Bale Drop Detection Using Elastic Deformation and Optical Sensing
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Solution Overview
Problem
Current bale drop detection systems in balers are prone to faults, crop interference, and high costs, making it difficult for operators to detect bale drops accurately due to the baler's size and design limitations.
Innovation Solution
A bale drop detection system with a bale chute and an elastically deformable member that supports the bale, where a sensor measures the deformation magnitude and rate, and a controller determines a bale drop event based on predefined conditions, without transferring loads through the sensor, allowing for accurate detection without mechanical parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical switches are used to detect bale presence, then detection capability is provided, but the system becomes faulty and susceptible to crop interference and jamming
Solution Approach 1:
The patent replaces mechanical switches with an optical detection system. An optical sensor (such as a photoelectric sensor or laser sensor) detects the presence of the bale by measuring light reflection or interruption, eliminating mechanical contact points that are susceptible to crop interference and jamming. This substitution maintains detection capability while removing the harmful effects of mechanical wear and crop material accumulation.
2Measurement precision
If optical sensors are used to detect bale presence, then detection accuracy is improved, but the sensors become blocked by crop material during use
Solution Approach 1:
The patent introduces an intermediary reflective surface or protective window that separates the optical sensor from the crop material environment. The sensor detects bale presence by measuring light reflected from this intermediary surface, which changes when a bale is present, without the sensor itself being exposed to crop material that could block or damage it.
3Reliability
If rear roller speed monitoring is used to detect bale motion, then functional detection is achieved, but the implement cost increases
Solution Approach 1:
The patent utilizes the existing motion of the rear roller as part of the detection system. The optical sensor detects bale presence and motion by monitoring light reflection changes caused by the roller's movement, rather than requiring separate monitoring mechanisms. This approach leverages the natural operational characteristics of the baler to achieve detection functionality without adding expensive specialized components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively detects bale drops without mechanical parts, reducing faults and crop interference, and providing reliable alerts to operators, enhancing safety and reducing operational costs.
Implementation Method 1
a first member operably connected to the bale chute, where the first member is elastically deformable between a first position in which the bale chute is empty or partially loaded and a second position in which the bale chute is fully loaded with the bale
Data Source
AI summary
A bale drop detection mechanism for use with a baler having a rear aperture. The bale drop detection mechanism including a bale chute coupled to the rear aperture of the baler, where the bale chute includes an upper surface configured to support a bale ejected from the rear aperture thereon. The bale drop detection mechanism also including a bracket coupled to the rear aperture of the baler, a support member extending between and coupled to both the bale chute and the bracket, and a controller in operable communication with the bale chute and configured to detect a bale drop event based at least in part on the level of force being applied to the upper surface of the bale chute.