Sensor Array Volume Measurement for Loose Material Containers
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Solution Overview
Problem
Existing methods for loading loose materials, such as grain, into containers face challenges in accurately determining the volume and achieving uniform distribution, especially when containers and unloading devices are in motion, leading to inefficiencies and material loss.
Innovation Solution
A system utilizing an array of linear distance sensors mounted on a support arm above the container, which emit sensing signals and determine discrete distance measurements to calculate the volume of the loose material by estimating the cross-sectional area and integrating it over the container's length, allowing for real-time control of the unloading process to ensure uniform distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an operator manually monitors and controls the unloading arm to achieve uniform loading, then loading uniformity can be improved, but labor intensity and operational complexity increase
Solution Approach 1:
The system enables automatic monitoring and control of the unloading arm through sensors and processors that independently measure material volume and adjust feeding operations without requiring manual operator intervention, thereby achieving uniform loading while reducing operational complexity
Solution Approach 2:
Manual visual monitoring and control operations are replaced with an automated sensing system using arrays of linear distance sensors, processors for data analysis, and electronic control mechanisms that objectively measure and regulate material distribution
2Loss of substance
If continuous manual monitoring is performed to prevent material loss, then material recovery can be improved, but operator workload and time consumption increase
Solution Approach 1:
The system continuously measures the volume of material in the container using sensor arrays and provides real-time feedback to the control system, which automatically adjusts the unloading arm operations to prevent overfilling and material loss without requiring continuous operator attention
Solution Approach 2:
Manual monitoring tasks are replaced with automated optical or electromagnetic sensing systems that continuously track material levels and feeding rates, enabling material loss prevention through objective measurement rather than human observation
3Measurement precision
If discrete distance measurements from multiple sensors are collected to calculate volume, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The volume measurement problem is segmented into multiple discrete distance measurements taken at different positions across the container cross-section, with each sensor providing localized data that is then integrated computationally to determine total material volume
Solution Approach 2:
The system transitions from single-point measurements to multi-dimensional spatial mapping by arranging sensors in arrays that capture distance information across multiple dimensions, enabling accurate volume calculation through geometric integration of the measured surface
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 system enables precise determination of the volume of loose materials within containers, improving the efficiency of loading operations by ensuring complete and uniform filling, even in dynamic conditions, thereby reducing material loss and optimizing container utilization.
Implementation Method 1
an array of linear distance sensors mounted over the container, where each sensor of the array can determine a discrete distance measurement between the array and an upper surface of the loose particulate material
Data Source
AI summary
A system for determining a volume of loose material within a container comprises a support arm mountable above the container, an array of one or more sensors mounted to the support arm, wherein each of the one or more sensors is configured to determine a discrete distance measurement between the array and a surface of the loose material or a surface of the container, and at least one processor in communication with the array of one or more sensors, the processor configured to estimate a volume of the loose material in the container from discrete distance measurements determined by the one or more sensors of the array.