METHODS

FIELD OF THE INVENTION

[0001] The present subject matter relates generally to agricultural harvesters, such as sugar cane harvesters, and, more particularly, to a sensor for detecting crop fill levels within on-board storage of an agricultural harvester and related systems and methods.

BACKGROUND OF THE INVENTION

[0002] Typically, agricultural harvesters are accompanied by a receiver for harvested crops, such as a truck that is driven beside or behind the harvester, or a wagon towed by a truck or tractor. An unloading conveyor or elevator extends from the harvester and is operable during the harvesting operation as it moves along the field for unloading the harvested crops to the accompanying receiver.

[0003] Some harvesters, particularly combine harvesters, have an on-board crop carrying capability, such as a large grain tank, so as to not need to be constantly accompanied by a receiver for the harvested crops. Other harvesters have only limited on-board carrying capability and require substantially constant accompaniment by an external receiver or storage device. For instance, sugar cane harvesters have an elongate, upwardly inclined elevator that utilizes one or more circulating chains to convey paddles or other crop carrying elements upwardly along an upwardly facing top span of the elevator, and downwardly along a downwardly facing bottom span of the elevator in an endless loop. Harvested sugar canes are typically cut into shorter billets and then carried by the paddles upwardly along the top span of the elevator and for subsequent discharge from the distal end of the elevator into the accompanying receiver, such as a billet cart.

[0004] When an external receiver for a sugarcane harvester is absent or is otherwise not properly positioned relative to the harvester, the unloading elevator must be stopped to prevent the conveyed billets from being discharged onto the ground. This situation can arise under a variety of conditions, such as if the accompanying receiver is full and must leave the harvester to unload. As another example, the receiver may often be a towed wagon that (along with its towing vehicle) defines a larger turning radius that the harvester itself. In such instances, when a turn is being executed at the end of the field, the receiver may not be immediately present for receiving the harvested crops. As a result, the harvester may have to pause operation until the receiver is able to be properly positioned relative to the harvester.

In either situation, there is significant loss in the productivity of the harvester.

[0005] Accordingly, systems and methods that allow for a harvester to continue harvesting when an external receiver is not properly positioned relative to the harvester would be welcomed in the technology. Furthermore, systems and methods that utilize a sensor to detect crop fill levels within on-board storage of an agricultural harvester would be welcomed in the technology.

BRIEF DESCRIPTION OF THE INVENTION

[0006] Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

[0007] In one aspect, the present subject matter is directed to a system for detecting crop levels within on-board storage of an agricultural harvester. The system may include an elevator extending between a proximal end and a distal end, with the elevator being configured to carry harvested crops between its proximal and distal ends. The system may also include a storage hopper positioned adjacent to the distal end of the elevator, with the storage hopper defining a volume configured to receive the harvested crops discharged from the distal end of the elevator. In addition, the system may include a fill level sensor provided in operative association with the storage hopper. The fill level sensor may be configured to detect a fill level of the harvested crops contained within the storage volume of the storage hopper.

[0008] In another aspect, the present subject matter is directed to a method for detecting crop levels within on-board storage of an agricultural harvester, with the harvester comprising an elevator assembly including an elevator extending between a proximal end and a distal end. The elevator assembly may further include a storage hopper positioned adjacent to the distal end of the elevator. The method may include initially operating the harvester in a discharge harvesting mode such that harvested crops are conveyed from the proximal end of the elevator to the distal end of the elevator and subsequently discharged from the harvester through a discharge opening defined by the storage hopper. Additionally, upon receipt of an input associated with operating the harvester in a storage harvesting mode, the method may include reducing an operating speed of the elevator and blocking the discharge opening defined by the storage hopper such that harvested crops expelled from the distal end of the elevator are stored within a storage volume of the storage hopper. Moreover, the method may include monitoring a fill level of the harvested crops within the storage hopper relative to a predetermined fill level threshold as the elevator as being operated at the reduced operating speed.

[0009] These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

[0011] FIG. 1 illustrates a simplified, side view of one embodiment of an agricultural harvester in accordance with aspects of the present subject matter;

[0012] FIG. 2 illustrates a side view of a distal portion of an elevator assembly of the harvester shown in FIG. 1, particularly illustrating components of a storage hopper of the elevator assembly at an open or discharge position(s) to allow harvested crops to be discharged from the elevator assembly in accordance with aspects of the present subject matter; [0013] FIG. 3 illustrates another side view of the distal portion of the elevator assembly shown in FIG. 2, particularly illustrating the components of the storage hopper at a closed or storage position(s) to allow harvested crops to be temporarily stored within the storage hopper in accordance with aspects of the present subject matter;

[0014] FIG. 4 illustrates an assembled view of one embodiment of a fill level sensor in accordance with aspects of the present subject matter;

[0015] FIG. 5 illustrates a partially exploded view of the fill level sensor shown in

FIG. 4;

[0016] FIG. 6 illustrates a cross-sectional view of the fill level sensor shown in FIG. 4 taken about line 6-6;

[0017] FIG. 7 illustrates a schematic view of one embodiment of a system for detecting crop levels within on-board storage of an agricultural harvester in accordance with aspects of the present subject matter;

[0018] FIG. 8 illustrates a flow diagram of one embodiment of a method for detecting crop levels within on-board storage of an agricultural harvester in accordance with aspects of the present subject matter; and

[0019] FIG. 9 illustrates another side view of the distal portion of the elevator assembly of the harvester shown in FIG. 2, particularly illustrating the distal portion of the elevator assembly resting on an external receiver or storage device in accordance with aspects of the present subject matter.

DETAILED DESCRIPTION OF THE INVENTION

[0020] Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

[0021] In general, the present subject matter is directed to a system and method for operating a harvester. Specifically, in several embodiments, an elevator assembly for an agricultural harvester may include a storage hopper at its distal end for temporarily storing harvested crops therein. For example, the storage hopper may include one or more movable hopper components configured to be moved between an open or discharge position(s), at which the harvested crops expelled from the distal end of the elevator may be discharged from the hopper into an external receiver or storage device (i.e., when operating in a discharge operating mode) and a closed or storage position(s) at which the harvested crops may be stored within a storage volume defined by the hopper (i.e., when operating in a storage harvesting mode). As such, when the external receiver or storage device is not properly positioned relative to the harvester, the hopper component(s) may be moved to the associated closed or storage position(s) to allow the harvested crops expelled from the distal end of the elevator to be stored within the storage volume of the hopper without

discontinuing operation of the elevator and/or the remainder of the harvester.

[0022] Moreover, in several embodiments, a fill level sensor(s) may be installed within and/or relative to the storage hopper to detect the fill level of billets contained therein. As will be described below, when operating in the storage harvesting mode, a controller of the disclosed system may be configured to monitor the billet fill level within the storage hopper based on data/signals received from the bill level sensor(s). When it is detected that the billet fill level has reached and/or exceeded a predetermined fill level threshold, the controller may be configured to initiate a suitable control action. For instance, in one embodiment, the controller may be configured to stop operation of the elevator to prevent additional billets from being expelled from the elevator into the storage hopper.

[0023] Referring now to the drawings, FIG. 1 illustrates a side view of one embodiment of an agricultural harvester 10 in accordance with aspects of the present subject matter. As shown, the harvester 10 is configured as a sugarcane harvester. However, in other embodiments, the harvester 10 may correspond to any other suitable agricultural harvester known in the art. [0024] As shown in FIG. 1, the harvester 10 includes a frame 12, a pair of front wheels 14, a pair of rear wheels 16, and an operator's cab 18. The harvester 10 may also include a primary source of power (e.g., an engine mounted on the frame 12) which powers one or both pairs of the wheels 14, 16 via a transmission (not shown). Alternatively, the harvester 10 may be a track-driven harvester and, thus, may include tracks driven by the engine as opposed to the illustrated wheels 14, 16. The engine may also drive a hydraulic fluid pump configured to generate pressurized hydraulic fluid for powering various hydraulic components of the harvester. 10.

[0025] Additionally, the harvester 10 may include various components for cutting, processing, cleaning, and discharging sugar cane as the cane is harvested from an agricultural field 20. For instance, the harvester 10 may include a topper assembly 22 positioned at its front end to intercept sugar cane as the harvester 10 is moved in the forward direction. As shown, the topper assembly 22 may include both a gathering disk 24 and a cutting disk 26. The gathering disk 24 may be configured to gather the sugar cane stalks so that the cutting disk 26 may be used to cut off the top of each stalk. As is generally understood, the height of the topper assembly 22 may be adjustable via a pair of arms 28 hydraulically raised and lowered, as desired, by the operator.

