Electromagnetic Bin Level Sensor Immune to Dust

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Solution Overview

Problem

Existing sensor technologies, such as optical and ultrasonic sensors, are prone to errors due to dust, dirt, and airborne contaminants, leading to inaccurate measurement of material levels in containers, which can result in overflowing or insufficient material distribution, particularly in seed planting applications.

Innovation Solution

A system using an electromagnetic signal to measure bin levels, where a transmitter and receiver antenna pair measures the phase shift of a signal as it passes through the bin, allowing a data processor to determine the seed type and estimate the bin level by referencing stored phase data, thereby providing accurate volume measurements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If optical or ultrasonic sensors are used to measure bin level, then the measurement can be performed, but the measurement precision deteriorates due to dust, dirt and airborne contaminants

Engineering Contradiction:

Improvebin level measurement precisionVSAvoiddust, dirt and airborne contaminants

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent replaces optical and ultrasonic sensing systems with an electromagnetic field-based measurement system. The system uses a transmitter to generate an electromagnetic field and a receiver to detect field characteristics (phase, amplitude, frequency) that change in response to material level. This substitution eliminates the direct line-of-sight requirement of optical sensors, making measurements immune to dust and airborne contaminants that scatter or block light and sound waves.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces an electromagnetic field as an intermediary between the measurement system and the material. Rather than directly detecting material properties with sensors exposed to the material environment, the system measures changes in electromagnetic field characteristics caused by the material's presence and level. This indirect measurement approach isolates the sensing mechanism from harmful environmental factors.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If electromagnetic signal is used to measure bin level, then measurement precision improves, but device complexity increases due to need for phase measurement and reference data

Engineering Contradiction:

Improvebin level measurement precisionVSAvoidphase measurement and reference data requirements

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent implements preliminary calibration by storing reference electromagnetic field characteristics corresponding to known material levels in memory before actual measurements. During operation, the system compares real-time field measurements against these pre-stored references to determine material level. This preliminary action eliminates the need for complex real-time calculations and enables straightforward lookup-based measurement, reducing operational complexity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses feedback by continuously comparing measured electromagnetic field characteristics against reference values and adjusting the material level determination accordingly. The phase measurement module feeds back phase information to the processor, which correlates it with stored reference data to provide accurate level readings. This feedback mechanism simplifies the measurement process by using predetermined reference patterns rather than requiring complex real-time analysis.

Inventive Principle:

Principle #23Feedback

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 provides precise and reliable estimation of bin levels, reducing errors and ensuring accurate seed distribution by accounting for variations in seed type and material properties, thus maintaining optimal container levels.

Implementation Method 1

measures the phase shift of a signal as it passes through the bin

Methodology Applied

Scientific EffectPhase shift:

Implementation Method 2

A measurement device, receiver, or phase measurement module measures an observed phase of a primary received signal

Methodology Applied

Scientific EffectElectromagnetic signal interaction with material: Dielectric Permittivity

Data Source

PatentEP3306279B1System for measuring a bin level via an electromagnetic signal

Publication Date: 2021.07.21 DEERE & CO

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Figure 3A~3B

AI summary

A data processor (44) retrieves or accesses a reference bin level versus reference phase for a determined seed type. A measurement device (34), receiver, or phase measurement module measures an observed phase of a primary received signal. The data processor is adapted to determine an estimated bin level of seeds, where the estimated bin level is established as the reference bin level that corresponds to a respective reference phase that is closest in value to the observed phase.