine,
based on predefined thresholds or user input, at what pressure
basket assembly 26 is full or control circuit 82 could generate a
basket level indication signal which provides a continuous
indication (via indicator 88) of measured pressure.
[0038] Transducer 84 transmits pressure signal 83 to control
circuit 82. Control circuit 82 is a timer module configured to
generate a basket level indication signal 91 based on the received
pressure signal 83. Control circuit 82 may alternatively be any
type of digital or analog control circuitry (e.g., a Motorola or
Intel microprocessor, application-specific integrated circuit,
etc.) configured to perform a variety of control operations.
[0039] Timer input device 86 may be a switch, dial, series of
buttons, icon on a computer screen, or other input device which
receives input from the operator regarding how much notice the
operator would like before basket assembly 24 is full. Timer input
device 86 provides a control signal representative of this input to
control circuit 82. Timer input device 86 may include additional
operator adjustable functions.
[0040] Indicator 88 may be a lamp, buzzer, icon on a computer
screen, or other indicator on an instrument panel. Indicator 88
receives a signal from control circuit 82 to indicate to the
operator the fill level of basket assembly 24, and to indicate to
the operator that basket assembly 24 will be "full" in a defined
period of time, as described in greater detail hereinbelow.
[0041] With reference to FIG. 5B, a timing diagram illustrates the
operation of apparatus 80 according to one exemplary embodiment of
the present invention. Control circuit 82 receives pressure signal
83 which, in this embodiment, alternates between the first state
and the second state depending on whether the measured pressure
moves below the first predetermined pressure threshold or moves
above the second pressure threshold, respectively. When basket
assembly 24 is empty and the harvesting has first begun (time 93),
basket assembly 24 is filled for a period of time (e.g., about 7
minutes) during which compaction members 62, which are constantly
rotating, are substantially free of harvested cotton. After this
period of time, harvested cotton begins to fill basket assembly 24
to a point where it exerts a pressure on compaction members 62.
When the pressure exceeds the second predetermined threshold,
transducer 84 switches pressure signal 83 from the first state to
the second state (time 94). During this time, compacting assembly
60 moves down into basket assembly 24 to compact the harvested
cotton and returns, which takes approximately 3 seconds. Upon
return of compacting assembly 60 (time 95), the pressure exerted on
compaction members 62 decreases to below the first predetermined
threshold, causing signal 83 to switch back to the first state.
[0042] This process repeats somewhat periodically for approximately
3 to 5 minutes until compaction members 62 can no longer compress
the harvested cotton to a point where the pressure exerted on
compaction members 62 drops below the first predetermined
threshold. When pressure signal 83 fails to switch to the second
state for a predetermined time 96, control circuit 82 changes the
state of signal 91 sent to indicator 88. Indicator 88 provides a
light, buzzer or other indicator to the operator in the cab to
indicate that the predetermined time 96 has passed. This indication
tells the operator that basket assembly 24 will be full or
approximately full in a certain amount of time. Timer input device
86 adjusts predetermined time 96 from, for example, 20 seconds to 5
minutes. The lower predetermined time 96 is set, the more time the
operator will have before basket assembly 24 is full, allowing the
operator to finish a row, finish a field, etc. The higher
predetermined time 96 is set, the less time the operator will have
before basket assembly 24 is full. (Typically, basket assembly 24
will be full after 10 to 15 minutes of harvesting.) Alternatively,
timer input device 86 can be adjusted to select not predetermined
time 96 but rather the amount of time until basket assembly 24 is
expected to be full, as calculated by control circuit 82. In a
further alternative embodiment, the operator could use timer input
device 86 to select at what percentage of basket full the operator
would like to receive an indication on indicator 88. For example,
the operator could select 80% on timer input device 86. Then, when
control circuit 82 determines that basket assembly 24 is
approximately 80% full based on known and measured conditions,
control circuit 82 would send a signal to indicator 88 to alert the
operator.
