A continuous round bale baler control system and method

Abstract

The present application relates to a kind of continuously operating round bale baler control system, the system includes: controller, human-computer interaction component is installed on the controller;Sensor component is connected with the controller, including front door sensor, bale position sensor, rear door sensor, lower door sensor, net inlet sensor, net cutter sensor and bale release sensor;Solenoid valve component is connected with the controller, including the solenoid valve I for controlling front door opening and closing oil cylinder, the solenoid valve II for controlling rear door opening and closing oil cylinder, the solenoid valve III for controlling lower door opening and closing oil cylinder;Net winding electromagnetic clutch is connected with controller, for controlling the power of net winding assembly.The automatic control of whole process is realized by the above setting.Compared with prior art, it reduces the labor intensity of artificial, and improves the baling efficiency, while also reducing the wear and tear of supporting tractor clutch.The present application also relates to a kind of continuously operating round bale baler control method.

Description

Technical Field

[0001] This invention relates to the field of agricultural baling equipment technology, specifically to a control system and method for a continuously operating round baler. Background Technology

[0002] A round baler is an agricultural machine used to bale hay, straw, and other crops into round bales. During operation, a front-mounted hay picker gathers hay from the ground and a transport mechanism evenly feeds it into the forming chamber. Inside the chamber, the hay is gripped and compressed by multiple rollers arranged around the perimeter, forming a closed space. Under the compression of the rollers, the hay is continuously compacted, and the diameter of the bale gradually increases. When the bale reaches the set diameter and density, it is then wrapped with a net and released.

[0003] In existing technology, when carrying out operations, it is necessary to stop and wait for the net to be wrapped and the bundle to be released after each bundle is made. The operator must first stop the tractor, automatically wrap the net or manually control the net wrapping and open the rear compartment to release the bundle through the tractor's hydraulic system, and then close the rear compartment door and start the vehicle to continue the operation.

[0004] However, the above-mentioned operation method requires manual repetition of stopping the tractor, wrapping and releasing the net, and starting the vehicle to continue the operation, which increases the labor intensity of the operator. At the same time, frequent starting and stopping can also easily lead to premature wear of the tractor's travel clutch. Summary of the Invention

[0005] This invention provides a control system and method for a round baler that can operate continuously, in order to solve the problem that frequent starting and stopping of existing round balers not only increases the labor intensity of operators, but also easily leads to accelerated wear of the clutch.

[0006] This invention discloses a control system for a continuously operating round baler, comprising: a controller, wherein a human-machine interface component is installed on the controller;

[0007] The sensor assembly, connected to the controller, includes a front door sensor, a bundling position sensor, a rear door sensor, a lower door sensor, a net entry sensor, a net cutting knife sensor, and a bundling release sensor.

[0008] The solenoid valve assembly, connected to the controller, includes solenoid valve I for controlling the opening and closing cylinder of the front compartment door, solenoid valve II for controlling the opening and closing cylinder of the rear compartment door, and solenoid valve III for controlling the opening and closing cylinder of the lower compartment door.

[0009] The electromagnetic clutch for the web winding assembly is connected to the controller and is used to control the power of the web winding assembly.

[0010] Furthermore, the front compartment door sensor is installed at the front compartment door. When the front compartment door is opened and exceeds the detection distance of the front compartment door sensor, the front compartment door sensor outputs a low level to the controller, and the controller displays the information on the human-machine interface component and issues an alarm.

[0011] Furthermore, when the front compartment door sensor outputs a low level to the controller, the controller controls the solenoid valve I to open the front compartment door and controls the solenoid valve III to open the lower compartment door.

[0012] Furthermore, the opening time of the lower compartment door is less than or equal to half the opening time of the front compartment door.

[0013] Furthermore, the bale position sensor is located between the front and rear compartments. When the front compartment door is opened, the bale is pushed to the rear compartment, triggering the bale position sensor. The bale position sensor is a proximity switch. When the bale position sensor detects one or more high-level signals, it is determined that the compartment switching is complete.

