Grain Unload Synchronization Using Radar Fill-Level Feedback
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Solution Overview
Problem
The synchronization of agricultural machine operations during crop transfer is laborious and challenging, especially in conditions with limited visibility or when using large receiving vehicles, due to the need for precise alignment of the unloading conveyor with the receiving vehicle's grain bin, which is complicated by dust, nighttime operations, and limited data communication and satellite signal availability.
Innovation Solution
A system equipped with electromagnetic detecting and ranging modules, such as LiDAR or RADAR, on agricultural harvesters and receiving vehicles to detect the location and fill level of the receiving vehicle, generating automated navigation data to align the unloading conveyor with the grain bin, enabling assisted or fully automated operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual alignment of receiving vehicle with unloading conveyor is used, then operator control flexibility is maintained, but operator workload and alignment accuracy deteriorate under limited visibility conditions
Solution Approach 1:
The patent replaces manual mechanical alignment operations with an automated optical alignment system. The system uses light detectors (such as lasers) mounted on the unloading conveyor to automatically determine the position and orientation of the receiving vehicle's grain bin, eliminating the need for manual visual alignment by the operator. This substitution of mechanical/manual alignment with optical automation directly resolves the contradiction by improving alignment accuracy while reducing operator workload.
Solution Approach 2:
The alignment system enables the unloading conveyor to self-align with the receiving vehicle without continuous operator intervention. The light detectors automatically track the receiving vehicle's position, and the system self-adjusts the conveyor's orientation and position to maintain optimal alignment. This self-service capability improves alignment precision while significantly reducing the operator's alignment tasks, especially valuable in dusty or nighttime conditions.
2Manufacturing precision
If receiving vehicle shifts position during unloading to evenly fill grain bin, then grain distribution improves, but alignment complexity increases
Solution Approach 1:
The patent implements a feedback control system where light detectors continuously monitor the position of the receiving vehicle and the fill level of the grain bin during unloading. This real-time feedback information is used to automatically adjust the unloading conveyor's position and the receiving vehicle's movement, enabling dynamic optimization of grain distribution. The feedback mechanism simplifies the complexity by providing automated guidance rather than requiring complex manual coordination.
Solution Approach 2:
The system enables dynamic adjustment of the receiving vehicle's position during the unloading process. Rather than requiring static perfect alignment, the system allows the receiving vehicle to move dynamically (shift position) while the automated alignment system continuously adapts to maintain optimal grain flow. This dynamic approach improves grain distribution uniformity while the automation reduces the perceived complexity for operators.
3Measurement precision
If automated alignment system is implemented, then alignment accuracy and operator safety improve, but system complexity and cost increase
Solution Approach 1:
The patent replaces complex manual alignment procedures with a relatively simple optical detection system. By using light detectors (lasers) and basic position sensors, the system achieves high alignment accuracy without requiring complex mechanical automation or multiple sophisticated sensors. This substitution strategy improves accuracy while keeping the added system complexity manageable.
Solution Approach 2:
The alignment system is designed to be multi-functional: the same light detectors and control system handle both the alignment of the unloading conveyor with the receiving vehicle and the monitoring of grain bin fill level. This universality reduces system complexity by using a single integrated system for multiple functions rather than separate dedicated systems for each function.
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 system improves the accuracy and efficiency of crop transfer by providing real-time position data and automated alignment, reducing operator workload and overcoming visibility and environmental limitations, ensuring consistent and reliable synchronization of machine movements during unloading operations.
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 the receiving vehicle
Data Source
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AI summary
An agricultural harvester (10) includes a crop processor, an unload conveyor (22) and first and second a first electromagnetic detecting and ranging modules (28, 32). One or more computing devices (44) are configured to receive first data from the first electromagnetic detecting and ranging module (28), the first data indicating the location of a receiving vehicle (36) relative to the agricultural harvester (10), receive second data from the second electromagnetic detecting and ranging module (32), the second data indicating at least one of a fill level and a distribution of grain in the receiving vehicle (36), and generate automated navigation data based on the first data and the second data, the automated navigation data to automatically control operation of at least one of the agricultural harvester (6) and the receiving vehicle (36) to align the unloading conveyor (22) with the receiving vehicle (36).