Acoustic Grain Loss Sensor Using Microphone and Signal Processor

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Piezoelectric grain loss sensors in agricultural combines are limited by their high cost, sensitivity to environmental conditions, and inability to accurately distinguish between different materials, leading to inaccurate crop yield and loss measurements.

Innovation Solution

An acoustic-based material sensing system using a microphone and signal processor to detect sound waves generated by particle impacts, allowing for real-time determination of material yield and loss, with a sensor housing and strike plate design that forms an environmental seal and processes sound waves to differentiate between grain and chaff impacts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If piezoelectric grain loss sensors are used to detect crop material, then grain loss detection capability is provided, but the sensor cost increases significantly and the sensor becomes sensitive to environmental conditions

Engineering Contradiction:

Improvegrain loss detection capabilityVSAvoidenvironmental sensitivity

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the piezoelectric mechanical sensing system with an acoustic sensing system using microphones and signal processors. The acoustic sensors detect grain loss through sound waves generated by impacting particles, eliminating the need for piezoelectric pads that are sensitive to environmental conditions while maintaining detection capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces signal processing algorithms as an intermediary between the acoustic sensor and the grain loss measurement. The signal processor filters and analyzes acoustic signals to distinguish grain impacts from other sounds, providing accurate measurement without direct environmental exposure of sensitive components.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If piezoelectric sensors are used to detect grain loss, then material loss detection is enabled, but the sensor cannot accurately distinguish between grain material and waste material

Engineering Contradiction:

Improvematerial loss detectionVSAvoidmaterial differentiation capability

Core Design Contradiction:

Measurement precisionVSLoss of information

Solution Approach 1:

The patent applies different signal processing techniques to different aspects of the acoustic signal. By analyzing specific characteristics of the sound waves (frequency, amplitude, duration), the system can distinguish between grain material and waste material impacts, providing material differentiation capability that piezoelectric sensors lack.

Inventive Principle:

Principle #3Local quality

3Reliability

If acoustic sensors are used for material detection, then environmental durability is improved, but the ability to distinguish between different materials requires advanced signal processing

Engineering Contradiction:

Improveenvironmental durabilityVSAvoidsignal processing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical piezoelectric sensor systems with simpler acoustic sensors (microphones) that are inherently more durable in environmental conditions. The complexity is shifted from the hardware to software-based signal processing, which is more easily updated and maintained.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The acoustic system provides accurate and durable measurements of crop yield and loss, adaptable for both grain loss and yield sensing, overcoming the limitations of piezoelectric sensors and enabling improved crop management through real-time data and yield mapping.

Implementation Method 1

the microphone is capable of detecting sound waves generated by the impact of particles on an exterior surface of the strike plate

Methodology Applied

Scientific EffectSound wave detection: Sound

Data Source

PatentUS9474208B2System and method for determining material yield and/or loss from a harvesting machine using acoustic sensors

Publication Date: 2016.10.25 PRECISION PLANTING LLC

AI summary

A system and method for determining material yield and/or loss from a harvesting machine using acoustic sensors and advanced signal processing capabilities is presented. The system consists of a sensor housing with an opening on one side of the sensor housing, a strike plate designed to fit into the opening, and an electronics module comprising a microphone and a signal processor designed to capture the sound waves created when material impacts on the strike plate, and convert them into an audio signal indicating the amount of material impacting the sensor at a given time.