Ultrasonic Sensor for Rolling Basket Plugging Detection

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Solution Overview

Problem

Farmers face difficulties in detecting plugging of rolling basket assemblies during tillage operations, as material accumulation on and within the baskets prevents optimal performance, and it is challenging to determine a plugged condition from the operator's cab.

Innovation Solution

An agricultural implement equipped with an ultrasonic sensor system that emits signals towards the basket assembly and receives return signals, with a computing system determining plugging based on the presence or absence of these signals, allowing for early detection and initiation of corrective actions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of information

If the operator visually monitors the basket assembly from the cab, then the operator can observe the implement during operation, but the operator cannot detect plugging conditions accurately

Engineering Contradiction:

Improvedetection capabilityVSAvoidoperator monitoring

Core Design Contradiction:

Loss of informationVSEase of operation

Solution Approach 1:

The patent introduces an ultrasonic sensor as an intermediary device that detects plugging conditions and transmits this information to the operator cab. The sensor acts as a mediator between the basket assembly and the operator, enabling accurate detection without requiring direct visual observation from the cab.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the mechanical/visual monitoring system with an ultrasonic sensing system. Instead of relying on the operator's visual inspection from the cab, the system uses ultrasonic waves to detect material accumulation on the basket assembly, substituting acoustic sensing for visual observation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If the operator stops to check the basket assembly manually, then the operator can detect plugging, but productivity is reduced due to operational interruptions

Engineering Contradiction:

Improveplugging detectionVSAvoidtillage operation continuity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent implements a feedback system where the ultrasonic sensor continuously monitors the basket assembly and provides real-time information about plugging conditions to the operator cab. This continuous feedback eliminates the need for manual stops to check for plugging, as the operator receives ongoing status updates and can respond appropriately without interrupting the tillage operation.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent enables continuous monitoring of the basket assembly throughout the tillage operation. The ultrasonic sensor operates continuously, maintaining detection capability without requiring the implement to stop or the operator to leave the cab, thus preserving the continuity of the useful tillage action.

Inventive Principle:

Principle #20Continuity of useful action

3Productivity

If material accumulation is allowed to proceed unchecked, then the implement operates without interruption, but performance degrades due to plugging

Engineering Contradiction:

Improveoperational continuityVSAvoidtillage performance

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent implements preliminary detection of plugging conditions before they significantly degrade performance. The ultrasonic sensor detects material accumulation on the basket assembly at early stages, allowing the operator to take corrective action before the plugging becomes severe enough to substantially reduce tillage effectiveness.

Inventive Principle:

Principle #10Preliminary action

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

Enables early detection of plugging before significant material accumulation occurs, allowing for timely corrective actions to maintain efficient tillage operations.

Implementation Method 1

an ultrasonic sensor configured to emit ultrasonic signals directed at the basket assembly and receive return signals based on reflections of the ultrasonic signals off of the basket assembly

Methodology Applied

Scientific EffectUltrasonic reflection: Reflection

Data Source

PatentUS20240268250A1System and method for monitoring plugging of basket assemblies of an agricultural implement

Publication Date: 2024.08.15 CNH INDUSTRIAL AMERICA LLC

AI summary

An agricultural implement includes a basket assembly configured to roll relative to a surface of a field as the agricultural implement travels across the field. The basket assembly, in turn, includes a plurality of bars spaced circumferentially about an outer perimeter of the basket assembly. Furthermore, the agricultural implement includes an ultrasonic sensor configured to emit ultrasonic signals directed at the basket assembly and receive return signals based on reflections of the ultrasonic signals off of the basket assembly. Additionally, the agricultural implement includes a computing system communicatively coupled to the ultrasonic sensor. In this respect, the computing system is configured to determine when the basket assembly is plugged based on at least one of the return signals being received by the ultrasonic sensor or a lack of return signals being received by the ultrasonic sensor for an agricultural implement.