Autonomous Grain Probe Using Optical Detection for Sampling Automation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manual operation of grain probing systems in grain handling facilities is labor-intensive, inefficient, and can lead to backups during peak seasons, making it difficult to identify and employ skilled operators.
Innovation Solution
An autonomous particulate probing system that includes a particulate sampling probe assembly, a programmable logic controller, an optical sensor, and a computer, which uses image data to identify vehicles, determine target areas, and position the probe for sampling without manual intervention, integrating with other systems for efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual operation of grain probing systems is used, then skilled operators can control the sampling process, but labor intensity increases and operational efficiency decreases
Solution Approach 1:
The system enables autonomous operation where the probing system serves itself by automatically detecting vehicles, determining target areas, positioning the probe, and retrieving sensor values without human intervention. The computer executes instructions to coordinate all components autonomously, eliminating the need for manual operation while maintaining sampling accuracy.
Solution Approach 2:
The patent replaces manual mechanical operation with an automated control system. The computer substitutes human operators by processing image data, calculating probe positions, and controlling the probe assembly through electronic signals rather than manual mechanical control.
2Productivity
If more skilled operators are employed to handle increased truck volume, then sampling quality can be maintained, but labor costs and operational complexity increase
Solution Approach 1:
The system performs all sampling operations autonomously without requiring skilled operators. The computer automatically detects vehicles, determines target areas, positions the probe, and coordinates with the PLC to execute sampling, thereby increasing truck handling capacity while reducing operational complexity.
Solution Approach 2:
The computer acts as an intermediary between the optical sensor, PLC, and probe assembly. It processes image data, determines probe target points, calculates sensor values, and transmits instructions to the PLC, thereby coordinating all components to handle increased truck volume efficiently.
3Ease of operation
If manual probing operation is used, then system simplicity is maintained, but operational hours are limited and backup occurs during peak season
Solution Approach 1:
The system operates autonomously without human intervention, enabling extended operational hours including overnight and continuous operation. The computer executes instructions to coordinate the probe assembly and PLC automatically, eliminating the need for manual operation and reducing operational downtime.
Solution Approach 2:
The autonomous system enables continuous operation without breaks or shifts required for manual operation. The computer can continuously process image data, position the probe, and coordinate sampling operations, allowing the grain handling facility to operate around the clock during peak season.
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 autonomous system reduces manual labor, increases efficiency, and allows for extended operating hours by automating the sampling process, reducing the need for skilled operators and minimizing downtime.
Implementation Method 1
an optical sensor that captures image data of a predefined probing environment
Data Source
AI summary
An autonomous probing system includes a computer, a probe assembly, a PLC, and an optical sensor. The optical sensor captures image data of a probing environment. The probe assembly includes a moveable probe portion and a sensor. The probe portion is moveable between a first and second position. The sensor has a first sensor value that is indicative of the first position. The computer receives image data from the optical sensor and detects a vehicle positioned within the probing environment. The computer then determines one or more target areas within the vehicle and an X coordinate position and a Y coordinate position of one or more probe target points within each of the target areas. Based on the first sensor value and the X and Y coordinate positions, the computer determines a second sensor value, which is indicative of the second position and transmits the value to the PLC.