As the world population continues to grow, there will be a concomitant increase in the demand for agricultural produce. The threat of climate change and its negative impact on the availability of agricultural land and of usable water supplies together with the global trend towards rural depopulation and urbanization is increasing the pressure for implementing a more efficient way of farming on a global scale. It is only with the innovative technologies of ‘precision farming' that these global demands can be met. The agricultural machinery industry is consolidating its pivotal role in the context of global food security. As in recent years, we can expect to see a veritable fireworks display of innovative farm equipment at this year's Agritechnica. The more than 300 nominations for the Agritechnica awards scheme are an expression of the unremitting innovative strength of the agricultural machinery industry which keeps on developing fascinating technology that not only inspires visitors to the exhibition but also injects progress into practice for the benefit of agriculture and society as a whole. The Agritechnica Innovations Commission has awarded four gold and 44 silver medals to outstanding examples of technological innovation in agriculture.
This year too, the trend towards further automation of processes coupled with intelligent data management systems continues to optimize the regulation and control of equipment, logistics, documentation, quality assurance and traceability. Further developments in the specialized areas of electronics, sensors and software form part of almost all of the nominations. For this reason, all such innovations have been grouped here under appropriate headings (tractors, tillage etc.) rather than showing them separately. Analogous to industry 4.0 (i.e. the fourth industrial revolution), digitization and networking of the agricultural value chain is taking on increased importance. Cloud Computing and Big Data have established themselves as part of agricultural terminology.
Agritechnica 2015 once again offers an insight into state-of-the-art agricultural engineering as it enters the next level of digitization and networking by means of rapid advances in electronics, sensors and farm management software right through to storage of data in the Cloud. Increasing constraints in the areas of data protection, data security and data sovereignty are the flipside of this development whilst themselves unleashing further innovative energy.
Tractors, mobile loading equipment, transport technology
Compliance with the latest European exhaust gas emission regulations has forced tractor manufacturers to cut back on development budgets, which in turn has led to a decrease in other innovations more relevant to agriculture. Even so, the tractors presented at the 2015 Agritechnica will again offer a host of exciting and useful new designs and updates, whether for engines, transmissions, chassis, cabs or the ever-growing sector for software, sensor technology, operator aids or electric drives displaying a bias toward a higher degree of automation between tractor and implement.
The Fendt 1000 Vario already presented by AGCO-Fendt has opened up a new standard-tractor segment from 400hp to 500hp. Now with its new, intelligent, variably controlled all-wheel drive and an integrated assistance system for optimum ballasting and tyre pressure it offers an impressive evolution of Fendt´s proven ground drive system. Both these innovations have been awarded a Silver Medal. Alongside this contribution to soil protection and efficiency, the manufacturer is introducing an absolutely novel design for controlling tyre inflation pressures using an additional, integrated interior tyre which enables the system to reduce the exterior tyre air volume while also acting as a pressure accumulator. Tyre pressure is controlled by a number of integrated sensors and valves. This impressive advance by AGCO-Fendt will be awarded a Gold Medal.
A prime example among the many assistance systems designed to reduce operator workload is John Deere´s iTEC AutoLearn system. This headland management system is the first ever system to automatically learn the operator´s control steps and actions (e.g. when turning at the headland). To do this, the system automatically detects any potentially useful and re-usable command sequences and then prompts them for storage in the on-board computer memory. This innovation has been awarded a Silver Medal. Another Silver Medal has been given to John Deere for its ballasting system which enables perfect tractor ballasting within a few seconds from the cab, freeing up tractor mounting locations. And another silver medal has been awarded to John Deere for an intelligent all-wheel drive system which automatically optimizes tractive force distribution depending on axle loads and wheel slip, turning itself on or off as needed. Purpose-built optical systems (such as a 360-degree 3D camera system) provide operators of large farm machines – whether tractor or combine – with an unprecedented level of all-round visibility for transport, field work or farmyard manoeuvring, while also promoting safety at work. For this and similar systems, several Silver Medals have been given to John Deere, AGCO-Fendt and Same Deutz Fahr.
Machinery and equipment for tillage and seed-bed preparation
The exhibition offers a vast array of proven technology for all tasks from stubble removal to primary or secondary tillage. Compact disc harrows for initial shallow tillage after harvest, versatile cultivators for stubble removal or primary tillage and ploughs used for conventional tillage – all implement groups offer a wealth of improvements in detail. More and more enhancements in tillage technology are turning towards automatic GPS and ISOBUS control. The relevant solutions are offered by John Deere, Lemken and Väderstad and has each been awarded a Silver Medal.
