Grain Transfer Control System for Even Fill
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Solution Overview
Problem
Current grain transfer systems face challenges in achieving an even fill of receiving containers during harvesting, particularly due to the difficulty in monitoring fill levels and adjusting nozzle positions while operating in uneven terrain or windy conditions, leading to grain spillage and increased operator workload.
Innovation Solution
A grain transfer control system that uses real-time modeling of fill level profiles based on nozzle positions and flow rates, employing radio frequency transceivers and transponders to automatically adjust the nozzle positions and container orientations for an even fill, allowing for continuous monitoring and prevention of spillage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If operators visually monitor fill level by looking backward at the unloading tube, then they can observe grain flow, but they cannot continuously monitor field conditions and machine alarms
Solution Approach 1:
The patent replaces the mechanical/visual monitoring system with an automated electronic monitoring system using sensors, processors, and display devices. The system automatically tracks fill levels, calculates trajectories, and provides visual feedback without requiring operators to physically observe the unloading tube, thereby eliminating the trade-off between fill level monitoring and field condition monitoring.
Solution Approach 2:
The patent introduces an intermediary automated control system that acts as a mediator between the unloading process and the operators. This system processes sensor data, calculates fill trajectories, and presents information through displays, allowing operators to monitor both fill levels and field conditions simultaneously without direct visual observation of the unloading tube.
2Manufacturing precision
If operators adjust nozzle position manually to achieve even fill, then they can control grain distribution, but operator workload increases and attention is diverted from forward field of view
Solution Approach 1:
The patent implements a self-service automated control system that autonomously adjusts nozzle position and trajectory without requiring continuous manual intervention. The system calculates optimal trajectories, monitors fill levels in real-time, and automatically controls the unloading process to achieve even distribution, freeing operators to maintain forward field of view and reducing overall workload.
Solution Approach 2:
The patent employs a feedback control mechanism where sensors continuously monitor fill levels, the processor calculates trajectory adjustments based on this data, and the system automatically modifies nozzle position and grain flow. This closed-loop feedback system achieves precise even fill distribution while eliminating the need for constant manual adjustment and operator attention to the unloading tube.
3Productivity
If receiving container size is increased to hold more grain, then productivity increases, but ability to visually monitor fill level of various regions decreases
Solution Approach 1:
The patent divides the large receiving container into multiple monitored regions with distributed sensors throughout the container volume. This segmentation allows the system to track fill levels in different regions independently, providing precise monitoring capability even in large-capacity containers that would be impossible to visually inspect.
Solution Approach 2:
The patent replaces visual inspection with an electronic sensor network and digital display system. Sensors distributed throughout the large container continuously measure fill levels in various regions, and the processor synthesizes this data into comprehensive fill status information displayed to operators, enabling precise monitoring of large-capacity containers without physical visual access.
4Productivity
If unloading is performed on the go with moving combine and receiving container, then harvesting efficiency increases, but achieving even fill becomes more difficult due to terrain and wind conditions
Solution Approach 1:
The patent implements a dynamic control system that continuously adapts to changing conditions during on-the-go unloading. The system real-time tracks the relative positions and movements of the combine and receiving container, adjusts trajectory calculations based on terrain variations and wind conditions, and dynamically modifies grain flow distribution to maintain even fill distribution despite the moving platform and environmental factors.
Solution Approach 2:
The patent employs real-time feedback control that continuously monitors actual fill levels during mobile unloading operations and automatically adjusts grain distribution. Sensors track fill status in various regions, the processor calculates necessary trajectory and flow rate adjustments based on container movement and environmental conditions, and the system implements corrections to maintain even distribution despite the challenges of on-the-go operation.
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
The system ensures a more even fill of the receiving container by continuously updating fill level profiles and automatically adjusting nozzle positions, reducing grain spillage and operator workload, even in challenging conditions.
Implementation Method 1
A reading device, such as a radio frequency transceiver, mounted on or near the nozzle and a first data device including at least a location of a first region of the receiving container, and an nth data device including at least a location of an nth region of the receiving container, respectively. The transceiver is configured to acquire information from the first data device through the nth data device. Based on that information, the sensing system is configured to determine positions of the nozzle relative to the first region through the nth region as a function of time.
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
A grain transfer control system for automatically controlling relative positions of an unloading system (24) discharge nozzle (28) of a work machine (20) and a receiving container (22) based on a real time model of a fill level profile (52) for regions of the receiving container (22), the profile being modeled using known or estimated rates of flow of grain and positions of the nozzle (28) relative to regions of the receiving container (22) as a function of time, the system adjusting the relative positions of the nozzle and the receiving container (22) to effect a generally even fill of the receiving container (22).