[0026] Additionally, the harvester 10 may include a crop divider 30 that extends upwardly and rearwardly from the field 20. In general, the crop divider 30 may include two spiral feed rollers 32. Each feed roller 32 may include a ground shoe 34 at its lower end to assist the crop divider 30 in gathering the sugar cane stalks for harvesting. Moreover, as shown in FIG. 1, the harvester 10 may include a knock-down roller 36 positioned near the front wheels 14 and a fin roller 38 positioned behind the knock-down roller 36. As the knock-down roller 36 is rotated, the sugar cane stalks being harvested are knocked down while the crop divider 30 gathers the stalks from agricultural field 20. Further, as shown in FIG. 1, the fin roller 38 may include a plurality of intermittently mounted fins 40 that assist in forcing the sugar cane stalks downwardly. As the fin roller 38 is rotated during the harvest, the sugar cane stalks that have been knocked down by the knock-down roller 36 are separated and further knocked down by the fin roller 38 as the harvester 10 continues to be moved in the forward direction relative to the field 20.

[0027] Referring still to FIG. 1, the harvester 10 may also include a base cutter assembly 42 positioned behind the fin roller 30. As is generally understood, the base cutter assembly 42 may include blades (not shown) for severing the sugar cane stalks as the cane is being harvested. The blades, located on the periphery of the assembly 42, may be rotated by a hydraulic motor powered by the vehicle’s hydraulic system. Additionally, in several embodiments, the blades may be angled downwardly to sever the base of the sugar cane as the cane is knocked down by the fin roller 30.

[0028] Moreover, the harvester 10 may include a feed roller assembly 44 located downstream of the base cutter assembly 42 for moving the severed stalks of sugar cane from base cutter assembly 42 along the processing path. As shown in FIG. 1, the feed roller assembly 44 may include a plurality of bottom feed rollers 46 and a plurality of opposed, top feed rollers 48. The various bottom and top feed rollers 46, 48 may be used to pinch the harvested sugar cane during transport. As the sugar cane is transported through the feed roller assembly 44, debris (e.g., rocks, dirt, and/or the like) may be allowed to fall through bottom rollers 46 onto the field 20. In one embodiment, one or both sets of the feed rollers 46, 48 may be rotationally driven, for example, by a hydraulic motor powered by the vehicle’s hydraulic system

[0029] In addition, the harvester 10 may include a chopper assembly 50 located at the downstream end of the feed roller assembly 44 (e.g., adjacent to the rearward-most bottom and top feed rollers 46, 48). In general, the chopper assembly 50 may be used to cut or chop the severed sugar cane stalks into pieces or“billets” which may be, for example, six (6) inches long. The billets may then be propelled towards an elevator assembly 52 of the harvester 10 for delivery to an external receiver or storage device (not shown). In one embodiment, the chopper assembly 50 may be rotationally driven, for example, by a hydraulic motor powered by the vehicle’s hydraulic system

[0030] As is generally understood, pieces of debris (e.g., dust, dirt, leaves, etc.) separated from the sugar cane billets may be expelled from the harvester 10 through a primary extractor 54, which is located behind the chopper assembly 50 and is oriented to direct the debris outwardly from the harvester 10. Additionally, an extractor fan 56 may be mounted at the base of the primary extractor 54 for generating a suction force or vacuum sufficient to pick up the debris and force the debris through the primary extractor 54. The separated or cleaned billets, heavier than the debris being expelled through the extractor 54, may then fall downward to the elevator assembly 52. [0031] As shown in FIG. 1, the elevator assembly 52 may generally include an elevator housing 58 and an elevator 60 extending within the elevator housing 58 between a lower, proximal end 62 and an upper, distal end 64. In general, the elevator 60 may include a looped chain or member 66 and a plurality of flights or paddles 68 attached to and evenly spaced on the looped member 66. The paddles 68 may be configured to hold the sugar cane billets on the elevator 60 as the billets are elevated along a top span 70 of the elevator 60 defines between its proximal and distal ends 62, 64. Additionally, the elevator 60 may include lower and upper rotational members 72, 74 (e.g., upper and lower sprockets) positioned at its proximal and distal ends 62, 64, respectively. As shown in FIG. 1, an elevator motor 76 may be coupled to one of the rotational members (e.g., the upper rotational member or sprocket 74) for driving the chain or looped member 66, thereby allowing the looped member 66 and the paddles 68 to travel in an endless loop between the proximal and distal ends 62, 64 of the elevator 60.

[0032] Moreover, pieces of debris (e.g., dust, dirt, leaves, etc.) separated from the elevated sugar cane billets may be expelled from the harvester 10 through a secondary extractor 78 coupled to the rear end of the elevator housing 58. As shown in FIG. 1, the secondary extractor 78 may be located adjacent to the distal end 64 of the elevator 60 and may be oriented to direct the debris outwardly from the harvester 10. Additionally, an extractor fan 80 may be mounted at the base of the secondary extractor 78 for generating a suction force or vacuum sufficient to pick up the debris and force the debris through the secondary extractor 78. The separated, cleaned billets, heavier than the debris expelled through the extractor 78, may then fall from the distal end 64 of the elevator 60. Typically, the billets may fall downwardly through a discharge opening 82 of the elevator assembly 52 into an external storage device (not shown), such as a sugar cane billet cart.

[0033] During operation, the harvester 10 is traversed across the agricultural field 20 for harvesting sugar cane. After the height of the topper assembly 22 is adjusted via the arms 28, the gathering disk 24 on the topper assembly 22 may function to gather the sugar cane stalks as the harvester 10 proceeds across the field 20, while the cutter disk 26 severs the leafy tops of the sugar cane stalks for disposal along either side of harvester 10. As the stalks enter the crop divider 30, the ground shoes 34 may set the operating width to determine the quantity of sugar cane entering the throat of the harvester 10. The spiral feed rollers 32 then gather the stalks into the throat to allow the knock-down roller 36 to bend the stalks downwardly in conjunction with the action of the fin roller 38. Once the stalks are angled downwardly as shown in FIG. 1, the base cutter assembly 42 may then sever the base of the stalks from field 20. The severed stalks are then, by movement of the harvester 10, directed to the feed roller assembly 44.

[0034] The severed sugar cane stalks are conveyed rearwardly by the bottom and top feed rollers 46, 48, which compress the stalks, make them more uniform, and shake loose debris to pass through the bottom rollers 46 to the field 20. At the downstream end of the feed roller assembly 44, the chopper assembly 50 cuts or chops the compressed sugar cane stalks into pieces or billets (e.g., 6 inch cane sections). Airborne debris or chaff (e.g., dust, dirt, leaves, etc.) separated from the sugar cane billets is then extracted through the primary extractor 54 using suction created by the extractor fan 56. The separated/cleaned billets then fall downwardly into the elevator assembly 52 and travel upwardly via the elevator 60 from its proximal end 62 to its distal end 64. During normal operation, once the billets reach the distal end 64 of the elevator 60, the billets fall through the discharge opening 82 to an external storage device. Similar to the primary extractor 54, chaff is blown out from harvester 10 through the secondary extractor 78 with the aid of the extractor fan 80.

[0035] Additionally, in accordance with aspects of the present subject matter, the elevator assembly 52 may also include a storage hopper 100 coupled to the elevator housing 58 at a location adjacent to the distal end 64 of the elevator 60 (e.g., at a location below the elevator 60 and the secondary extractor 78). As shown in FIG. 1, the storage hopper 100 may be configured to at least partially define the discharge opening 82 of the elevator assembly 52. As will be described in greater detail below, the storage hopper 100 may include a hopper gate 102 that is movable between a discharge position and a storage position. When the hopper gate 102 is located at its discharge position, the harvester 10 may be operated in its typical unloading mode (e.g., referred to hereinafter as its discharge harvesting mode) in which the billets expelled from the distal end 64 of the elevator 60 fall through the discharge opening 82 to an associated external storage device. However, when the hopper gate 102 is located at its storage position, the hopper gate 102 may cover or block the discharge opening 82 to prevent the billets from being discharged from the elevator assembly 52. In such operating mode, the billets expelled from the distal end 64 of the elevator 60 may fall into a storage volume 104 defined by the storage hopper 100 for temporary storage therein. [0036] Moreover, in several embodiments, the harvester 10 may also include one or more crop flow sensors 204 configured to monitor one or more crop flow parameters of the harvester 10. In general, the crop flow parameter(s) may correspond to any suitable operating parameter(s) of the harvester 10 that provides an indication of or that may otherwise be correlated to a crop mass flow or throughput of the harvested material through the harvester 10. As such, the crop flow sensor(s) 204 may generally correspond to any suitable sensor or sensing device that is configured to monitor a given crop flow parameter(s). For instance, the crop flow sensor(s) 204 may correspond to one or more pressure sensors for monitoring a fluid pressure of the hydraulic fluid supplied within a hydraulic circuit of the vehicle hydraulic system, one or more torque sensors for monitoring an operating torque of one or more rotating components of the harvester 10, one or more position sensors for monitoring the relative position of one or more components that are configured to move with changes in the crop mass flow, one or more yield sensors configured to directly or indirectly monitor the crop throughput, and/or any other suitable sensors.

