Optical Tailings Sensor in Tri-Sweep Housing
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Solution Overview
Problem
Current tailings sensors in agricultural harvesters are not durable and often provide false readings due to poor positioning and the diffuse nature of tailings flow, failing to accurately measure the volume of tailings moving through the tailings conveyance.
Innovation Solution
A tailings conveyance system equipped with optical sensors positioned near the rotating elements, such as impellers, which detect the obstruction caused by tailings as they are compacted and then recycled, allowing for accurate calculation of the volume passing through by measuring the angular velocity and time of obstruction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical arm type sensors are used to measure tailings volume, then the sensor can detect tailings flow, but the sensor lacks durability and becomes stuck providing false readings
Solution Approach 1:
The patent replaces mechanical arm type sensors with an optical detection system consisting of an optical emitter and optical receiver. This substitution eliminates mechanical contact with the diffuse tailings material, preventing sensor sticking and improving reliability while maintaining measurement capability through optical detection of tailings presence in the conveyance path.
Solution Approach 2:
The patent introduces optical energy as an intermediary between the sensor system and the tailings material. The optical emitter sends light through the conveyance path and the optical receiver detects interruptions in the light path caused by tailings, providing indirect but reliable measurement without mechanical contact.
2Measurement precision
If sensors are positioned in the tailings conveyance path, then tailings volume can be measured, but the diffuse nature of tailings flow causes poor positioning and inaccurate readings
Solution Approach 1:
The optical detection system allows the sensor to be positioned outside the direct tailings flow path, mounted on the housing structure. The optical emitter and receiver detect tailings by measuring light path interruption through the conveyance opening, eliminating the need for precise positioning within the diffuse material stream.
Solution Approach 2:
The patent transitions from direct spatial positioning within the tailings flow to a dimensional approach where optical detection occurs through the conveyance housing structure. The sensor system measures tailings volume by detecting the presence of material in the optical path rather than requiring direct contact or precise positioning within the material stream.
3Measurement precision
If optical sensors are positioned at the point of tangency near rotating elements, then accurate tailings volume measurement is achieved, but the device complexity increases
Solution Approach 1:
The optical detection system replaces complex mechanical positioning requirements with a simpler optical arrangement. The emitter and receiver are mounted on fixed housing structures at strategic locations, using optical paths to detect tailings without requiring complex mechanical adjustments or positioning mechanisms.
Solution Approach 2:
The patent positions the optical emitter and receiver in advance at predetermined locations on the housing structure, such that the optical path naturally intersects with the tailings conveyance path near the point of tangency. This preliminary positioning ensures accurate measurement without requiring complex real-time 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
The system accurately measures the volume of tailings despite their diffuse state, providing robust and reliable data for operators, improving the recycling process in agricultural harvesters.
Implementation Method 1
at least one optical sensor, which may include an optical emitter mounted to the front plate or to the back plate, and an optical receiver mounted to the opposite of the front plate or back plate
Data Source
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AI summary
A tailings conveyance (98) including a housing (100) having a front plate (112), a back plate (114), and a wall (110), and is adapted to recycle tailings (80) through a cleaning system (26) of a combine using at least one impeller (104,104A). The wall (110) of the housing (100) describes an arc near the impeller paddles (106) over a segment of a circle described by the circumference of the impeller (104,104A). The wall (110) further continues on a tangent away from the circle at a point of tangency (118). A sensor (150) is positioned proximate to the point of tangency (118), and senses whether a space between the front plate (112) and the back plate (114) directly adjacent to the sensor (150) is obscured by tailings (80) as the impeller (104,104A) rotates. A controller or control system connected to the sensor (150) calculates an amount or percentage of time the space between the front plate (112) and the back plate (114) directly adjacent to the sensor (150) is obscured by tailings (80) as the impeller (104,104A) rotates.