Automated silage bale production device
The automated silage bale making device addresses uneven compaction and odor detection issues by using sensors and hydraulic compaction, enabling efficient and high-quality silage bale production without professional intervention.
Patent Information
- Application Number
- DE202024106412
- Authority / Receiving Office
- DE · DE
- Patent Type
- Utility models
- Current Assignee / Owner
- Filing Date
- 2024-11-08
- Publication Date
- 2024-12-24
- Estimated Expiration
- 2034-11-30
AI Technical Summary
Existing silage bale production devices lack the ability to regulate the cutting process according to leaf temperature, leading to uneven compaction and spoilage, and do not effectively detect foul odor, requiring professional intervention and inefficient production processes.
An automated silage bale making device with sensors to monitor leaf position, speed, and temperature, coupled with a motorized cutting mechanism, hydraulic rods for compaction, and odor detection, allowing user-defined production without manual effort.
Enables precise silage bale formation with reduced time and effort, preventing spoilage by detecting foul odor and ensuring uniform compaction, thus improving production efficiency and animal feed quality.
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Abstract
Description
AREA OF INVENTION
[0001] The present invention relates to an automated device for the production of silage bales, which is capable of producing silage bales by pressing fresh leaves according to the quantity of pressed silage to be produced specified by the user, without the need for a skilled worker, thereby avoiding physical exertion in the production of the silage bale. BACKGROUND OF THE INVENTION
[0002] Silage bales are a nutrient-rich feed source for livestock during the winter months, helping to maintain their health and productivity. Furthermore, silage bales help farmers efficiently store surplus forage for future use, reducing waste and ensuring a stable feed supply for their animals. Overall, silage bales are a cost-effective and convenient way for farmers to preserve high-quality feed and feed it to their livestock. This method also helps farmers manage their resources effectively and sustainably throughout the year. By using silage bales, farmers also reduce the risk of spoilage and mold growth in their stored feed, resulting in improved animal health overall.To make silage bales, the farmer uses leaves which are pressed with a certain pressure and wrapped with a film, which allows the film to loosen.
[0003] Traditionally, there is only a limited number of devices and equipment, such as bale wrappers, bale handlers, and bale spikes, available for the efficient packaging and handling of silage bales for storage and transport. Bale wrappers are used to protect the silage bales from the elements, while bale handlers and spikes help to move and stack the bales easily. However, these devices and equipment have shortcomings in the pressing process itself, such as uneven compaction leading to spoilage, as well as issues with maintenance and repair. Proper operator training and regular maintenance schedules help to mitigate these problems and ensure efficient silage bale production.
[0004] EP0950348A1 discloses a baler with a plurality of endless belts and opposing side walls, forming a chamber between them for receiving forage material and forming a bale. Each belt is designed as a full-width belt, extending essentially across a transverse distance from one side wall to the other. To maintain proper belt guidance across the entire width, a drive roller for each belt is provided with a sleeve located centrally on the drive roller, forming a rim for the roller and improving traction between the roller and the belt. Furthermore, each belt has a different stiffness across its entire width, exhibiting greater stiffness against bending about an axis perpendicular to the rollers (Y) than stiffness against bending about an axis parallel to the rollers (X).To facilitate the removal of debris from an area adjacent to the inner surface of the belt, a roller for guiding the belt is provided with a spiral structure, the spiral acting as a screw to convey the debris away from the center and towards the ends of the roller. Although EP'348 provides a method for bale forming generally for round balers and specifically for round balers used for pressing silage, and improvements thereto to limit the accumulation of waste and improve the waste, it lacks the detection of putrid odor in the cut leaves, which impairs the forming process.
[0005] US5433059A discloses a device and a method for wrapping roll material around a round bale within a bale-forming chamber of a round baler, comprising a drive belt tensioner, a wrapping material brake, and a wrapping material cutting knife, all arranged on a carriage pivoting between a wrapping material feed position and a cutting / stop position. Upon completion of baling, a signal is given to move to the feed position, where the wrapping material is held under tension to maintain bale compaction. After sensor data is fed back to a controller to indicate that the feed has continued for the desired duration and / or the desired length of wrapping material has been dispensed, the device pivots to the cut position to cut the wrapping material and complete the bale-wrapping process.A mechanism for returning crop material can also be provided to guide scattered material back into the baling chamber. While US'059 offers a way to form a silage bale by using a drive for feeding the wrapping material, a brake for the feed roller, and a mechanism for cutting the wrapping material, all mounted on a single carriage that pivots between a position for feeding the wrapping material and a position for stopping or cutting the bale material, it lacks regulation of the cutting process according to the position and temperature of the foliage, which can lead to faulty bale formation.