[0043] Referring now to FIG. 6, a basket level indicator apparatus
100 according to an alternative embodiment of the present invention
is shown. Apparatus 100 includes a control circuit 102, a raise
compactor solenoid 104, a lower compactor solenoid 106, an
indicator 108, a plurality of compactor motors 110, each compactor
motor 110 having a sensor 112 associated therewith, and an input
device 114. Control circuit 102 is coupled to sensors 112 which are
each coupled to one of compactor motors 110. It is understood that
apparatus 100 could have only one motor 110 and sensor 112 or could
have one sensor 112 in a hydraulic conduit supplying a plurality of
motors 100. Sensors 112 each sense the pressure exerted by the
harvested cotton upon motors 110 and each provide a signal
representative of this sensed pressure to control circuit 102.
Sensors 112 are pressure switches which generate a digital signal
depending on whether the sensed pressure has dropped below a first
threshold or exceeded a second threshold, but sensors 112 could
alternatively be other types of transducers indicating pressure
thresholds or instantaneous pressure. Control circuit 102 receives
the signals from sensors 112 and generates a determination of how
full basket assembly 24 is based upon one or more of these signals.
For example, control circuit 102 could determine that the pressure
exerted on motors 110 has reached the first or second threshold
when one, two or three of sensors 112 have so indicated, or when
the average pressure sensed by the three sensors so indicates.
[0044] Control circuit 102 is also coupled to a raise compactor
solenoid 104 and a lower compactor solenoid 106. When control
circuit 102 determines that the harvested cotton must be compacted
based on signals received from sensors 102, it engages lower
compactor solenoid 104 by sending a first signal of a first state
(e.g., +12 VDC) along bus 116 to lower compactor solenoid 106. When
compacting assembly 60 is completely extended, control circuit 102
switches the first signal to a second state (e.g., 0 VDC) and sends
a second signal along bus 118 to engage compactor solenoid 104 to
raise compacting assembly 60. One cycle of compacting assembly 60
lowering and raising is a single compactor stroke. Control circuit
102 determines the need to lower compactor assembly 60 via the
first and second predetermined threshold method described above
with respect to FIGS. 5A and B. Alternatively, other methods of
determining the need to lower assembly 60 may be used.
[0045] Control circuit 102 is also coupled to indicator 108 via bus
116. When the first signal is in its first state, it also enables
indicator 108, which may be a light, buzzer, or other indicator in
cab 22 of vehicle 12 to indicate to the operator that compacting
assembly 60 is lowering. Thus, when compacting assembly 60 is in
the lowering portion of the compactor stroke, indicator 108 is
enabled. When compacting assembly 60 is in the raising portion of
the compactor stroke, indicator 108 is disabled. Accordingly, the
operator in cab 22 receives an indication of the frequency with
which compacting assembly 60 cycles through compactor strokes. As
control circuit 102 increases the rate of compactor strokes, the
operator is aware that basket assembly 24 is filling up. Finally,
when control circuit 102 is constantly lowering compacting assembly
60, the operator knows that basket assembly 24 is full or
approximately full. Of course, control circuit 102 could
alternatively enable indicator 108 only on the raise portion of the
compactor stroke, or during both raise and lower portions of the
compactor stroke.
[0046] Input device 114 is optionally provided to allow the
operator to select between a number of options for indicating the
level of basket assembly 24. For example, the operator may select
how many of sensors 112 will be considered in determining when to
begin a compactor stroke. The operator may also select whether an
indication is provided on every lowering portion of the compactor
stroke, every raising portion of the compactor stroke, during both
portions, or intermittently between compactor strokes. In this way,
the indication provided by indicator 108 may be tailored for the
desires of specific operators. Also, the operator may use input
device 114 to select between a first indication (e.g., a lamp)
during the lowering portion of the compactor stroke and a second
indication (e.g., a buzzer) when the control circuit 110 determines
that basket assembly 24 is full or approximately full. Yet another
alternative embodiment includes control circuit 102 counting the
frequency with which lower compactor solenoid 106 is engaged and
generating a basket full indicator signal when the frequency
reaches a predetermined frequency.
[0047] Referring now to FIG. 7, a basket level indicator apparatus
120 according to an alternative embodiment of the present invention
is shown. Apparatus 120 determines the level of harvested cotton in
basket assembly 24 based on the weight of the harvested cotton.
