Optical Sensor Assembly for Combine Harvester Mixture Height Detection
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Solution Overview
Problem
Combine harvesters face challenges in accurately detecting the height and uniformly distributing the mixture of grain and contaminants on the conveyor floor and sieve, leading to inefficiencies in the cleaning process.
Innovation Solution
A sensor assembly comprising at least two light-sensitive sensors positioned one above the other, an emitter attached to the upper side of the conveyor floor or sieve, and an analysis device to generate an output signal representing the mixture height, which can activate actuators to control the lateral distribution of the mixture through flaps or guide plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional cleaning systems are used without height detection, then the device complexity is low, but the manufacturing precision of mixture distribution is poor
Solution Approach 1:
The patent replaces complex mechanical height measurement systems with an optical detection system. Light-sensitive sensors detect the height of the mixture layer by measuring light intensity variations, substituting mechanical measurement mechanisms and achieving precise distribution control without complex mechanical structures.
Solution Approach 2:
The patent introduces light as an intermediary medium between the mixture and the detection system. Light-sensitive sensors detect height variations by measuring light intensity changes caused by the mixture layer, using light as a mediator to achieve non-contact, precise measurement.
2Productivity
If manual monitoring of mixture height is used, then the device complexity is low, but the productivity is reduced
Solution Approach 1:
The patent implements a feedback control system where light-sensitive sensors continuously detect mixture height, the control unit processes this information, and actuators automatically adjust the cross conveyor or guide plates to maintain optimal distribution. This closed-loop feedback enables automatic adaptation to varying conditions, significantly improving productivity.
Solution Approach 2:
The cleaning system performs self-adjustment through automatic control. The sensor assembly and control unit enable the system to automatically monitor and correct mixture distribution without external intervention, allowing the system to service itself and maintain optimal performance continuously.
3Loss of substance
If uniform mixture distribution is not controlled, then the device complexity is low, but the loss of substance increases due to contaminant accumulation
Solution Approach 1:
The patent performs preliminary detection and adjustment of mixture distribution before the cleaning process becomes ineffective. The sensor assembly detects height variations early, and the control system proactively adjusts the cross conveyor or guide plates to prevent contaminant accumulation and grain loss before problems occur.
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 sensor assembly effectively detects the mixture height and adjusts the distribution to ensure uniformity, enhancing the efficiency of the cleaning process by preventing contaminants from accumulating unevenly, thus improving the overall harvesting and processing efficiency.
Implementation Method 1
an emitter positioned at a distance from the sensors, wherein the emitter is attached to an upper side of the conveyor floor and/or the sieve, wherein the sensors are configured to receive light radiated from the emitter while a path of the light from the emitter to the sensors is not interrupted by the mixture
Data Source
AI summary
A sensor assembly for detecting the height of a mixture on a conveyor floor and/or a sieve of a cleaning system of a combine harvester is assembled with the combine harvester. The sensor assembly includes at least two light-sensitive sensors, positioned one above the other, and an emitter at a distance from the sensors, are attached on the upper side of the conveyor floor and/or the sieve. The sensors are configured to receive light radiated from the emitter as long as the light is not absorbed by the mixture, and the sensors are connected to an analysis device which is configured to generate an output signal representative of the height of the mixture on the basis of the output signal of the sensors.