Single Sensor Fill Tube for Agricultural Hopper Level Detection
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Solution Overview
Problem
Conventional fill level detection systems in agricultural implements require two separate sensors to determine when a container is full or empty, which can be cumbersome and less efficient compared to using a single sensor that can provide variability in detecting the product level relative to a variable fill line.
Innovation Solution
A single electronic sensor is positioned at various heights within a fill tube to detect the product level in a hopper, providing a full signal until product is dispensed and an empty signal when the level falls below a predefined threshold, allowing for efficient monitoring of the product supply and operation control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two separate sensors are used to detect full and empty levels, then detection reliability is improved, but device complexity increases
Solution Approach 1:
The patent combines two separate sensor functions (full level detection and empty level detection) into a single sensor assembly that provides both detection capabilities. The sensor assembly includes a sensor body with a sensing element that can detect both full and empty conditions by monitoring product level changes, thereby reducing the number of components while maintaining detection reliability.
Solution Approach 2:
The single sensor assembly is designed to perform multiple functions: detecting both full level and empty level conditions, and providing both visual indication and electrical signals. This multi-functional design eliminates the need for separate dedicated sensors for each detection purpose, reducing overall system complexity.
2Measurement precision
If two separate sensors are used for full and empty detection, then measurement precision is improved, but ease of operation deteriorates
Solution Approach 1:
The patent merges two separate sensor installations into a single integrated sensor assembly, reducing the number of components that need to be installed, adjusted, and maintained. This simplification improves ease of operation while the sensor's ability to detect both full and empty levels maintains measurement precision through a single unified detection mechanism.
3Device complexity
If a single sensor is used to detect product level, then device complexity is reduced, but detection reliability may worsen
Solution Approach 1:
The single sensor assembly is designed with multi-functionality to detect both full and empty product levels, as well as provide both visual indication and electrical signals. This universal detection capability ensures reliable operation for multiple detection purposes simultaneously, compensating for the reduced number of sensors through enhanced sensor functionality.
Solution Approach 2:
The sensor assembly acts as an intermediary mechanism that translates product level changes into both visual and electrical signals. This dual-signal output provides redundant information channels, enhancing detection reliability by offering multiple ways to interpret the same physical condition (full or empty level) from a single sensor source.
4Ease of operation
If a single sensor is used for level detection, then ease of operation is improved, but measurement precision may worsen
Solution Approach 1:
The sensor assembly serves as an intermediary that converts product level information into multiple signal types (visual and electrical). This multi-signal output provides redundant measurement information, ensuring precise detection of both full and empty levels while maintaining operational simplicity through a single sensor installation point.
Data Source
AI summary
A fill tube and sensor assembly has a single electronic sensor to detect the level of product in a hopper of an agricultural implement relative to a fill line. The electronic sensor can be positioned at various heights relative to the fill tube to provide variability in the height of the fill line. The sensor provides a full level signal until product is drawn from the fill tube. Once the product is dispensed from the fill tube and into the general interior volume of the hopper, the single sensor provides an empty level signal that can be used to alert an operator of a diminished product supply or control operation of the farm implement.