Crop Transfer Arm Vision for Grain Bin Alignment in Low Visibility
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Solution Overview
Problem
Operators of receiving vehicles face challenges in aligning grain bins with combine and forage harvesters during crop transfer, especially in conditions like excessive dust or nighttime, due to limited visibility and the need to evenly fill large bins without seeing into the bin from the cabin.
Innovation Solution
A vision system with two cameras positioned on opposite sides of the crop transfer arm, each with a wide field of view of at least 140 degrees, angled to overlap partially and separated by a distance of at least 20 centimeters, combines image data to form a single two-dimensional image and stereo image, enabling the determination of the receiving vehicle's location relative to the harvester for precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the operator manually aligns the grain bin with the spout during motion, then the unload operation can proceed, but the labor intensity and difficulty increase significantly, especially in poor visibility conditions
Solution Approach 1:
The patent replaces manual mechanical alignment with an automated vision-based system. Cameras mounted on the harvester capture images of the grain bin, and image processing algorithms automatically calculate the relative position and orientation, substituting the operator's manual visual estimation and physical adjustment with an automated optical-mechanical system.
Solution Approach 2:
The patent introduces an intermediary image processing system between the harvester and grain bin. This intermediary system processes visual information from cameras and provides alignment guidance, acting as a mediator that translates visual data into actionable alignment information without requiring direct operator intervention.
2Volume of stationary object
If the receiving vehicle has a large grain bin, then the storage capacity increases, but the difficulty of evenly filling the bin increases due to inability to see into the bin from the cabin
Solution Approach 1:
The patent implements a feedback mechanism where cameras continuously monitor the grain bin's fill status and position relative to the spout. The image processing system analyzes this visual feedback and provides real-time guidance for adjusting the grain bin's position, enabling precise control of the fill pattern even for large bins that cannot be visually monitored from the operator's cabin.
Solution Approach 2:
The patent creates a visual copy of the grain bin's interior and fill status through camera imaging. Instead of requiring direct visual observation from the operator's cabin, the system captures images that replicate the view of the bin's contents and position, allowing the operator or automated system to assess fill patterns accurately without physical line-of-sight.
3Manufacturing precision
If the operator shifts the grain bin position during unload, then even filling is achieved, but the operator cannot see into the bin and must estimate fill pattern, increasing operation difficulty
Solution Approach 1:
The system provides continuous visual feedback on the grain bin's fill status and position through mounted cameras. As the operator or automated system adjusts the grain bin position, the cameras capture real-time images showing the fill pattern and spout alignment, enabling precise position adjustments without relying on estimation or trial-and-error approaches.
Data Source
AI summary
A vision system for a harvester includes a first camera positioned on a first side of a crop transfer arm of the harvester and a second camera positioned on a second side of the crop transfer arm of the harvester, the second side being opposite the first side. A center of the first field of view and a center of the second field of view are angled away from one another by an angle of at least ten degrees. A first portion of the first field of view overlaps at least a portion of the second field of view and a second portion of the first field of view does not overlap the second field of view, and a first portion of the second field of view overlaps at least a portion of the first field of view and a second portion of the second field of view does not overlap the first field of view.