Seed Counting Sensor with Optical Masks for Blockage Detection
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Solution Overview
Problem
Pneumatic grain seeding machines face challenges in accurately counting seeds and reliably detecting blockages in seed conveying pipes due to high seed speeds and non-uniform distributions, leading to inaccurate detection and potential missed blockages.
Innovation Solution
A seed counting sensor with a detection chamber, multiple equidistant light sources and detectors, and optical masks that reduce interference, allowing for precise seed counting and blockage detection through signal processing and adaptive sensitivity adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If optical masks with parallel channels are introduced to reduce light interference, then measurement precision of seed detection is improved, but device complexity increases
Solution Approach 1:
Optical masks with parallel channels are introduced as intermediary elements between light sources and light detectors. These masks restrict and direct light paths, ensuring that each light detector receives light primarily from its corresponding light source, thereby reducing cross-interference and improving seed detection accuracy.
Solution Approach 2:
The optical mask is segmented into multiple parallel channels, each corresponding to a specific light source-detector pair. This segmentation physically separates the light paths, preventing overlapping and interference between adjacent detection zones, thus enhancing measurement precision.
2Measurement precision
If multiple light sources and detectors are used to cover the entire cross-section, then seed counting accuracy is improved, but device complexity increases
Solution Approach 1:
The detection system is segmented into multiple independent light source-detector pairs arranged along the cross-section of the seed flow path. Each pair independently monitors a specific zone, and the signal processing unit integrates signals from all pairs to achieve accurate seed counting across the entire cross-section.
Solution Approach 2:
The detection approach transitions from a single-point detection to multi-point detection across the cross-sectional dimension. By distributing light sources and detectors along the cross-section and using optical masks to define detection zones, the system achieves comprehensive coverage and accurate counting in two-dimensional space.
3Reliability
If signal processing with adaptive sensitivity adjustment is implemented, then blockage detection reliability is improved, but device complexity increases
Solution Approach 1:
The signal processing unit implements adaptive sensitivity adjustment by continuously monitoring signals from light detectors and dynamically adjusting detection thresholds. When blockage is detected or suspected, the system adapts its sensitivity to distinguish between reduced seed flow and complete blockage, improving detection reliability.
Solution Approach 2:
The detection system transitions from static threshold-based detection to dynamic adaptive detection. The sensitivity and thresholds are adjusted in real-time based on operating conditions, seed flow characteristics, and detected signal patterns, enabling reliable blockage detection across varying operational states.
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 solution enables accurate seed counting and reliable blockage detection in pneumatic seeding machines, improving operational efficiency and reducing false negatives in seed dispensing.
Implementation Method 1
a plurality of light sources arranged within the house, outside the detection chamber, at predetermined distances from each other
Implementation Method 2
optical masks arranged in front of the light sources and the light detectors, respectively, and made of a non-transparent material, said optical masks having a plurality of parallel channels opening into the detection chamber
Implementation Method 3
a plurality of light detectors arranged within the house, outside the detection chamber at predetermined distances from each other, said light detectors being in the same plane as the light sources
Data Source
AI summary
The seed counting sensor (200) for pneumatic seeding machines comprises a detection chamber (210) within a house (204), said detection chamber allowing the seeds to pass through the sensor and having a center axis (211) extending in the flow direction of the seeds (102); a plurality of light sources (240) arranged within the house (204), outside the detection chamber (210), at predetermined distances from each other, said light sources being in a plane (P) extending substantially perpendicularly to said center axis of the sensor; a plurality of light detectors (250) arranged within the house (204), outside the detection chamber (210) at predetermined distances from each other, said light detectors being in the same plane (P) as the light sources, wherein the number of the light detectors equals to the number of the light sources, and a signal processing unit (502) for controlling operation of the light sources (240) and for processing the electronic signals produced by the light detectors (250).