Sensor-Guided Grain Filling to Reduce Spillage at High Transfer Rates
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Solution Overview
Problem
Harvesting operations for agricultural materials like grains face issues with grain spillage due to overflow or misalignment during transfer, labor intensity, and inefficiencies in filling transport containers, especially when operating at high transfer rates or varying densities.
Innovation Solution
An automated grain filling system using sensors and processors to detect the upper perimeter and surface of receiving containers, adjusting the grain transfer element's operation based on these detections to minimize spillage and optimize filling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If grain transfer operations are conducted at high transfer rates, then productivity is improved, but grain spillage increases due to overflow or misalignment
Solution Approach 1:
The system employs sensors to continuously monitor the grain level in the receiving container and feeds this information back to the control system. The grain transfer element adjusts its operation based on this real-time feedback, reducing transfer rate when the grain level approaches the container's upper perimeter, thereby preventing spillage while maintaining high productivity during safe operating windows
Solution Approach 2:
The grain transfer element is designed with adjustable parameters including variable transfer rates and controllable discharge location. The system dynamically modifies these parameters based on real-time sensor data about grain level and container fill status, allowing optimization of transfer performance across varying operating conditions without causing overflow
2Loss of substance
If operators manually monitor and adjust grain transfer operations, then grain spillage is reduced, but labor requirements increase
Solution Approach 1:
The system performs self-monitoring and self-adjustment through integrated sensors and automated control. The grain level sensors continuously detect the upper perimeter and grain surface, and the control system automatically modulates the grain transfer element without operator intervention, eliminating the need for manual monitoring while maintaining spill prevention
Solution Approach 2:
The patent replaces manual mechanical monitoring and adjustment operations with automated sensor-based detection and electronic control systems. Sensors detect grain level positions and the control system electronically adjusts transfer parameters, substituting human labor with automated technological systems
3Loss of substance
If transport containers are not filled to capacity, then spillage risk is reduced, but time efficiency and cost efficiency decrease
Solution Approach 1:
The system uses real-time sensor feedback to determine the optimal fill level that maximizes container capacity while maintaining safe operating margins. By continuously monitoring grain level relative to the container's upper perimeter and adjusting transfer rates accordingly, the system achieves near-capacity fills without excessive spillage risk, optimizing both time efficiency and safety
Solution Approach 2:
The system dynamically changes operational parameters including transfer rate, discharge location, and container positioning based on real-time grain level detection. This allows the system to push containers to higher fill levels than conventional practices by adjusting parameters to maintain safety margins throughout the fill process
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
Reduces grain spillage and enhances filling efficiency by dynamically adjusting the grain transfer process, ensuring complete utilization of transport containers and reducing labor requirements.
Implementation Method 1
The sensor may include at least one of a LIDAR scanner, a stereoscopic camera, a proximity sensor, a time-of-flight sensor, a time-of-flight camera, and/or a global positioning system receiver.
Implementation Method 2
The sensor may include at least one of a LIDAR scanner, a stereoscopic camera, a proximity sensor, a time-of-flight sensor, a time-of-flight camera, and/or a global positioning system receiver.
Data Source
AI summary
An automated grain filling system including a sensor and a processor. The sensor is configured to detect at least a portion of an upper perimeter of a receiving container and at least a portion of an upper surface of a grain mound in the receiving container. The processor is configured to compare the detected portion of the upper perimeter and the detected portion of the upper surface, and direct the operation of a grain transfer element. The grain transfer element is configured to transfer grain from a supplying container to the receiving container. The directed operation of the grain transfer element is based at least in part on a result of the comparison of the detected portion of the upper perimeter and the detected portion of the upper surface.