Ultrasonic Seed Flow Sensing for High-Rate Particle Counting

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Solution Overview

Problem

Existing optical sensors in air seeders are inadequate for accurately counting individual seeds or fertilizer particles in high-flow crops due to their limited cross-sectional area, leading to unreliable and inaccurate particle counts.

Innovation Solution

Implementing a system with ultrasonic sensors and electrical control systems to measure duty cycle and pulse frequency, using closed-loop feedback control to regulate air flow and distribution, and employing mathematical formulas to estimate particle frequency and population based on duty cycle and pulse frequency calculations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If typical optical sensors with limited cross-sectional area are used, then the device complexity is reduced, but the measurement precision deteriorates due to inability to sense individual particles in high-flow crops

Engineering Contradiction:

Improveparticle count accuracyVSAvoidsensor system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces optical sensors with ultrasonic sensors that use acoustic waves instead of light to detect particles. The ultrasonic sensor emits sound waves through the air stream and detects particles by measuring changes in the acoustic field, enabling accurate particle counting in high-flow conditions where optical sensors fail due to insufficient cross-sectional area

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the detection parameter from optical (light beam interruption) to acoustic (ultrasonic wave interaction). By measuring duty cycle and pulse frequency of the ultrasonic sensor output, the system can accurately determine particle frequency and planting population even when particles are densely packed in high-flow crops

Inventive Principle:

Principle #35Parameter changes

2Reliability

If optical sensors are used for high-flow crops, then the ease of operation is maintained, but the reliability deteriorates due to inaccurate particle counts

Engineering Contradiction:

Improveparticle count reliabilityVSAvoidsystem operation simplicity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent implements a feedback control system where the ultrasonic sensor continuously monitors the air stream for particles, and the controller adjusts the air flow rate based on the detected particle frequency. The system measures duty cycle and pulse frequency to determine if the air flow rate is appropriate for the current crop type and conditions, automatically adjusting to maintain reliable particle counting accuracy

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The ultrasonic sensor system is designed to handle multiple crop types and flow conditions with a single sensor configuration. By detecting duty cycle and pulse frequency patterns, the system can accurately count particles for both low-flow and high-flow crops, eliminating the need for different sensor types or complex manual adjustments

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If the air flow rate is increased to handle high-flow crops, then the productivity is improved, but the measurement precision deteriorates because individual particles cannot be distinguished

Engineering Contradiction:

Improveseeding rateVSAvoidparticle frequency accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent replaces optical detection with ultrasonic detection that can penetrate and interact with particles in high-velocity air streams. The ultrasonic sensor's acoustic waves can detect individual particles even when they are densely packed at high flow rates, maintaining measurement precision while enabling increased productivity through higher seeding rates

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enhances the accuracy of seed and fertilizer distribution by providing precise control over air flow, ensuring uniform application and reducing mechanical issues, thereby improving planting efficiency and uniformity.

Implementation Method 1

sensing flow of a product or particle through a product or particle line

Methodology Applied

Scientific EffectUltrasonic detection: Ultrasound

Data Source

PatentUS12543628B2Methods and systems for measuring duty cycle and pulse frequency of sensors to determine seed or particle metrics

Publication Date: 2026.02.10 PRECISION PLANTING LLC

AI summary

An electrical control system comprises a display device to display data and at least one sensor to detect or measure a duty cycle and to detect or measure a pulse frequency from a sensor output for sensing flow of a product or particle through a product or particle line of an agricultural implement. Processing logic is coupled to the at least one sensor. The processing logic is configured to determine an amount of product or particles flowing through the product or particle line of the agricultural implement based on the measured duty cycle and the measured pulse frequency of the at least one sensor.