Apparatus 120 includes a control circuit 122, an operator interface
124, and one or more sensors 126. Control circuit 122 is coupled to
and receives signals from sensors 126. Sensors 126 are transducers
(e.g., load cells such as Part No. 65058 manufactured by
Sensortronics), but may alternatively be other types of sensors
configured to sense the weight of basket assembly 24. Sensors 126
are coupled between basket assembly 24 and vehicle 12 such that the
weight of basket assembly 24 and, in particular, the weight of
harvested cotton in basket assembly 24 may be sensed. Sensors 126
may measure the weight of the entire basket assembly 24 in which
case control circuit 122 subtracts a known weight of basket
assembly 24 from the measured weight to find the weight of
harvested cotton in basket assembly 24. Alternatively, sensors 126
may be placed at various locations on and about basket assembly 24
(e.g., between wheels 14 and/or 16 and vehicle 12) provided that
sensors 126 are in a position to sense the weight of harvested
cotton in basket assembly 24.
[0048] Control circuit 122 is further coupled to an operator
interface 124 having an indicator and an input device (not shown).
The indicator provides a visible or audible indication to the
operator of the level of harvested cotton in basket assembly 24.
For example, the indicator could indicate only when basket assembly
24 is full, or the indicator could indicate the instantaneous level
of harvested cotton in basket assembly 24. Control circuit 122 may
optionally include an input device to receive operator input to
select, for example, between receiving an indication of basket full
or instantaneous basket level, or to select at what percentage of
basket full the basket full indicator should be enabled. Also, the
input device could be configured to receive a time period before
basket assembly 24 is completely full at which the operator would
like to receive the indication, in order to give the operator
sufficient time to finish a row, or otherwise plan ahead.
[0049] In operation, control circuit 122 monitors the weight of
harvested cotton in basket assembly 24 via one or more sensors 126.
Control circuit 122 compares the sensed weight to a predetermined
weight representative of a maximum weight of harvested cotton
basket assembly 24 may hold. The predetermined weight is based on
known characteristics of vehicle 12 such as the volume of basket
assembly 24 in its extended state (e.g., 1,150 cubic feet in the
2555 Cotton Express.RTM. Picker) and the limits of compacting
assembly 60 and compaction motors 64. The 2555 Cotton Express.RTM.
Picker has a weight capacity of approximately 8,500 pounds of
harvested cotton. When control circuit 122 determines that basket
assembly 24 is full or approximately full, control circuit 122
sends a signal to operator interface 124 to indicate the level of
harvested cotton in basket assembly 24 to the operator.
Alternatively, control circuit 122 may periodically send a signal
to interface 124 indicating the instantaneous level of cotton in
basket assembly 24, interface 124, in turn, indicating this
directly to the operator.
[0050] Referring now to FIGS. 8A and 8B, a basket level indicator
apparatus 130 according to an alternate embodiment of the present
invention is shown. Apparatus 130 determines the level of harvested
cotton in basket assembly 24 based on the density of the harvested
cotton. As indicated previously, cotton is unlike other harvested
crops in that it can be compacted to significantly increase the
amount of cotton that can be stored in a defined space. In cotton
harvester 10, compacting assembly 60 compacts the harvested cotton
as it is gathered in basket assembly 24. The density of this
compacted cotton can be measured to give an indication to the
operator of cotton harvester 10 of how full basket assembly 24
is.
[0051] Apparatus 130 includes a control circuit 132, an operator
interface 134, a first transducer 136 and a second transducer 138.
Control circuit 132 is coupled to first transducer 136 and second
transducer 138. These transducers are ultrasonic or acoustic
transducers, first transducer 136 configured to transmit an
ultrasonic signal and second transducer 138 configured to receive
the ultrasonic signal. Transducers 136 and 138 may be, for example,
Part No. 945-F4Y-2D-001-180E manufactured by Honeywell, or may be
any other type of transducer that can detect the density of a
substance by, for example, the attenuation of the signal from one
point to another (e.g., an optic or infrared transducer and
infrared light source). Transducers 136, 138 are mounted on an
interior surface 140 of basket assembly 24 as shown with greater
detail in FIG. 8B. A suitable mounting device 142, 144 is used to
mount each transducer 136, 138, respectively, to basket assembly
24. Transducers 136, 138 are mounted on adjacent sides of basket
assembly 24 such that a signal transmitted between transducers 136,
138 travels through a portion of harvested cotton 146. Transducers
136, 138 may alternatively be mounted in other locations (e.g.,
opposite sides of basket assembly 24) provided that a portion of
harvested cotton 146 is between transducers 136, 138. Yet another
alternative embodiment is to have only one transducer operating as
both a transmitter and a receiver, the transmitted signal being
reflected off an opposite wall of basket assembly 24 or off a
reflector plate inserted into harvested cotton 146 near the
transducer.