[0006] Many devices and apparatuses for producing silage bales from leaves are known in the prior art, but they are not capable of regulating the cutting process of the leaves according to their temperature. Furthermore, such devices and apparatuses are not capable of compressing the desired quantity of leaves to produce the silage bale.
[0007] To overcome the aforementioned disadvantages, the technical need is to develop a device capable of producing silage bales from leaves according to the desired quantity of leaves to be compressed, by regulating the cutting process of the leaves according to the temperature of the leaves in order to compact the silage with appropriate pressure. OBJECTS OF INVENTION
[0008] The main objective of the present invention is to overcome the disadvantages of the prior art.
[0009] One object of the present invention is to provide a device capable of producing a means for converting fresh leaves into silage in accordance with user-defined quantities of pressed silage, without any requirement of skilled personnel, thereby reducing the time required for the production of silage bales.
[0010] Another objective of the present invention is to develop a device capable of detecting the presence of putrid odor in cut leaves in order to generate a voice command that informs the user of the detected putrid odor in order to avoid its use in silage production.
[0011] Another objective of the present invention is to develop a device capable of detecting the position of the foliage, the speed at which the foliage is cut, and the temperature of the foliage in order to regulate the cutting process of the foliage.
[0012] The foregoing and other objects, features and advantages of the present invention will become readily apparent upon closer examination of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings. SUMMARY OF THE INVENTION
[0013] The present invention relates to an automated device for the production of silage bales, which is capable of producing silage bales from fresh leaves according to the amount of leaves required for pressing, without the user applying pressure in order to reduce the time required for the formation of the silage.
[0014] According to one embodiment of the present invention, an automated device for producing silage bales comprises a housing positioned above a ground surface by means of several legs, a funnel-shaped filling hopper arranged above the top of the housing and accessible to a user for introducing fresh leaves into the hopper to be converted into silage, a touch-interactive display panel installed above the housing to allow the user to input values relating to the quantity of pressed silage to be produced, a microcontroller connected to the display panel that actuates a motorized cutting unit installed in the neck of the hopper to cut the leaves into smaller pieces, a cylindrical chamber arranged below the hopper to collect the cut leaves, and a weight sensor installed in the chamber.to monitor the weight of the cut leaves, a pair of hydraulic rods installed inside the hopper; a platform configured with the base of the housing to hold the silage bale; a hydraulic rod configured between the base of the housing and the platform to retract and position the platform and silage bale within the housing; a pair of motorized rollers wrapped with film, installed inside the housing to unwind the film; a pair of robot grippers installed inside the housing to grasp the unwound film and engage it around the silage bale; a motorized ball joint installed between the platform and the rod to allow the platform to rotate around an axis to wrap the silage bale with film.which is how the silage bale is packed.
[0015] According to another embodiment of the present invention, the proposed device comprises a sensor module with a position sensor, a speed sensor, and a temperature sensor installed in the hopper to monitor the positioning of the leaves, the speed of the cutting unit, and the temperature of the leaves; an odor sensor installed in the chamber to determine the presence of putrid odor in the cut leaves; a loudspeaker installed above the housing to generate a voice command to notify the user of the detected foul odor; a lid connected to the housing by means of a motorized hinge joint to rotate and position the lid at an angle above the surface to allow the user to remove the silage bale; and a battery connected to the device.to supply energy to electrically and electronically operated components connected to the device.
