Curved Grain Flow Sensor Plate for Harvester Mass Measurement
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Solution Overview
Problem
Existing grain mass flow sensors in agricultural combines face challenges in accuracy due to variations in grain bulk properties, inclines, vibrations, and harsh environmental conditions, leading to non-linear relationships between grain flow and sensor signals, and require additional weight to compensate for slopes, which increases susceptibility to errors.
Innovation Solution
A grain mass flow sensor assembly using a single point load cell torque or moment compensated force transducer connected to a continuously curved sensor plate, combined with a dual axis slope sensor or dummy load cell, to provide a robust and accurate measurement system that minimizes calibration needs and is independent of frictional properties, crop type, and moisture content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a traditional grain mass flow sensor is used, then the measurement system is simpler, but the measurement precision deteriorates due to non-linear relationships between grain flow and sensor signals
Solution Approach 1:
The patent applies a continuously curved sensor plate instead of a flat plate to receive grain flow. The curvature is specifically designed to match the natural arc of grain flow from the grain elevator, ensuring that grain impacts the plate along its entire length. This geometric optimization linearizes the relationship between grain mass flow rate and sensor signal, significantly improving measurement precision while maintaining a relatively simple device structure.
Solution Approach 2:
The patent changes the geometric parameter of the sensor plate from flat to continuously curved, with the curvature radius specifically optimized to match grain flow characteristics. This parameter change transforms the non-linear grain-plate interaction into a linear relationship, enabling accurate mass flow measurement without complex additional components.
2Measurement precision
If additional weight is added to compensate for slopes, then the measurement accuracy improves, but the reliability deteriorates due to increased susceptibility to vibrations and errors
Solution Approach 1:
The patent replaces the mechanical compensation method (adding physical weight to counteract slope effects) with an electronic compensation approach using a dual-axis slope sensor. The slope sensor electronically detects and compensates for incline effects on the sensor signal, eliminating the need for additional mechanical weight. This substitution maintains measurement accuracy while improving reliability by reducing susceptibility to vibrations and mechanical errors.
Solution Approach 2:
The patent introduces a dual-axis slope sensor as an intermediary device to detect and compensate for slope effects. This intermediary component electronically measures the incline angle and applies correction factors to the grain mass flow sensor signal, achieving accurate measurements on sloped terrain without adding mechanical weight that would increase vulnerability to vibrations.
3Measurement precision
If a flat sensor plate is used, then the device complexity is lower, but the measurement precision deteriorates due to non-linear grain flow relationships
Solution Approach 1:
The patent employs a continuously curved sensor plate with a specifically optimized radius of curvature that matches the natural arc of grain flow from the grain elevator outlet. This curvature ensures that grain impacts the plate along its entire length rather than at a single point, creating a linear relationship between grain mass flow rate and the force measured by the load cell. The curved geometry alone achieves the precision improvement without adding complex mechanical or electronic components.
4Measurement precision
If the sensor is sensitive to frictional properties, then the adaptability to different grain types improves, but the measurement precision deteriorates due to variations in bulk properties
Solution Approach 1:
The patent replaces friction-based measurement mechanisms with a direct force measurement approach using a load cell. The curved sensor plate directs grain flow to impact in a controlled manner, and the load cell measures the direct force of grain impact without relying on frictional properties. This substitution eliminates sensitivity to variations in grain bulk properties such as moisture, coefficient of friction, and cohesiveness, achieving both high precision and broad adaptability across different grain types.
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 solution achieves high instantaneous accuracy and a linear or non-linear correlation between grain mass flow rate and sensor signal, functioning reliably in harsh conditions without adding extra weight, and requiring minimal calibration, thus improving measurement precision and durability.
Implementation Method 1
The continuously curved sensor plate is configured to change the direction of the grain flow in order to generate a reaction force for measuring the grain mass flow rate of the grain flow
Implementation Method 2
The single point load cell torque or moment compensated force transducer produces a mass flow sensor signal that is linearly or non-linearly proportionate to the grain mass flow rate
Data Source
Figure 1
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Figure 4~5
AI summary
A grain mass flow sensor assembly (100) of an agricultural harvester (10) has a continuously curved sensor plate (102) positioned to receive a grain flow (80) from an exit (76) of the grain elevator (60). The continuously curved sensor plate (102) is configured to change the direction of the grain flow (80) in order to generate a reaction force for measuring the grain mass flow rate (150) of the grain flow (80). The continuously curved sensor plate (102) is attached to a sensor plate to load cell mounting bracket (104). The sensor plate to load cell mounting bracket (104) is attached to a single point load cell torque or moment compensated force transducer (112) at a single mounting point. The single point load cell torque or moment compensated force transducer (112) produces a mass flow sensor signal (152) that is proportionate to the grain mass flow rate (150).