Optical Sensor for Seeder Tank Fill Level Measurement
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Solution Overview
Problem
Current fill level indicators in agricultural seeders provide only rough estimates of material quantity in tanks, limiting precision and accuracy, especially when trying to determine when a tank is about to be exhausted, which can lead to inefficient resupply and inaccurate seeding distribution.
Innovation Solution
A sensor system that generates output signals indicative of material attributes, such as weight or shape, which a controller uses to perform programmatic calculations for precise volume determination within the tank, incorporating variables like sensor readings, tank geometry, and material density to provide continuous and accurate fill level information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If load cells are used to measure tank weight continuously, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces the mechanical load cell system with an optical sensing system. A sensor (such as a camera or optical sensor) mounted on the tank captures images or optical data of the material surface, and a controller processes this data to calculate fill level. This substitution eliminates the need for mechanical load cells while achieving continuous measurement precision.
Solution Approach 2:
The patent introduces an intermediary computational process between the sensor and the measurement output. The controller uses image processing and calculations based on tank geometry and material properties to derive fill level from optical data, serving as an intermediary that transforms simple optical inputs into precise fill measurements without requiring complex mechanical weighing systems.
2Measurement precision
If load cells are used to support each tank, then measurement precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent employs inexpensive optical sensors (such as standard cameras or simple optical sensors) instead of expensive load cells. These sensors can be mass-produced at low cost and integrated into the tank structure without requiring precision mechanical components, significantly reducing manufacturing expenses while maintaining measurement capability.
Solution Approach 2:
By replacing the expensive mechanical load cell system with an optical sensing and computational approach, the patent eliminates the need for costly precision mechanical components. The system uses affordable sensors combined with software-based calculation to achieve the same measurement function at a fraction of the manufacturing cost.
3Measurement precision
If tanks are isolated from neighboring elements for accurate weighing, then measurement precision is improved, but space utilization decreases
Solution Approach 1:
The patent replaces the mechanical weighing system that required physical isolation with an optical sensing system. The sensor mounted on each tank captures data independently, eliminating the need for physical gaps between tanks. This allows tanks to be positioned closely together for optimal space utilization while each tank's fill level is measured independently through its own optical sensor.
4Measurement precision
If load cells are used to measure tank contents, then measurement precision is improved, but stress on tank structure increases
Solution Approach 1:
The patent replaces the mechanical load cell system that required balancing the tank on support points (creating high stress concentrations) with a non-contact optical sensing system. The sensor mounted on the tank measures fill level optically without requiring the tank to be supported in a way that creates stress points, eliminating the structural stress problem entirely.
Data Source
AI summary
A sensor generates an output signal indicative of an attribute of a limited amount of material above the sensor. A controller receives the output signal and incorporates a corresponding variable into a programmatic calculation of an indication of a volume of material in a tank.