Grain Level Sensor with Floater Linkage for Shape Profile Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing grain bin level sensor systems only detect the height of grain at the sides and do not provide an indication of the shape profile, leading to potential grain spillage when traversing inclines or encountering overhead obstacles.
Innovation Solution
A grain level sensor system featuring a floater coupled with the grain conveyor outlet and a low-friction linkage, allowing the floater to move relative to the outlet and accurately indicate the peak grain level, combined with side level sensors to determine the grain shape profile, and a data display system for operator alerts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If simple level sensors are provided around the periphery of the grain bin, then the height of grain at the sides can be detected, but the shape profile of the grain cannot be determined
Solution Approach 1:
The system divides the grain bin monitoring into multiple measurement points: side level sensors detect grain height at the periphery, while the floater assembly at the outlet detects grain level at the center/peak location. This segmentation of measurement locations enables comprehensive shape profile determination.
Solution Approach 2:
The system transitions from one-dimensional side-level measurements to three-dimensional shape profiling by adding the floater measurement at the outlet location. The controller combines these measurements to determine the grain shape profile, effectively adding spatial dimensionality to the monitoring.
2Measurement precision
If the floater is connected to the conveyor outlet with a linkage, then the floater can follow the grain level accurately, but the system complexity increases
Solution Approach 1:
The linkage acts as an intermediary mechanical element that transmits the floater's vertical movement relative to the conveyor outlet to the sensor system. This intermediary mechanism enables accurate level detection while maintaining a relatively simple overall structure.
Solution Approach 2:
The patent considers alternative embodiments where mechanical linkages are replaced with cable-based or rod-based systems that have fewer moving parts and lower friction, reducing mechanical complexity while maintaining measurement accuracy.
3Loss of information
If the floater is positioned above the conveyor outlet, then the peak grain level can be detected, but the device complexity increases compared to fixed side sensors
Solution Approach 1:
The floater assembly is designed to be movable rather than fixed, allowing it to dynamically follow the grain level at the outlet. This dynamic positioning enables detection of peak grain levels that may vary with conveyor angle and grain flow conditions.
Solution Approach 2:
The floater assembly serves multiple functions: it detects peak grain level, provides reference for shape profile calculation, and adapts to varying conveyor positions. This multi-functionality justifies the increased device complexity by consolidating multiple measurement capabilities into one assembly.
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
Provides accurate and comprehensive monitoring of grain levels and shape profiles, reducing the risk of grain spillage by enabling operators to take preventive measures based on real-time data and terrain conditions.
Implementation Method 1
a floater adapted to sit on top of expelled grain from the grain conveyor
Implementation Method 2
the linkage used to connect the floater and the outlet is a low-friction linkage, such that minimal force is required to move the floater and connected linkage
Data Source
Figure 1
Figure 2~3
AI summary
There is described a grain level sensor system for a grain bin. The grain level sensor system has a floater which is arranged to sit on top of the level of grain in the grain bin. The floater is coupled with the outlet of a grain conveyor such that the height of the grain level in the bin can be calculated based at least in part by measuring the height of the floater above the conveyor outlet. Accordingly, the peak height of grain in the grain bin can be determined.