Abstract:
A counter for seeds in a duct includes a first point source transmitter on a first mounting on one side of the duct spaced outwardly from the duct so as to project light through a front wall and a set of phototransistors in a transverse row carried on a second mounting on a rear wall. The side walls of the duct lie on a triangle with an apex at the light source. The phototransistors are connected in series so that the output current is determined by that phototransistor on which the majority of the shadow from the seed falls. In this way the momentary reduction in current output has a larger amplitude to better distinguish from dust in the duct. The duct is formed by a housing attached to the peripheral wall of the metering device with a seed transport tube attached to the bottom of the housing.

Description:
This application claims the benefit under 35 USC 119 of the priority of Provisional Application 61/314,247 filed Mar. 16, 2010. 
    
    
     This invention relates to a seed counting apparatus for use in a planter monitor for generating a seed count value in response to a series of seeds moving through a seed transport duct of the planter. 
     BACKGROUND OF THE INVENTION 
     While various techniques have been explored for detecting seeds falling in a tube, the most commonly used technique is that of a light source and photo sensor which detect the passage of seeds by counting pulses generated by the momentary reduction in light intensity from the steady state intensity caused by the passage of a seed between the light source and the sensor. 
     The vast majority of products of this type actually manufactured and sold in the marketplace have been manufactured by Dickey-John Corporation and they have obtained issue of a number of patents in this field. In particular the following patents of Dickey-John have some relevance in this field. 
     U.S. Pat. No. 3,723,989 (Fathauer) discloses an arrangement in which the intensity of the light source is varied to accommodate changes in reception by the sensor due to dirt or dust collecting between the light source and the sensor. 
     U.S. Pat. No. 3,974,377 (Steffen) discloses an arrangement in which the diode transmits light across the duct to two phototransistors which are connected in parallel to generate pulse signal information across a resistor where it is amplified and filtered. 
     U.S. Pat. No. 4,555,624 (Steffen) discloses a technique for analyzing the pulses generated by the momentary change in intensity value by following the changes in direction in the pulse and by generating individual positive and negative square-wave pulses in response to each change in direction. 
     U.S. Pat. No. 4,307,390 (Steffen) discloses an arrangement including a plurality of light sensitive sensors and an arrangement in which the number of counts or pulses recorded is increased relative to the number of input signals in dependence upon which one or ones of the plurality of light sensitive sensors are activated and in dependence upon the rate at which the signals are produced. 
     U.S. Pat. No. 4,166,948 (Steffen) discloses an arrangement in which the amplitude of the pulses is maintained above a predetermined minimum value by the sensor circuit, despite reductions in light intensity due to the accumulation of dirt and dust. 
     U.S. Pat. No. 5,635,911 (Landers) discloses an algorithm for calculating a seed count from pulses generated by the photo-transistor. 
     U.S. Pat. No. 4,491,241 (Knepler) a plurality of sensor circuits coupled in series circuit, one of the sensor circuits being coupled intermediate each of the sensors and a common signal line. 
     As set out in the above patents, one problem which arises in relation to seed counters of this type relates to the accumulation of dust and dirt which can vary the intensity of light normally received by the sensor. 
     A yet further problem relates to the geometry of the light source and the sensor which can either leave areas of the duct which are not properly monitored or can generate spurious reflections thus distorting the pulses. 
     Another arrangement which has become widely used is that manufactured by the present Assignees which is shown and described in U.S. Pat. No. 5,883,383 (Dragne) issued Mar. 16, 1999, U.S. Pat. No. 5,969,340 (Dragne) issued Oct. 19, 1999. Another patent relevant to this field is U.S. Pat. No. 6,661,514 (Tevs) issued Dec. 9, 2003. 
     The sensor unit it typically mounted on a seeder in the seed delivery duct at a position thereon downstream of the metering system and spaced from the discharge end of the duct. One problem which has arisen with arrangements of this type has been that of dust arising from the discharge end of the duct. This problem is particularly exacerbated by the use of so-called vacuum metering systems of the type shown for example in U.S. Pat. No. 7,152,542 (Eben) issued Dec. 26, 2006 to Kinze. This discloses an air seed meter for an agricultural planter, which has a vacuum chamber defining central opening, where atmospheric pressure is applied to vacuum side of the seed cells, when a seed orifice passes beneath the terminating end wall of the vacuum chamber. 