[0037] Additionally, as shown in FIG. 1, the crop flow sensor(s) 204 may be provided in operative association with any number of harvester components and/or installed at any suitable location within and/or relative to the harvester 10. For instance, as shown in the illustrated embodiment, one or more crop flow sensors 204 may be provided in operative association with one or more of the components of the vehicle feed train system, such as one or more components associated with the base cutter assembly 42, the feed roller assembly 44, and/or the chopper assembly 50. Alternatively, the crop flow sensor(s) 204 may be provided in operative association with any other suitable components and/or installed at any other suitable location that allows for a crop flow parameter(s) of the harvester 10 to be monitored, such as at a location within the elevator housing 58 of the elevator assembly 52.

[0038] Referring now to FIGS. 2 and 3, side views of a distal portion of the elevator assembly 52 shown in FIG. 1 are illustrated in accordance with aspects of the present subject matter, particularly illustrating the storage hopper 100 located adjacent to the distal end 64 of the elevator 60. Specifically, FIG. 2 illustrates the hopper gate 102 of the storage hopper 100 at its discharge position to allow the harvester 10 to be operated in its discharge harvesting mode. Similarly, FIG. 3 illustrates the hopper gate 102 of the storage hopper 100 at its storage position to allow the harvester 10 to be operated in its storage harvesting mode. [0039] In several embodiments, the storage hopper 100 may be positioned at or adjacent to the distal end 64 of the elevator 60 such that billets expelled from the elevator 60 at its distal end 64 fall downwardly into the storage hopper 100. For instance, as shown in FIGS. 2 and 3, the storage hopper 100 may extend downwardly from the elevator housing 58 such that the hopper 100 includes a bottom side 108 spaced vertically apart from the elevator housing 58 at a location below the distal end 64 of the elevator 60 and a rear side 110 (FIG.

2) positioned below the secondary extractor 78.

[0040] In several embodiments, the storage hopper 100 may include a hopper gate

102 movable along the bottom side 108 of the hopper 100 and a rear deflector 112 movable relative to the rear side 110 of the hopper 100. The storage hopper 100 may also include a pair of sidewalls 114 (only one of which is shown) extending outwardly from the elevator housing 58 to the bottom and rear sides 110, 112 of the hopper 100. Additionally, as shown in FIGS. 2 and 3, the storage hopper 100 may include a front deflector 116 spaced forward of the rear side 110 of the hopper 100. In one embodiment, the discharge opening 82 of the elevator assembly 52 may be defined between the front deflector 116 and the rear deflector 112 along the bottom side 108 of the hopper 100.

[0041] As indicated above, the hopper gate 102 may be configured to be moved between a discharge position (FIG. 2) and a storage position (FIG. 3). Additionally, in one embodiment, the rear deflector 112 may be movable between an opened position (FIG. 2) and a closed position (FIG. 3). In several embodiments, when it is desired to operate the harvester 10 in its discharge harvesting mode, the hopper gate 102 may be moved to its discharge position while the rear deflector 112 may be moved to its opened position. For instance, as shown in FIG. 2, when in the discharge position, the hopper gate 102 may be moved away from the rear side 110 of the hopper 100 (e.g., in the direction of arrow 118) to expose the discharge opening 82 defined along the bottom side 108 of the hopper 100 between the front and rear deflectors 116, 112. Similarly, as shown in FIG. 2, when in the opened position, the rear deflector 112 may be pivoted relative to the rear side 110 of the hopper 100 away from both the hopper gate 102 and the front deflector 116 (e.g., in the direction of arrow 120) to enlarge the discharge opening 82. As such, harvested crop expelled from the distal end 64 of the elevator 60 may fall through the discharge opening 82 and, thus, may be discharged from the elevator assembly 52. [0042] Moreover, when it is desired to operate the harvester 10 in its storage harvesting mode, the hopper gate 102 may be moved to its storage position while the rear deflector 112 may be moved to its closed position. For instance, as shown in FIG. 3, when in the storage position, the hopper gate 102 may be moved towards the rear side 110 of the hopper 100 (e.g., in the direction of arrow 122) to cover the discharge opening 82 defined along the bottom side 108 of the hopper 100. Similarly, as shown in FIG. 3, when in the closed position, the rear deflector 112 may be pivoted relative to the rear side 110 of the hopper 100 towards both the hopper gate 102 and the front deflector 116 (e.g., in the direction of arrow 124) until the rear deflector 112 contacts or is otherwise positioned directly adjacent to the hopper gate 102. When the hopper gate 102 and the rear deflector 112 are located at such positions, the storage hopper 100 may be configured to define a storage volume 104 for storing the harvested crop expelled from the distal end 64 of the elevator 60. Specifically, as shown in FIG. 3, the storage volume 104 may extend between a forward end 126 defined by the front deflector 116 and a rear end 128 defined by the rear deflector 112. Additionally, the storage volume 104 may extend crosswise between the opposed sidewalls 114 of the hopper 100 and vertically between the distal end 64 of the elevator 60 and the hopper gate 102. Thus, harvested crops expelled from the distal end 64 of the elevator 60 may fall down onto the bottom of the storage volume 104 defined by the hopper gate 102 and accumulate within the storage volume 104 between the front and rear deflectors 116, 112 and the opposed sidewalls 114.

[0043] It should be appreciated that the storage volume 104 defined by the storage hopper 100 may generally correspond to any suitable volume sufficient to store a desired amount of billets within the hopper 100. However, in several embodiments, the storage hopper 100 may be configured such that the storage volume 104 is substantially equal to the maximum storage volume defined by the top span 70 of the elevator 60 (i.e., the top side of the elevator 60 along which the billets are conveyed between the elevator’s proximal and distal ends 62, 64). As used herein, the storage volume 104 defined by the storage hopper 100 may be considered to be substantially equal to the maximum storage volume defined by the top elevator span 70 if the storage volume 104 is within +/- 20% of the maximum storage volume defined by the top elevator span 70, such as within +/- 10% of the maximum storage volume defined by the top elevator span 70 or within +/- 5% of the maximum storage volume defined by the top elevator span 70 and/or any other subranges therebetween. [0044] Additionally, it should be appreciated that, in other embodiments, the rear deflector 112 may not be movable, but, instead, may be fixed or stationary. In such embodiments, only the hopper gate 102 may be configured to be moved to switch the operation of the harvester 10 between its discharge and storage harvesting modes. For instance, when it is desired to operate the harvester 10 in its storage harvesting mode, the hopper gate 102 may be moved towards the fixed rear deflector 112 to the storage position at which the hopper gate 102 contacts or is otherwise positioned directly adjacent to the deflector 112. Similarly, when it is desired to operate the harvester 10 in its discharge harvesting mode, the hopper gate 102 may be moved away from the rear deflector 112 to expose the discharge opening 82 of the elevator assembly 52.

[0045] As shown in FIGS. 2 and 3, in several embodiments, the elevator assembly 52 may include a gate actuator 130 configured to move the hopper gate 102 between its discharge and storage positions. In general, the gate actuator 130 may correspond to any suitable actuation mechanism and/or device. For instance, in one embodiment, the gate actuator 140 may include a gear and rack assembly for moving the hopper gate 102 between its discharge and storage positions. Specifically, as shown in FIGS. 2 and 3, the hopper gate 102 may include a rack 132 configured to engage a corresponding drive gear 134 coupled to a motor 136 (e.g., an electric motor or a hydraulic motor powered by the vehicle’s hydraulic system). In such an embodiment, by rotationally driving the drive gear 134 in one direction or the other via the motor 136, the hopper gate 102 may be linearly actuated between its discharge and storage positions (e.g., as indicated by arrows 118, 122). Alternatively, the gate actuator 130 may correspond to any other suitable actuation mechanism and/or device, such as any other suitable linear actuator (e.g., a cylinder) and/or the like.