While most tillage implements are adjusted hydraulically from the tractor´s spool valves, e.g. to set the working depth, some manufacturers are using electric control for these functions. The TruSet TM implement control system developed by John Deere is the first to provide control, monitoring and calibration of each of the tools in a tillage combination via the central ISOBUS terminal in the cab. Another technical innovation is the automatic compensation feature for these tools. Up to now, operators had to adjust each tool section separately. In this system, when adjusting one of the toolbrs within the combination (e.g. the discs), all other sections (cultivator, press roll, tine harrow) will be adjusted automatically. For varying working conditions the settings profiles can be quickly adjusted on the go, thereby relieving stress on the operator and avoiding adjustment errors.
When working with a semi-mounted reversible plough, the fixed tractor and plough locations, which act as two invariable pulling points, create a pulling line whose position or direction cannot be influenced. This generates a torque around the vertical axis of the tractor which acts on the rear axle centre point and causes the front axle to drift sideways. The results are a narrow front-furrow width and increased fuel consumption. The newly developed pulling point adjustment system uses hydraulic preloading to shift the pulling line towards the rear axle centre point which reduces the level of drift. With the drift removed, there is no need for the operator to correct the steering, which significantly relieves stress on the operator and results in reduced fuel consumption.
Väderstad´s GYRO movement sensor provides real-time data capturing to transmit machine adjustment signals to the controller. The controller in turn automatically manages the optimum machine settings. For example, the CrossBoard leveller uses pressure sensors to automatically adjust its height. This ensures the leveller will constantly push the same amount of soil. Plus, it optimizes levelling efficiency and fuel consumption. The system automatically adjusts the tool unit parallel to the soil surface by measuring the angle between the implement tongue and frame.
While the plough is still an essential part of tillage systems particularly in Germany and Western Europe, ploughless tillage and sowing methods are gaining importance, mostly based on the use of cultivators and min-till seed drills. In some regions, more and more farmers are beginning to use strip-till methods, mostly for maize fields where liquid manure is applied during tillage. No-till farming means a permanent abandonment of any type of tillage. In Germany and Western Europe only few farmers use no-till systems. Given the increasing tendency towards the use of cover crops, however, this method might gain importance in the future.
Machinery and equipment for drilling and sowing
Developments in seed drill and fertilizer spreader technology are characterized by a further increase in efficiency and precision when applying expensive farm inputs. Given the rising costs for seeds and fertilizer as well as the ever stricter environmental and water protection regulations, the precise metering and spreading of these inputs is becoming increasingly important. The growing requirements placed on quality assurance, traceability and documentation can only be met using electronic monitoring and control systems supported by intelligent software.
Seed drill technology
Electrically driven metering systems, seed tube flow sensors, GPS-controlled tramline control, section control, multi-hopper machines for the combined application of seed and fertilizer or additional seed types have become state of the art. Here are two examples of some impressive new designs in this area: GPS Switch and AutoPoint (Amazone) for air seed drills creates a perfect seed pattern at the headland. A sensor detects when the seed is delivered to the opener. The implement control system uses this information to automatically calculate the optimum moment for starting and stopping the metering system at the headland. An assistance system teaches the operator the optimum driving style to adapt to the automatic switching process. This solution has been awarded a Silver Medal and provides the benefits of higher acreage, considerable seed savings and significantly less stress on the operator.
Lemken has developed an automatic seed calibration procedure which involves bypass weighing of the seed for the seeder´s metering unit.
The metering unit provides fully automatic adjustment during calibration. Before starting the calibration process the operator only needs to enter the required parameters such as seed rate, seed population, seed weight and maximum ground speed.
When the automatic calibration process starts, the metering system is activated so that seeds from all meters are fed to a load cell via a bypass. After weighing and transmitting the weight value to the system, the seeds are automatically discharged back into the seed hopper. Now the operator needs to confirm the weighing value and the achievable work rate before drilling may begin. This eliminates the need for time-consuming manual calibration. This innovation has been awarded a Silver Medal.
Precision drilling
The technical development of precision planters in the past few years has been particularly characterized by improvements to seed-singling technology for accurate seed placement at high ground speeds of up to 20km/h.
John Deere presents its ExactEmerge row unit with in-field automatics, a novel system providing maximum work quality for high-speed planting. This system is an all-new approach to sensor-based monitoring, control and documentation of the sowing process. New automation solutions are maximizing seed distribution accuracy and seed placement quality in varying working conditions.