[0016] While the invention has been described and shown with particular reference to the preferred embodiment, it is obvious that variations are possible which would fall within the scope of the present invention. BRIEF DESCRIPTION OF THE DRAWING
[0017] These and other features, aspects and advantages of the present invention will be better understood with reference to the following description, the attached claims and the attached drawing: Fig. Figure 1 shows an isometric view of an automatic device for the production of silage bales. DETAILED DESCRIPTION OF THE INVENTION
[0018] The following description contains the preferred best embodiment of an embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to the embodiments shown, but that the invention also includes a multitude of modifications and embodiments thereof. Therefore, the present description should be regarded as illustrative and not limiting. While the invention is open to various modifications and alternative designs, it should be understood that there is no intention to limit the invention to the specific form disclosed; on the contrary, the invention is intended to cover all modifications, alternative designs, and equivalents that fall within the spirit and scope of the invention, as defined in the claims.
[0019] In each embodiment described herein, the open terms “comprising”, “comprises” and the like (which are synonymous with “including”, “with” and “characterized by”) can be replaced by the respective partially closed expressions “consists substantially of”, “consists substantially of” and the like, or the respective closed expressions “consists of”, “consists of” and the like.
[0020] As used herein, the singular forms “a”, “an” and “die” denote both the singular and the plural unless explicitly stated that only the singular is meant.
[0021] The present invention relates to an automated device for the production of silage bales, which is capable of converting fresh leaves into silage in accordance with the quantity of pressed silage to be produced specified by the user, without the need for a person skilled in the art, thereby preventing mismanagement in the production of the silage bale.
[0022] Referring to Fig.Figure 1 shows an isometric view of an automatic silage bale producing device comprising a housing 101 with multiple legs 102, a funnel-shaped feed hopper 103 arranged above the top part of the housing 101, a touch-sensitive interactive display panel 104 installed above the housing 101, a motorized cutting device 105 installed in the neck part of the hopper 103, a cylindrical chamber 106 arranged below the hopper 103, a pair of hydraulic rods 107 installed in the inner part of the chamber 106, each provided with a semi-cylindrical element 108, a platform 109 connected to the base part of the housing 101 and the platform 109, a pair of motorized rollers 111 wrapped with a wrapping film 112 installed inside the housing 101, and a Pair of motorized rollers 111, which are wrapped with a wrapping film 112,a platform 109 formed with the base part of the housing 101, a hydraulic rod 110 formed between the base of the housing 101 and the platform 109, a pair of motorized rollers 111 wrapped with a covering film 112 installed inside the housing 101, a pair of robot grippers 113 installed inside the housing 101, a motorized ball joint 114 installed between the platform 109 and the rod 110, a loudspeaker 115 installed above the housing 101, and a cover 116 connected to the housing 101 by means of a motorized hinge joint 117.
[0023] The proposed device consists of a housing 101, which is made of any element, including a metallic material or a wood-based material, to support the load of all components connected to the device and to operate the device accordingly. The housing 101 is positioned above a ground surface by means of several legs 102. A funnel-shaped filling hopper 103 is arranged above the top of the housing 101, which a user can access to introduce fresh leaves into the hopper 103, which are to be converted into silage. Furthermore, an interactive touch display 104 is installed above the housing 101, which the user can access to input data regarding the quantity of pressed silage to be produced.
[0024] The display panel 104 shown here consists of small wires that close the circuit when the user touches the panel 104 to make an input, which further changes the electrical charge at the point of contact and is registered as input in the panel 104. The input commands are then stored in a database of an integrated microcontroller connected to the display panel 104 for processing. After processing the user input, the microcontroller actuates a motorized cutting device 105, installed in the neck area of the hopper 103, to cut the foliage into smaller pieces.
[0025] The cutting device 105 described herein is coupled to a DC motor, which is activated by the microcontroller to set the cutting device 105 into a circular motion. The operating principle of a DC motor is based on the interaction between a magnetic field and an electric current. When an electric current flows through the wire coil, also called the armature, it generates a magnetic field. This magnetic field interacts with the stationary magnets, called the stator, and sets the armature in rotation. The rotation is achieved by reversing the direction of current flow in the armature coil with the aid of a commutator and brushes, which ensure continuous movement of the motor, resulting in a circular motion of the cutting device 105 to cut the foliage into smaller pieces.
