Electrical Generation on Combine Headers for MacDon Industries
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Date
2017-12-06
Authors
Treichel, Calene
Huang, Yidan
Shaker, Basem
Hiebert, Devan
Liao, Shengchao
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Abstract
The project described in this report was completed for MacDon Industries, with the objective of designing a system to generate electrical energy from the rotational energy of a combine header adapter and harness the energy to power various header accessories. The major deliverable of the project was electrical designs for a system which successfully achieves the project objective. The need for this project arises due to the increasing use of electrical power on MacDon combine headers but, as a supplier of headers for several combine models, MacDon cannot modify the existing electrical connection between the combine and header to allow more power to the header. The product developed by the project team solves this problem because it is capable of generating electricity on board the combine header adapter, eliminating the need for a modified or additional combine to header electrical connection. The major constraints imposed on this project were that the system must generate a minimum of 25 amps and 12 volts and that the total cost must not exceed $500. The final design developed during this project is an add-on kit for MacDon combine header adapters which is comprised of several mechanical and electrical components. The major mechanical components are a pair of gears to increase the header rotational speed, which are integrated into an existing gearbox, and a shaft to transmit the rotational energy to an automotive alternator. The automotive alternator generates electricity from the high-speed mechanical rotation and sends direct current power to the electrical system. The electrical system is composed of a battery, as well as a series of fuses, relays, and switches, which function to prevent current from exceeding the design current and prevent current flow in the circuit when a master switch is opened. The system was designed for 12 volts and 40 amps, with a total cost of approximately $450 for all components and manufacturing. The main features of the final design and details for all components of which the final system is comprised are described within this report. The detailed problem, needs, and methodology are also described in further detail in the...