SENSING ARRAY FOR GRAIN TANK

A combine harvester includes (i) a grain tank for storing separated grain and having a bottom end and a top end, and (ii) a grain tank level sensor array for detecting a level of grain in the grain tank. The grain tank level sensor array includes a plurality of sensors, wherein the grain tank level sensor array extends between the bottom end and the top end of the grain tank. The sensors are spaced apart between the bottom end and the top end. A spacing between adjacent sensors decreases in a direction towards the top end of the grain tank.

FIELD

The disclosure relates to grain tank measurement systems.

BACKGROUND

Harvesters (e.g. combines) are used to harvest crops. Operations performed by conventional combines include chopping the crop and collecting grain in a grain tank. These conventional combines utilize grain quantity measurement devices. Improvements in such devices are continually sought in the interests of, for example, avoiding spillage of the grain.

SUMMARY

A combine harvester includes (i) a grain tank for storing separated grain and having a bottom end and a top end, and (ii) a grain tank level sensor array for detecting a level of grain in the grain tank. The grain tank level sensor array includes a plurality of sensors, wherein the grain tank level sensor array extends between the bottom end and the top end of the grain tank. The sensors are spaced apart between the bottom end and the top end. A spacing between adjacent sensors decreases in a direction towards the top end of the grain tank.

DETAILED DESCRIPTION

Aspects of the disclosure provide methods and systems for operator adjustable tank level measurement for implementation in a harvester combine.

The terms “grain,” “straw,” and “tailings” are used principally throughout this specification for convenience but it is to be understood that these terms are not intended to be limiting. Thus “grain” refers to that part of the crop material which is threshed and separated from the discardable part of the crop material, which is referred to as non-grain crop material, material other than grain (MOG).

As is described in U.S. Patent App. Pub. No. 20200022305, which is incorporated by reference herein in its entirety and for all purposes,FIG.1Adepicts one embodiment of an agricultural harvester in the form of a combine10, which generally includes a chassis12, ground engaging wheels14and16, a header18, a feeder housing20, an operator cab22, a threshing and separating system24, a cleaning system26, a grain tank28, and an unloading auger30.

Front wheels14are larger flotation type wheels, and rear wheels16are smaller steerable wheels. Motive force is selectively applied to front wheels14through a power plant in the form of a diesel engine32and a transmission (not shown). Although combine10is shown as including wheels, is also to be understood that combine10may include tracks, such as full tracks or half-tracks.

Header18is mounted to the front of combine10and includes a cutter bar34for severing crops from a field during forward motion of combine10. A rotatable reel36feeds the crop into header18, and a double auger38feeds the severed crop laterally inwardly from each side toward feeder housing20. Feeder housing20conveys the cut crop to threshing and separating system24, and is selectively vertically movable using appropriate actuators, such as hydraulic cylinders (not shown).

Threshing and separating system24is of the axial-flow type, and generally includes a rotor40at least partially enclosed by and rotatable within a corresponding perforated concave42. The cut crops are threshed and separated by the rotation of rotor40within concave42, and larger elements, such as stalks, leaves and the like are discharged from the rear of combine10. Smaller elements of crop material including grain and non-grain crop material, including particles lighter than grain, such as chaff, dust and straw, are discharged through perforations of concave42.

Grain separated by the threshing and separating assembly24falls onto a grain pan44and is conveyed toward cleaning system26. Cleaning system26may include an optional pre-cleaning sieve46, an upper sieve48(also known as a chaffer sieve), a lower sieve50(also known as a cleaning sieve), and a cleaning fan52. Grain on sieves46,48and50is subjected to a cleaning action by fan52which provides an airflow through the sieves to remove chaff and other impurities such as dust from the grain by making this material airborne for discharge from straw hood54of combine10. Grain pan44and pre-cleaning sieve46oscillate in a fore-to-aft manner to transport the grain and finer non-grain crop material to the upper surface of upper sieve48. Upper sieve48and lower sieve50are vertically arranged relative to each other, and likewise oscillate in a fore-to-aft manner to spread the grain across sieves48,50, while permitting the passage of cleaned grain by gravity through the openings of sieves48,50.

Clean grain falls to a clean grain auger56positioned crosswise below and in front of lower sieve50. Clean grain auger56receives clean grain from each sieve48,50and from bottom pan62of cleaning system26. Clean grain auger56conveys the clean grain laterally to a generally vertically arranged grain elevator60for transport to grain tank28. Tailings from cleaning system26fall to a tailings auger trough64. The tailings are transported via tailings auger64and return auger66to the upstream end of cleaning system26for repeated cleaning action. A pair of grain tank augers68at the bottom of grain tank28convey the clean grain laterally within grain tank28to unloading auger30for discharge from combine10.

The non-grain crop material proceeds through a residue handling system70. Residue handling system70includes a chopper, counter knives, a windrow door and a residue spreader. When combine10operating in the chopping and spreading mode, the chopper is set to a relatively high speed (e.g. 3,000 RPM), the counter knives may be engaged, the windrow door is closed and the residue spreader is running (e.g. rotating).