The quality assurance system introduced at the exhibition involves all parameters relevant to seed placement, which ensures optimum sowing quality and seed distribution even at high speeds of up to 16km/h. At the same time the system records the process data and provides online and offline data retrieval and visualization at any time. By combining this technology with the AutoTrac auto-steer system and the iTEC Pro headland automatics, all machine processes in the field are run automatically. During field work there is no more need for operator intervention (in-field automatics). The tractor´s control sequences required for these processes are automatically activated when connecting the implement via the ISO-bus system. The operator has room to focus on monitoring the sowing process. This solution has been awarded a Silver Medal.
Machinery and equipment for fertilising
Courtesy of GPS and ISO-bus controlled spreader technology, uniform metering and distribution of fertilizers and precise boundary spreading at field edges while complying with the new fertilizer application regulations have become state of the art for leading manufacturers of farm machinery. Nonetheless, even fertilizer technology leaves room for innovative improvements – not just for the application process but also for monitoring of the spread pattern.
In a joint effort with manufacturers Land Data Eurosoft, VISTA, Rauch and Sulky, John Deere has developed a previously unknown solution which goes far beyond the mere improvement of a particular machine. This solution is to be awarded a Gold Medal. Connected Nutrient Management is a user-friendly, optimized nutrient management system enabling the demand-oriented, precise application of organic and artificial N and P fertilizers. The system supports planning and optimization with a holistic, overall observation of the harvest history and includes technologies for highly precise fertilizer application. The partner companies´ data, knowledge and key technologies have been tied up in a smart bundle to offer the user an agronomically optimized, site-specific nutrient application system complying with the fertilizer application regulations.
The system presented integrates innovative solutions from John Deere, Land Data Eurosoft, VISTA, Rauch and Sulky in an all-new, holistic approach. It ensures higher precision when planning and applying organic or artificial fertilizers, cuts costs, optimizes yields in terms of quantity and quality while complying with the strict fertilizer regulations, and offers site-specific documentation. For the first time ever, farmers will be able to precisely determine, apply and document nutrient demands (for nitrogen, phosphates etc.) for specific sub-areas, regardless of the type of organic or artificial fertilizer. Since nutrient distribution is optimized according to on variable demands and vegetation time, it provides a higher level of nutrient efficiency and at the same time optimizes nutrient balances. There has never before been a similar integrated solution offering maximum customer value while proactively considering the prevailing environmental and legislative constraints.
Manufacturer Amazone introduces EasyCheck, a digital mobile testing station for determining the transverse distribution quality of centrifugal spreaders using a smartphone app and a set of collection sheets. The operator collects the fertilizer granules on a set of flexible, easy-to-handle, adhesive sheets and takes a picture using their smartphone. This image is then evaluated by an image-processing app installed on the smartphone which automatically calculates the optimum spreader settings. Compared to testing with a collection pan, the EasyCheck digital mobile test station cuts the time spent on this test by around 25 percent. The operator may keep the digital mobile test station in the tractor cab, which provides significant advantages for the farm´s workflow and organizational structures. This novel, globally unique technology is offered at a very competitive price and will significantly increase the degree of market acceptance for transverse distribution tests in the field. It is expected to quickly become popular among farmers. Considering the new fertilizer application regulations, this will generate value for the customer and serves to protect the environment. This simple yet highly innovative solution has been awarded a Silver Medal.
Machinery and equipment for plant protection
The overriding objective of sprayer technology has always been precise application at minimum rates while complying with the applicable legal requirements and delivering maximum biological effectiveness. These objectives may seem easy to achieve, but they can only be met by intelligent sprayer technology with maximum levels of sophisticated electronics, sensors and software. Two examples highlight this development:
Connected Crop Protection and Chemical Application Manager (developed by John Deere, BASF, ISIP - Information System for Integrated Plant Production, ZEPP - German Central Institute for Decision Support Systems in Crop Protection, KTBL - Association for Technology and Structures in Agriculture, JKI - German Federal Research Institute for Cultivated Plants) is an intuitive decision-making system for targeted,well-timed and precise application of chemicals. The innovation partners have found a unique way to integrate key technologies for crop protection recommendations, operator assistance for filling and emptying the sprayer while automatically considering water protection regulations as well as providing complete documentation of these processes. The partner companies´ data, knowledge and tools have been tied up in a smart bundle to offer the user an agronomically optimized, site-specific chemical application system complying with all applicable regulations.
This system comprises two essential, complementary designs creating true added value for the user. One of the key elements is the provision of machine-readable water protection regulations, calculated using the services provided by ISIP, KTBL, JKI and ZEPP, as well as the precise automatic application and documentation by BASF, John Deere and their partners. The second element is the automated crop protection recommendation by BASF and John Deere which is also provided electronically and can be used directly in the system itself. Currently there is no system on the market offering a similarly high level of comprehensive support for this complex issue in a simple integrated system.