[0046] Additionally, in several embodiments, the elevator assembly 52 may include a deflector actuator 138 configured to move the rear deflector 112 between its opened and closed positions. In general, the deflector actuator 138 may correspond to any suitable actuation mechanism and/or device. For instance, in one embodiment, the deflector actuator 138 may correspond to a linear actuator, such as a fluid-driven cylinder actuator or an electric actuator (e.g., a solenoid-activated actuator). Specifically, as shown in FIGS. 2 and 3, the deflector actuator 138 may be coupled to a portion of the elevator housing 58 and/or a portion of the secondary extractor 78 and may include a drive rod 140 secured to a portion of the rear deflector 112. In such an embodiment, by linearly actuating the drive rod 140 in one direction or the other, the rear deflector 112 may be pivoted relative to the rear side 110 of the hopper 100 between its opened and closed positions. Alternatively, the deflector actuator 138 may correspond to any other suitable actuation mechanism and/or device, such as any other suitable linear actuator (e.g., a gear and rack assembly) and/or the like.

[0047] It should be appreciated that, in several embodiments, the operation of the gate actuator 130 and/or the deflector actuator 138 may be configured to be electronically controlled via a controller 202 of the harvester 10. For instance, as shown in FIGS. 2 and 3, the controller 202 may be communicatively coupled to the gate actuator 130 and the deflector actuator 138 via one or more communicative links 144, such as a wired connection and/or a wireless connection. In the event that the gate actuator 130 and/or the deflector actuator 138 corresponds to a fluid-driven component(s), the controller 202 may, instead, be

communicatively coupled to suitable electronically controlled valves and/or other suitable fluid-related components for controlling the operation of the actuator(s) 130, 138.

Regardless, by providing the disclosed communicative links between the controller 202 and the actuators 130, 138, the controller 202 may be configured to control the operation of the actuators 130, 138 based on inputs received from the operator of the harvester 10. For instance, as will be described below, the controller 202 may be configured to receive operator inputs associated with the desired operating mode for the harvester 10. Specifically, the operator may provide an operator input indicating the desire to switch the operation of the harvester 10 from the discharge harvesting mode to the storage harvesting mode. In such instance, the controller 202 may be configured to electronically control the operation of the actuators 130, 138 to move the hopper gate 102 to its storage position and the rear deflector 112 to its closed position. Similarly, if the operator provides an operator input indicating the desire to switch the operation of the harvester 10 from the storage harvesting mode back to the discharge harvesting mode, the controller 202 may be configured to electronically control the operation of the actuators 130, 138 to move the hopper gate 102 to its discharge position and the rear deflector 112 to its opened position.

[0048] Referring still to FIGS. 2 and 3, in several embodiments, a sealing device 150 may be provided at the top end of the front deflector 112 for sealing the gap defined between the front deflector 116 and the paddles 68 of the elevator 60 as the paddles 68 are conveyed past the deflector 116. For instance, in one embodiment, the sealing device 150 may correspond to a flexible sealing member, such as a brush seal or an elastic seal. In such an embodiment, the sealing device 150 may be configured to flex or bend as the paddles 68 are conveyed past the front deflector 116. By providing the sealing device 150, the billets stored within the storage volume 104 of the hopper 100 when the harvester 10 is operating in its storage harvesting mode may be prevented from tumbling over the top of the front deflector 116 and/or being pulled back down the bottom span of the elevator 60 via the passing paddles 68.

[0049] Additionally, in several embodiments, the elevator assembly 52 may also include one or more fill level sensors 160 provided in operative association with the storage hopper 100. In general, the fill level sensor(s) 160 may be configured to detect the fill level of the billets contained within the storage hopper 100. As such, the fill level sensor(s) 160 may generally be installed within and/or relative to the storage hopper 100 at any suitable location(s) that allows the sensor(s) 160 to detect the fill level of billets contained therein.

For instance, as shown in the illustrated embodiment, the fill level sensor(s) 160 may be installed at or adjacent to the forward end 126 of the storage hopper 100, such as by mounting a single fill level sensor(s) 160 to the inner side of the front deflector 116 or by mounting an array of fill level sensors 160 across the front deflector 116. However, in other embodiments, the fill level sensor(s) 160 may be mounted at any other suitable location within and/or relative to the storage hopper 100, such as by mounting a fill level sensor(s) 160 to the rear deflector 112, one or both of the sidewalls 114, and/or any other suitable component that allows the sensor(s) 160 to detect the fill level of the billets contained within the storage hopper 100.

[0050] It should be appreciated that any suitable number of fill level sensors 160 may be installed relative to the storage hopper 100, such as a single fill level sensor 160 or two or more fill level sensors 160. Additionally, when the elevator assembly 52 includes two or more fill level sensors 160, the fill level sensors 160 may be configured to be supported by or installed on a common component or differing components. For example, as indicated above, the elevator assembly 52 may include an array of fill level sensors 160 mounted to a given component, such as the front deflector 116, the rear deflector 112, and/or one of the sidewalls 114. However, in other embodiments, differing fill level sensor(s) 160 may be installed relative to different components, such as by installing one or more fill level sensors 160 on the front deflector 116 and one or more other fill level sensors 160 on one or more other components, such as the rear deflector 112, and/or one or both of the sidewalls 114. Additionally, it should be appreciated that, when utilizing multiple fill level sensors 160, the sensors 160 may be installed at the same relative height within the storage hopper 100 or at differing heights. For example, depending on the type of sensor being utilized, it may be desirable to position each fill level sensor 160 at the same height within the storage hopper 100 such that each sensor 160 is configured to provide an indication as to when the fill level of billets within the hopper 100 has reached or exceeded a given fill level threshold defined at the installation height of the sensors 160. Alternatively, the fill level sensors 160 may be positioned at differing heights within the storage hopper 100 to allow each sensor 160 to detect when the fill level of billets within the hopper 100 has reached or exceeded a fill level threshold associated with that sensor 160, thereby providing the capability to monitor the billet fill level relative to two or more fill level thresholds.

[0051] It should also be appreciated that the fill level sensor(s) 160 may generally correspond to any suitable sensor(s) capable of detecting the fill level of the billets contained within the storage hopper 100. For example, in one embodiment, the fill level sensor(s) 160 may correspond to one or more contact sensors, such as one or more pressure sensors, load sensors and/or the like. In such an embodiment, the contact-based fill level sensor(s) may be configured to be positioned within the storage hopper 100 at or adjacent to a fill level height(s) corresponding to an associated fill level threshold(s), thereby allowing the sensor(s) to provide an indication as to when the actual billet fill level within the storage hopper 100 has reached and/or exceeded such predetermined fill level threshold. In another embodiment, the fill level sensor(s) 160 may correspond to one or more non-contact sensors, such as one or more optics-based sensors (e.g., an IR beam sensor(s), a camera(s), a LIDAR sensor or other laser range-finding sensor), one or more acoustic-based sensors (e.g., an ultrasonic sensor(s)), one or more radar sensors and/or the like. In such an embodiment, the non-contact-based fill level sensor(s) may be positioned within the storage hopper 100 at any suitable location that allows the sensor(s) to detect the fill level of the billets relative to one or more fill level thresholds.

[0052] As will be described in greater detail below, the fill level sensor(s) 160 may be communicatively coupled to the associated system controller 202 (e.g., via a communicative link(s) 144), thereby allowing the controller 202 to receive sensor data or signals from the fill level sensor(s) 160. As such, based on the data/signals received from the sensor(s) 160, the controller 202 may determine when the fill level of the billets within the storage hopper 100 has reached or exceeded a predetermined fill level threshold. For example, in one

embodiment, a fill level threshold may be selected that is associated with a fill level height below the height at which the elevator 60 is capable of pulling billets back down the bottom span of the elevator 60 via the passing paddles 68, such as by selecting a fill level threshold corresponding to a fill level height defined at or adjacent to the top of the front deflector 116. In such an embodiment, the fill level sensor(s) 160 may serve to provide an indication that the billet fill level has a reached a height at which it is likely that the elevator 60 will soon begin to pull billets back down into its bottom span. Additionally, in response to the determining that the bill fill level has reached/exceeded the fill level threshold, the controller 202 may also be configured to initiate one or more related control actions, such as by stopping or adjusting the operation of the elevator 60, updating a timing parameter associated with operation of the harvester 10 within its storage harvesting mode and/or initiating any other suitable control action(s) (e.g., initiating vehicle-to-vehicle communications with a separate vehicle, such as an associated receiver).

[0053] Referring now to FIGS. 4-6, several views of one embodiment of a particular sensor configuration that may be used for one or more of the fill level sensors 160 described above with reference to FIGS. 2 and 3 are illustrated in accordance with aspects of the present subject. Specifically, FIGS. 4-6 illustrate an embodiment of a contact-based sensor configuration for a fill level sensor(s) 160. However, in other embodiments, the disclosed fill level sensor(s) 160 may have any other suitable sensor configuration, including any other suitable contact-based sensor configuration and/or any other suitable non-contact-based sensor configuration.

