Grain Unload Synchronization Using LiDAR Bin Fill Sensing
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Solution Overview
Problem
The challenge of synchronizing the operation of agricultural harvesters and receiving vehicles during grain unloading is laborious and challenging due to limited visibility, environmental interference, and the need for precise alignment, especially with large grain bins, which can lead to inefficiencies and grain spillage.
Innovation Solution
An agricultural harvester system equipped with electromagnetic detecting and ranging modules (LiDAR or RADAR) to detect the location of receiving vehicles and grain bin fill levels, generating real-time graphical representations to assist or automate the alignment and movement of vehicles for precise grain transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
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 effort and time required increases significantly due to limited visibility and environmental challenges
Solution Approach 1:
The patent replaces the manual mechanical alignment process with an automated optical alignment system. The harvester includes a camera and processor that automatically detect the grain bin position and generate alignment guidance, substituting the operator's manual visual alignment task with an automated image processing system. This resolves the contradiction by maintaining high unloading speed while eliminating the operator effort and visibility challenges.
Solution Approach 2:
The patent creates a visual copy or representation of the grain bin's position and orientation relative to the unload conveyor through captured images and processed graphical displays. This graphical representation provides the operator with enhanced visual information that is not available through direct observation, making alignment easier and more accurate without requiring the operator to physically maneuver the vehicle based on limited direct visibility.
2Quantity of substance
If the receiving vehicle has a large grain bin to increase capacity, then more grain can be transported per trip, but it becomes more difficult to align and fill the bin evenly without spilling
Solution Approach 1:
The automated alignment system using cameras and image processing replaces the manual alignment process, providing precise visual feedback for positioning large grain bins. The system processes images to generate alignment guidance that accounts for the larger dimensions of extended grain bins, enabling accurate alignment that would be difficult to achieve manually.
Solution Approach 2:
The system continuously captures images of the grain bin and processes them to provide real-time feedback on the bin's position and orientation relative to the unload conveyor. This feedback loop allows the operator to make precise adjustments to alignment and filling position, ensuring even distribution of grain across large bin capacities while minimizing spillage.
3Ease of operation
If the operator tries to visually align the grain bin with the spout in challenging conditions (excessive dust, nighttime), then alignment may be achieved, but the time required and operator fatigue increase
Solution Approach 1:
The patent replaces the operator's visual alignment process with an automated camera-based detection and image processing system. The camera captures images of the grain bin and the system processes these images to generate alignment guidance, eliminating the operator's need to visually search and align under challenging conditions. This maintains alignment capability while dramatically reducing the time and fatigue associated with manual visual alignment in dusty or nighttime environments.
4Productivity
If the receiving vehicle moves closely behind the forage harvester to receive crop material, then continuous transfer is possible, but visibility and alignment challenges persist similar to combine harvesters
Solution Approach 1:
The automated alignment system with camera and image processing replaces the operator's manual visual tracking and alignment tasks when following the forage harvester. The system automatically detects the harvester's position and the grain bin's orientation, providing continuous alignment guidance that enables smooth crop transfer without the operator needing to constantly adjust based on limited visibility.
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
Enhances operational efficiency by providing accurate, real-time positioning data for seamless grain transfer, reducing operator effort and minimizing grain spillage, even in challenging environmental conditions.
Implementation Method 1
a first electromagnetic detecting and ranging module for detecting the location of a receiving vehicle relative to the agricultural harvester
Implementation Method 2
a second electromagnetic detecting and ranging module for detecting at least one of a fill level and a distribution of processed crop in a grain bin of the receiving vehicle
Data Source
AI summary
A harvester includes a first electromagnetic detecting and ranging module for detecting the location of a receiving vehicle and a second electromagnetic detecting and ranging module for detecting at least one of a fill level and a distribution of processed crop in a grain bin of the receiving vehicle. One or more computing devices are configured to receive first data from the first electromagnetic detecting and ranging module, receive second data from the second electromagnetic detecting and ranging module and use the first data and the second data to generate graphic data defining a graphical representation illustrating the relative positions of an unload conveyor of the harvester and the grain bin and illustrating at least one of a fill level and a distribution of processed crop in the grain bin. An electronic device is configured to use the graphic data to present the graphical representation on a graphical user interface.