A controller (412inFIG.4) measures the collected grain to determine if the grain tank28is full. The controller measures the grain with the aid of grain level sensors located within grain tank28. In one example, shown inFIG.1B, a first grain tank level sensor array100and a second grain tank level sensor array102are located along the interior walls of grain tank28. A third grain tank level sensor array101and a fourth grain tank level sensor array103(e.g. center arrays) are located in the center of grain tank28and extend from the base of the grain tank away from the tank walls towards the center of the grain tank. Grain tank level sensor arrays100,101,102and103may include an array of acoustic sensors, pressure sensors, optical sensors, and/or the like that detect the presence of grain in the tank in a local region surrounding the sensor.

Grain tank level sensor arrays100-103inFIG.1Bextend from a bottom end or portion of the grain tank to a top end or portion of the tank. Grain tank level sensor arrays100-103may include optical sensors such as infrared (IR) sensors that transmit an IR beam of light. If grain fills the tank and covers an IR sensor, the IR light reflects back to the IR receiver, thereby triggering the sensor. Alternatively, the individual sensors150(FIG.1C) may be diaphragm sensors or pressure transducers, for example. Those skilled in the art will recognize that various sensors can be used to sense the level of grain within tank28.

A controller receives a trigger signal from the sensor and determines the level of grain in the tank based on the known location of the sensor within the tank. For example, when grain pile104is present in the tank, the 1st-9th sensors in arrays100and102trigger, and the 1st-8th sensors in arrays101and103trigger. Each sensor is schematically represented by a dash mark inFIG.1B. The triggered sensors correspond to a predetermined level (e.g. 75%) of grain within the tank. In this example, when the grain triggers the sensors, the controller determines that the grain heap surface is located at the location of the 9th sensor. Notifications such as a display of the tank level, tank volume, or a trigger of an alarm are output to the operator.

The shape of the grain pile within the tank depends on various factors including the slope of the ground that the combine is traveling on. Having multiple arrays of sensors at multiple locations within the tank provides a system that is able to more accurately detect grain level when the grain pile is not uniform. For example, as shown inFIG.1B, on level ground, the detected levels between arrays are generally similar (e.g. sensors100and102both show 75% full) due to a uniform grain pile in the tank. However, when the combine is harvesting on a slope or a hill, and leaning forward, backward, to the left, or to the right, the levels detected by sensor arrays100and102may not coincide due to the slope of a non-uniform grain pile in the tank (e.g. if the combine is harvesting downhill, sensors in sensor array100may detect 75% and sensors in sensor array102may detect only 50%). This discrepancy is important to detect, because the side of the tank with the highest grain level is more likely to overflow and spill out of the top of the grain tank. Such spillage results in lost revenue.

FIG.1Cis a detailed view of the top end of the sensor array100. The array100includes sensors150a-150c(in addition to other sensors located beneath sensor150a). Each sensor150a-150c(referred to collectively or individually as sensor(s)150) is mounted on the side wall154of the tank28by a spacer152. It is noted that the side wall154(optionally) extends obliquely with respect to a vertical axis or plane. Sensor150are spaced from side wall154by a predetermined uniform distance ‘C.’ Alternatively, sensors150may be spaced from side wall154by different distances. The offset between the side wall154and the sensors150reduces the amount that crop flow is slowed and/or diverted by the sensing arrays in regions that are already highly susceptible to flow restriction, e.g.. nearby the interior walls. Spacer152may be a fastener, screw, rod, standoff or sleeve, for example. The surfaces of the spacer152are preferably rounded to limit the amount of crop that can accumulate thereupon.

The vertical distance between adjacent sensors150decreases as viewed in a direction towards toward the top end156of the tank28. As shown inFIG.1C, the distance between sensors150aand150bis represented by dimension ‘B’, and the distance between sensors150band150cis represented by dimension ‘A.’ It can be appreciated that distance B is greater than distance A, and that distance A is located closer to top end156than distance B. The significance of this arrangement is that the sensors150are clustered closer together towards the top end156of the tank28. Because spillage occurs at the top end156of the tank, rather than at the bottom end of the tank, the sensors150are clustered at the top end of the tank28. Accordingly, as the grain approaches the top end156of the tank28, the sensors150send signals to a controller412(as will be described below), and the controller correspondingly warns the operator of the combine harvester that a spillage may occur.

The spacing between adjacent sensors150may have two pitch values, i.e., one larger pitch for the lower region of the tank28, and one smaller pitch for the higher region of the tank. Alternatively, the pitch of the sensors150could gradually and uniformly reduce from a larger spacing at the lower region of the tank to a smaller spacing at the higher region of the tank (e.g, 18 inches followed by 16 inches followed by 14 inches, etc.).

It is noted that the details regarding the sensors150shown inFIG.1Ccan apply to any of the arrays shown herein. The array of sensors150may zig-zag or may be oriented obliquely, for example. Although not shown, the sensors150may also be positioned on extensions or covers what are mounted on the top side of the grain tank28.

