Bale NIR Sampling With Cut-and-Mix Homogenization
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Solution Overview
Problem
Existing methods for evaluating baled plant material are inaccurate due to non-homogeneous sampling, reliance on generic calibrations, and lengthy laboratory analysis, which can result in significant variations in test results and fail to represent the overall quality of the bales.
Innovation Solution
A system and method that includes a cutter mechanism to cut plant material into similarly-sized particles, a mixer to create a homogeneous aggregate, and an NIR testing system to analyze near-infrared radiation, ensuring accurate evaluation by associating a unique identifier with each bale for calibration and evaluation information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a core sample is taken from a bale for laboratory testing, then the plant material properties can be determined, but the sample may not be representative of the overall bale quality and the process requires lengthy laboratory analysis time
Solution Approach 1:
The patent replaces the mechanical/core sampling and lengthy laboratory wet chemistry testing process with an optical NIR (near-infrared) sensing system that provides rapid on-site analysis. The NIR sensor captures spectral information from the plant material in real-time, eliminating the need for physical sample transport and extended laboratory processing while maintaining measurement accuracy.
Solution Approach 2:
The patent introduces an NIR sensor as an intermediary device between the plant material and the evaluation process. This sensor acts as a mediator that captures spectral characteristics of the material without requiring physical removal or transport of samples, enabling immediate on-site quality assessment and bridging the gap between field conditions and quality determination.
2Reliability
If an NIR sensor is mounted in the compression chamber to scan the finished bale, then the sampling rate is reduced and the outer surface area is limited, but the baling process effects are minimized
Solution Approach 1:
The patent applies preliminary action by preparing the plant material surface before NIR scanning occurs. A surface preparation mechanism (such as a brush or comb) is positioned to disrupt the compacted bale surface, creating a more open and representative sampling area. This preliminary surface disruption ensures that the NIR sensor captures light from deeper within the material and from a more heterogeneous sample, improving measurement precision while maintaining the reliability benefits of post-compression scanning.
3Ease of manufacture
If generic calibration methods are used for NIR testing, then the testing process is simplified, but the results may vary significantly between labs and do not meet specific customer standards
Solution Approach 1:
The patent applies local quality by implementing customer-specific calibration models tailored to individual customer requirements and standards. Rather than using a single generic calibration for all customers, the system creates localized calibration profiles for each customer that reflect their specific quality criteria. This ensures that each customer receives measurements calibrated to their unique standards while maintaining the overall simplicity of the NIR testing platform.
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
This approach provides more precise and representative evaluation of baled plant material properties by ensuring homogeneity and accurate calibration, allowing for real-time, on-site testing that meets specific customer standards.
Implementation Method 1
light having wavelengths between, e.g., 780 nm and 2500 nm, is emitted by the instrument and at least a portion is reflected by the plant material
Implementation Method 2
In an NIR testing system, light having wavelengths between, e.g., 780 nm and 2500 nm, is emitted by the instrument and at least a portion is reflected by the plant material; received, filtered, and converted to a voltage or current; and then analyzed to determine the properties of the plant material
Data Source
AI summary
A system and method for preparing a sample area of a bale in order to more accurately evaluate the plant material incorporated into the bale. A baler receives, compresses, shapes, and secures material into the bale. A cutter mechanism cuts a portion of the material in the bale into similarly-sized particles. A mixer mechanism mixes the particles into a homogenous aggregate. A compression mechanism compresses the homogenous aggregate into the bale. An NIR testing system receives and analyzes near-infrared radiation reflected by the homogenous aggregate, and generates evaluation data reflecting properties of the material. The cutter may include knives mounted in a compression chamber of the baler. The mixer may be a relief feature on a center rail, the compressor may be a projecting feature on the center rail, and an NIR sensor may be mounted to the center rail so as to press against the surface of the bale.