Precision Combine Controller/PCCTM
Model C Version 4
Lets consider how a combine threshes, separates, and cleans grain. These three steps are a function of cylinder (rotor) speed, concave adjustments, fan speed, and sieve settings. Whenever the amount of material passing through the combine changes, each of these adjustments will have to be altered to maintain maximum efficiency of the combine. This creates an opportunity to increase a combines efficiency by either automatically changing the adjustments as grain flow volume changes or maintain an even flow rate of material through the machine. The latter is what Acu-Grain has accomplished with the Load Master.
Once a consistent flow of material through the combine is accomplished another interesting opportunity is created. This opportunity is simply the ability to increase the flow rate of material through the combine to its maximum capacity. By increasing the engine load (reducing engine RPM) the combine travels faster and increases the rate of flow of material through the combine. When a change in engine RPM is detected the speed ot the combine is adjusted to maintain the same rate of flow of material through the machine (maintain same engine RPM). With a microprocessor controlling the hydrostatic or variable speed drive, much greater load capacities can be maintained on the combine (lower RPM's) than can safely be accomplished by a human operator. Under human control, at the higher capacity, the combine is in danger of choking - causing either extreme grain loss or plugging. Acu-Grain's "Gran-Daddy" System with the Load Master can be programmed to control any combine to any degree of load to keep a combine cutting a maximum capacity though out the day. Its unique ability to maintain the correct cutting speed for all crop conditions gives the operator the ability to take the average combine performance of 50% - 70% of capacity to maximum capacity. This like having another combine in the field for only a fraction of the cost.
The Load Control is vaguely similar to a cruise control on a car. But instead of maintaining ground speed. The Load Control regulates crop load speed going into the machine. In other words, it maintains the maximum amount of crop entering the machine at all times. So when you enter a field you no longer limit your harvesting capacity to the heaviest spots in the field. Now you operate your combine to speed up in the lighter spots and slow down in the heavier spots allowing the machine to perform at its maximum capacity all day.
The Load Control senses RPM variances within plus or minus one RPM. Something a human is not capable of detecting. When the Load Control senses an increase in RPM's it increases the machine's forward speed to maintain constant RPM. Thus maintaining maximum capacity. The reverse is true for heavier spots in the field. The machine slows forward speed. The result is constant engine RPM and even flow through the combine.
Beside making your combine, 20% to 100% more efficient, there are numerous other benefits. Lets look at them.
Minimum Grain Loss Maintained: Throughout the day as the combine is maximizing the amount of grain harvested per hour, it is also maintaining the same consistent low level of grain loss. If you switch to manual control you will notice the inability to maintain the same consistent low level of grain loss. A unique situation is the ability of the Load Master to adjust the combine to the correct speed when the toughness and moisture conditions change throughout the day, thereby maintaining absolute minimum grain loss. When cutting at night and the grain is getting tougher, the combine speed is automatically adjusted to lower speeds, thus maintaining the same threshing efficiency.
Wind-Rows: The microprocessor controlled Load Master is a unique solution to the problem of picking up wind-rows with varying densities, and moisture levels. Only a microprocessor can evaluate and make the quick adjustments needed to maintain consistent flow levels of grain through the machine.
Reduce Engine Hours: The cost of a Load Master is a fraction of the cost of an engine overhaul, and may save such an overhaul with less engine hours.
Combine Life Expectancy: The life expectancy of any combine is greatly enhanced when considering the number of acres you can now cut for the same number of engine hours. This is like having another combine for only a few hundred dollars per year. If we consider depreciating the Load Control at 5 years; the rate of depreciation is approximately $1,600.00.
Combine Depreciation: Combines by and large tend to loose $60.00 of resale value for each hour put on them. If you operate 500 hours per year your combine will have lost about $30,000.00 in value. If those hours are reduced by 20% you will have retained $60,000.00 in value per year. A combine owned for an average of 5 years translates into a $30,000.00 SAVINGS! This equals $12.00 per hour savings.
Acres Cut: If you do custom cutting and can increase your acres cut by 20% in the same amount of time, it works out like this, an average custom cutter cuts 6,500 acres per machine, per year. A 20% increase equals 1,300 acres. At $20.00 per acre it equals $26,000.00 in extra profitg generated minus the trucking costs. Remember you will not use more harvesting labor or fuel in your combine.
Down Time: Down time is reduced dramatically. Crop slugs and undue stress on belts, chains and other drive parts are significantly reduced.
Operator: Operator ease and efficiency are greatly enhanced by the Load Control. For the highly skilled operator it reduces fatigue. Allows the operator more time to do other things. For the low experienced operator it is a dream come true. That operator can harvest with as much or more efficiency than a highly experienced one. In a recent field test, we put a Load Control on a machine with a low experienced operator. This operator had been cutting at 1/2 the rate the other, experienced operator was. His level had been raised above that of the experienced operator who didn't have a Load Control. The advantages of this are many. As the day wears on an operator looses efficiency due to lack of attention. An owner may wish to put a relief driver in who lacks a lot of experience. With a Load Control, efficiency is not lost nor is down time occurring to negate what the owner is trying to accomplish with the relief driver.
One Time Purchase: Your Load Master System is easily installed on any combine with a hydrostatic or variable speed drive. If you are considering a lease or demo combine, the unit can be soft wired into the machine in less than one hour. You can get a much better idea of how any new purchase can meet your needs. You are in control of the machine at all times. The Load Control keeps you and your machine performing at peak capabilities, increasing your harvest profits substantially.
It makes no economic sense to invest $150,000.00 to $300,000.00 in a combine to get 50% - 70% of rated capacity (95% of today's combines operate at 50% - 70% of capacity performance) and not invest a small percentage more to get peak performance from you combine. A Load Master costs far less than a good auger today, and can return $20,000 to $30,000 annually. Considering the total expenses in farming today this is actually a small budget item, which can actually reduce the number of combines purchased over a generation of farming.