Optical Bulk Material Filling Control System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for filling containers with bulk material during agricultural harvesting are inefficient, leading to material losses and suboptimal loading due to reliance on manual monitoring and lack of adjustable outflow chute positions, resulting in time-consuming and inefficient processes.
Innovation Solution
An arrangement that uses a measurement device to capture image data and determine fill values, generating control commands to position the outflow opening relative to the fill opening and adjust the quantity of bulk material, creating a three-dimensional image of the bulk material surface to optimize filling independently of subjective influences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual monitoring is used to control the filling process, then the device complexity is reduced, but the filling precision and material loss control deteriorate
Solution Approach 1:
The patent replaces manual mechanical monitoring with an automated optical measurement system consisting of a camera, light source, and evaluation unit. The camera captures images of the bulk material surface, the light source illuminates the material, and the evaluation unit processes the images to determine fill height and material distribution, eliminating subjective human judgment and enabling precise automated control of the filling process.
Solution Approach 2:
The patent implements a feedback control loop where the evaluation unit continuously analyzes images of the bulk material surface and provides real-time information about fill height and material distribution. This feedback is used to automatically adjust the outflow opening position and quantity, creating a closed-loop system that maintains optimal filling conditions throughout the process.
2Device complexity
If the outflow chute position is fixed, then the device complexity is reduced, but the adaptability to different container positions and loading conditions deteriorates
Solution Approach 1:
The patent transforms the fixed outflow chute into a dynamic, adjustable component. The outflow opening can be positioned at different heights and azimuth angles according to the measured fill height and container position. This dynamic adjustment capability allows the system to adapt to varying container positions, material flow conditions, and loading requirements without requiring multiple fixed chutes or complex manual repositioning operations.
3Quantity of substance
If repeated emptying of the tank is performed during harvesting, then the container capacity is maximized, but the loss of time increases
Solution Approach 1:
The patent enables continuous filling operation by automatically monitoring and adjusting the outflow opening throughout the harvesting process. The system maintains optimal filling conditions continuously, allowing the container to be filled to capacity without interruption for manual inspection or adjustment. This continuous operation eliminates the need to stop harvesting for repeated emptying operations, thereby maximizing both loading capacity and time efficiency.
4Device complexity
If the outflow opening quantity is not adjusted, then the device complexity is reduced, but the manufacturing precision of material distribution deteriorates
Solution Approach 1:
The patent implements feedback control of the outflow opening quantity based on real-time images of the bulk material surface. The evaluation unit continuously measures fill height and material distribution, and the control unit automatically adjusts the outflow opening quantity to maintain uniform distribution. This closed-loop control ensures precise material distribution without requiring complex manual adjustment mechanisms.
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 solution enables optimal filling of containers with minimal material loss and reduced filling time by automatically adjusting the outflow opening based on three-dimensional image data, ensuring even distribution and maximizing loading capacity.
Implementation Method 1
a measurement device (13) for the periodic capture of images data of the surface (7) of the bulk material (3) during the filling process
Data Source
AI summary
The invention relates to an arrangement for filling a container (5) with bulk material (3), comprising a filling device with an outflow opening (6) for the bulk material (3) and a container (5) with a filling opening, through which the bulk material (3) passes into the container (5). According to the invention, an arrangement of the abovementioned type is equipped with a measuring device (13) for the repeated detection of image data from the surface (7) of the bulk material (3) in the container (5) during filling and for the repeated determination of filling state values h which are equivalent to the level of the filled bulk material in predefined regions of the bulk material surface, and with a signal processing device for generating control commands from the filling state values h for positioning the outflow opening (6) and the filling opening relative to one another and/or for influencing the quantity of bulk material (3) which flows out of the outflow opening (6) per unit time.