Infrared Thermal Sensor Array for Grain Loss Detection
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Solution Overview
Problem
Current agricultural harvesters lack an automatic method to detect and distinguish between grain loss at the harvesting head (harvest loss) and pre-harvest loss, leading to inefficient operation and significant economic losses due to undetected incorrect settings or mechanical failures.
Innovation Solution
An automatic grain loss sensor array system using infrared thermal imaging devices or focused thermal sensors attached to the header of a combine harvester to capture images or video of the ground, detecting temperature differences to identify and quantify grain loss, and differentiate between harvest loss and pre-harvest loss, providing real-time feedback to the operator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection methods are used to detect grain loss, then operators can identify some loss, but the method is labor-intensive, slow, and cannot provide real-time feedback for adjustments
Solution Approach 1:
The patent replaces manual mechanical inspection with an optical sensing system. Sensors mounted on the combine header use light reflection principles to detect grain kernels on the ground, automatically converting optical signals into electrical signals for real-time measurement and display, eliminating manual labor and time delays
Solution Approach 2:
The patent creates an optical copy or representation of the ground surface by using sensors to detect reflected light patterns. The sensor array captures visual information about grain loss and transmits it to the cab display, creating a replicated view of loss conditions without requiring physical inspection
2Loss of information
If operators manually inspect grain loss by observing the ground, then some loss can be detected, but the operator must dismount the combine and the process is distracting and unsafe
Solution Approach 1:
The patent introduces an intermediary sensing system between the grain loss on the ground and the operator. Sensors mounted on the combine header act as intermediaries, detecting grain loss automatically and transmitting information to the cab display, eliminating the need for the operator to leave the cab and improving safety
Solution Approach 2:
The combine harvesting system performs self-monitoring through mounted sensors that automatically detect and report grain loss conditions. The system serves itself by providing its own diagnostic information without requiring external manual inspection, allowing the operator to remain attentive to operation and safety
3Productivity
If no automatic detection system is used, then the combine structure remains simple, but operators cannot make informed real-time adjustments to header settings, leading to continued grain loss
Solution Approach 1:
The patent divides the detection system into multiple sensor elements mounted at different positions on the header. Each sensor monitors a specific zone, and the combined data provides comprehensive coverage. This segmented approach enables detailed loss measurement without requiring a single complex sensor system
Solution Approach 2:
The sensor array system serves multiple functions: it detects grain loss quantity, provides spatial distribution information, triggers alerts, and guides operational adjustments. This multi-functional approach maximizes productivity benefits while keeping the overall system integrated and manageable rather than adding separate specialized devices
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
Enables operators to make informed adjustments to reduce grain loss by providing instantaneous, cumulative, and geographical information on loss distribution, optimizing header settings and reducing unnecessary crop loss, thereby enhancing harvesting efficiency and economic returns.
Implementation Method 1
An automatic grain loss sensor array system using infrared thermal imaging devices or focused thermal sensors attached to the header of a combine harvester to capture images or video of the ground, detecting temperature differences to identify and quantify grain loss
Implementation Method 2
detecting temperature differences to identify and quantify grain loss, and differentiate between harvest loss and pre-harvest loss
Data Source
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AI summary
A grain loss sensor array system (98) is provided for an agricultural harvester (10). At least one thermal sensing device (100) is attached to a header (18) of the agricultural harvester (10) and captures infrared images or video of the ground. A controller (110) detects pre-harvest loss (106) and harvest loss (108) using the infrared images or video by recognizing a temperature difference or a characteristic thermal difference between the pre-harvest loss (106), the harvest loss (108), and the ground. The controller (110) may communicate with or be integrated with a yield monitor (112) to provide information concerning the pre-harvest loss (106) and harvest loss (108) to an operator of the agricultural harvester (10).