Real-Time Moisture Sensor Inoculant Dispensing Control
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Solution Overview
Problem
Existing systems for applying inoculants to forage materials struggle with inaccurate application due to retrospective moisture content measurement, which leads to uneven distribution and potential spoilage, as they measure moisture only after the forage has been baled, failing to account for variations within the crop.
Innovation Solution
A system with sensors that measure moisture content in real-time as forage enters the baling machine, using a control system to adjust the amount of inoculants based on feed rate, moisture, and humidity, with multiple sensors providing a weighted moving average to ensure accurate application across the entire bale.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If moisture content is measured retrospectively after baling, then the measurement is easier to perform on compressed material, but the inoculant application becomes inaccurate due to moisture variations within the crop
Solution Approach 1:
The system measures moisture content of the forage material before it enters the baling machine, rather than after baling. This preliminary measurement allows the control system to adjust inoculant application rates in real-time based on actual moisture conditions of each section of forage being processed, ensuring accurate application despite moisture variations within the crop.
Solution Approach 2:
The system continuously monitors moisture content of incoming forage material and uses this feedback to dynamically adjust the inoculant application rate. The control system receives real-time moisture data from sensors positioned at the intake area and automatically modifies dispensing rates to maintain optimal inoculant-to-forage ratios, resolving the contradiction between measurement ease and application precision.
2Measurement precision
If multiple sensors are used to measure moisture content across the windrow, then the measurement accuracy improves, but the device complexity increases
Solution Approach 1:
The system divides the windrow measurement into multiple segments by positioning sensors at different locations across the intake area of the baling machine. This segmentation allows the system to capture moisture variations across different sections of the forage material, improving overall measurement accuracy while keeping each individual sensor simple and manageable.
Solution Approach 2:
The multiple moisture sensors serve the universal function of monitoring forage moisture content across the entire windrow width. Rather than using different types of sensors for different purposes, the system employs multiple instances of the same moisture measurement technology, simplifying the overall system architecture while achieving comprehensive coverage and improved accuracy.
Data Source
AI summary
An automated system and method are provided for application of inoculant products onto forage material. Real time data measurements are taken for relative humidity and moisture content of the forage material in order to timely adjust the dispense rate of the inoculant applied to the forage material. Data gathering capabilities are provided with this system controller to enable an operator to view, adjust, and record various production records, as well as detailed information as to the amounts of inoculant applied. The components associated with the system of the present invention includes an inoculant bin or container including a dispense auger which dispenses a controlled amount of inoculant which is then conveyed to the intake opening of the baling machine the forage material enters the machine. The control system includes various sensors positioned at the intake opening of the baling machine which measures moisture content, and optionally the mass or volume of the incoming forage material. The control system provides a number of user interface options for controlling the dispensing of the inoculant product, as well as capturing data relating to the operation of the baling machine and the application of the inoculant product. In one embodiment, multiple sensors are used to measure moisture over short periods of time in order to provide fine tuning in a control loop that determines the amounts of inoculants to be applied.