[0052] Control circuit 132 is also coupled to an operator interface
134 having an indicator and an input device (not shown). Operator
interface 134 may include a number of indicators and display
options, the display options being adjusted by the input
device.
[0053] In operation, control circuit 132 sends a transmit signal to
first transducer 136. The signal is a digital pulsed signal with
sufficient amplitude to excite the crystal of transducer 136.
Transducer 136, in response, generates an ultrasonic or acoustic
signal and transmits the ultrasonic signal through a portion of
harvested cotton 146. This ultrasonic signal is received by
transducer 138 and sent to control circuit 132 for processing.
Alternatively, transducer 138 could include signal processing
circuitry that conditions the received signal for further
processing by control circuit 132. The received signal is sent to
control circuit 132 which evaluates the density of the portion of
harvested cotton 134 based on the attenuation of the transmitted
signal through the harvested cotton. Control circuit 132 then
provides an indication to the operator of the level of harvested
cotton in basket assembly 24 via operator interface 134.
[0054] Referring now to FIGS. 9A and 9B, a basket level indicator
apparatus 150 according to an alternate embodiment of the present
invention is shown. Apparatus 150 senses the height of harvested
cotton stored in basket assembly 24 to give an indication to the
operator as to how full basket assembly 24 is. Apparatus 150
includes a control circuit 152, an operator interface 154 and a
sensor assembly 156. Control circuit 152 is coupled to and receives
signals from sensor assembly 156 representing the height of
harvested cotton in basket assembly 24. Sensor assembly 156
includes a plurality of light-sensitive transducers 158 sensitive
to ambient light, each transducer 158 located at a different height
in basket assembly 24. Sensor assembly 156 also includes a mounting
assembly 160. Transducers 158 may be, for example, Part No.
X11594-SVP infrared sensors manufactured by Honeywell.
Alternatively, transducers 158 may be acoustical sensors to measure
the reflection of a sound wave off nearby harvested cotton 146.
Another alternative to transducers 158 is a multi-position switch
having a plate for engaging the harvested cotton when the harvested
cotton rises above a predetermined level. An alternative to sensor
assembly 156 is an assembly having a single transducer 158 located
at a selected height, said height indicating a height of harvested
cotton 146 corresponding to a full state of basket assembly 24.
[0055] Control circuit 152 is also coupled to an operator interface
154 having an indicator and an input device (not shown). Operator
interface 134 may include a number of indicators and display
options adjustable by the input device.
[0056] In operation, control circuit 152 monitors transducers 158
of sensor assembly 156. As harvested cotton 146 is propelled
through duct structure 26 into basket assembly 24, the level of
harvested cotton 146 in basket assembly 24 will rise. Each
transducer 158 is continuously monitoring the presence or absence
of ambient light in its vicinity. As harvested cotton 146 rises to
the bottom of sensor assembly 156, the lowest of transducers 158 is
covered with cotton, preventing ambient light from reaching the
lowest of transducers 158. The lowest of transducers 158 then sends
a signal to control circuit 152 indicating that harvested cotton
146 has reached its level. As harvested cotton 146 continues to
rise, successively higher transducers 158 are covered with
harvested cotton 146. Each transducer 158 covered with harvested
cotton 146 no longer senses the presence of ambient light and
consequently sends a signal to control circuit 152 indicating that
harvested cotton 146 has reached its level. It is recognized that
cotton harvesters may be adapted for operation after sun-down when
little or no ambient light is available. In such situations, a lamp
or other light source (not shown) is provided on or near basket
assembly 24 to provide the necessary ambient light to ensure proper
functionality of light-sensitive transducers 158 in the embodiment
of FIGS. 9A and 9B.
