Bale Orientation Control via Electro-Hydraulic Gate Actuation
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Solution Overview
Problem
Agricultural round balers face challenges in orienting bales correctly, leading to wrap material hanging loose and getting caught during transportation, which increases complexity and cost with existing systems that use clutches to stop bale rotation.
Innovation Solution
A bale orientation system that uses sensors and an electro-hydraulic control valve to monitor the bale's orientation and open the gate only when the bale is in the desired position, eliminating the need for a clutch by stopping bale rotation through gate actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a clutch arrangement is used to stop bale rotation, then the bale orientation can be controlled, but the device complexity and cost significantly increase
Solution Approach 1:
The patent removes the clutch component from the system entirely. Instead of using a clutch to stop bale rotation, the invention uses the existing gate mechanism to achieve the same functional outcome, thereby eliminating the complex clutch arrangement while maintaining bale orientation control capability
Solution Approach 2:
The gate mechanism is given a dual function: it serves both as the discharge opening for bales and as the bale orientation control mechanism. By actuating the gate at specific moments during bale rotation, the system uses the gate's movement to control bale orientation without requiring dedicated clutch components
2Ease of manufacture
If the wrap material end is located between 7:00 and 11:00 o'clock positions, then the bale can be formed, but the wrap material tends to become loose and fall down
Solution Approach 1:
The system proactively controls bale rotation and discharges the bale at the precise moment when the wrap end reaches the optimal position (1:00-5:00 o'clock). This preliminary action prevents the wrap from becoming loose during subsequent handling and transport, rather than reacting after the problem occurs
Solution Approach 2:
The bale orientation sensor continuously monitors the position of the wrap end and provides feedback to the control system. This feedback enables the controller to determine when the optimal discharge moment has been reached and actuate the gate accordingly, ensuring reliable wrap retention
3Productivity
If the gate is opened to discharge the bale, then the bale can be released, but the bale rotation cannot be stopped without a clutch
Solution Approach 1:
The patent combines the bale discharge function and the bale orientation control function into a single gate actuation action. The gate opening serves dual purposes: it releases the bale for discharge and simultaneously stops bale rotation by removing the driving force, eliminating the need for separate clutch and discharge mechanisms
Solution Approach 2:
The system uses dynamic control of the gate actuation timing to achieve precise bale orientation. By controlling when the gate opens during the bale rotation cycle, the system dynamically adjusts bale discharge timing to ensure the wrap end is in the optimal position, maintaining manufacturing precision while enabling productivity
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 solution reduces the complexity and cost of the baler by ensuring bales are discharged in the correct orientation, minimizing wrap material loss and preventing it from getting caught during transport, while replacing the costly clutch with a less expensive electro-hydraulic valve.
Implementation Method 1
a gate actuation cylinder connected with a source of hydraulic pressure, and one or more controllers. The baler also includes a hydraulic system in communication with the gate actuation cylinder
Data Source
AI summary
A system and method are provided for controlling the orientation of a bale discharged from an agricultural round baler according to the position of the discharge gate. When the bale reaches the desired orientation inside the bale forming chamber, such as when a segment or the cut end of the bale wrap is within a desired angular position, an electro-hydraulic control valve is activated, manually or automatically, to actuate the gate cylinders to open the gate, thereby stopping bale rotation and discharging the bale in the desired orientation.