     Dust is stirred up through the process of planting and this can generate a signal similar to a seed resulting in a false count. This is due to the fact that dust moving through the tube may block a similar percentage of the light transmitted from the emitter to the detector as would be blocked by a seed. With the current design shown in the above patents of the present Assignees, a seed passing through the beam might obstruct 5% of the light. This reduction in photocurrent is amplified and if of sufficient amplitude, will produce a seed pulse. If a puff of dusty air with 95% transmissivity moves through the tube with similar passage time to a seed, the result will be a signal which is virtually indistinguishable from that produced by a seed falling through. 
     SUMMARY OF THE INVENTION 
     In general it is an object of the present invention to provide an improved seed counter for use in a planter monitor. 
     According to one aspect of the invention there is provided an apparatus for producing a seed count value in response to movement of seeds in a duct comprising: 
     a light source arranged to be mounted at one side of the duct; 
     a set of light sensors arranged to be mounted at an opposed side of the duct each for receiving light from the source; 
     the set of light sensors being arranged such that passage of a seed through the duct between the source and the set of light sensors causes a shadow of the seed to fall on at least one of the light sensors; 
     each light sensor being arranged to produce an output signal proportional to light intensity falling on the light sensor so as to generate a momentary change in the output signal therefrom proportional to the extent to which the shadow falls on the light sensor; 
     and an electronic circuit into which the set of light sensors are connected; 
     the light sensors and the electronic circuit being arranged so as to produce a resultant output signal where an amplitude of a momentary change in the resultant output signal in response to the passage of the seed is greater than an average change of the amplitudes in the output signals of all the light sensors of the set of light sensors. 
     It will be appreciated that dust in the duct will generate a reduction in light received by all of the phototransistors by an average amount and thus the reduction by an increased value will assist in distinguishing from dust. 
     Preferably the light sensors and the electronic circuit are arranged so that the amplitude of the momentary change in the resultant output signal in response to the passage of the seed is substantially proportional to the extent to which the shadow falls on that one or more of the light sensors which has the largest effect. 
     Preferably the light sensors and the electronic circuit are arranged so that the amplitude of the momentary change in the resultant output signal in response to the passage of the seed is determined solely by that one or more of the light sensors which has the largest effect. 
     In accordance with one simple arrangement which obtains this effect, preferably the light sensors are connected in series. This series connection has the effect that the amplitude of the momentary change in the resultant output signal in response to the passage of the seed is substantially proportional to the extent to which the shadow falls on that one or more of the light sensors which has the largest effect. As this is considerably larger than the average of all the sensors, the resultant signal is much greater in amplitude allowing the system to more effectively distinguish from dust. 
     In an alternative arrangement, however, the signals from all of the sensors of the row are detected and compared and the electronic circuit is arranged to select to generate the resultant output signal from that one or more of the light sensors which has the largest effect. 
     Preferably the light sensors and the electronic circuit are arranged so that the amplitude of the momentary change in the resultant output signal in response to the passage of the seed is substantially proportional to the extent to which the shadow falls on that one or more of the light sensors which has the largest effect. 
     That is, the light sensors and the electronic circuit are arranged so that the amplitude of the momentary change in the resultant output signal in response to the passage of the seed is determined solely by that one or more of the light sensors which has the largest effect. 
     Preferably the set of light sensors are arranged in a row transversely across the duct. 
     Preferably the light source is substantially a point source. 
     Preferably the duct includes a front wall, two side walls and a rear wall defining an interior of the duct; the light source is located at one side of the duct outside the front wall such that the light therefrom enters the duct in a beam across the front wall; the set of light sensors is arranged in a row across the rear wall parallel to the beam; and the two side walls are arranged to lie substantially on an imaginary triangle having an apex at the light source so that light from the light source causes any seed passing though any location in the interior of the duct to form a shadow from the light source on the row of light sensors. 
