Grain Tank Sensor Array Layout for Uneven Fill Detection
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Solution Overview
Problem
Conventional grain tank measurement systems in combines are inadequate in preventing grain spillage due to inaccuracies in grain level detection, particularly when harvesting on uneven terrain.
Innovation Solution
Implementing multiple arrays of sensors at various locations within the grain tank, including side and center arrays, with varying sensor spacings and orientations to accurately detect grain levels and prevent spillage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single sensor array is used in the grain tank, then the device complexity is low, but the grain level detection accuracy is insufficient particularly on uneven terrain
Solution Approach 1:
The grain tank is divided into multiple zones with separate sensor arrays positioned at different locations (front, center, rear, and side walls). Each sensor array independently monitors grain levels in its specific zone, allowing the system to detect non-uniform grain distribution across the tank while maintaining manageable complexity through modular segmentation.
Solution Approach 2:
Different sensor arrays are positioned at specific locations within the grain tank to detect local grain level variations. The system uses local quality information from each position to determine overall grain fill status, enabling accurate detection of non-uniform grain piles and terrain-induced variations without requiring a single complex comprehensive sensor.
2Adaptability or versatility
If multiple sensor arrays with varying spacings are implemented, then the adaptability to non-uniform grain piles improves, but the device complexity increases
Solution Approach 1:
The sensor arrays are configured with varying spacings between sensors to dynamically adapt to different grain fill conditions. Closer spacing near the tank bottom detects early grain accumulation, while wider spacing in upper regions efficiently monitors near-full conditions. This dynamic spacing configuration optimizes detection capability across all grain levels without requiring uniform complex spacing throughout.
Solution Approach 2:
The system transitions from single-point or single-plane measurement to multi-dimensional monitoring by placing sensor arrays at different heights and positions throughout the grain tank volume. This spatial distribution across multiple dimensions enables comprehensive detection of non-uniform grain piles and provides redundant measurement perspectives for improved accuracy.
3Measurement precision
If sensors are positioned close to the grain pile, then the detection accuracy improves, but the sensors are more susceptible to grain damage and contamination
Solution Approach 1:
The sensor arrays are positioned as intermediaries between the grain pile and the tank wall, at an optimal distance that allows accurate detection of grain level while preventing direct contact between sensors and grain. This intermediary positioning enables the sensors to detect grain presence through near-field effects without being subjected to grain impact, abrasion, or contamination.
Solution Approach 2:
The sensor positioning strategy provides beforehand protection by maintaining a protective distance between the grain and sensor elements. This spatial cushioning prevents grain from directly contacting and damaging the sensors during grain flow, filling, and discharge operations, while still allowing sufficient proximity for accurate detection.
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A combine harvester includes (i) a grain tank for storing separated grain and having a bottom end and a top end, and (ii) a grain tank level sensor array for detecting a level of grain in the grain tank. The grain tank level sensor array includes a plurality of sensors, wherein the grain tank level sensor array extends between the bottom end and the top end of the grain tank. The sensors are spaced apart between the bottom end and the top end. A spacing between adjacent sensors decreases in a direction towards the top end of the grain tank.