Optical Sensor Unit for Biogenic Multiphase Flow Measurement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current sensor technologies in combine harvesters are inadequate for reliably measuring the solid phase of biogenic multiphase flows and fluid mechanical parameters of the gaseous phase, leading to incomplete separation and increased grain loss due to measurement errors and limited control over machine settings.
Innovation Solution
A sensor unit combining transmitters and receivers for measuring solid and gaseous phases, designed with a keel-shaped housing to minimize flow interference, using electromagnetic radiation and hot-film anemometry for flow velocity and static pressure measurement, and featuring a protective pane for reduced wear and improved accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If piezoelectric or vibration sensors are positioned within or at the edge of the multiphase flow to measure solid phase, then measurement of grain flow is possible, but measurement errors occur due to foreign particles and incomplete solid phase measurement
Solution Approach 1:
The patent introduces an optical intermediary (light beam) that passes through the multiphase flow without being contaminated by foreign particles. The light serves as a mediator between the transmitter and receiver, allowing measurement of solid phase characteristics without direct contact between sensors and the harsh flow environment, thus eliminating measurement errors caused by particle contamination.
Solution Approach 2:
The patent replaces mechanical piezoelectric or vibration sensors with an optical measurement system. Instead of using mechanical elements that directly contact the multiphase flow and are subject to particle contamination, the invention uses electromagnetic radiation (light) to measure solid phase properties, substituting a mechanical sensing approach with a non-contact optical approach that is immune to particle interference.
2Measurement precision
If sensors are positioned in the multiphase flow to measure grain load, then separation rate detection is possible, but sensors become dirty and measurement accuracy decreases
Solution Approach 1:
The optical beam acts as an intermediary that traverses the multiphase flow without being contaminated. The transmitter emits light through the flow and the receiver detects the light on the other side, allowing separation rate measurement without sensors becoming dirty. The light interacts with the solid phase particles temporarily but does not deposit or accumulate, maintaining measurement accuracy over time.
Solution Approach 2:
The patent replaces physical sensors that would become contaminated with dust and particles with a non-contact optical system. The electromagnetic radiation passes through the flow environment without being affected by particle accumulation, eliminating the reliability issue of sensors becoming dirty while maintaining precise separation rate measurement capability.
3Measurement precision
If imaging sensors are used to monitor material flow and determine particle proportions, then grain loss detection is possible, but image recognition complexity and uncertainty increase
Solution Approach 1:
The patent replaces complex imaging sensors and image recognition algorithms with a simpler optical measurement system using transmitters and receivers. Instead of capturing and analyzing images to determine particle proportions, the system uses optical properties (light transmission, scattering, or absorption) to directly measure grain load and separation rate, significantly reducing system complexity while maintaining measurement accuracy.
Solution Approach 2:
The patent extracts only the essential measurement function from complex imaging systems. Rather than using full imaging capability to analyze particle characteristics, the invention isolates and measures specific optical parameters (such as light attenuation or scattering intensity) that directly correlate with grain load, simplifying the measurement approach while maintaining precision.
4Quantity of substance
If existing sensors are used to measure solid phase in combine harvesters, then grain throughput monitoring is possible, but fluid-mechanical parameters of the gaseous phase cannot be measured
Solution Approach 1:
The patent creates a universal optical measurement system that can measure multiple parameters including solid phase grain throughput and fluid-mechanical parameters of the gaseous phase (such as flow velocity and density) using the same transmitter-receiver configuration. By measuring the optical properties of the multiphase flow, the system simultaneously derives information about both solid and gaseous phases, eliminating the need for separate measurement systems and enhancing versatility.
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
Enables precise monitoring of grain flow and flow-mechanical parameters, reducing grain loss and improving the control of harvesting machine settings for optimal performance.
Implementation Method 1
The sensor unit is designed in a flow-optimized shape... The sensors for measuring the fixed phase of the biogenic multiphase flow are preferably arranged laterally on the keel-shaped sensor unit. Preferably, the sensors are designed as light emitters (transmitters) and/or receivers (receivers)...
Implementation Method 2
measurement of the fluid-mechanical parameters of the gaseous phase, in particular the flow velocity and the static pressure... by hot-film anemometry
Implementation Method 3
measurement of the fluid-mechanical parameters of the gaseous phase, in particular the flow velocity and the static pressure...
Data Source
Figure 1~2
Figure 3
Figure 4a~4c
AI summary
The present patent application relates to a sensor unit for use in the multiphase flow of a harvesting machine, wherein the sensor unit comprises sensors for transmitting and/or receiving electromagnetic radiation. Furthermore, the sensor unit has at least one device for detecting flow parameters of the multiphase flow. The measured values of the sensor unit can advantageously be used to control the operation of the harvesting machine.