     Preferably the duct is formed in a housing where the housing defines a support for the light source spaced outwardly from the front wall of the housing. 
     Preferably the front and rear walls are parallel. 
     Preferably the light source is arranged centrally of the front wall such that the angle of each of the side walls to the front wall is the same. However other geometric arrangements can be used. 
     Preferably the duct is formed in a housing and wherein a seed transportation tube is connected to the housing at a bottom of the housing for carrying the seed from the housing to a seeding device. 
     Preferably the housing is arranged for connection to a metering device arranged for metering the seeds into the duct for supply in a metered stream to the seeding device. 
     Preferably the housing includes a mouth for receiving the seeds from the metering device, the mouth being formed in an arcuate wall arranged for attachment to a peripheral wall of the metering device. 
     Preferably the housing includes a mounting bracket for attachment of the housing to the metering device. 
     According to a second aspect of the invention there is provided an apparatus for producing a seed count value in response to movement of seeds in a duct comprising: 
     a light source arranged to be mounted at one side of the duct; 
     a set of light sensors arranged to be mounted at an opposed side of the duct each for receiving light from the source; 
     the set of light sensors being arranged such that passage of a seed through the duct between the source and the set of light sensors causes a shadow of the seed to fall on at least one of the light sensors; 
     and an electronic circuit into which the set of light sensors are connected for generating an output responsive to the shadow; 
     wherein the duct includes a front wall, two side walls and a rear wall defining an interior of the duct; 
     wherein the light source is located at one side of the duct outside the front wall such that the light therefrom enters the duct in a beam across the front wall; 
     wherein the set of light sensors is arranged in a row across the rear wall parallel to the beam; 
     and wherein the two side walls are arranged to lie substantially on an imaginary triangle having an apex at the light source; 
     so that light from the light source passes causes any seed passing though any location in the interior of the duct to form a shadow from the light source on the row of light sensors. 
     According to a third aspect of the invention there is provided an apparatus for producing a seed count value in response to movement of seeds in a duct comprising: 
     a light source arranged to be mounted at one side of the duct; 
     a set of light sensors arranged to be mounted at an opposed side of the duct each for receiving light from the source; 
     the set of light sensors being arranged such that passage of a seed through the duct between the source and the set of light sensors causes a shadow of the seed to fall on at least one of the light sensors; 
     each light sensor being arranged to produce an output signal proportional to light intensity falling on the light sensor so as to generate a momentary change in the output signal therefrom proportional to the extent to which the shadow falls on the light sensor; 
     and an electronic circuit into which the set of light sensors are connected arranged so as to produce a resultant output signal where a momentary change in the resultant output signal is generated in response to the passage of the seed; 
     wherein the light sensors are connected in series. 
     This arrangement can provide the advantages that, with the series connected detector (phototransistor) array, the photo current is determined by the darkest of the detectors, not the average illuminance as with the current design. A valid seed will result in a significant percentage of light blocked to one detector, and limit the overall current due the series configuration. The presence of dust would continue to only block a small portion of light to all of the detectors which will result in a much smaller photocurrent reduction. 
     As in the example described above, if a puff of dusty air with 95% transmissivity moves through the tube with similar rise and fall times to a seed, the result will be a similar signal to that which would be produced with the current design; i.e. that which results from a 5% reduction in photocurrent. A seed falling through the tube might also obstruct 5% of the total light, but it will not be evenly distributed amongst the detectors. Instead, there would be a significantly higher reduction of incident light on perhaps one or two detectors. Because the detectors (phototransistors) are series-connected, the photocurrent is determined by the darkest one. If in this example the seed shadow cast from the point-source onto the detector array results in a 50% reduction of light on one or more detectors, the photocurrent will be reduced by 50%, and signal amplitude will be ten-fold stronger than that produced by the dust. This will allow a comparator threshold setting which produces reliable seed pulses without false pulses caused by dust. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       One embodiment of the invention will now be described in conjunction with the accompanying drawings in which: 
         FIG. 1  is an overview of a system for counting seeds using an arrangement according to the present invention. 