This system provides maximum customer value combined with a substantial contribution to environmental and water protection. It has earned a Gold Medal award.
AmaSpot from Amazone is an intelligent sensor/nozzle system to reduce spray rates in crop protection. It detects the green plant against the soil background and ensures highly precise chemical application. For example, the system enables the highly precise application of glyphosate directly to the plant, reducing input use by 20 to 80 per cent. Advanced infra-red sensors, high-speed PWM and low-drift nozzle technology ensure highly accurate 24/7 application at square-centimetre level and speeds of up to 20km/h. This innovation has earned Amazone a Silver Medal.
Tillage, drilling, spreading and spraying
New developments in tillage technology contribute to sustainable soil protection avoiding erosion and compaction. Innovations in seeding technology support the site-specific optimization of plant production to achieve higher yields. Significant improvements in fertilizer and chemical application will lead to a much more resource-saving and environmentally friendly use of farm inputs. In the past, farmers would take an isolated look at new developments without considering their influence on other areas. Today, more and more professional farmers perceive these areas and their development as a coherent system. The tillage method chosen by the farmer determines subsequent seeding technology, suitable fertilizers and the relevant crop protection strategy. This systematic approach is now being challenged by manufacturers of farm machinery. The aim is to adapt this approach to modern farm requirements using innovative enhancements in the areas of electronics, sensor technology and software. The first examples of such integrated solutions are shown at Agritechnica and have been awarded several medals.
Machinery and equipment for combining
At Agritechnica 2015, combine manufacturers will present enhancements which increase the efficiency of their machines. This will include type-specific modifications to threshing and separation systems as well as chassis and propulsion systems and, most importantly, methods for process control within the combine and optimization of combine usage. This trend is highlighted by five example solutions from Claas and John Deere, each of which was awarded a Silver Medal.
Claas will debut with a blockage avoidance system for its Lexion rotary combines. All previous approaches, such as reversing the rotors, simply aim at removing the blockage after the damage has been done. Automatic crop flow control, however, protects the combine from blockages in the first place. If the threshing unit and/or the rotors detect an overload, the operator is not only notified of the blockage risk via a warning message, but – if the throughput control is active – the combine will also reduce its ground speed. If the overload exceeds the limit value, the cutterbar will be deactivated by a quick-stop function. Automatic crop flow control enables the operator to drive the combine to its performance limit and reduces potential repair costs caused by blockages.
Claas´s new 4D system increases the machine's operational reliability on slopes. The rotor cage cover panels were previously used to optimize performance. Now their number has been changed from two to three. The panels for each cage segment consist of two sections of identical size and can be opened and closed as needed. Using the values from the electronic slope detector the panels are controlled to direct the separated material towards the uphill section of the grain pan. This ensures the downhill section of the cleaning system receives less material from the grain pan, which relieves load from this section und avoids additional losses at higher throughputs.
Integrated Combine Adjustment (ICA2) is John Deere´s new adjustment optimization system. At the core of this new system are two cameras located in the grain elevator and the returns elevator. Both cameras transmit their images to the computer and to the cab screen. If the operator agrees with the current work quality, he or she can save them as the target value. ICA2 will then continually compare the actual images from both cameras with the target images. If the actual and target values do not match, the system automatically adjusts the relevant combine setting. Also, John Deere is the first manufacturer to integrate rotor speed and concave clearance into the control system, thus automating even the direct manipulation of grain quality. A time-coded settings list tells the operator which adjustments have been made to maintain the combine´s performance level. This unique system for optimizing all continuous axial combine settings is further proof of the industry´s tendency to equip harvesting machinery with an increasing number of intelligent control systems and to automate more and more processes.
Yield sensor technology has remained almost unchanged for many years. An interesting development comes in the form of John Deere´s Active Yield system for automatic calibration. The grain tank contains three weighing panels. They measure the vertical forces exerted by the increasing volume of grain inside the tank while the computer compares them with the values measured by the yield sensor. Taking into account the grain moisture information, the system calculates a calibration value for the yield sensor so the yield sensor accuracy remains within ±3% deviation from the actual yield. This design increases the combine´s overall yield sensor accuracy as operators or owners tend to neglect periodic re-calibration of the sensor – one of the main reasons being the complexity of this process. More accurate data provide a more reliable basis for precision farming.