[0054] As particularly shown in FIGS. 4 and 5, the fill level sensor 160 generally corresponds to a sensor assembly including a sensor housing 162 and a sensor element 164 configured to be coupled to or otherwise supported by the sensor housing 162. In addition, the fill level sensor 160 includes a cover plate 166 configured to extend over and at least partially cover the sensor element 164. In this regard, the cover plate 166 may shield or otherwise protect the sensor element 164 from contact with the billets so as to prevent the billets from damaging the sensor element 164. As will be described in greater detail below, the sensor 160 may be configured to be installed relative to the storage hopper 100 such that an outer side 168 (FIG. 5) of the cover plate 166 is exposed to the billets contained within the hopper 100. As such, when billets begin to contact or stack-up against the cover plate 166 as the billets reach the fill level associated with the installation height of the sensor 160 within the hopper 100, an inner side 170 (FIG. 5) of the cover plate 166 may be pressed or pushed into contact with the sensor element 164. Based on such contact, the sensor element 164 may output a signal(s) indicating that the billet fill level has reached the installation height of the fill level sensor 160 within the storage hopper 100. Upon receipt of the signal(s), the associated controller 202 may then be configured to initiate a suitable control action, such as by stopping or adjusting the operation of the elevator 60, updating a timing parameter associated with operation of the harvester 10 within its storage harvesting mode and/or initiating any other suitable control action(s) (e.g., initiating vehicle-to-vehicle

communications with a separate vehicle, such as an associated receiver).

[0055] In general, the sensor housing 162 may have any suitable configuration that allows it to function as described herein. As shown in the illustrated embodiment, the sensor housing 162 may include or define various features for mounting the sensor 160 within the storage hopper 100 and/or for accommodating the sensor element 164 and/or the cover plate 166. For example, as particularly shown in FIG. 5, the sensor housing 162 may define fastener openings 172 (only two of which are shown) at locations around its outer perimeter for receiving mechanical fasteners (not shown) for coupling the housing 162 within and/or relative to the storage hopper 100 (e.g., to the front deflector 116). Additionally, as shown in FIG. 5, a recessed area 174 may be defined relative to an outer face 176 of the sensor housing 162 that is configured to receive the cover plate 166. For example, in the illustrated embodiment, the recessed area 174 is generally square-shaped to match the shape of the cover plate 166. As will be described below, the sensor housing 162 may also include various other features for coupling the cover plate 166 to the housing 162 and/or for positioning the cover plate 166 relative to the sensor element 164, such as by defining one or more pivot openings 178 for receiving corresponding pivot posts 180 of the cover plate 166 and/or one or more tab openings 182 for receiving corresponding tabs 184 of the cover plate 166.

[0056] Moreover, as shown in FIG. 5, the sensor housing 162 may also include an opening 186 defined in the center of the recessed area 174 through which a portion of the sensor element 164 extends when the sensor element 164 is coupled to or otherwise supported by the housing 162. For example, as shown in the cross-sectional view of FIG. 6, a portion of the sensor element 164 may extend through the opening 186 such that a sensor membrane or active sensing portion 188 of the sensor element 164 is positioned forward of a bottom surface 190 of the recessed area 174 of the sensor housing 162.

[0057] Referring still to FIGS. 4-6, in several embodiments, the cover plate 166 may generally include a base plate 191 and a corresponding rib or contact protrusion 192 extending outwardly from the base plate 191. As shown in FIG. 5, in one embodiment, the base plate 191 may have a planar profile defining a shape generally matching the shape of the recessed area 174 of the sensor housing 162, thereby allowing the base plate 191 to be received within the recessed area 174 when assembling the cover plate 166 relative to the sensor housing 162. Additionally, the contact protrusion 192 may generally be configured to extend from the base plate 191 such that, when the base plate 191 is received within the recessed area 174, the protrusion 192 projects outwardly from the recessed area 174 at least partially beyond the outer face 176 of the sensor housing 162. For example, as shown in the cross-sectional view of FIG. 6, the contact protrusion 192 extends from the base plate 191 such that an outer portion 193 of the protrusion 192 projects outwardly relative to the outer face 176 of the sensor housing 162 by a given lateral distance 194. In such an embodiment, by ensuring that a portion of the contact protrusion 192 is exposed or otherwise protrudes proud relative to the outer face 176 of the sensor housing 162, the billets may be configured to contact the protrusion 192, regardless of their orientation within the storage hopper 100, when the fill level of the billets reaches the position of the fill level sensor 160, thereby allowing the billets to activate or otherwise push the cover plate 166 into and/or against the sensor membrane or active sensing portion 188 of the sensor element 164.

[0058] Moreover, as shown in FIG. 5, the cover plate 166 may also include a pair of pivot posts 180 extending outwardly from opposed sides of the base plate 191 that are configured to be received within corresponding post openings 178 (one of which is shown) defined in the sensor housing 162. For example, as shown in FIG. 5, the post openings 178 are defined in the sensor housing 162 along the sides of the recessed area 174. As such, when installing the cover plate 166 relative to the sensor housing 162, the base plate 191 may be positioned within the recessed area 174 such that the pivot posts 180 are received within the pivot openings 178, thereby allowing the cover plate 166 to pivot relative to both the sensor housing 162 and the sensor element 164 supported thereby. For example, as will be described below, a bottom or lower portion of the cover plate 166 may be normally biased away from both the bottom surface 190 of the recessed area 174 and the sensor element 164. However, when the fill level of billets within the storage hopper 100 reaches the level of the sensor 160 such that one or more billets contact or press against the cover plate 166 (e.g., via the contact protrusion 192), thereby pushing the cover plate 166 towards both the bottom surface 190 of the recessed area 174 and the sensor element 164 to allow the cover plate 166 to activate or trigger the sensor element 164.

[0059] Additionally, as shown in FIG. 5, the cover plate 166 may also include a pair of biasing tabs 184 (only one of which is shown) extending from the inner side 170 of the plate 166 that are configured to be received within corresponding tab openings 182 (one of which is shown) defined in the sensor housing 162. As shown in FIG. 5, the tab openings 182 are defined through the bottom surface 190 of the recessed area 174. As such, when the cover plate 166 is installed relative to the recessed area 174, the tabs 184 may extend through the tab openings 182 to the opposed side of the housing 162. Moreover, as particularly shown in FIG. 5, a biasing member 195 (e.g., a spring) may be configured to be received on each tab 184 such that the biasing member 195 is compressed between the cover plate 166 and the bottom surface 190 of the recessed area 174 of the sensor housing 162 when the tabs 184 are received within the tab openings 182. In such an embodiment, the biasing member

195 may apply a biasing force against the cover plate 166 that biases the plate 166 away from both the bottom surface 190 of the recessed area 174 and the sensor element 164. As shown in FIG. 5, to limit pivotal movement of the cover plate 166 in such direction, a stop flange

196 may be provided at the end of each tab 184 that is configured to catch on a portion of the sensor housing 162 adjacent to each tab opening 182. Thus, the biasing force applied via the biasing member 195 may serve to pivot the cover plate 166 away from both the bottom surface 190 of the recessed area 174 and the sensor element 164 to a given rotational extent (e.g., less than 5 degrees) limited by the relative travel allowed between the tabs 184 and the sensor housing 162 by the associated stop flanges 196.

[0060] As shown in the cross-sectional view of FIG. 6, in one embodiment, the cover plate 166 may also include a sensor pad 197 extending outwardly from its inner side 170 that is configured to contact the sensor membrane or active sensor portion 188 of the sensor element 164 when the cover plate 166 is pivoted towards the sensor element 164 due to contact with billets within the storage hopper 100. For example, in the absence of billets, the sensor pad 197 may be configured to be spaced apart from the active sensor portion 188 due to the biasing action of the biasing members 195. However, as one or more billets begin contact the cover plate 166, the cover plate 166 may be pivoted inwardly towards the sensor element 164, thereby pressing the sensor pad 197 against the associated active sensor portion 188 of the sensor element 164. In one embodiment, the sensor pad 197 may be formed from a relatively soft material (e.g., a soft rubber material) so as to prevent damage to the active sensor portion 188 with repeated contact between such components.

