Optical Grain Sensing for Bin Routing Accuracy
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Solution Overview
Problem
Current grain storage and processing facilities lack a system to accurately detect different types of grain, leading to potential mixing and contamination between bins, resulting in significant losses due to accidental misrouting.
Innovation Solution
An optical sensing system is integrated into the grain transport line, using an optical sensor with a transparent window and machine learning algorithms to identify grain types and prevent mixing by comparing the detected grain with the intended bin contents, and automatically adjusting the distribution to prevent contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual supervision and control is used by operator, then operational flexibility is maintained, but grain mixing and misrouting errors occur frequently
Solution Approach 1:
The patent replaces the manual mechanical control system with an automated optical sensing and control system. The optical sensor detects grain type automatically, and the control system routes grain without human intervention, eliminating manual errors while maintaining operational flexibility through programmable logic.
Solution Approach 2:
The system enables self-service by allowing the optical sensing system to automatically identify grain type and direct routing decisions without requiring operator intervention. The grain flow is self-regulated through automated control based on real-time optical detection.
2Measurement precision
If optical sensor is positioned in grain transport line, then real-time grain detection is achieved, but system complexity increases
Solution Approach 1:
The optical sensing system is designed to perform multiple functions: identifying grain type, detecting grain presence, and providing feedback for routing control. This multi-functionality reduces the need for separate detection and control systems, thereby managing complexity while enhancing detection precision.
Solution Approach 2:
The optical sensor acts as an intermediary between the grain flow and the control system. It converts physical grain properties into detectable optical signals without requiring direct physical contact or complex mechanical interaction with the grain stream.
3Area of stationary object
If grain bins are positioned closely to one another, then space efficiency is improved, but risk of mixing between bins increases
Solution Approach 1:
The optical sensing system provides real-time feedback on grain type being routed to each bin. The control system uses this feedback to verify that the correct grain type is being loaded into each bin, preventing mixing errors even when bins are positioned closely together.
Solution Approach 2:
The system performs preliminary detection of grain type before routing occurs. By identifying the grain type in advance and pre-configuring the routing path, the system prevents mixing before it can occur, allowing bins to be positioned closer without increasing contamination risk.
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 system effectively prevents grain mixing by accurately identifying grain types and automatically directing them to the correct bins, reducing losses and ensuring the quality of stored grains.
Implementation Method 1
an optical sensor with a transparent window positioned in the grain transport line
Data Source
Figure 1
Figure 2A~2B
Figure 3~4
AI summary
A grain facility has a grain receiving station and a grain transport line with a grain elevator, a distributor with at least one input spout, and at least one grain bin. The grain transport line moves grain from the grain receiving station to one of the at least one grain bins and the distributor directs the grain to a selected bin of the at least one grain bin. The grain facility further includes an optical sensing system having at least one optical sensor positioned in the grain transport line at or before the distributor, wherein the optical sensing system senses the type of grain in the grain transport line. A control system determines if the grain passing through the grain transport line is suitable for the selected grain bin and produces an alarm if the grain in the grain transport line is not suitable for the selected grain bin.