[0014] Furthermore, when the bundling sensor detects that the compartment change is complete, the controller controls the solenoid valve I to close the front compartment door.

[0015] Furthermore, after the rear compartment door sensor is triggered, the controller controls the solenoid valve III to close the lower compartment door.

[0016] Furthermore, after the lower compartment door sensor is triggered, the controller controls the winding electromagnetic clutch to engage, causing the winding assembly to start working. When the inlet sensor does not detect a level signal of its inherent frequency, the controller controls the interactive component to display that the net has been used up.

[0017] Furthermore, when the bale is wrapped with netting and the netting cutter falls, the netting cutter sensor is triggered, and the controller controls the solenoid valve II to open the rear compartment door;

[0018] After the release sensor is triggered, the controller controls the solenoid valve II to close the rear compartment door.

[0019] This invention also discloses a control method for a continuously operating round baler, applied to the aforementioned continuously operating round baler control system, comprising the following steps:

[0020] The system detects when the front compartment door is opened. When the front compartment door is detected to be opened, the front compartment door and the lower compartment door are opened.

[0021] The system detects the passing of hay bales. When a hay bale is detected, the front compartment door is closed, allowing the material to be continuously conveyed to the rear compartment through the open lower compartment door.

[0022] The rear compartment door is detected to be open. When the rear compartment door is detected to be open, the lower compartment door is closed, and the electromagnetic clutch for winding is engaged, so that the winding assembly starts to work.

[0023] The signal of the cutting blade is detected. When the cutting blade is detected to be falling, the electromagnetic clutch of the winding system is controlled to disengage, so that the winding assembly stops working and the rear door is opened to allow the bales to fall.

[0024] The system detects the bale release signal and, upon detecting the bale falling, controls the rear compartment door to close.

[0025] The control system and method for a continuously operating round baler provided by this invention can achieve the following technical effects:

[0026] By connecting the human-machine interface component to the controller, operators can configure the system through the interface and control the solenoid valves according to the set logic, thereby controlling each working cylinder. During operation, sensors monitor the working conditions of each component in real time and feed the signals back to the controller. The controller judges the working conditions and logic based on the signals and sends signals to the solenoid valves and the winding electromagnetic clutch. The solenoid valves and clutch control each component to work according to the logic, thus achieving fully automated control. Compared with existing technologies, this reduces manual labor intensity, improves bundling efficiency, and reduces clutch wear.

[0027] The above general description and the description below are exemplary and explanatory only, and are not intended to limit the invention. Attached Figure Description

[0028] One or more embodiments are illustrated by way of example with reference to the accompanying drawings. These illustrative descriptions and drawings do not constitute a limitation on the embodiments. Elements having the same reference numerals in the drawings are considered similar elements, and wherein:

[0029] Figure 1 This is a baling process diagram of a continuously operating round baler in an embodiment of the present invention;

[0030] Figure 2 This is a framework diagram of the control system of a continuously operating round baler in an embodiment of the present invention;

[0031] Figure 3 This is a control flowchart for the forming of hay bales in the front warehouse in an embodiment of the present invention;

[0032] Figure 4 This is a control flowchart of the transfer of hay bales to the rear warehouse in an embodiment of the present invention;

[0033] Figure 5This is a control flowchart for the formation of hay bales in the rear compartment in an embodiment of the present invention;

[0034] Figure 6 This is a control flowchart for the bundling and unbundling of straw in an embodiment of the present invention;

[0035] Figure 7 This is a flowchart illustrating the steps of a control method for a continuously operating round baler in an embodiment of the present invention. Detailed Implementation

[0036] To provide a more detailed understanding of the features and technical content of the embodiments of the present invention, the implementation of the embodiments of the present invention will be described in detail below with reference to the accompanying drawings. The accompanying drawings are for illustrative purposes only and are not intended to limit the embodiments of the present invention. In the following technical description, for ease of explanation, several details are used to provide a full understanding of the disclosed embodiments. However, one or more embodiments may still be implemented without these details. In other cases, well-known structures and devices may be shown in a simplified manner to simplify the drawings.