[0061] It should be appreciated that the sensor membrane or active sensor portion 188 of the sensor element 164 may generally correspond to any suitable sensing device that is configured to detect contact by the sensor pad 197 as the cover plate 166 is pivoted towards the sensor element 164. For example, in one embodiment, the active sensor portion 188 may include or form part of a pressure sensor element that is configured to detect the pressure applied against the sensor element 164 via contact by the sensor pad 197. In another embodiment, the active sensor portion 188 may include or form part of any other suitable type of force or load-based sensor element (e.g., a load cell) or any other suitable sensor element that is configured to detect contact between the sensor element 164 and the sensor pad 197.

[0062] It should also be appreciated that the sensor element 164 may include an output interface 198 that is configured to be communicatively coupled to the system controller 202 (e.g., via the wired or wireless link 144 shown in FIGS. 2 and 3). As such, when the sensor membrane or active sensor portion 188 detects contact between cover plate 166 and the sensor element 164, the sensor element 164 may be configured to transmit suitable data and/or signals to the controller 202 indicative of such contact. The controller 202 may then utilize the sensor data/signals to determine when the fill level of billets within the storage hopper 100 has reached or exceeded the associated fill level threshold.

[0063] Referring now to FIG. 7, one embodiment of a system 200 for detecting crop levels within on-board storage of an agricultural harvester is illustrated in accordance with aspects of the present subject matter. In general, the system 200 will be described herein with reference to the harvester 10 described above with reference to FIGS. 1-3 and the fill level sensor 160 described herein with reference to FIGS. 4-6. However, it should be appreciated that the disclosed system 200 may generally be utilized with harvesters having any other suitable configuration and/or with fill level sensors having any other suitable sensor configuration. [0064] In several embodiments, the system 200 may include a controller 202 and various other components configured to be communicatively coupled to and/or controlled by the controller 202, such as one or more components for controlling the operational speed of the elevator 60 (e.g., the elevator motor 76), one or more components for actuating the hopper gate and the rear deflector (e.g., the gate actuator 130 and the deflector actuator 138), one or more sensors for monitoring one or more operating parameters of the harvester 10 (e.g., the crop flow sensor(s) 204 and/or the fill level sensor(s) 160), and/or the like. As will be described in greater detail below, the controller 202 may be configured to control the operation of the harvester 10 such that the harvester 10 is normally operated within its discharge harvesting mode during which the billets expelled from the distal end 64 of the elevator 60 fall through the discharge opening 82 to an associated external storage device. However, upon receipt of an input (e.g., an operator input), the controller 202 may be configured to transition the harvester into operation within its storage harvesting mode during which the hopper gate 102 is moved to its storage position and the rear deflector 112 is moved to its closed position to allow the billets to be temporarily stored within the storage volume 104 defined by the storage hopper 100. Additionally, when transitioning to the storage harvesting mode, the controller 202 may be configured to initially reduce the operational speed of the elevator 60. Thereafter, the controller 202 may, for example, be configured to actively adjust the elevator speed, as desired or necessary, based on one or more monitored crop flow parameters of the harvester 10 to match the elevator speed with the current or instantaneous cross mass flow or throughput of the harvester 10, thereby maximizing the storage capacity within the elevator assembly 52 and the associated storage hopper 100 while preventing plugging of the elevator 60. Moreover, in one embodiment, when it is detected that the fill level of the billets within the storage hopper 100 has reached a given fill level threshold, the controller 202 may be configured to stop operation of the elevator 60 to prevent further billets from being discharged from the elevator 60 into the hopper 100.

[0065] In general, the controller 202 may correspond to any suitable processor-based device(s), such as a computing device or any combination of computing devices. Thus, as shown in FIG. 7, the controller 202 may generally include one or more processor(s) 210 and associated memory devices 212 configured to perform a variety of computer-implemented functions (e.g., performing the methods, steps, algorithms, calculations and the like disclosed herein). As used herein, the term“processor” refers not only to integrated circuits referred to in the art as being included in a computer, but also refers to a controller, a microcontroller, a microcomputer, a programmable logic controller (PLC), an application specific integrated circuit, and other programmable circuits. Additionally, the memory 212 may generally comprise memory element(s) including, but not limited to, computer readable medium (e.g., random access memory (RAM)), computer readable non-volatile medium (e.g., a flash memory), a floppy disk, a compact disc-read only memory (CD-ROM), a magneto-optical disk (MOD), a digital versatile disc (DVD) and/or other suitable memory elements. Such memory 212 may generally be configured to store information accessible to the processor(s) 210, including data 214 that can be retrieved, manipulated, created and/or stored by the processor(s) 210 and instructions 216 that can be executed by the processor(s) 210.

[0066] In several embodiments, the data 214 may be stored in one or more databases.

For example, the memory 212 may include a parameter database 218 for storing data associated with one or more monitored parameters of the harvester 10, such as one or more crop flow parameters and/or the billet fill level within the storage hopper 100. As indicated above, the crop flow parameter(s) may generally correspond to any suitable operating parameter of the harvester 10 that provides an indication of or may otherwise be correlated to a crop mass flow or throughput of the harvested material through the harvester 10, such as hydraulic pressure(s), operating torque(s), certain component position(s), yield data, and/or the like. Thus, in several embodiments, sensor data associated with one or more such operating parameters may be stored within the crop flow parameter database 218.

[0067] As particularly shown in FIG. 7, to allow the controller 202 to monitor the crop flow parameter(s), the controller 202 may be communicatively coupled to one or more crop flow sensors 204. As indicated above, the crop flow sensor(s) 204 may generally correspond to any suitable sensor or sensing device that is configured to monitor a given crop flow parameter(s). For instance, in one embodiment, the crop flow sensor(s) 204 may correspond to one or more pressure sensors configured to monitor a fluid pressure of the hydraulic fluid supplied to one or more hydraulic motors of the vehicle’s hydraulic system via an associated hydraulic circuit, such as the hydraulic circuit associated with the base cutter assembly 42, the feed roller assembly 44, and/or the chopper assembly 50. In another embodiment, the crop flow sensor(s) 204 may correspond to one or more torque sensors configured to monitor an operating torque of one or more rotating components of the harvester 10, such as the hydraulic motor(s) configured to rotationally drive the rotating blades of the base cutter assembly 42, the rollers 46, 48 of the feed roller assembly 44, and/or the chopper assembly 50. In a further embodiment, the crop flow sensor(s) 204 may correspond to one or more position sensors configured to monitor the relative position of one or more harvester components whose position is dependent on the mass flow or crop throughput of the harvester 10. In yet another embodiment, the crop flow sensor(s) 204 may correspond to one or more yield sensors configured to provide an indication of the crop mass flow through the harvester 10.

[0068] Referring still to FIG. 7, in several embodiments, the instructions 216 stored within the memory 212 of the controller 202 may be executed by the processor(s) 210 to implement a discharge harvesting module 220. In general, the discharge harvesting module 220 may be configured to control the operation of the harvester 10 such that the harvest 10 is operated within its discharge harvesting mode. Specifically, to allow for operation within the discharge harvesting mode, the controller 202 may be configured to control the relevant components of the harvester 10 (e.g., the gate actuator 130 and the deflector actuator 138) to ensure that the hopper gate 102 and the rear deflector 112 are moved to their associated discharge and opened positions, respectively (e.g., as shown in FIG. 2), thereby allowing the billets expelled from the distal end 64 of the elevator 60 to fall through the storage hopper 100 and be discharged from the elevator assembly 52 via the discharge opening 82. The billets discharged from the elevator assembly 52 may then fall into an external storage device, such as a sugar cane billet cart. In addition, when operating within the discharge harvesting mode, the controller 202 may be configured to control the operation of the elevator 60 (e.g., via control of the elevator motor 76) such that the elevator 60 is operated at a given elevator speed. As will be described below, the elevator speed for the discharge harvesting mode may be greater than the elevator speed used when operating within the storage harvesting mode.

[0069] Additionally, as shown in FIG. 6, the instructions 216 stored within the memory 212 of the controller 202 may also be executed by the processor(s) 210 to implement a storage harvesting module 222. In general, the storage harvesting module 222 may be configured to control the operation of the harvester 10 such that the harvester 10 is operated within its storage harvesting mode. Specifically, to allow for operation within the storage harvesting mode, the controller 202 may be configured to control the relevant components of the harvester 10 (e.g., the gate actuator 130 and the deflector actuator 138) to ensure that the hopper gate 102 and the rear deflector 112 are moved to their associated storage and closed positions, respectively (e.g., as shown in FIG. 3) to cover or block the discharge opening 82 of the storage hopper 100, thereby allowing the billets expelled from the distal end 64 of the elevator 60 to be stored within the storage volume 104 defined by the storage hopper 100. Additionally, simultaneous with covering or blocking the discharge opening 82 (or immediately before or after such control action), the controller 202 may be configured to reduce the operational speed of the elevator 60. For example, when initiating the storage harvesting mode, the controller 202 may be configured to reduce the operational speed of the elevator from its normal operating speed to a pre-set or predetermined default elevator speed setting. This speed setting may, for instance, correspond to a manufacturer-defined setting and/or an operator-defined setting. In addition, the default speed setting may be adjusted, as desired or necessary, by the operator to fine tune such default speed setting based the anticipated or expected pour rate of the harvester 10.