Referring now toFIG.2A, in order to more accurately measure grain tank level, and avoid spillage, the combine also includes multiple arrays (e.g. 3 or more) of sensors at various locations within the grain tank (e.g., one center array in the middle of the tank and two side arrays along the tank wall).FIG.2Ashows a 3-dimensional view of an example of such a grain tank configuration. Specifically, the grain tank in this example has a 3-dimensional trapezoid-like shape extending from base200to top rim202. The grain tank includes four side arrays of level sensors204,206,208and210positioned in the corners of the tank separated by an array spacing and extending along an array length from base200to top rim202. These sensor arrays are similar to the sensor arrays100and102shown inFIG.1B. The grain tank also includes two center arrays of level sensors209and211positioned extending along an array length from base200at an angle towards the center of top rim202. These sensor arrays are similar to the sensor arrays101and103shown inFIG.1B.

The six sensor arrays inFIG.2Aprovide the ability to detect six grain level points at six different locations within the tank. In this example, these arrays each have 12 sensors, which provide each array with a resolution of 12 detectable grain levels. In general, the accuracy of the system increases as the number of arrays and number of sensors within each array are increased. Thus, the number of arrays, the number of sensors within each array, and the locations of the arrays within the tank are configurable to achieve the desired accuracy.

For example,FIG.2Bshows a top view of tank212(i.e., looking down on the top of the tank) that includes 12 side sensor arrays214positioned from each other by a set array spacing around the inner wall of the tank and one center sensor array215positioned in the center of the tank. This configuration provides 13 data points of grain tank levels around the entire perimeter and the center of the tank. Assuming each array includes 10 sensors, each array would be able to detect the tank fill level at 10 discrete levels. As was described above, the spacing of the arrays may be equidistant, or may follow other spacing patterns. In addition, the sensor arrays can extend along a partial height of the grain tank, and may not necessarily be vertical (i.e., they could be diagonal) or may not be directly in the center of the tank. In some examples, the arrays may be curved (e.g. curved to follow the tank geometry), and segmented (e.g. positioned in portions of the tank). In general, any mathematically describable array configuration can be used to detect the grain.

FIG.3Ashows multiple views of optical IR grain tank sensors used within the arrays. Each sensor includes a housing304(e.g., plastic), an electrical circuit308for driving the sensor components and communicating with the controller, and a channel that allows a wire bundle306to pass through. Views302A,302B and302C show various perspective views of the same sensor, while view302D shows a side view of the sensor. An isolated view of electronic circuit308is also shown. In one example, electronic circuit308may include an IR transmitter, an IR receiver, and a driver circuit that drives the IR transmitter as well as transmit/receive information to/from a controller (not shown). In this example, the sensors within the array may also be housed in a cube-like sleeve310made from transparent material (e.g., clear plastic) which aligns the sensors in a package that is easily mountable within the grain tank, as well as protects the sensors from damage due to the grain and other external factors. In other examples, other types of sensors may be used in place of or in combination with the IR sensors. These other sensors include but are not limited to acoustic sensors, laser sensors, radio frequency sensors and pressure sensors.

An example of the sensor array within cube-like sleeve310is shown inFIG.3B. In this example, the sensor array includes 5 sensors312spaced equidistant throughout the array length of sleeve310. Sensors312electrically connect to the controller via wire bundle314that runs within cube-like sleeve310. Although only 5 sensors are shown, it is noted that more than 5 sensors may be utilized. It is also noted that the sensors could be spaced apart in at different sensor spacing intervals that do not have to be equidistant. In addition, although not shown, the end of the wire bundle shown on the left of the figure connects to the combine controller.

FIG.4shows an example of a system400for controlling the combine. The system400includes an interconnection between a control system410of combine10, a remote PC406and a remote server402through network404(e.g. Internet). It should be noted that combine10does not have to be connected to other devices through a network. The controller of combine10can be a standalone system that receives operating instructions (e.g. tank level instructions such as alert levels) through a user interface, through a removable memory device (e.g. Flash Drive) or from a server402via transceiver417(e.g. Wi-Fi, Bluetooth, Cellular, etc.).

Prior to operating combine10, an operator may designate the tank level alerts and other tank level related instructions. In one example, the operator uses interface411of the combine control system or PC406located at a remote location. Interface411and PC406allow the operator to view locally stored parameters from memory device415and/or download parameters from server402through network404. The operator may select (via Interface411or PC406) appropriate tank level related instructions based on various factors including, among others, the type of crop to be harvested by the combine, and the terrain. Once the tank level related instructions are selected, the operator can begin harvesting. Combine controller412then controls actuators414(e.g. thresher, chopper, etc.) based on the instructions. For example, sensors416(e.g. tank level sensor) may be used during harvesting to more accurately determine the grain level to avoid spillage. The sensors416can comprise any of the foregoing sensors described with reference toFIGS.1A-3B. GPS receiver413produces information to track harvesting and monitor terrain.