Sensor Cable Mapping for Void Detection in Bulk Aggregate
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Solution Overview
Problem
Conventional sensors for detecting conditions in bulk aggregate materials, such as grain in storage bins, suffer from delays and inaccuracies due to line-of-sight limitations and non-detection of voids, leading to potential grain avalanches and improper reporting of volume and temperature.
Innovation Solution
A sensor cable system with multiple sensor sets along its axial length, including proximity sensors, temperature sensors, and humidity sensors, coupled with a controller to generate precise spatial maps and control signals for ventilation systems, enabling rapid and accurate detection of bulk aggregate conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If range-finding sensors such as plumb bobs, radar, LiDAR, or optical sensors are used to detect the upper surface of the grain, then the detection capability is improved, but the system is limited by line of sight which results in delays or improper reporting of volume and other conditions
Solution Approach 1:
The sensor cable is divided into multiple discrete sensor sets spaced along its axial length, with each sensor set containing proximity sensors, temperature sensors, and humidity sensors. This segmentation allows each sensor to independently detect conditions at its specific location, eliminating line-of-sight limitations and enabling immediate local measurement without delays.
Solution Approach 2:
The sensor cable acts as an intermediary element enmeshed within the bulk aggregate material. By placing sensing elements directly within the grain mass rather than relying on external range-finding sensors, the system achieves direct contact measurement of volume, temperature, and moisture conditions without line-of-sight constraints.
2Reliability
If conventional sensors are used to detect conditions in bulk aggregate materials, then the detection function is provided, but inaccuracies occur due to line-of-sight limitations and non-detection of voids
Solution Approach 1:
Multiple sensor sets spaced along the axial length of the cable provide distributed measurement points throughout the bulk aggregate. This segmentation ensures comprehensive coverage including voids and irregularities that would be invisible to single-point external sensors, improving both reliability and precision.
Solution Approach 2:
Each sensor set provides localized measurement of proximity, temperature, and humidity conditions at its specific position within the aggregate. This local quality approach allows detection of specific conditions such as voids, moisture pockets, and temperature gradients that compromise overall accuracy.
3Temperature
If temperature cables are enmeshed into grain to detect hotspots, then temperature detection is possible, but the system relies on changes to ambient conditions over many hours or even days
Solution Approach 1:
The sensor cable merges multiple sensor types (proximity sensors, temperature sensors, humidity sensors) into integrated sensor sets that operate simultaneously. This combination allows immediate detection of temperature changes, voids, and moisture conditions without relying on slow ambient condition changes, reducing response time from hours to minutes.
Solution Approach 2:
The sensor cable provides continuous monitoring of bulk aggregate conditions through its distributed sensor sets. Unlike intermittent ambient-based detection, the continuous presence of sensors within the material enables real-time detection of temperature gradients, voids, and moisture changes as they occur.
4Device complexity
If non-detection of substantial voids in grain is allowed, then the sensor system remains simple, but grain flows (grain avalanches) may occur
Solution Approach 1:
The distributed segmentation of sensor sets along the axial length creates multiple detection points that can identify voids and abnormal grain flow patterns. This segmented approach maintains relative system simplicity while providing comprehensive monitoring capability to prevent grain avalanches through early detection.
Solution Approach 2:
The sensor cable system provides continuous feedback on bulk aggregate conditions including void presence and grain flow characteristics. This feedback enables real-time detection of conditions that could lead to grain avalanches, allowing for timely intervention while maintaining manageable system 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
The system provides improved accuracy and granularity in detecting the presence and condition of bulk aggregates, allowing for timely adjustments to ventilation and preventing issues like grain avalanches by quickly identifying voids and moisture levels.
Implementation Method 1
the proximity sensors include an infrared sensor/emitter pair configured to detect the presence of the bulk aggregate
Data Source
AI summary
Bulk aggregate management is provided. A method includes generating a spatial map corelating each multiple first sensors of one or more sensor cables to a location within a storage container for bulk aggregate. The method includes receiving, from the first sensors, a proximity detection signal. The method includes determining, from the proximity detection signal, a position of the bulk aggregate. The method includes generating control signals for conditioning the bulk aggregate.