[0026] A sensor module disclosed herein is installed in the hopper 103 to detect the position of the foliage, the speed of the blade 105, and the temperature of the foliage in order to regulate the cutting process. The sensor module comprises a position sensor, a speed sensor, and a temperature sensor that work together to detect the position of the foliage, the speed of the blade 105, and the temperature of the foliage in order to regulate the cutting process. The position sensor detects changes in the position of the foliage and converts this information into an electrical signal. This signal is then transmitted to the microcontroller to analyze and determine the position of the foliage.
[0027] The speed sensor described here measures the speed at which the cutting tool 105 moves and converts this information into an electrical signal. This signal is then processed by the microcontroller to determine the speed of the blade 105. The temperature sensor operates on the principle of detecting the infrared radiation emitted by the leaves. The essential components of this sensor include a thermoreceptor, an optical array, and a sensing module. The thermoreceptor captures the infrared radiation emitted by the leaves and uses the optical array to focus the radiation onto a sensitive element. This sensitive element, which differs from a conventional detector, converts the received infrared energy into an electrical signal. Electronic components then process this signal and convert it into a temperature value.The cutting process of the leaves is regulated based on the detection of the position of the foliage, the speed of the cutting machine 105 and the temperature of the foliage.
[0028] Below the hopper 103 is a cylindrical chamber 106 that collects the cut leaves. A weight sensor is installed in the chamber 106 to detect the weight of the cut leaves. The weight sensor includes a transducer that converts the weight of the cut leaves into an electrical signal, which exerts a downward force on the weight sensor. Strain gauges are located in the sensor's load cell; these deform slightly under the weight. This deformation causes a change in the electrical resistance of the strain gauges. The sensor then calibrates this resistance to determine the weight of the cut leaves.
[0029] When the weight of the leaves matches the value specified by the user, the microcontroller actuates a pair of hydraulic rods 107, installed inside the chamber 106, to extend a semi-cylindrical element 108 configured with the rods 107 and compress the cut leaves into a cylindrical silage bale. The rods 107 are equipped with a hydraulic power unit, activated by the microcontroller, to extend and retract the rods 107. The hydraulic power unit consists of a hydraulic oil compressor that draws oil from the hydraulic tank and drives an electric pump, also controlled by the microcontroller. The electric pump includes a turbine that creates a partial vacuum to draw the hydraulic oil from the hydraulic tank.
[0030] The turbine is then controlled by the microcontroller to increase the hydraulic oil pressure. This pressure, in turn, forces the hydraulic oil in compressed form out of the pump and through the pipes stored in the oil cylinders. The compressed oil is then released via electronic valves, actuated by the microcontroller, to drive the piston that assists in extending and retracting the rods 107. This extends and compresses the cut foliage over element 108 into the cylindrical silage bale, which is housed on a platform 109 configured with the bottom part of chamber 106.
[0031] Chamber 106 is equipped with an odor sensor that detects the presence of a putrid odor in the cut leaves. The sensor works by detecting and analyzing the volatile organic compounds (VOCs) released by the food. These VOCs are released as gases and carry specific odor molecules that are identified by the sensor. The sensor consists of a sensitive material that interacts with the VOCs, causing a change in its electrical properties. This change is then measured and interpreted to determine the presence of a putrid odor in the cut leaves.
[0032] After detecting the foul odor, the microcontroller activates a speaker 115, which is installed above the housing 101, to inform the user about the detected foul odor.
[0033] The loudspeaker 115 contains a diaphragm, typically made of a lightweight and rigid material such as paper, plastic, or metal. It is designed to vibrate and produce sound waves when electrical signals are applied to it. A voice coil (a tightly wound coil of wire) is connected to the diaphragm of the loudspeaker 115. The voice coil is suspended in a magnetic gap. When an electric current flows through the coil, it interacts with the magnetic field generated by the magnet assembly, creating a force that moves the coil. The magnet assembly generates a magnetic field within the loudspeaker 115. It consists of a permanent magnet and a metal structure, such as a pole piece or a magnetic plate. The magnet assembly creates a fixed magnetic field through which the voice coil moves. The strength and configuration of the magnet assembly affect the performance and efficiency of the loudspeaker 115.
