Grain Loss Sensor Layout Using Centrifugal Separation
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Solution Overview
Problem
Existing grain detection methods in combine harvesters face challenges in accurately counting lost grains due to varying throughput and crop properties, and distinguishing grains from non-grain materials, especially when using impact plate sensors and cameras, which require complex calibration and struggle with visual differentiation in mixed streams.
Innovation Solution
A sensor arrangement with a rotating conveying device and electro-optical sensors, such as cameras, positioned downstream to exploit centrifugal separation of grains and other residues, facilitating optical differentiation and improved grain detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If impact plate sensors are used to detect grains, then grain detection is possible, but accurate recording of absolute grain counts is problematic due to unknown parameters such as throughput and crop properties
Solution Approach 1:
The patent changes the detection parameters from mechanical impact detection to optical detection using electro-optical sensors. This parameter change eliminates the need for calibration related to throughput and crop properties, as optical detection directly captures grain visual characteristics without being influenced by mechanical vibration intensity variations.
Solution Approach 2:
The patent replaces the mechanical impact plate sensor system with an optical detection system using electro-optical sensors. This substitution eliminates the fundamental limitation of mechanical sensors that require calibration for accurate grain counting, as optical sensors directly detect grain visual properties.
2Measurement precision
If cameras are used to detect lost kernels, then grain detection is possible, but it is not easy to visually distinguish grains from non-grain material due to similar color and shape
Solution Approach 1:
The patent applies local quality by positioning the electro-optical sensor specifically on the downstream side of the conveying device where grain and non-grain material have different spatial distributions. This localized positioning exploits the fact that grains tend to concentrate on the outer circumference due to centrifugal force, creating a local area with higher grain density and better visual differentiation opportunities.
Solution Approach 2:
The patent adds the temporal dimension to the detection process by capturing images at specific moments when grains and non-grain material are spatially separated during rotation. This dimensional approach transforms a static visual differentiation problem into a dynamic temporal-spatial separation problem, making grain identification easier.
3Measurement precision
If material is detected in free flight or stationary sample examination, then grain detection is possible, but a relatively large amount of non-grain material flows past the camera locations and lost grain constitutes only a small fraction
Solution Approach 1:
The patent applies preliminary action by using the conveying device to pre-separate grains from non-grain material before detection occurs. The centrifugal separation that happens during rotation concentrates grains on the outer circumference, creating a more favorable detection condition before the electro-optical sensor captures the image.
Solution Approach 2:
The patent improves signal-to-noise ratio by locally targeting the detection to areas where grains are concentrated (outer circumference of the conveying device) rather than attempting to detect all material throughout the entire flow path. This localized detection approach focuses the sensor on regions with higher grain density.
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
Enhances grain detection accuracy by concentrating grains on the outer circumference through centrifugal force, allowing easier optical differentiation and reducing the need for complex calibration, thereby improving grain counting and operational control.
Implementation Method 1
the conveying device rotates, and centrifugal force creates a separation effect between relatively heavy grain on the one hand and relatively lighter, other crop residues (chaff, straw particles) on the other
Data Source
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AI summary
A sensor arrangement for detecting grains in a material stream containing grains and non-grain components in a combine harvester (10) comprises: a conveying device comprising an inlet and an outlet (74) in which the material stream can be set into a rotating motion; an electro-optical sensor arranged on the outer circumference of the conveying device and facing the material stream; and an electronic processing device for detecting grains in the material stream based on the signal from the electro-optical sensor, wherein the electro-optical sensor is arranged on the downstream side of the conveying device.