[0037] The terms "first," "second," etc., used in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate for the embodiments of the invention described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion.

[0038] In this embodiment of the invention, the terms "upper," "lower," "inner," "middle," "outer," "front," and "rear," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are primarily for better describing the embodiments of the invention and their implementations, and are not intended to limit the indicated devices, elements, or components to having a specific orientation, or to require them to be constructed and operated in a specific orientation. Furthermore, some of the above terms may be used to indicate other meanings besides orientation or positional relationship; for example, the term "upper" may in some cases indicate a dependency or connection relationship. Those skilled in the art can understand the specific meaning of these terms in the embodiments of the invention according to the specific circumstances.

[0039] Furthermore, the terms "set up," "connect," and "fix" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral structure; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, or it can be an internal connection between two devices, components, or parts. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of this invention according to the specific circumstances.

[0040] Unless otherwise stated, the term "multiple" means two or more, and "multiple groups" means two or more groups.

[0041] It should be noted that, unless otherwise specified, the embodiments and features described in the embodiments of the present invention can be combined with each other.

[0042] like Figure 1 As shown, this invention discloses a control system for a continuously operating round baler. In this system, the entire operation of the continuously operating round baler is divided into four stages, with the working sequence being: front chamber bale forming, bale transfer to the rear chamber, rear chamber bale forming, netting, and bale release. Figure 2 As shown, the system includes:

[0043] The controller is equipped with human-computer interaction components.

[0044] The sensor assembly, connected to the controller, includes a front door sensor, a bundling position sensor, a rear door sensor, a lower door sensor, a net entry sensor, a net cutting knife sensor, and a bundling release sensor.

[0045] The solenoid valve assembly, connected to the controller, includes solenoid valve I for controlling the opening and closing cylinder of the front compartment door, solenoid valve II for controlling the opening and closing cylinder of the rear compartment door, and solenoid valve III for controlling the opening and closing cylinder of the lower compartment door.

[0046] The electromagnetic clutch for the wire mesh is connected to the controller and is used to control the power of the wire mesh assembly.

[0047] In an embodiment of the present invention, the entire control system comprises: a human-machine interface, a controller, a front door sensor, a bundling position sensor, a rear door sensor, a lower door sensor, a wire cutting knife sensor, a wire feeding sensor, a bundling release sensor, a feeding base plate sensor, and corresponding hydraulic cylinders and their control solenoid valves for each working component. The human-machine interface and the controller communicate via a CAN bus, and the sensors, solenoid valves, electromagnetic clutches, etc., are connected to the controller via wiring harnesses.

[0048] The human-machine interface displays various operating information, and operators can also configure the system and control the solenoid valves to manage the hydraulic cylinders. During operation, sensors monitor the operating conditions of each component in real time and feed the signals back to the controller. The controller then judges the operating conditions and logic based on the signals and sends signals to the solenoid valves and the winding electromagnetic clutch. These valves and clutches control the components to operate according to the logic, achieving fully automated control. Compared to existing technologies, this reduces manual labor intensity, improves bundling efficiency, and reduces clutch wear. It should be noted that those skilled in the art can increase or decrease the number of sensors, solenoid valves, and working parts of the system as needed; the structural requirements of the working parts and the form of the hydraulic cylinder can be adjusted; in the embodiments of the present invention, the interactive interface in the human-machine interaction component can interact through various forms of expression such as text, graphics, animation, sound, and warning lights; control links can also be added or reduced in the control method and logic according to different structures and functions; in addition, different methods can be used for signal transmission, such as transmission via lines or wireless transmission.

[0049] Specifically, such as Figure 3 As shown, the front compartment door sensor is located at the front compartment door. When the front compartment door is opened and exceeds the detection distance of the sensor, the sensor outputs a low-level signal to the controller. The controller then displays the information on the human-machine interface and issues an alarm. At startup, material enters the front compartment. Once the compartment reaches the set density, the door opens and exceeds the sensor's detection distance. At this point, the sensor outputs a low-level signal to the controller, which displays the information on the human-machine interface via the CAN bus and issues an alarm sound. Specifically, the display can show that the front compartment is full in a graphical and textual format, while simultaneously emitting a "beep, beep, beep" alarm sound.