[0034] The cone / diaphragm is connected to the speaker frame of the 115 via a suspension assembly that includes the surround and spider. As the electrical signal passes through the voice coil, it generates a magnetic field that interacts with the fixed magnetic field produced by the magnet assembly. When the electrical current varies, the magnetic field generated by the voice coil changes, causing the voice coil and the attached cone / diaphragm to move back and forth. This movement creates pressure fluctuations in the surrounding air, generating sound waves that alert the user to the detected unpleasant odor.
[0035] Furthermore, a hydraulic rod 110 is arranged between the base of the housing 101 and the platform 109 to move and position the platform 109 and the silage bale within the housing 101. The rod 110 is equipped with a hydraulic unit that is activated by the microcontroller to allow the extension and retraction of the rod 110 for positioning the platform 109 and the silage bale within the housing 101. Inside the housing 101, a pair of motorized rollers 111 are installed, wrapped with a wrapping film 112 and arranged opposite each other to unwind the film 112. The rollers 111 are coupled to a motor that is activated by the microcontroller to rotate the rollers 111 at a specific speed to unwind the wrapping film 112.
[0036] The microcontroller then actuates a pair of robot grippers 113, installed in housing 101, to grasp the unwound film 112 and wrap it around the silage bale. The gripper is equipped with a pneumatic unit, activated by the microcontroller, to extend and retract the gripper. The pneumatic unit consists of an air compressor, an air cylinder, air valves, and a piston. The air valve allows compressed air from the compressor to enter and exit. The valve opens, and the compressed air enters the cylinder, increasing the cylinder's air pressure. The piston is connected to the cylinder, and due to the increased air pressure, the piston extends, causing the gripper to expand and grasp the unwrapped film 112 around the silage bale.
[0037] When the film 112 is applied, the microcontroller actuates a motorized ball joint 114, which is installed between the platform 109 and the rod 110, to rotate the platform 109 around its axis and wrap the silage bale with the film 112. The ball joint 114 is a mechanical arrangement consisting of a spherical component that fits into a socket, with a motor supplying the necessary energy to drive the rotation, thus giving the platform 109 an angular movement around its axis to wrap the silage bale with the film 112 and thus packing the silage bale.
[0038] After the silage bale is wrapped, the microcontroller actuates a motorized hinge joint 117, which is integrated into a lid 116 configured with a specific side of the housing 101, to rotate the lid 116 and position it at an angle above the surface so that the user can remove the silage bale. The hinge joint 117 is typically a mechanical joint that allows rotational movement about a fixed axis by means of a motor or actuator that provides the rotational force required to move the joint. The motor is usually controlled by an electronic control unit that regulates its speed and direction. The hinge joint 117 consists of a hinge mechanism that allows rotation about a fixed axis. It typically comprises two parts: a fixed part and a moving part.The fixed component is rigidly connected to one part of the lid 116, while the movable component is connected to the other part, which must rotate the lid 116 and position the lid 116 at an angle above the surface so that the user can remove the silage bale.
[0039] A battery (not shown in the diagram) is connected to the device to power all the electrical and electronic components required for its proper operation. The battery is connected to the microcontroller and supplies direct current to it. The microcontroller then sends this current to the specific electrical or electronic components according to the sequence of operations, enabling them to perform their respective functions effectively.
[0040] The present invention works best in the following manner, where the housing 101 is positioned over a ground surface with the aid of the 102. A funnel-shaped filling hopper 103 is configured above a top portion of the housing 101, which a user accesses to introduce fresh leaves into the hopper 103 to be converted into silage. The interactive touch display 104 allows the user to input the quantity of compressed silage to be produced. Based on the user input, the microcontroller connected to the display 104 actuates the motorized cutting device 105, which is installed in the neck region of the hopper 103, to cut the leaves into smaller pieces that are collected in the cylindrical chamber 106.The weight sensor detects the weight of the cut leaves, and as soon as the monitored weight matches the value specified by the user, the microcontroller actuates the pair of hydraulic rods 107, which are connected to the semi-cylindrical element 108, to extend and compress the cut leaves into the cylindrical silage bale. Furthermore, the microcontroller actuates the platform 109, which is configured with the bottom part of the chamber 106 that holds the silage bale, and the hydraulic rod 110 to retract and position the platform 109 and the silage bale within the chamber 106 housing 101. Subsequently, the motorized rollers 111, which are wrapped with a film 112, are actuated by the microcontroller to unwind the film 112.The two robot grippers 113 are controlled by the microcontroller to grasp the unwound film 112 and wrap it around the silage bale. As the film 112 is grasped, the microcontroller actuates a motorized ball joint 114, installed between the platform 109 and the rod 110, to rotate the platform 109 around its axis and wrap the silage bale with the film 112, thus packaging the silage bale. Furthermore, the special side of the housing 101 is provided with a cover 116, which is connected to the housing 101 by means of a motorized hinge 117. This hinge is actuated by the microcontroller during the wrapping process to rotate the cover 116 and position it at an angle above the surface, allowing the user to remove the silage bale.