GoHarvest Premium is the first realistic combine simulator offering physical or real-world haptic controls for training options throughout the year. The advanced software creates a highly realistic machine operation and harvesting experience. Various learning modules with increasing levels of complexity provide gradual, repeatable skill training.
Set up at dealerships or offered for rent, these simulators will help practise different scenarios from manoeuvring or cutterbar hook-up procedures to actual harvesting work and combine adjustments. The training aims to professionalize and perfect the use of combines of increasing size and cost levels.
Machinery and equipment for lifting (potatoes, beets)
The self-propelled sugar beet harvester – most of them offered with 6 or 9 rows, a few with 12-rows – is continuing its conquest of the world. Dogwalk steering combined with state-of-the-art tyre technology or rubber tracks ensure an efficient, soil-friendly harvest. The soil benefits from several advancements in tyre technology (reducing the inflation pressure to 1.4bars and thereby increasing the tyre contact patch). Directional stability, side-slope capability and axle-load distribution have been improved, while ride quality has been optimized using new, sophisticated (hydraulic) chassis concepts. The minimal-topping process involves a modified defoliating process (using a combination of rubber and steel flails) and is currently replacing the conventional topper with its low-height leaf chopper. In a joint effort with Michelin, manufacturer ROPA has developed a new chassis concept called R-Soil Protect which reduces ground pressure. Five years ago it seemed impossible to run a three-axle sugar beet harvester with 1.4bars of tyre pressure in all wheels. With the new ROPA Tiger 5, ROPA and Michelin are providing the required basis. The result is the first ever networked, three-axle chassis system with hydraulic load distribution, suitable for side slopes of up to 10 percent, which was adapted to Michelin´s new CerexBib IF 1000/55R32 flotation tyre. Particularly in uneven terrain, this avoids peak loads on individual axles or wheels. The vehicle´s mass is distributed over a larger contact area (up to 49 percent more on the rear wheels) – similar to rubber tracks. Minimizing the tyre patch pressure particularly for the rear axles (approx. 33 percent reduction) means better soil protection for sustainable farming practices. This innovative concept has been awarded a Silver Medal.
Machinery and equipment for chopping, mowing, conditioning and baling of mowed material
The primary aim of forage harvesting technology is to produce top-quality forage. To achieve this you need high-performing harvesting processes that combine outstanding quality output with maximum efficiency. With the benefit of powerful mowing and conditioning technology, trailers, balers and forage harvesters can all produce top-notch products geared precisely to the farm's conditions. Modern machines also generally feature electronic and sensor-based assistance systems. Alongside these, however, a number of remarkable engineering enhancements for trailers, balers and forage harvesters have been introduced, for which no fewer than six silver medals have been awarded. What's more, two outstanding innovations have won gold.
Mobile pellet harvester
The Premos5000 is Krone's brand new mobile pellet harvester which, for the first time, enables forage to be harvested and pelleted in the field with one machine. The crop is collected from the swath with a pickup and compressed into 16mm diameter pellets with two interlocking die rollers without the need for pre-crushing. Besides being designed for use in the field, it can also be used stationary. It needs around 300 kW of power to cope with a throughput of 5 t/h. The pellets can be used as fuel, feed or bedding, and as a free-flowing product they allow for a high level of automation at a comparatively low specific energy consumption. Apart from agricultural feed crops, this system is extremely adept at handling a wide range of similar plant residues that lend themselves for raw material or energy recovery. A vast area with great prospects for this outstanding innovation.
John Deere ProCut
Two inductive sensors in the counterblade on the cutterhead of this machine measure the distance between the knives and their sharpness without contact. Both of these parameters have a major impact on chop quality and the forage harvester's fuel consumption. This new solution is the only system on the market that enables knife sharpness and counterblade gap to be measured directly and constantly and that tells the operator, via an assistance system, the right time to sharpen the knives and adjust the counterblade. As an added bonus it ensures a constant quality chop and has the potential to reduce fuel consumption. An impressive innovation with significant benefits for the customer.
Conclusion
Complex products such as the award-winning machines at Agritechnica do not manufacture themselves; they are not even produced by robot but rather by human hand. Indeed, without well-qualified researchers, engineers and assembly line workers, we would have no innovations at all. These are the people who will also solve the technical issues surrounding the fourth industrial revolution for the benefit of Agriculture 4.0, which allows farmers to control their fleet with accuracy using intelligent network technology and cloud computing as well as to map out their entire operation in virtual space. However, without sound concepts on the ownership, protection and security of data and the related issue of legal protection for manufacturers, dealers and users, the intelligently networked agriculture described here will remain more a wish than a reality in practice.
Source: Agritechnica