         FIG. 2  is a transverse horizontal cross sectional view of one of the ducts of  FIG. 1  showing the mechanical mounting of the source and sensors according to the present invention. 
         FIG. 3  is a transverse vertical cross sectional view of one of the ducts of  FIG. 1  showing the mechanical mounting of the source and sensors according to the present invention. 
         FIG. 4  is a schematic illustration of the circuit according to the present invention including the light sensors of  FIGS. 2 and 3 . 
         FIG. 5  is a side elevational view of a seed metering device for mounting on a planter including mounted thereon a further embodiment of the apparatus for counting seeds according to the present invention. 
         FIG. 6  is an exploded view of the apparatus for counting of  FIG. 5 . 
         FIG. 7  is an isometric view of the apparatus for counting of  FIG. 5  taken from the bottom end of the housing and showing only the main central housing portion defining the duct, with the two outer portions of the housing removed for convenience of illustration. 
         FIG. 8  is a cross-sectional view along the lines  8 - 8  of  FIGS. 6 and 7 . 
     
    
    
     In the drawings like characters of reference indicate corresponding parts in the different figures. 
     DETAILED DESCRIPTION 
     The planter monitor of the present invention includes a central monitor unit  10  which communicates with a plurality of seeding counting sensors  11  each arranged at a respective one of a plurality of seed transfer ducts  12  so that the seeds passing through each duct are counted by the respective sensor unit  11  and information concerning the number of seeds counted is transmitted from the respective sensor unit to the central monitor unit for displaying information to the operator. 
     The general construction of each of the seed sensor units is shown in U.S. Pat. No. 5,883,383 (Dragne) issued Mar. 16, 1999, the disclosure of which is incorporated herein by reference. 
     A first embodiment is shown in  FIGS. 2 and 3 . In this embodiment, each seed sensor unit includes components  15  and  16  to be mounted on the duct  12 . These components are shown in more detail in  FIGS. 2 and 3 . The duct  12  is rectangular with sides  12 A and  12 B which are generally longer sides with shorter sides  12 C and  12 D. On each of the sides  12 C and  12 D is formed an opening  12 E into which a respective one of the components  15  and  16  is mounted for obtaining data relating to the passage of seeds through the duct  12 . 
     The components  15  and  16  are interconnected by a mounting arrangement  17  which extends along one side  12 B to connect the two components together for structural mounting on the duct and also for electrical interconnection using a cable  18  which communicates between the two components and further cable  19  which communicates to the sensor unit  11  associated with the duct  12 . 
     The components  15  and  16  are mounted in the rectangular opening  12 E in each of the side walls and are shaped so that the component extends across the full width of the conduit  12  and partly along the length of the conduit  12  at the rectangular opening  12 E. 
     The component  15  carries upper set of light communication elements generally indicated at  20  and a lower set of communication elements  21 . These communication elements in the upper set  20  include a single point source LED  22  and a row of phototransistors or receptors  23 . In symmetrical manner the lower set include a transmitting LED  24  and a row of receptors  25 . The LED is arranged at one side of the opening  12 E adjacent one of the side walls and in the embodiment shown this is adjacent the side wall  12 B. Symmetrically the LED  24  is also arranged adjacent one side and this can be the same side or the opposite side as preferred. 
     The point source generated by the LED on one side therefore generates a beam of light which scans across the duct  12  toward the row of receptors  23 . 
     Assuming the absence of any reflection, the light falls on all of the receptors from the point source so that the presence of a seed or other particle  27  causes a shadow  28  to fall on some or all of the receptors and typically on a limited number of the receptors  23 . As the seed is relatively small in dimension relative to the duct, this typically leaves a number of the receptors  23  which are still exposed to the light from the source  22  and therefore have no reduction in their output. Thus the shadow from which falls primarily on a limited number of the receptors and these particular receptors have a significant reduction in the output therefrom which of course is proportional to the light falling on those receptors and thus proportional to the reduction of the light caused from the shadow of the seed. 
