Grain Tank Fill Level Detection for Automated Unload Synchronization

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Solution Overview

Problem

The challenge lies in synchronizing the movement of agricultural machines, such as combine harvesters and forage harvesters, with receiving vehicles during the transfer of crop material, which is laborious and can be challenging due to limited visibility, dust, or nighttime operations.

Innovation Solution

The system employs an electromagnetic detecting and ranging module to detect the fill level of the grain tank and the location of the receiving vehicle relative to the harvester, generating data to create a graphical representation of the relative positions of the unload conveyor and the grain bin, presented on a graphical user interface to assist operators or automate the alignment process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the receiving vehicle operator manually aligns the grain bin with the unload conveyor spout during motion, then the unloading operation can proceed, but the operator workload increases and alignment accuracy decreases under challenging conditions

Engineering Contradiction:

Improveoperator workloadVSAvoidalignment accuracy

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The patent replaces the manual mechanical alignment process with an automated optical/electronic system. Sensors detect the relative position between the grain bin and unload conveyor spout, and the system automatically adjusts the receiving vehicle's position, eliminating the need for manual visual alignment while improving precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system creates a visual copy or representation of the alignment state through displays and indicators that show the relative position of the grain bin and spout. This allows the operator to see alignment status without direct visual observation, improving accuracy under challenging environmental conditions.

Inventive Principle:

Principle #26Copying

2Productivity

If the receiving vehicle has a large or elongated grain bin to increase capacity, then productivity improves, but the difficulty of aligning and evenly filling the bin increases

Engineering Contradiction:

Improvegrain storage capacityVSAvoidbin alignment and filling control

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The system provides continuous feedback about the grain bin's fill status and position relative to the spout. Sensors monitor the distribution of grain within the bin and provide real-time data to the control system, which adjusts the vehicle position to achieve even filling across the entire bin length.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system enables dynamic adjustment of the receiving vehicle's position during the unloading process. The vehicle can automatically shift laterally and longitudinally to optimize grain distribution across the elongated bin, making large capacity bins easier to operate.

Inventive Principle:

Principle #15Dynamics

3Productivity

If unloading occurs while the combine harvester is in motion to avoid frequent stops, then productivity increases, but the complexity of maintaining proper alignment increases

Engineering Contradiction:

Improveharvesting continuityVSAvoidsynchronization system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent replaces manual synchronization operations with automated sensor-based systems that continuously monitor and adjust the relative position of the harvester and receiving vehicle, enabling motion-based unloading without increasing operational complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system performs self-adjustment of the alignment between vehicles during motion. The sensors and control system automatically compensate for relative movement, eliminating the need for complex manual coordination and allowing continuous operation.

Inventive Principle:

Principle #25Self-service

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

This solution enhances the efficiency and accuracy of crop transfer operations by providing real-time positional data and graphical representations, reducing operator workload and improving synchronization between machines, even in challenging environmental conditions.

Implementation Method 1

an electromagnetic detecting and ranging module positioned at or above a top of the grain tank for detecting a fill level of the grain tank and the location of a receiving vehicle relative to the combine harvester

Methodology Applied

Scientific EffectElectromagnetic radiation detection: Radar

Data Source

PatentUS12262659B2System and method of assisted or automated grain unload synchronization

Publication Date: 2025.04.01 AGCO INT GMBH

AI summary

An agricultural harvester includes a crop processor, a grain tank, an unload conveyor, and an electromagnetic detecting and ranging module positioned at or above a top of the grain tank for detecting a fill level of the grain tank and the location of a receiving vehicle relative to the combine harvester. One or more computing devices receive data from the electromagnetic detecting and ranging module, the data indicating the fill level of the grain tank and the location of the receiving vehicle relative to the combine harvester, and use the data to generate graphic data defining a graphical representation illustrating the relative positions of the unload conveyor and a grain bin of the receiving vehicle. An electronic device including a graphical user interface presents the graphical representation on the graphical user interface.