Grain Cart Fill Control Using Open-Loop Volumetric Estimation
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Solution Overview
Problem
Existing agricultural harvesting systems face limitations in managing the unloading of agricultural material from harvesters, particularly when sensors such as cameras are obscured or require additional components, limiting their applicability to legacy harvesters without modifications.
Innovation Solution
An open-loop fill management system for agricultural harvesters that uses a controller, user interface, and wireless communication to adjust the position of receiving vehicles based on auger speed and torque sensors, eliminating the need for closed-loop sensors and camera hardware.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If closed-loop systems with cameras and machine vision are used to monitor fill level, then automated fill management capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the fill level monitoring function from complex optical systems and implements it through simple volumetric calculation using basic sensor data (augur speed, torque, time) and known geometry, eliminating the need for cameras and machine vision components
Solution Approach 2:
The invention replaces expensive, complex camera systems with inexpensive, readily available sensors (augur speed and torque sensors) that are already present on most harvesters, making the solution cost-effective and suitable for legacy equipment
2Extent of automation
If closed-loop systems with cameras are implemented, then automated fill monitoring is improved, but ease of manufacture and applicability to legacy harvesters deteriorates
Solution Approach 1:
The patent creates a universal fill management solution that works across different harvester models by using standard sensors and communication protocols already present on most equipment, eliminating the need for custom camera installations
Solution Approach 2:
The system utilizes existing harvester components (augur drive motor, sensors, control system) to perform fill level monitoring, allowing the harvester to self-monitor and self-adjust without external observation systems
3Measurement precision
If sensors are exposed to monitor fill level directly, then measurement capability is improved, but reliability deteriorates when sensors are obscured by dust or residue
Solution Approach 1:
The patent uses volumetric calculation as an intermediary method to determine fill level indirectly through augur performance metrics, avoiding the need for direct optical observation that would be obscured by dust and residue
Solution Approach 2:
The invention replaces optical measurement systems with mechanical sensor data (augur torque and speed) that are not affected by visual obstructions from dust or agricultural residue
Data Source
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AI summary
An agricultural harvester includes a cutting head configured to harvest an agricultural material, a transfer mechanism configured to transfer the harvested agricultural material from the agricultural harvester, and a fill management system. The fill management system is configured to provide open-loop control of an automated transfer of the agricultural material from the agricultural harvester. The fill management system includes a controller, a user interface module coupled to the controller and configured to receive user input indicative of a selected nudge direction, and a wireless communication module coupled to the fill management system and configured to communicate wirelessly with a receiving vehicle. The wireless communication module is configured to obtain storage dimensions relative to the receiving vehicle from the receiving vehicle. At least one sensor is operably coupled to the transfer mechanism and provides a sensor signal that is indicative of flow of the agricultural material through the transfer mechanism. The controller is configured to automatically generate relative positional adjustments between the agricultural harvester and the receiving vehicle based on the signal indicative of flow through the transfer mechanism and the storage dimensions relative to the receiving vehicle.