[0041] Although the field of the invention has been described here with limited reference to specific embodiments, this description should not be understood in a restrictive sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the invention, will be obvious to the person skilled in the art by reference to the description of the invention. QUOTES INCLUDED IN THE DESCRIPTION
[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature
[0000] EP 0950348A1
[0004] US 5433059A
[0005]
Claims
[1] Automated device for producing silage bales, comprising: i) a housing 101 positioned above a ground surface by means of a plurality of hoppers 102, with a funnel-shaped feed hopper 103 configured above an apex portion of the housing 101 to which a user has access to introduce fresh foliage into the hopper 103 to be converted into silage; ii) a touch-interactive display panel 104 installed above the housing 101 to allow the user to provide inputs regarding the compressed silage to be produced and its quantity, wherein, based on the user inputs, a microcontroller connected to the display panel 104 actuates a motorized cutting device 105 installed in the neck area of the hopper 103 to cut the foliage into smaller pieces; iii) a cylindrically shaped chamber 106 arranged below the hopper 103 for collecting the cut leaves, wherein a weight sensor is installed in the chamber 106 to monitor the weight of the cut leaves, and once the monitored weight matches the amount specified by the user, the microcontroller actuates a pair of hydraulic rods 107 installed in the inner part of the chamber 106 and each configured with a semi-cylindrical element 108 to extend and compress the cut leaves into a cylindrically shaped silage bale; iv) a platform 109 configured with the base portion of the chamber 106 that receives the silage bale, with a hydraulic rod 110 configured between the base of the housing 101 and the platform 109 that is actuated by the microcontroller to retract and position the platform 109 and the silage bale within the housing 101; v) a pair of motorized rollers 111 wrapped with a wrapping film 112, installed in the housing 101 and arranged opposite each other, which are actuated by the microcontroller to unwind the film 112; and vi) a pair of robotic grippers 113 installed within the housing 101 and instructed by the microcontroller to grasp the unwrapped sheet 112 and to grip it around the silage bale, wherein upon gripping the sheet 112 the microcontroller actuates a motorized ball joint 114 installed between the platform 109 and the rod 110 to cause rotation of the platform 109 about the axis to wrap the silage bale with the sheet 112, thereby packing the silage bale. [2] The apparatus of claim 1, wherein a sensor module is installed in the hopper 103 to monitor the positioning of the foliage, the speed of the cutting device 105 and the temperature of the foliage to regulate the cutting operation of the foliage. [3] The device according to claim 1, wherein the sensor module comprises a position sensor, a speed sensor and a temperature sensor. [4] The device according to claim 1, wherein an odor sensor is installed in the chamber 106 to detect the presence of foul odor in the cut leaves, and upon detecting the foul odor, the microcontroller actuates a speaker 115 installed above the housing 101 to generate a voice command to inform the user of the detected foul odor. [5] Apparatus according to claim 1, wherein a particular side of the housing 101 is provided with a lid 116 connected to the housing 101 by means of a motorised hinge joint 117 which is actuated by the microcontroller during wrapping of the silage bale to rotate the lid 116 and position it at an angle above the surface to allow the user to remove the silage bale. [6] The device of claim 1, wherein a battery is connected to the device to power electrical and electronically operated components connected to the device.
Citation Information
Patent Citations
Silage round baler
EP0950348A1
Round bale wrapping
US5433059A
Cited By
Silage film wrapping mechanism and feed production line
CN121225048A