[0057] In response to signals received from sensor assembly 156,
control circuit 152 generates a basket level indication signal and
transmits this signal to operator interface 154. In response,
operator interface 154 displays to the operator the level of
harvested cotton in any one of a number of formats: instantaneous
level of harvested cotton, an indication that basket assembly 24 is
full, or an indication that basket assembly 24 will be full in a
predetermined amount of time. The format of this display can be
controlled by a suitable input device (not shown) on operator
interface 154. For example, operator interface 154 could display a
series of light-emitting diodes (LEDs) in a vertical row, one LED
corresponding to each transducer 158. In this embodiment, the
operator can monitor the level of harvested cotton. Naturally, as
the harvested cotton is compacted, the level will decrease, and as
the harvested cotton continues to fill basket assembly 24, the
level will increase. Thus, the operator can view the series of LEDs
and determine an approximate time when basket assembly 24 will
require unloading.
[0058] Alternatively, sensor assembly 156 may include control
circuitry sufficient to monitor transducers 158 and generate an
indication of the level of harvested cotton 146 in basket assembly
24. In this embodiment, control circuit 152 merely receives a
basket level indication signal from sensor assembly 156 and
transmit this signal to operator interface 154 for display to the
operator.
[0059] Referring now to FIG. 10, a basket level indicator apparatus
170 according to an alternative embodiment of the present invention
is shown. Apparatus 170 monitors volume of harvested cotton in
basket assembly 24. Apparatus 170 includes a control circuit 172,
an operator interface 174 and a flow transducer 176. Control
circuit 172 is coupled to flow transducer 176. Flow transducer 176
is coupled to one of header 20, duct structure 26 and basket
assembly 24 in a position whereby the flow of harvested cotton can
be monitored. Flow transducer 176 is a cotton flow transducer, Part
No. 224597A3 manufactured by Case Corporation, but may be other
types of cotton flow sensors. Flow transducer 176 may be mounted at
various locations on vehicle 12 provided it is in a position to
monitor the flow or volume of harvested cotton into basket assembly
24.
[0060] Control circuit 172 is also coupled to an operator interface
174 having an indicator and an input device (not shown). Operator
interface 174 may include a number of indicators and display
options, the display options being adjusted by the input
device.
[0061] In operation, flow transducer 176 monitors or measures the
flow of harvested cotton into basket assembly 24. Flow transducer
176 generates a harvested cotton flow signal indicating the flow of
harvested cotton. Control circuit 172 receives the harvested cotton
flow signal and calculates the cumulative volume of cotton flowing
into basket assembly 24. When the cotton flow reaches a
predetermined volume (i.e., near or equal to the compressed cotton
volumetric capacity of basket assembly 24), control circuit 172
generates a basket level indication signal and transmits this
signal to operator interface 174. Operator interface 174 indicates
to the operator that basket assembly is full or approximately full
via a lamp, buzzer, or other indicator. Alternatively, control
circuit 172 can generate a basket level indication signal
continuously (e.g., in an embodiment wherein the predetermined
volume is a first measurable trace of harvested cotton), thereby
providing a constant indication to the operator via operator
interface 174 of the volume of cotton harvested. In this alternate
embodiment, the operator can determine, based on the indication and
based on prior experience, how soon basket assembly 24 will be full
and in need of unloading. Operator interface 174 may further
optionally include an input device operable by the operator to
select between various display options. For example, the operator
could select between receiving a buzzer indication when basket
assembly 24 is full and receiving a constant indication of the
volume of cotton in basket assembly 24.
[0062] It is understood that, while detailed drawings and specific
examples given describe exemplary embodiments of the present
invention, they are for the purpose of illustration only. The
present invention is not limited to the precise details, methods,
materials, and conditions disclosed. For example, the specific
sensors and transducers expressly recited are merely exemplary of
the wide range of similarly-functioning sensors and transducers
that could replace those expressly recited. Also, while a harvester
having a compacting assembly as shown in FIGS. 3-4 has been used as
an exemplary cotton harvester, the present invention will find
applications in cotton harvesters having various other compacting
assemblies, other cotton harvesters and other cotton harvesting
machinery. Accordingly, the present invention is not to be limited
to any specific embodiments herein, but rather is to extend to all
embodiments now known or later developed that fall within the
spirit and scope of the present invention as defined by the claims
appended hereinafter.
* * * * *