[0050] Optionally, such as Figure 3 As shown, when the front compartment door sensor outputs a low level to the controller, the controller controls solenoid valve I to open the front compartment door and solenoid valve III to open the lower compartment door. At the same time, it outputs a high level to the solenoid valves of the front compartment cylinder and the lower compartment door cylinder. At this time, the front compartment door and the lower compartment door open simultaneously, and the opening time of the lower compartment door is less than or equal to half of the opening time of the front compartment door. During the opening process, the front compartment pushes the bales of hay to the rear compartment.

[0051] Optionally, such as Figure 4As shown, the bale position sensor is located between the front and rear compartments. When the front compartment door opens, it pushes the bale into the rear compartment and triggers the bale position sensor, which is a proximity switch. When the sensor detects one or more high-level signals, it determines that the bale transfer is complete. During the opening process, the front compartment pushes the bale into the rear compartment and triggers the bale position sensor, which is also a proximity switch. Normally, it outputs a low-level signal. After the bale is transferred, the sensor will detect one or more high-level signals, indicating that the bale transfer is complete and outputting a high-level signal to the controller. If no high-level signal is transmitted during the transfer, it is determined that the transfer is incomplete, and a low-level signal is output to the controller. The controller then displays the information on the human-machine interface and prompts for manual intervention. After the intervention is complete, the controller displays the information on the human-machine interface via the CAN bus, indicating that the bale has arrived in the rear compartment, and may also provide an audible reminder. For example, when no hay bale is detected passing by, the position of the hay bale between the front and rear compartments can be displayed on the screen in a graphic and text format, while an alarm sounds rapidly with the text "Please handle manually". At this time, the vehicle functions need to be manually switched to manual mode. After the problem is resolved, it can be manually switched back to automatic mode. When a hay bale is detected passing by, the display can show that the hay bale has reached the rear compartment in a graphic and text format, and an alarm sounds with a "ding".

[0052] Optionally, such as Figure 4 As shown, when the bundling sensor detects that the compartment change is complete, the controller controls solenoid valve I to close the front compartment door. Simultaneously, the controller outputs a high-level signal to the front compartment cylinder solenoid valve, controlling the front compartment cylinder to close the front compartment. Upon closing, the front compartment door sensor is triggered, outputting a high-level signal to the controller. The controller then displays the "front compartment door closed" information via the CAN bus through the human-machine interface, and simultaneously outputs a high-level signal to the front compartment door solenoid valve to close the hydraulic circuit and stop the front compartment door cylinder's operation. The specific display information can be a graphic combined with text indicating that the front compartment is closed.

[0053] Optionally, such as Figure 5 As shown, after the rear door sensor is triggered, the controller controls solenoid valve III to close the lower door. After the front door closes, material continues to be conveyed to the rear compartment through the open lower door until the material in the rear compartment reaches the set density. At this point, the rear compartment expands, causing the rear door sensor to lose signal and output a low level to the controller. The controller then displays the information on the human-machine interface via the CAN bus, and can also provide an audible alert. Simultaneously, it outputs a high level to the lower door hydraulic cylinder solenoid valve, closing the lower door. The specific display information can be a graphic and textual indication that the rear compartment is full, accompanied by a "ding, ding, ding" audible alarm until the lower door is fully closed and the alarm stops. Simultaneously, it can also display a graphic and textual indication that the lower door is closing or has already closed.

