Acoustic Sensor System for Agricultural Component Wear Detection

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Solution Overview

Problem

Agricultural machine operators face challenges in detecting worn or damaged components, such as bearings and ground engaging tools, due to the inability to hear the associated sound changes from the cab, leading to potential increased wear and damage from collisions with rocks.

Innovation Solution

A system comprising first and second acoustic sensors positioned at different locations on the agricultural machine, with a controller determining acoustic parameters from the sensors' data to identify when components are worn or damaged by comparing differences in sound emissions, and initiating control actions to prevent further damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If operators rely on hearing sound changes to detect worn or damaged components, then they can identify component issues, but they cannot hear the sounds from the cab of the vehicle

Engineering Contradiction:

Improvecomponent detection accuracyVSAvoidoperator accessibility to sound data

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent introduces acoustic sensors as intermediaries that capture sound waves from component locations and transmit this data to the controller. The controller then processes and presents the data to operators, serving as a mediator between the physical sound source and the operator's perception capability.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the mechanical/acoustic system of direct human hearing with an electronic acoustic detection system. Acoustic sensors convert sound waves into electrical signals that can be processed and displayed, substituting the biological hearing mechanism with an electronic sensing and processing system.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If operators continuously monitor component conditions, then they can detect wear early, but this requires constant attention and increases operational complexity

Engineering Contradiction:

Improvecomponent condition monitoringVSAvoidmonitoring system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent implements a feedback system where acoustic sensors continuously monitor component sounds, the controller compares acoustic parameters against predetermined thresholds, and operators receive notifications only when wear or damage is detected. This automated feedback loop eliminates the need for continuous operator attention while maintaining reliable monitoring.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The monitoring system performs self-assessment by automatically comparing acoustic parameters to predetermined thresholds and generating wear or damage determinations without requiring operator intervention or interpretation, allowing the system to monitor itself autonomously.

Inventive Principle:

Principle #25Self-service

3Measurement precision

If acoustic sensors are positioned at multiple locations to detect component sounds, then detection accuracy improves, but system complexity and sensor quantity increase

Engineering Contradiction:

Improveacoustic parameter detection accuracyVSAvoidsensor network complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent divides the monitoring task into segments by positioning acoustic sensors at specific locations near different components (e.g., bearings, ground engaging tools). Each sensor monitors its local acoustic environment, and the controller integrates data from multiple sensors to provide comprehensive component condition assessment.

Inventive Principle:

Principle #1Segmentation

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 system effectively detects worn or damaged components by analyzing acoustic data, allowing for timely adjustments to operating parameters and reducing further wear and damage, thereby improving machine efficiency and longevity.

Implementation Method 1

a first acoustic sensor positioned at a first location on the agricultural machine and a second acoustic sensor positioned at a second location on the agricultural machine

Methodology Applied

Scientific EffectAcoustic detection: Sound

Data Source

PatentUS11475717B2System and method for detecting worn or damaged components of an agricultural machine based on acoustic data

Publication Date: 2022.10.18 BLUE LEAF I P INC

AI summary

In one aspect, a system for detecting worn or damaged components of an agricultural machine may include first and second acoustic sensors positioned at first and second locations on the agricultural machine, respectively, with the second location being spaced apart from the first location. A controller of the system may be configured to determine a first acoustic parameter associated with the first location of the agricultural machine based on acoustic data received from the first acoustic sensor. The controller may also be configured to determine a second acoustic parameter associated with the second location of the agricultural machine based on acoustic data received from the second acoustic sensor. Furthermore, the controller may be configured to determine a component of the agricultural machine is worn or damaged when the first acoustic parameter differs from the second acoustic parameter by a predetermined amount.