Grain Cart Automatic Unloading via Load Cell Feedback
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Solution Overview
Problem
Manual unloading of a predetermined weight of crop material from a grain cart is challenging due to the need for constant operator attention, leading to potential over or under-unloading, especially in larger carts where discharge rates are high, and existing automation solutions are complex and involve hydraulic modifications.
Innovation Solution
A grain cart equipped with load cells to measure weight, a gate actuator system controlled by an indicator and conductor wires to automatically close the unloading gates when a predetermined weight is reached, allowing for automated unloading without continuous operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual monitoring is used to unload a predetermined weight of crop material, then the operator can control the unloading process, but constant operator attention is required and over or under-unloading may occur
Solution Approach 1:
The system enables self-service operation where the grain cart automatically monitors its own weight via load cells and autonomously controls gate closure when the predetermined weight is reached, eliminating the need for constant operator attention while maintaining precise weight control
Solution Approach 2:
The system implements continuous feedback through load cells that monitor the weight of crop material in the grain cart and provide real-time data to the control system, which automatically compares the current weight against the predetermined target weight and triggers gate closure when the threshold is reached
2Extent of automation
If automated unloading systems are implemented, then operator attention is reduced, but the systems are overly complex and involve hydraulic modifications
Solution Approach 1:
The invention extracts the complex hydraulic control system from the automation solution and replaces it with a simple electrical control system using load cells, conductor wires, and gate actuators, thereby achieving automation while significantly reducing system complexity
Solution Approach 2:
The patent replaces complex mechanical-hydraulic control mechanisms with an electrical control system that uses load cells for weight sensing and electrical conductors for signal transmission, simplifying the overall system architecture while maintaining automated functionality
3Quantity of substance
If larger grain carts are used to increase capacity, then more crop material can be transported, but the discharge rate increases making manual control more difficult
Solution Approach 1:
The load cell-based feedback system continuously monitors the weight of crop material and provides real-time data to the control system, enabling precise control of the discharge rate regardless of the grain cart's size or capacity, thereby allowing large carts to unload accurately at high speeds
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
Ensures accurate and efficient unloading of a specific weight of crop material by automating the process, reducing the risk of over or under-unloading and simplifying the modification process compared to previous automation attempts.
Implementation Method 1
at least one load cell positioned on the grain cart to measure a weight of crop material in the grain cart
Data Source
AI summary
A grain cart is provided having a storage hopper for holding crop material, load cells positioned on the grain cart to measure a weight of crop material in the grain cart and an indicator connected to the load cells. The indicator can be operative to receive signals from the load cells indicating the weight measured by the load cells and to send an electrical signal on an output connection in response to a predetermined weight of crop material being removed from the grain cart. The output connection can be electrically connected to a close gate conductor wire that is operatively connected to the gate actuator, so an electrical signal generated by the indicator on the output connection of the indicator causes the gate actuator to close gates in the storage hopper stopping crop material from being discharged from the storage hopper.