     The analysis of the output from the receptors is arranged so that the resultant output signal has an amplitude which is decreased by the passage of the seed. However the analysis is arranged so that the momentary change in the resultant output signal in response to the passage of the seed is greater than an average change in the amplitudes of the output signals of all of the light sensors or receptors of the set. 
     In the preferred embodiment shown herein, this is arranged by placing the phototransistors in series as shown in  FIG. 4 . In this way the output signal has an amplitude of the momentary change in the resultant output signal which is substantially proportional to the extent to which the shadow falls on that one or more or those ones of the light sensors which have the largest effect. It will be appreciated that the series arrangement shown in  FIG. 4  causes a reduction across all of the photo transistors which is proportional to the largest change in any of the photo transistors. For example if one of the photo transistors reduces its output by 50% and the others reduce their output only by 20% or some lower value, the maximum reduction of the 50% value is effectively that which is seen across the whole series of the photo transistors. 
     The series arrangement is only one way in which this analysis can occur and is selected because it is a simple arrangement. However it is of course also possible to individually compare the output signals from each of the photo transistors and to select as the output signal that one or more which has the largest change in amplitude. In some cases a single sensor will have the largest signal. In other cases the shadow falls equally on a number of them so that they all have the same signal. In other cases, all are covered. This can be done by receiving and detecting the output signal from each of the photo transistors and making an actual comparison therebetween. However the series arrangement in effect obtains the same result but with a simple hardware arrangement rather than a software analysis of the output signals. 
     It will of course be appreciated that the simple analysis based upon the absence of any reflections is in practice not what occurs and there are internal reflections from the inside surface of the duct and also from the seed. However the arrangement described above acts to maximize the effect of the shadow of the seed on a limited number of the light receptors. 
     However it will be appreciated that the point source on one side which is associated with a row on the other side only provides coverage of approximately one half of a duct of rectangular shape. The coverage is approximately triangular from the point source to the row. One way to overcome this problem, as shown in the second embodiment, is to provide a duct which is similarly generally triangular so that the point source and the row effectively cover the whole area of the duct. 
     However with ducts that are rectangular it is necessary to provide a second array using a similar row and a separate point source so as to cover the other half of the duct and thus the other triangle which is not covered by the first set. For this reason the second lower set of light components is provided as shown in  FIG. 3  including the point source  24  and the receptors  25 . In practice the point source  24  is arranged diagonally opposite to the point source  22  so that the light from that point source fills the other triangle to the row  25  on the same side as the point source  22 . The location of the point source is arranged so that there is a slight overlap between the two triangles. In this way the whole of the rectangular area of the duct is covered by the two separate arrays. The counting of seeds therefore can be effected by detecting the momentary reduction in amplitude from either the first or the second set. 
     The second set is located at a position spaced longitudinally of the duct from the first set by a predetermined distance. This has the result that any seed which passes through the overlap area between the two sets would normally generate two separate signals. However by analyzing the signals received from the two sets, in the event that a signal from the second set is time delayed by a time difference approximately equal to the time necessary to traverse between the first and second sets, the second pulse can then be discounted as likely to be a duplicate of the first pulse rather than a second seed. 
     Also the spacing of the sets is used to reduce the effects of reflections from the source of one set on the sensors of the other set. 
     Turning now to the second embodiment shown in  FIGS. 5 to 8 , there is shown an apparatus for producing a seed count value in response to movement of seeds in a duct  40 . As previously described, this includes a light source  41  mounted at a position spaced from the duct on one side of the duct  40 , and a set of light sensors  42  mounted at an opposed side of the duct each for receiving light from the source. As previously described, the light sensors are connected in series as shown in  FIG. 4  to obtain the effects previously described. 