[0054] Optionally, such as Figure 6 As shown, after the lower compartment door sensor is triggered, the controller activates the electromagnetic clutch for winding the net, causing the net winding assembly to start working. Simultaneously, the display shows that net winding is in progress in a graphical and textual format. When the net entry sensor does not detect a signal at its inherent frequency, the controller controls the interactive component to display that the net is used up. For example, this could be displayed graphically and textually, indicating that the net is used up and needs to be replaced. In this case, the power needs to be manually cut off, and the net needs to be installed. As the lower compartment door closes, it triggers the lower compartment door sensor, which outputs a high-level signal to the controller. The controller then displays this information on the human-machine interface (HMI). Simultaneously, it outputs a high-level signal to the lower compartment door cylinder solenoid valve and the web-winding electromagnetic clutch. The solenoid valve stops the lower compartment door cylinder's movement, and the electromagnetic clutch engages upon receiving the electrical signal, thus combining with the power of the web-winding assembly. The web-winding assembly then begins to work. During operation, the web-entry sensor detects a frequency-based electrical signal and inputs it to the controller. The controller then displays the web-winding information on the HMI. If the web-entry sensor does not detect a frequency-based electrical signal, the controller will display a "web used up" message on the HMI, providing a reminder. Once the web is manually loaded, the system returns to the engaged position of the web-winding electromagnetic clutch, and the process proceeds to the next step.

[0055] Optionally, such as Figure 6 As shown, after the bale is wrapped with netting, the netting cutter falls, and when the netting cutter sensor is triggered, the controller controls solenoid valve II to open the rear compartment door. After the bale release sensor is triggered, the controller controls solenoid valve II to close the rear compartment door. When the bale is completely wrapped with netting, the netting cutter falls, cutting the netting rope and triggering the netting cutter sensor, which outputs a high-level signal to the controller. If, during the period between the closing of the lower compartment door and the netting cutter sensor inputting a low-level signal to the controller, the netting cutter inputs a low-level signal to the controller prematurely, or if the netting sensor senses a frequency-based signal, the controller will display a message on the human-machine interface via the CAN bus stating "Netting caught in bale," and prompt for manual cleaning. After manual cleaning, the program will return to the starting position. For example, at this point, manual mode can be clicked to manually troubleshoot and reinstall the netting. After troubleshooting, it is necessary to manually click to enter automatic mode.

[0056] When the cutting knife sensor inputs a high-level signal to the controller, the controller outputs high-level signals to the winding electromagnetic clutch and the rear compartment cylinder solenoid valve, while simultaneously displaying "winding stopped" and "rear compartment open" on the human-machine interface. For example, the "winding stopped" and "rear compartment open" indicators can be displayed on the screen in a graphic and textual format. Upon receiving a low-level signal, the winding electromagnetic clutch disengages, and the winding assembly stops working. Upon receiving a signal, the rear compartment cylinder solenoid valve engages the rear compartment door cylinder, causing the cylinder to open the rear compartment door, allowing the bales to roll to the ground. During this rolling process, the bale release sensor is triggered, transmitting a high-level signal to the controller. Upon receiving the signal, the controller displays "bale release complete" on the human-machine interface, outputs a high-level signal to the rear compartment cylinder solenoid valve, and controls the cylinder to close the rear compartment. When the rear compartment closes, it triggers the rear compartment sensor, transmitting a high-level signal to the controller. The controller then displays "rear compartment closed" on the human-machine interface and increments the daily bale count by 1. For example, the display can show that the rear compartment is closed in a graphic and textual format, and increment the current number of work bundles and the total number of work bundles by 1.

[0057] like Figure 7 As shown in the embodiments of the invention, a control method for a continuously operating round baler is also provided, applied to the aforementioned continuously operating round baler control system. This control method has been described in detail in the control system section above, and those skilled in the art can understand it based on the context. It includes the following steps:

[0058] S10: Detect the opening of the front compartment door. When the front compartment door is detected to be opened, open the front compartment door and the lower compartment door.

[0059] S20: Detects the passing of hay bales. When a hay bale is detected, the front compartment door is closed, allowing the material to be continuously conveyed to the rear compartment through the open lower compartment door.

