Longitudinal axial flow rice thresher feeding rate monitoring based on force sensing resistors

The threshing unit is the main working unit of the combine harvester and plays an essential role in rice threshing efficiency, seed loss, and damage. Every thresher has its limitation for feeding, and when the feeding quantity exceeds the maximum rated amount, the thresher gets blocked, resulting in higher losses, low threshing efficiency, more power consumption, and combine overloading shutting down. This study constructed a longitudinal axial flow rice threshing platform, and a stress monitoring system for the threshing drum top cover was designed using force sensing resistors. The sensors were installed on the thresher top cover inner surface to detect the impact and extrusion forces caused by the threshing process and detect the feeding rate when it exceeds the suitable feeding. Three feeding rates (0.8, 1.1, and 1.4 kg/s) and three thresher speeds (1100, 1300, and 1500 rpm) were tested. The time of the testing process was calculated using high-speed photography. The obtained results revealed that the force signals collected by thin-film sensors significantly correlated with thresher rotating speed and feeding rate. The thresher top cover’s average stress, average strain, and average total deformation were simulated using ANSYS finite element analysis. This study provides a new method for threshing drum real-time feeding quantity monitoring and early warning of thresher blockage.