Convex Reflection Panel for Crop Level Sensing
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Solution Overview
Problem
Conventional systems for sensing harvested crop levels in agricultural harvesters require precise alignment and adjustment of reflection panels, which is time-consuming and inefficient, especially when the crop level is below a certain vertical position, preventing accurate reflection and detection of the sensor beam.
Innovation Solution
A system that includes a convex reflection panel positioned at a minimum detectable crop level within the crop tank, which diffuses the sensor beam upon reflection, allowing it to be received by the sensor regardless of the panel's orientation, eliminating the need for precise mounting and simplifying installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional flat reflection panel is used to reflect the sensor beam when crop level is below minimum detectable level, then the sensor can detect crop levels, but the panel must be mounted at a precise orientation requiring time-consuming alignment and adjustment procedures
Solution Approach 1:
The patent applies a convex curved reflection panel instead of a flat panel. The convex shape causes the sensor beam to reflect and disperse in multiple directions, creating a broader reflection pattern that can be detected by the sensor regardless of the panel's mounting orientation. This eliminates the need for precise alignment procedures during installation while maintaining crop level detection accuracy.
2Measurement precision
If a conventional flat reflection panel is used, then the sensor beam can be reflected, but the panel must be precisely oriented to reflect the beam in a direction the sensor can receive, increasing device complexity
Solution Approach 1:
The convex curved surface of the reflection panel disperses the reflected sensor beam across multiple directions rather than reflecting it in a single direction. This allows the sensor to receive the reflected beam even when the panel is mounted at various orientations, significantly reducing the complexity of mounting requirements while ensuring reliable reflection.
3Measurement precision
If the crop tank geometry prevents the sensor beam from contacting the top surface of harvested crop at low levels, then accurate sensing cannot be achieved, but adding a reflection panel mounted at precise orientation is complex
Solution Approach 1:
The convex curved reflection panel is designed to intercept the sensor beam when the crop level is below the minimum detectable level and reflect it back to the sensor. The curved surface ensures that the beam is dispersed in multiple directions, making the installation process simple as precise orientation is no longer required, while maintaining sensing accuracy.
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
Enables efficient and accurate sensing of crop levels across a range of orientations, reducing installation complexity and ensuring reliable detection of crop levels both above and below the minimum detectable level, enhancing operational efficiency in agricultural harvesters.
Implementation Method 1
the sensor may be configured to emit a sensor beam, such as an ultrasonic beam, into the crop tank for reflection off of a top surface of the harvested crop stored within the crop tank. The sensor may also be configured to receive the sensor beam after reflection off of the harvested crop.
Implementation Method 2
The reflection panel may be convex such that the reflection panel diffuses the at least one sensor beam as it reflects off of the reflection panel.
Data Source
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AI summary
In one aspect, a system for sensing harvested crop levels within an agricultural harvester may include a crop tank configured to receive harvested crop. The system may further include a sensor configured to emit a sensor beam into the crop tank for reflection off of the top surface of the harvested crop. Additionally, the system may include a reflection panel positioned at a minimum detectable crop level within the crop tank. The reflection panel may be configured to reflect the sensor beam when the current crop level is vertically below the minimum detectable crop level. A center of the reflection panel may be positioned closer to the sensor than an outer edge of the reflection panel such that the reflection panel diffuses the sensor beam as it reflects off of the reflection panel.