Autonomous Silo Crop Compaction for Uniform Density Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for filling and compacting silos with crops are not optimally designed, leading to inefficiencies in compaction performance and installation processes, often resulting in human error and prolonged silo filling times, which can disrupt the harvesting process and increase energy consumption.
Innovation Solution
Implementing an autonomous operation system for compaction machines, where a control device plans and executes the compaction process independently, optimizing distribution and compaction performance, and coordinating multiple machines to ensure uniform compaction and reduce human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual operation of compaction machines is used, then flexibility and adaptability are maintained, but human error increases and productivity decreases
Solution Approach 1:
The compaction machine is equipped with sensors that automatically detect crop layer height and compaction status, enabling the system to self-regulate the compaction process without human intervention. The machine autonomously determines when to compact and when to allow further crop loading, eliminating human error while maintaining consistent compaction quality.
Solution Approach 2:
A feedback mechanism is implemented where sensors continuously monitor the crop layer height and compaction status, and this information is fed back to the control system. Based on this feedback, the system automatically adjusts the compaction machine's operation, ensuring optimal compaction performance and preventing both under-compaction and over-compaction.
2Productivity
If compaction machine operates continuously, then compaction performance is maximized, but energy consumption increases
Solution Approach 1:
Instead of continuous operation, the compaction machine operates periodically based on sensor-detected crop layer height. The machine compacts when the crop layer reaches a predetermined height and stops when compaction is complete, allowing the next crop layer to be loaded. This periodic operation maintains high compaction performance while significantly reducing energy consumption compared to continuous operation.
Solution Approach 2:
The compaction machine's operation is made dynamic and adaptive rather than static and continuous. The system continuously monitors crop layer conditions and adjusts the compaction machine's operation in real-time, activating compaction only when necessary and deactivating it when the crop layer needs to be replenished, thereby optimizing energy usage.
3Productivity
If multiple compaction machines are used, then compaction performance is enhanced, but coordination complexity and device complexity increase
Solution Approach 1:
Each compaction machine is designed as a universal, self-sufficient unit equipped with its own sensors, control system, and decision-making capability. Each machine can independently detect crop layer conditions and execute compaction operations without requiring complex external coordination, thereby enhancing overall compaction capacity while minimizing system coordination complexity.
Solution Approach 2:
The compaction system is segmented into independent, autonomous units rather than a centralized coordinated system. Each compaction machine operates as an independent module with its own sensing and control capabilities, allowing parallel operation across different silo sections without requiring complex inter-machine communication or coordination protocols.
4Manufacturing precision
If compaction period is extended to ensure thorough compaction, then compaction quality improves, but silo filling time increases
Solution Approach 1:
The system replaces prolonged mechanical compaction with sensor-based detection and intelligent control. Instead of extending the compaction period, the system uses sensors to precisely detect when compaction is complete and when the crop layer needs replenishment, enabling rapid decision-making and minimizing the time the compaction machine needs to operate while ensuring thorough compaction quality.
Solution Approach 2:
The system performs preliminary detection of crop layer height and compaction status before initiating or extending compaction operations. By using sensors to pre-assess the crop layer condition, the system can determine the exact compaction period needed, avoiding both insufficient compaction and unnecessarily extended compaction times, thereby optimizing the balance between compaction quality and filling speed.
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
This approach enhances efficiency by reducing energy consumption, shortening compaction time, minimizing oxidation of the crop, and allowing for quicker silo closure, while reducing the need for manual labor and minimizing disruptions to the harvesting process.
Implementation Method 1
The harvested crop located in the silo is continuously driven over by means of at least one compacting machine, at least for the duration of a compaction period, with at least one weight of the compacting machine acting on the harvested crop. The crop is compacted at least by the effect of the weight of the compacting machine.
Implementation Method 2
at least one weight of the compacting machine acting on the harvested crop. The crop is compacted at least by the effect of the weight of the compacting machine.
Implementation Method 3
Furthermore, compaction machines can have a vibration function that noticeably increases compaction performance.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present application relates to a method for filling a silo (1) with crops (2) to be stored, in particular a flat silo with chopped corn, comprising the following method steps: a) The crops (2) to be stored are distributed in the silo (1). . b) The harvested crop (2) in the silo (1) is continuously run over by means of at least one compacting machine (3, 5) for at least the duration of a compaction period, with at least one weight of the compacting machine (3, 5) acting on the harvested crop (2) acts. c) The crop (2) is compacted by the effect of the weight of the compacting machine (3, 5). In order to provide a method by means of which the filling of a silo can be fundamentally optimized, the following method step is proposed according to the invention: d) The compaction machine (3, 5) is operated autonomously at least during the compaction period, with the compaction machine (3, 5) being Control device (4) is controlled.