[0070] It should be appreciated that, in one embodiment, the default speed setting may generally correspond to a given percentage of the normal operational speed for the elevator 60 during operation within the discharge harvesting mode. For instance, in one embodiment, the default elevator speed setting for the storage harvesting mode may correspond to a speed that is less than about 75% of the normal operational speed of the elevator 60 during operation within the discharge harvesting mode, such as a speed ranging from about 10% to about 50% of the normal operating speed and/or a speed ranging from about 10% to about 25% of the normal operating speed.

[0071] Once the operational speed of the elevator 60 has been reduced to the default speed setting, the storage harvesting module 222 may, in several embodiments, then be configured to continuously monitor the crop flow parameter(s) of the harvester 10 (e.g., via the crop flow sensor(s) 204) to detect changes in the crop mass flow through the harvester 10. Thereafter, the storage harvesting module 222 may be configured to actively adjust the operational speed of the elevator 60 when it is determined that a change in the crop mass flow has occurred. For instance, if it is determined based on the monitor crop flow parameter(s) that the crop mass flow through the harvester 10 has increased, the storage harvesting module 222 may be configured to increase the operational speed of the elevator (e.g., via control of the elevator motor 76). Similarly, if it is determined based on the monitor crop flow parameter(s) that the crop mass flow through the harvester 10 has decreased, the storage harvesting module 222 may be configured to reduce the operational speed of the elevator 60 (e.g., via control of the elevator motor 76). In doing so, the magnitude of the elevator speed adjustment made by the controller 202 may vary, for example, based on the magnitude of the detected change in the crop mass flow.

[0072] It should be appreciated that, in one embodiment, the storage harvesting module 222 may be configured to initiate the transition between the operating modes when an operator input is received by the controller 202 that is associated with switching the operation of the harvester 10 from its discharge harvesting mode to its storage harvesting mode. For instance, as indicated above, it may be desirable to operate the harvester 10 in its storage harvesting mode when an associated external storage device is not properly positioned relative to the discharge opening 82 for collecting the discharged billets, such as when rotating the billet carts and/or when turning/resuming harvesting at the end of row without the billet cart being in position. In such instance(s), the operator may be allowed to provide a suitable operator input to the controller 202 indicating the desire to switch operation of the harvester 10 to the storage harvesting mode. For instance, a suitable input device (e.g., a button, knob, lever, switch, etc.) may be provided within the operator’s cab 18 to allow the operator to provide the operator input to the controller 202. Alternatively, the storage harvesting module 222 may be configured to initiate the transition between the operating modes when any other suitable input is received by the controller 202 that is associated with switching the operation of the harvester 10 from its discharge harvesting mode to its storage harvesting mode. For instance, the controller 202 may be configured to receive vehicle-to- vehicle communications indicating that the associated external storage device is about to leave or is otherwise not properly positioned relative to the harvester 10. In such instance, upon receipt of the input, the controller 202 may configured to initiate the harvester’s storage harvesting mode.

[0073] It should also be appreciated that, in several embodiments, the storage harvesting module 222 may be configured to continue operation of the elevator 60 at the reduced operational speed(s) until it is detected that the fill level of the billets within the storage hopper 100 has reached a given fill level threshold. For example, using the sensor configuration described above with reference to FIGS. 4-6, the fill level sensor 160 may be configured to transmit sensor data/signals to the storage harvesting module 222 when the billet fill level reaches and exceeds the installation location of the sensor 160. In such instance, based on the sensor data/signals received form the fill level sensor 160, the storage harvesting module 222 may determine that the billet fill level has reached a predetermined fill level threshold (e.g., an acceptable fill level prior to billets being pulled back down along the bottom span of the elevator 60 via the passing paddles 68). The storage harvesting module 222 may then stop or halt the operation of the elevator 60 to prevent further billets from being discharged into the storage hopper 100.

[0074] In another embodiment, the storage harvesting module 222 may be configured to continue operation of the elevator 60 at the reduced operational speed(s) for a

predetermined time period (e.g., a time period during which it is anticipated that the elevator 60 will be moved a conveyance distance corresponding to the distance of the top elevator span). For example, in a particular embodiment, when operating in the storage harvesting mode, the elevator 60 may only be configured to be operated at the reduced operational speed(s) for a given time period during which the elevator 60 is moved one half of its total travel distance (i.e., the conveyance distance defined along the top span 70 of the elevator 60 between its proximal and distal ends 62, 64). In doing so, as the elevator 60 is moved such conveyance distance, the billets initially contained within the top elevator span 70 may be dumped into the storage volume 104 while concurrently filling the paddles 68 moving into the top elevator span 70 to their maximum fill level.

[0075] In such an embodiment, the storage harvesting module 222 may be configured to utilize the sensor data/signals received from the fill level sensor(s) 160 to override or adjust such a control mode. For instance, if the storage harvesting module 222 detects that the bill fill level has reached or exceeded the fill level threshold prior to expiration of the time period across which the elevator 60 is to continue operating, the storage harvesting module 222 may immediately halt the operation of the elevator 60 despite any time remaining within the predetermined time period to prevent excessive billets from being discharged into the storage hopper 100. Similarly, if the predetermined time period has ended, but the storage harvesting module 222 has not yet detected that the bill fill level has reached or exceeded the associated fill level threshold, the storage harvesting module 222 may, optionally, continue operation of the elevator 60 until it is detected that the fill level threshold within the storage hopper 100 has been reached.

[0076] In one embodiment, the storage harvesting module 222 may also be configured to monitor the harvesting time period during which the elevator 60 is operated at its reduced speed within the storage harvesting mode to allow the controller 202 to update the predetermined time period stored within the controller’s memory 212. For instance, upon initiation of the storage harvesting mode, the controller 202 may be configured to start a timer that monitors the time period until the instance at which the billet fill level within the storage hopper 100 reaches or exceeds the predetermined fill level threshold. This monitored harvesting time period may then be used to update the predetermined time period, such as by increasing the predetermined time period when the monitored time period exceeds the previously stored time period or by decreased the predetermined time period when the monitored time period is less than the previously stored time period. In addition, the monitored time period may also be used in combination with the data received from the crop flow sensor(s) 204. For instance, the controller 202 may be configured to store the monitored time period in combination with the crop throughput estimated or determined based on the monitored crop flow parameter(s) to create a look-up table that correlates crop throughput to the time period for operating the elevator 60 during the storage harvesting mode.

[0077] It should be appreciated that, when relying on sensor data from the fill level sensor(s) 160 to detect the fill level of billets within the storage hopper 100, the controller 202 may, in several embodiments, be configured to disregard or filter out temporary and/or instantaneous signals received from the fill level sensor(s) 160 that may be indicative of a billet bouncing into or otherwise temporarily contacting the sensor(s) 160 prior to the actual billet fill level reaching the associated fill level threshold. In such embodiments, the controller 202 may, for example, be configured to monitor and compare the signals received from the fill level sensor(s) 160 over time in order to determine whether the billet fill level has actually reached the predetermined fill level threshold. For instance, if the sensor(s) 160 is triggered continuously over a given time period (e.g., 1-2 seconds) or otherwise detects billets at the fill level threshold more than a given number of times over such time period, the controller 202 may determine that it is likely that the sensor(s) 160 has detected that the billet fill level has reached the fill level threshold as opposed to detecting false triggers as billets bounce off of or temporarily contact the sensor(s) 160.

[0078] Moreover, in one embodiment, after stopping the operation of the elevator 60, the remainder of the harvester 10 may be maintained operational to allow harvested crops to be stored within a lower storage volume of the elevator assembly 52 for a predetermined time period. Specifically, upon stopping the elevator 60, the harvester 10 may continue to be used to harvest sugar cane for a given time period (e.g., three to ten seconds). In such instance, the harvested billets may be stored within a lower storage hopper 152 (FIG. 1) defined at or adjacent to the proximal end 62 of the elevator 60. Once the predetermined time period has elapsed, the operation of the harvester 10 may be stopped. Specifically, following the continued operation of the harvester 10 for the predetermined time period after stopping the elevator 60, it may be assumed that the elevator assembly 52 is at full capacity. In such instance, the harvester 10 may be stopped to discontinue harvesting of the sugar cane.

