Perception Sensors for Automated Fill Level Control
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Solution Overview
Problem
Current agricultural and construction machinery face inefficiencies in material unloading due to the need for manual control of unloading spouts and flaps, leading to uneven filling and material loss, especially in dynamic harvesting conditions, and existing automation solutions are insufficient for integrated systems.
Innovation Solution
The integration of perception sensors, such as cameras, Lidar, radar, and ultrasonic sensors, with onboard and distributed communication units in material unloading containers to provide real-time multidimensional profiling and material property data, enabling autonomous control and improved logistics management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual control of unloading spouts and flaps is used, then the operator can control the unloading process, but the operator needs to devote a large amount of attention to controlling the forage harvester, resulting in reduced harvesting efficiency
Solution Approach 1:
The unloading container is equipped with perception sensors (cameras, Lidar, radar, ultrasonic sensors) that automatically detect and monitor the unloading process, fill levels, and material properties. The system self-regulates the unloading operation without requiring continuous operator intervention, thereby freeing the operator to focus on harvesting operations while maintaining control over the unloading process through automated feedback mechanisms.
2Manufacturing precision
If the operator controls the position of the unloading spout and flap to fill the truck or cart evenly, then the container can be filled properly, but momentary misalignment may result in hundreds of pounds of harvested material being dumped on the ground
Solution Approach 1:
Perception sensors mounted on the unloading container continuously monitor the fill level, material profile, and positioning of the unloading spout. This real-time feedback is processed by a control system that automatically adjusts the spout and flap positions to maintain proper alignment with the container, preventing misalignment and material spillage while ensuring even filling.
Solution Approach 2:
The patent replaces manual mechanical control of the unloading spout and flap with an automated control system based on perception sensor data. This substitution eliminates human reaction time delays and improves positioning precision, thereby preventing material loss due to misalignment while maintaining accurate fill levels.
3Measurement precision
If conventional scales are used to measure fill levels in wagons and trailers, then weight information can be obtained, but the devices are prone to error and heavily influenced by moisture content of the material
Solution Approach 1:
The patent replaces conventional mechanical scales with a non-contact perception sensing system comprising cameras, Lidar, radar, and ultrasonic sensors. These sensors directly measure the fill level and material properties by detecting the physical characteristics of the material (reflectivity, distance, density) without being influenced by moisture content, thereby providing more reliable and accurate measurements.
Solution Approach 2:
The perception sensors act as an intermediary between the material and the measurement system, detecting material properties through electromagnetic radiation (light, radio waves, sound waves) rather than direct mechanical contact. This intermediary approach eliminates the influence of moisture on weight measurements while providing direct information about fill levels and material characteristics.
4Extent of automation
If automation is applied to container detection and material unloading process, then some operator requirements can be diverted, but existing automation solutions are insufficient for integrated systems that coordinate multiple machines
Solution Approach 1:
The unloading container is designed as a multi-functional platform that integrates perception sensing, data processing, communication, and control functions. The perception sensors not only monitor fill levels but also detect material properties, while the communication system coordinates with both the harvesting machine and logistics management systems, creating a universal automated system that handles multiple tasks simultaneously.
Solution Approach 2:
The patent implements a nested system architecture where perception sensors are mounted on the unloading container, which itself is part of a larger integrated system comprising the harvesting machine, communication network, and logistics management platform. Each level of the nested system operates autonomously while contributing to the overall automated operation, allowing for scalable automation without excessive complexity.
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
This solution enhances the efficiency of material unloading by providing accurate, real-time data on fill levels and material properties, reducing material loss and improving logistics planning, allowing for more precise and automated control of the unloading process.
Implementation Method 1
Exemplary perception sensors could include cameras at different frequencies, Lidar, radar, ultrasonic, capacitive sensors, pressure sensors, etc.
Implementation Method 2
Exemplary perception sensors could include cameras at different frequencies, Lidar, radar, ultrasonic, capacitive sensors, pressure sensors, etc.
Implementation Method 3
Exemplary perception sensors could include cameras at different frequencies, Lidar, radar, ultrasonic, capacitive sensors, pressure sensors, etc.
Data Source
AI summary
An intelligent fill level system includes a material unloading container having an interior and a material entryway and a plurality of perception sensors mounted along a rim of the entryway, each sensor configured to generate perception data representative of a profile of unloaded material in at least a portion of the interior. A data processing unit, which may for example be onboard the material unloading container, determines one or more multidimensional profile characteristics, such as for example a fill level, of the unloaded material within the material unloading container at least via fusion of the perception data from the plurality of perception sensors, and a communications unit, which may also for example be onboard the container, transmits output signals representative of the determined one or more multidimensional profile characteristics to one or more remote data processing units associated with respective material loading work machines.