     In this embodiment, the duct includes a front wall  43 , a rear wall  44  parallel to the front wall, and two side walls  45 ,  46  defining an interior  47  of the duct. The light source  41  is located at one side of the duct outside the front wall  43  such that the light therefrom enters the duct through the wall  43  across the full width of the front wall  43 . For this purpose, the housing is formed from a material which is transparent to infra-red light. Suitable acrylic or polycarbonate materials of this type are well known and commercially available. The set of light sensors  42  is arranged in a row across the rear wall  44  parallel to the beam from the source  41 . The two side walls  45 ,  46  are arranged to lie substantially on an imaginary triangle  48  having two sides  48 A and  48 B converging to an apex  48 C at the light source  41 , as shown best in  FIG. 8 . 
     In this way light from the light source  41  passes through the wall  43  and causes any seed passing though any location in the interior of the duct to cause a shadow from the light source on the row of light sensors  42  carried on a circuit board  42 A. This is because the whole of the interior  47  is illuminated and all light from the source  41  within that interior falls onto the sensors  42 . 
     The light source  41  is arranged centrally of the front wall such that the triangle  48  is an isosceles triangle with the angle of each of the side walls to the front wall being the same. The source  41  is spaced outwardly from the wall  43  by a distance such that the converging sides  45  and  46  differ from a rectangle by angles which do not interfere with the operation of the duct to carry the seeds from the mouth at the seeding device to the seed tube. 
     The duct  40  is formed in a housing  50  with a center portion  50 A, a first side portion  51  and a second side portion  52 . The side portion  51  of the housing  50  defines a support for a circuit board  41 A carrying the light source  41  spaced outwardly from the front wall  43  of the housing. 
     The duct  40  is therefore formed by the housing  50  which extends from a mouth  53  at the seed metering device  54  to a seed transportation tube  55  which is connected to the housing  50  at a bottom  56  of the housing for carrying the seed from the housing to a seeding device schematically indicated at  57 . 
     The housing is formed in three pieces  50 A,  51  and  52  connected together at cooperating faces  501  and  505  by adhesive. The center piece  50 A defines the duct  40  and provides supports for the circuit boards  41 A and  42 A. Thus the housing  50 A at the side  501  thereof includes two elements  502  forming a track for the edges of the board  41 A and a snap finger  503  to engage into a hole  504  to hold the edge of the board  41 A against the wall side  501  at the wall  43  with the board extending outwardly at right angles to the wall  42  and parallel to the strip of sensors  42 . In this way the beam of light from the source  41  extends parallel to the board  41 A through the wall  43  to impact on the sensors  42  at the wall  44 . 
     The board  42 A lies flat against the side  505  of the portion  50 A and thus presents the row of sensors  42  against the wall  44 . The housing portions  51  and  52  are shaped to carry the boards  41 A and  42 A and the electronics associated therewith. The housing portions  51  and  52  each include a flange  56 A,  56 B each on a respective side of the mouth  53  for attachment of the housing  50  to the seed metering device  54 . The housing portion  51  carries three prongs  58 ,  59  and  60  which project across the housing portion  50 A to engage with suitable components  61  of the metering device  54 . The housing portions  51  and  52  include hollow components  51 A and  52 A projecting outwardly to respective sides of the side faces  502  and  505  of the center portion  50 A with suitable cover components  51 B providing access for wiring and the like. 
     The details of the metering device are not shown since these are well known to persons skilled in this art and can vary depending on the manufacturer of this component. Thus it suffice to say that the metering device receives seeds from a supply tank at an upper end and deposits the seeds in a metered stream through an outlet opening in a peripheral wall into the housing  50 . For this purpose the housing includes mounting bracket  56  defined by the flanges  56 A and  56 B at the mouth  53  for mounting the housing on the metering device. The mouth forms an opening in an arcuate wall arranged for attachment to the peripheral wall of the metering device over the discharge opening therein. 
     Thus the counting of the seeds takes place in specially designed and dedicated housing located at the outlet of the metering device at a location up stream of the transportation duct  55  rather than as part of the duct  55  itself. Thus the housing construction can be formed with an interior duct shape best suited to allow the triangular pattern of the monitoring unit to be used. 
     Since various modifications can be made in my invention as herein above described, and many apparently widely different embodiments of same made within the spirit and scope of the claims without departing from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense.