Visual Cart Identification for Automatic Grain Fill Control

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Solution Overview

Problem

Operators of agricultural harvesters face challenges in maintaining efficient filling of receiving vehicles, such as grain carts and semitrailers, due to varying soil and crop conditions, leading to inefficiencies and material spillage during unloading.

Innovation Solution

An automatic fill control system uses a camera to capture images of the receiving vehicle, processes visual features, and applies pre-defined settings from stored maps to control the harvester's spout and flap positions for optimal filling, without requiring constant operator intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the operator manually controls the forage harvester to maintain harvesting efficiency under varying conditions, then harvesting efficiency is maintained, but the operator requires large amounts of attention and constant intervention

Engineering Contradiction:

Improveharvesting efficiencyVSAvoidoperator attention required

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The system enables automatic cart filling control by having the harvester system itself monitor cart position and control spout/flap positioning without continuous operator intervention. Sensors and control systems allow the equipment to self-adjust based on detected parameters

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual operator control is replaced with automated sensing and control systems that use optical sensors, position detection, and automated actuation mechanisms to control the spout and flap positioning based on cart location

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If the operator manually positions the unloading spout and flap to fill the cart evenly, then even filling is achieved, but momentary misalignment causes material spillage

Engineering Contradiction:

Improvefilling uniformityVSAvoidmaterial spillage

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The system continuously monitors cart position relative to the spout and automatically adjusts positioning to maintain optimal alignment. Real-time feedback from sensors ensures the spout remains correctly positioned over the cart opening

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system proactively positions the spout and flap before material flow begins, and maintains positioning throughout the filling process to prevent misalignment and spillage

Inventive Principle:

Principle #10Preliminary action

3Productivity

If the operator continuously adjusts control settings to adapt to changing soil and crop conditions, then harvesting efficiency is maintained, but operational complexity increases

Engineering Contradiction:

Improveharvesting efficiencyVSAvoidcontrol system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system dynamically adjusts control parameters based on real-time detection of cart position, fill level, and operational conditions. The control system adapts automatically without requiring operator intervention to change settings

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS12439851B2Automatic fill control based on visual identification of grain receiving vehicles

Publication Date: 2025.10.14 DEERE & CO

AI summary

A camera captures an image of a portion of a cart and accesses stored maps that map visual features of carts to a set of settings that are applied to an automatic fill control system. A map that matches visual features of the cart, in the captured image, is identified and the settings in that map are applied to the automatic fill control system.