[0079] Furthermore, as shown in FIG. 7, the controller 202 may also include a communications interface 224 to provide a means for the controller 202 to communicate with any of the various other system components described herein. For instance, one or more communicative links or interfaces 226, l44(e.g., one or more data buses) may be provided between the communications interface 224 and the crop flow sensor(s) 204 and/or the fill level sensor(s) 160 to allow the controller 202 to receive measurement signals from the sensor(s) 204, 160. Similarly, one or more communicative links or interfaces 228 (e.g., one or more data buses) may be provided between the communications interface 224 and the elevator motor 76 (and/or a related component configured to control the operation of the motor 76, such as a related control valve) to allow the operation of the elevator motor 76 to be controlled by the controller 202. Additionally, as indicated above, one or more communicative links or interfaces 144 (e.g., one or more data buses) may be provided between the communications interface 224 and both the gate actuator 130 and the deflector actuator 138 (and/or a related component(s) configured to control the operation of the actuator(s) 130, 138, such as a related control valve(s)) to allow the operation of such components to be controlled by the controller 202.

[0080] Referring now to FIG. 8, a flow diagram of one embodiment of a method 300 for detecting crop levels within on-board storage of an agricultural harvester is illustrated in accordance with aspects of the present subject matter. In general, the method 300 will be described herein with reference to the embodiment of the harvester 10 described above with reference to FIGS. 1-3, the embodiment of the fill level sensor 160 described above with reference to FIGS. 4-6, and the system 200 described above with reference to FIG. 7.

However, it should be appreciated by those of ordinary skill in the art that the disclosed method 300 may generally be implemented with any harvester having any suitable harvester configuration, with any fill level sensor(s) have any suitable sensor configuration, and/or within any system having any suitable system configuration. In addition, although FIG. 8 depicts steps performed in a particular order for purposes of illustration and discussion, the methods discussed herein are not limited to any particular order or arrangement. One skilled in the art, using the disclosures provided herein, will appreciate that various steps of the methods disclosed herein can be omitted, rearranged, combined, and/or adapted in various ways without deviating from the scope of the present disclosure.

[0081] As shown in FIG. 8, at (302), the method 300 may include initially operating the harvester in a discharge harvesting mode such that harvested crops are conveyed from the proximal end of the elevator to the distal end of the elevator and subsequently discharged from the harvester through a discharge opening defined by the storage hopper. Specifically, as indicated above, when operating in the discharge harvesting mode, the hopper gate 102 and the rear deflector 112 may be moved to their associated positions shown in FIG. 2 (e.g., the discharge position and the opened position, respectively) for allowing the billets expelled from the distal end 64 of the elevator 60 to fall through the storage hopper 100 and be discharged from the elevator assembly 52 via the discharge opening 82. The billets discharged from the elevator assembly 52 may then fall into an external storage device, such as a sugar cane billet cart.

[0082] Additionally, at (304), the method 300 may include receiving an input associated with switching the operation of the harvester from its discharge harvesting mode to its storage harvesting mode. For instance, as indicated above, it may be desirable to operate the harvester 10 in its storage harvesting mode when an associated external storage device is not properly positioned relative to the discharge opening 82 for collecting the discharged billets, such as when rotating the billet carts and/or when turning/resuming harvesting at the end of row without the billet cart being in position. In such instance(s), the operator may be allowed to provide a suitable operator input to the controller 202 indicating the desire to switch operation of the harvester 10 to the storage harvesting mode.

Alternatively, the controller 202 may be configured to detect that the associated external storage device is not properly positioned relative to the harvester 10 based on any other suitable input(s), such as based on inputs from a sensor configured to detect the position of the associated external storage device or inputs associated with vehicle-to-vehicle communications. [0083] Moreover, at (306), the method 300 may include reducing an operating speed of the elevator upon receipt of the input. As indicated above, when operating in the storage harvesting mode, the controller 202 may be configured to reduce the operating speed of the elevator 60 (e.g., via control of the elevator motor 76) from its normal operating speed to a reduced speed setting. In several embodiments, such default speed setting may correspond to a manufacturer-defined setting and/or an operator-defined setting and may be adjustable, as desired or necessary, by the operator or automatically by the controller 202.

[0084] Referring still to FIG. 8, at (308), the method 300 may include blocking or covering the discharge opening defined by the storage hopper upon receipt of the input. Specifically, in several embodiments, when operating the harvester 10 in the storage harvesting mode, the hopper gate 102 may be configured to be moved to its storage position and the rear deflector 112 may be configured to be moved to its closed position so that the storage hopper 100 defines a storage volume 104 for receiving the billets expelled from the distal end 64 of the elevator 60. As indicated above, the controller 202 may be configured to automatically move the hopper gate 102 and the rear deflector 112 to their respective positions upon receiving the input indicating that the harvester 10 should be operated in its storage harvesting mode. Such control action may be performed simultaneously with reducing the operating speed of the elevator 60 or may occur immediately before or after the elevator speed adjustment.

[0085] Additionally, at (310), the method 300 may include monitoring a fill level of the harvested crops within the storage hopper relative to a predetermined fill level threshold as the elevator as being operated at the reduced operating speed. Specifically, as indicated above, the controller 202 may be configured to monitor the fill level of the billets contained within the storage hopper 100 relative to a predetermined fill level threshold via the data/signals received from the fill level sensor(s) 160. In such instance, when it is determined that the billet fill level has reached and/or exceeded the associated fill level threshold, the controller 202 may be configured to initiate a suitable control action, such as by stopping the operation of the elevator 60 to prevent further billets from being discharged into the storage hopper and/or by updating a predetermined time period associated with operating the elevator 60 within the storage harvesting mode.

[0086] It should be appreciated that the disclosed system/method may allow a harvester 10 to be operated without unloading harvested crops for a significant period of time (e.g., fifteen to forty seconds depending on the throughput of the harvester 10 and the length/capacity of the elevator 60), thereby providing sufficient time to allow an external storage device (e.g., a billet cart) to be positioned relative to the harvester 10. In general, it is anticipated that the external storage device may be properly positioned relative to the harvester 10 prior to the billet fill level within the storage hopper reaching the predetermined fill level threshold. As such, in most instances, it is believed that the operation of the harvester 10 can be switched back to its discharge harvesting mode prior to the operation of the elevator 60 needing to be stopped. However, in the event that the external storage device is not properly positioned relative to the harvester 10 prior to such point, the storage harvesting mode may be continued as described above, such as by stopping the elevator and by continuing to operate the remainder of the harvester to allow billets to be stored within the lower storage hopper of the harvester for a given time period.

[0087] It should also be appreciated that, although the disclosed fill level sensor(s)

160 has generally been described herein in association with operation of a harvester 10 within its storage harvesting mode, the data/signals from the fill level sensor(s) 160 may also be utilized when operating the harvester 10 in its discharge harvesting mode. Specifically, the fill level sensor(s) 160 may be utilized to detect when billets have begun to back-up within the storage hopper 100 even though the hopper gate 102 and the rear deflector 112 are moved to their associated discharge and opened positions, respectively to allow billets to be discharged from the hopper 100. For example, FIG. 9 illustrates another view of the distal portion of the elevator assembly 52 shown in FIGS. 2 and 3, particularly illustrating the distal portion of the elevator assembly 52 resting upon a portion of an external receiver or storage device 400 as the harvester 10 is being operated within its discharge harvesting mode such that billets 402 are discharged from the hopper 100 into the external storage device 400. As shown in FIG. 9, when the external storage device 400 is at or near full capacity and the distal portion of the elevator assembly 52 is resting or supported on the storage device 400, the billets 402 may begin to stack-up within the storage hopper 100 as additional billets are discharged from the distal end 64 of the elevator 60. In such instance, the fill level sensor(s) 160 may detect that the billets 402 have begun to back-up within the hopper 100. The controller 202 may then initiate a suitable control action to prevent further billets from stacking up within the hopper 100. For example, in one embodiment, the controller 202 may be configured to stop or halt the operation of the elevator 60. In another embodiment, the controller 202 may be configured to transmit a communication(s) to the vehicle towing the external storage device 400 (e.g., via vehi cl e-to- vehicle communications) indicating that the storage device 400 is full and that the storage device 400 should be taken away to be unloaded. In such an embodiment, upon transmitting such communication(s) or upon detecting that the storage device 400 is no longer properly positioned relative to the harvester 10, the controller 202 may be configured to transition the harvester 10 to its storage harvesting mode to allow the harvester 10 to continue harvesting until another external storage device 400 has been positioned relative to the harvester 10.

[0088] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.