Grain Truck Fill Detection for Autonomous Cart Unloading

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Solution Overview

Problem

Grain cart operation requires manual control by operators to ensure efficient and accurate unloading into grain trucks, which is challenging due to the need to monitor multiple functions and estimate fill levels, leading to potential operator error and inefficiencies.

Innovation Solution

A system with ranging devices and controllers is used to autonomously control grain carts, determining their position relative to grain trucks, identifying fill levels, and optimizing the unloading process based on truck configurations, using cameras and lidar for precise alignment and depth perception to manage fill thresholds.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual operator control is used for grain cart operation, then the operator can monitor multiple functions and make decisions, but operator error and inefficiencies occur due to the difficulty of monitoring many functions simultaneously

Engineering Contradiction:

Improveoperation reliabilityVSAvoidoperation complexity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The grain cart system performs self-monitoring and self-control functions through automated sensors and controllers that detect fill levels, monitor unloading progress, and adjust operations without human intervention, eliminating operator error while maintaining continuous monitoring

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual visual monitoring and estimation by operators is replaced with electronic sensors, ranging devices, and automated control systems that precisely measure fill levels and truck positioning, converting mechanical/operator-based operations to automated electronic control

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If operators visually estimate fill levels, then no additional equipment is needed, but measurement precision is insufficient leading to overfilling or underfilling

Engineering Contradiction:

Improvefill level measurement accuracyVSAvoidsystem complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

Visual estimation by operators is replaced with electronic ranging devices and sensors that use electromagnetic radiation (laser, ultrasonic, or infrared) to precisely measure fill levels, providing accurate quantitative data instead of subjective visual assessment

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Sensors and ranging devices act as intermediary elements between the grain material and the control system, providing indirect but precise measurement of fill levels without requiring direct visual contact or manual intervention

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If operators manually control unloading position, then flexibility in positioning is maintained, but positioning precision is insufficient leading to improper weight distribution in the truck

Engineering Contradiction:

Improvepositioning precisionVSAvoidoperation difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

Manual positioning control by operators is replaced with automated ranging devices and GPS systems that precisely determine the grain cart's position relative to the truck, enabling accurate positioning for optimal weight distribution without requiring operator skill or attention

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Automated grain cart operation reduces operator error and enhances efficiency by ensuring accurate and optimized unloading into grain trucks, improving load distribution and preventing overfilling.

Implementation Method 1

The ranging device is configured to identify a distance to the top edge of the truck box and identify a distance to an area in the truck box

Methodology Applied

Scientific EffectTime of Flight: Time of Flight

Data Source

PatentUS20260107880A1Grain truck fill detection

Publication Date: 2026.04.23 MACDON INDS

AI summary

A method for controlling a grain cart relative to a grain truck. The grain cart includes a grain tank and an unload auger configured to transfer crop material out of the grain tank. The grain truck includes a truck box extending from a first end to a second end. The method includes the steps of identifying a distance to a top edge of the truck box, identifying a distance to an area in the truck box, determining a position of the grain cart relative to the grain truck, and determining whether the grain cart is positioned near the first end of the truck box. The method includes the steps of determining a fill level, whether the fill level exceeds a threshold, and if it is determined that the fill level does not exceed the threshold, starting the unload auger.