Grain Tank Sensing Array With Graduated Spacing for Spillage Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional grain quantity measurement devices in combines are inadequate in preventing grain spillage, particularly when harvesting on uneven terrain, leading to revenue loss.
Innovation Solution
A grain tank level sensor array with sensors spaced closer together towards the top end of the tank, combined with multiple arrays at various locations, provides accurate grain level detection and alerts operators to potential spillage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are uniformly spaced throughout the grain tank, then the device complexity is reduced and manufacturing is easier, but the measurement precision deteriorates because non-uniform grain piles on uneven terrain cannot be accurately monitored
Solution Approach 1:
The sensor array implements non-uniform spacing where sensors are concentrated closer together in the upper portion of the tank (within the top 3-4 feet) and spaced farther apart in the lower portion. This local differentiation in sensor density matches the local quality of grain accumulation patterns, providing high-resolution monitoring where spillage risk is highest while reducing overall system complexity compared to uniform high-density spacing throughout.
2Measurement precision
If sensors are concentrated only at the top end of the tank, then the measurement precision for detecting potential spillage is improved, but the loss of information increases because grain level data from lower portions is insufficient
Solution Approach 1:
The sensor array is segmented into two distinct zones: an upper concentration zone with sensors spaced 6-12 inches apart for high-precision spillage detection, and a lower distribution zone with sensors spaced 2-4 feet apart for comprehensive grain level coverage. This segmentation allows each zone to perform its specialized function while collectively providing complete information about grain levels throughout the entire tank.
3Reliability
If conventional uniform sensor spacing is used, then the device complexity is low, but the reliability deteriorates when harvesting on uneven terrain causing non-uniform grain piles
Solution Approach 1:
The sensor array parameters are changed from uniform spacing to a graduated non-uniform spacing pattern. The spacing parameter varies continuously along the vertical axis, transitioning from wider spacing (2-4 feet) in the lower tank portion to narrower spacing (6-12 inches) in the upper portion. This parameter change enables the system to reliably detect grain levels in non-uniform piles caused by uneven terrain while maintaining manageable device complexity.
Data Source
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.