[0060] S30: Detects the opening of the rear compartment door. When the rear compartment door is detected to be opened, the lower compartment door is closed, and at the same time, the electromagnetic clutch of the winding net is engaged, so that the winding net assembly starts to work.

[0061] S40: Detects the cutting blade signal. When the cutting blade is detected falling, it controls the winding electromagnetic clutch to disengage, causing the winding assembly to stop working and opening the rear compartment door to allow the bales to fall.

[0062] S50: Detects the baling signal. When the bale is detected falling, controls the rear compartment door to close and repeats the above baler control steps.

[0063] The foregoing description and accompanying drawings fully illustrate embodiments of the invention to enable those skilled in the art to practice them. Other embodiments may include structural and other changes. The embodiments represent only possible variations. Individual components and functions are optional unless explicitly required, and the order of operation may vary. Some portions and features of some embodiments may be included or substituted for portions and features of other embodiments. Embodiments of the invention are not limited to the structures described above and shown in the accompanying drawings, and various modifications and changes may be made without departing from their scope. The scope of the invention is limited only by the appended claims.

Claims

1. A control system for a continuously operating round baler, characterized in that, include: A controller, on which a human-computer interaction component is installed; The sensor assembly, connected to the controller, includes a front door sensor, a bundling position sensor, a rear door sensor, a lower door sensor, a net entry sensor, a net cutting knife sensor, and a bundling release sensor. The solenoid valve assembly, connected to the controller, includes solenoid valve I for controlling the opening and closing cylinder of the front compartment door, solenoid valve II for controlling the opening and closing cylinder of the rear compartment door, and solenoid valve III for controlling the opening and closing cylinder of the lower compartment door. The electromagnetic clutch for winding the net is connected to the controller and is used to control the power of the net winding assembly; The front compartment door sensor is installed at the front compartment door. When the front compartment door is opened and exceeds the detection distance of the front compartment door sensor, the front compartment door sensor outputs a low level to the controller, and the controller displays the information on the human-machine interface component and issues an alarm. When the front compartment door sensor outputs a low level to the controller, the controller controls the solenoid valve I to open the front compartment door and controls the solenoid valve III to open the lower compartment door. The opening time of the lower compartment door is less than or equal to half the opening time of the front compartment door; The bale position sensor is located between the front and rear compartments. When the front compartment door is opened, the bale is pushed to the rear compartment, triggering the bale position sensor. The bale position sensor is a proximity switch. When the bale position sensor detects one or more high-level signals, it is determined that the compartment switching is complete. When the bundling sensor detects that the compartment change is complete, the controller controls the solenoid valve I to close the front compartment door; When the rear compartment door sensor is triggered, the controller controls the solenoid valve III to close the lower compartment door; After the lower compartment door sensor is triggered, the controller controls the winding electromagnetic clutch to engage, causing the winding assembly to start working. When the inlet sensor does not detect a level signal of its inherent frequency, the controller controls the human-machine interface component to display that the net has been used up. After the bale is wrapped with netting, the netting cutter falls, and when the netting cutter sensor is triggered, the controller controls the solenoid valve II to open the rear compartment door; After the release sensor is triggered, the controller controls the solenoid valve II to close the rear compartment door.

2. A control method for a continuously operating round baler, applied in the continuously operating round baler control system as described in claim 1, characterized in that, Includes the following steps: The system detects when the front compartment door is opened. When the front compartment door is detected to be opened, the front compartment door and the lower compartment door are opened. The system detects the passing of hay bales. When a hay bale is detected, the front compartment door is closed, allowing the material to be continuously conveyed to the rear compartment through the open lower compartment door. The rear compartment door is detected to be open. When the rear compartment door is detected to be open, the lower compartment door is closed, and the electromagnetic clutch for winding is engaged, so that the winding assembly starts to work. The signal of the cutting blade is detected. When the cutting blade is detected to be falling, the electromagnetic clutch of the winding system is controlled to disengage, so that the winding assembly stops working and the rear door is opened to allow the bales to fall. The system detects the bale release signal and, upon detecting the bale falling, controls the rear compartment door to close.

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