Smart Junction Bank Diagnostics for Agricultural Load Cells
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Solution Overview
Problem
Electronic scale systems in agriculture are prone to failures due to harsh conditions, leading to inefficiencies and downtime, and existing diagnostics require manual disconnection of components for individual analysis.
Innovation Solution
A smart junction controller that converts analog signals from load cells to digital, enabling automated diagnostics, predictive maintenance, and simulated outputs for faulty cells using AI and machine learning to maintain accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If analog signals from multiple load cells are combined in a single junction box, then the system can process weight measurements, but individual diagnostics cannot be performed without manual disconnection of components
Solution Approach 1:
The patent divides the combined analog signal into separate digital channels, allowing individual load cell diagnostics without physical disconnection. Each load cell's signal is processed independently through separate ADC channels, enabling isolated monitoring and diagnosis of each component while maintaining electrical connectivity.
Solution Approach 2:
The patent introduces a smart junction box with microcontroller and ADC as an intermediary between load cells and the scale indicator. This intermediary device performs individual signal conversion and diagnostic analysis, enabling remote monitoring and elimination of manual disconnection requirements.
2Measurement precision
If manual disconnection is required for individual load cell diagnostics, then component isolation is achieved, but operator technical knowledge and time are increased
Solution Approach 1:
The smart junction box performs self-diagnosis of each load cell by automatically analyzing electrical characteristics such as resistance, signal integrity, and output values. The system identifies faulty load cells without operator intervention, reducing reliance on technical knowledge and minimizing diagnostic time.
Solution Approach 2:
The patent implements feedback mechanisms where the smart junction box continuously monitors load cell signals and provides real-time diagnostic information to the scale indicator. This feedback loop enables automatic detection and reporting of load cell issues, eliminating the need for manual disconnection and complex operator procedures.
3Productivity
If a load cell fails in harsh agricultural conditions, then the scale system must stop operation for repairs, but continuous operation is needed for farm efficiency
Solution Approach 1:
The patent implements preliminary diagnostic monitoring that continuously assesses load cell health before complete failure occurs. The smart junction box detects early signs of load cell degradation through resistance measurements and signal analysis, allowing proactive maintenance scheduling that minimizes operational disruption and maintains farm productivity.
Data Source
AI summary
A plurality of analog signals each of which is representative of a portion of the load measured by a corresponding plurality of load cells. Converting the plurality of analog signals into a plurality of digital signals corresponding to the plurality of load cells. Running a diagnostic on each of the plurality of digital signals to determine an operational condition of each of the plurality of load cells.