Hall Effect Grain Level Switch with Pivotable Magnet

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Solution Overview

Problem

Existing grain level switches face issues such as environmental concerns, high costs, maintenance challenges, and inefficiencies due to reliance on mercury switches, rotating paddles, and capacitive sensors, which are not responsive to all grain flow directions and can provide false readings.

Innovation Solution

A Hall effect grain level switch with a pivotable elongate member and a grain contact member, coupled with a Hall-voltage generator and magnet, providing distinct output states based on grain contact, allowing for responsive detection of grain levels regardless of flow direction and reducing false triggering.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a mercury electrical contact switch is used, then the switch is simple and responsive, but it causes environmental problems and disposal issues

Engineering Contradiction:

Improveswitch responsivenessVSAvoidenvironmental impact

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the mercury electrical contact switch with a magnetic field-based detection system using a Hall effect sensor and magnet. This substitution eliminates the mechanical moving parts and toxic mercury while maintaining the ability to detect grain level changes through magnetic field variations caused by grain contact with the elongate member.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If a rotating paddle with motor and slip clutch is used, then grain level can be detected, but electricity is consumed unnecessarily and component costs are high

Engineering Contradiction:

Improvegrain level detectionVSAvoidelectricity consumption

Core Design Contradiction:

Measurement precisionVSUse of energy by moving object

Solution Approach 1:

The system uses passive magnetic field detection where the Hall effect sensor detects changes in the magnetic field caused by grain contact with the elongate member. No active motor operation or power consumption is required during the detection process, as the grain itself causes the magnetic field distortion that triggers the detection.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces the active motor-driven rotating paddle system with a passive magnetic field-based detection system. The Hall effect sensor and magnet arrangement detects grain level through magnetic field changes without requiring motor operation, eliminating continuous electricity consumption.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If a capacitive sensor is used, then grain level can be detected, but false readings occur at low temperatures or with condensation

Engineering Contradiction:

Improvecapacitance readingVSAvoidreading accuracy

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent replaces the capacitive sensor with a magnetic field-based detection system using a Hall effect sensor and magnet. This substitution eliminates the sensitivity to temperature and condensation issues that plague capacitive sensors, as magnetic field detection is not affected by these environmental factors.

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

The Hall effect grain level switch effectively detects grain levels with reduced environmental impact, lower costs, and improved responsiveness, minimizing delays and false readings, making it suitable for grain enclosures like dryers and storage bins.

Implementation Method 1

A Hall effect grain level switch includes a housing which encloses a Hall-voltage generator and a magnet. One of the Hall-voltage generator and the magnet is coupled to the housing in a fixed position within the housing. An elongate member is pivotably coupled to the housing with the other one of the Hall-voltage generator and the magnet being mounted adjacent a proximal end of the elongate member.

Methodology Applied

Scientific EffectHall effect: Hall Effect

Data Source

PatentUS8981884B2Hall effect grain level switch

Publication Date: 2015.03.17 CTB INC

AI summary

A Hall effect grain level switch is positioned adjacent a grain fill opening at an upper portion of a grain enclosure. A Hall-voltage generator is coupled to the housing in a fixed position. An elongate member is pivotably coupled to the housing with the magnet being mounted adjacent a proximal end of the elongate member. A grain contact member is coupled adjacent a distal end of the elongate member. The Hall-voltage generator and magnet are positioned adjacent each other to provide a first output signal state when the elongate member extends vertically in a rest position. The Hall-voltage generator and magnet are distanced from each other to provide a second output signal state when the elongate member is pivoted to a non-vertical switched position in response to grain moving the contact member.