Bale Weight Control via Real-Time Pressure Feedback
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Solution Overview
Problem
Current baler control systems fail to produce bales with consistent densities and weights, leading to overloading of baler systems and exceeding transport truck payloads due to simple algorithms that are not effective with crop variations.
Innovation Solution
A system and method that includes an interface, memory, and processing element to set and achieve a target bale weight by adjusting pressure in the forming chamber, using sensors to gather data and adjust the tension mechanism to ensure bales meet the desired weight within a specified range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If higher density baling is used to increase productivity, then bale weight increases, but this causes overloading of baler systems and exceeds transport truck payloads
Solution Approach 1:
The system continuously monitors actual bale weight during formation and compares it to the target weight, then adjusts tension mechanism pressure in real-time to maintain consistent bale weights. This feedback loop enables high productivity through rapid baling while preventing overweight bales that would exceed transport limits or damage equipment.
Solution Approach 2:
The system dynamically changes the pressure parameter applied by the tension mechanism based on real-time bale weight measurements. By adjusting pressure during the baling process, the system can produce bales at high speed while maintaining consistent weights within acceptable ranges, thus achieving both high productivity and weight control.
2Reliability
If simple load-based control algorithms are used to protect baler systems, then system protection is achieved, but bale weight consistency deteriorates with crop variations
Solution Approach 1:
The system uses real-time feedback from weight sensors to continuously adjust tension mechanism pressure, enabling precise control of bale weight consistency. This goes beyond simple load-based protection by actively monitoring and adjusting to maintain target weights even when crop characteristics vary.
Solution Approach 2:
The control system transitions from static, pre-programmed load limits to dynamic, real-time adjustments based on actual bale weight measurements. The tension mechanism pressure is continuously modified during the baling process to adapt to crop variations, achieving both system protection and consistent bale weights.
3Manufacturing precision
If increased tension mechanism pressure is applied to control bale weight, then bale weight consistency improves, but system complexity increases
Solution Approach 1:
The system uses automated feedback control with sensors and electronic controllers to manage the increased complexity. By implementing real-time monitoring and automatic adjustment of tension mechanism pressure, the system achieves consistent bale weights while the electronic control handles the complexity, reducing the need for manual intervention.
Solution Approach 2:
The system replaces manual or simple mechanical control with electronic sensing and control mechanisms. Weight sensors, processors, and electronic controllers automate the adjustment of tension mechanism pressure, achieving precise bale weight consistency while the electronic systems manage the operational complexity.
4Manufacturing precision
If real-time pressure adjustment is implemented to achieve target bale weight, then bale weight control precision improves, but processing time increases
Solution Approach 1:
The system performs pressure adjustments continuously during the baling process rather than in discrete steps. The tension mechanism pressure is modulated in real-time as the bale forms, allowing the system to achieve precise weight control without interrupting the continuous baling operation, thus minimizing time loss.
Solution Approach 2:
The system begins adjusting tension mechanism pressure early in the bale formation process based on initial weight measurements, rather than waiting until the bale is complete. This preliminary action allows corrections to be made during formation, achieving precise weight control without extending the overall processing time.
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 allows for consistent bale weights and densities, preventing overloading of baler systems and ensuring compliance with transport regulations, while providing users with greater control over bale production.
Implementation Method 1
a tension mechanism configured to apply a pressure to the bale in the forming chamber
Implementation Method 2
a plunger configured to compress the crop material in the forming chamber into a growing bale
Data Source
AI summary
A system and method for producing a bale having a target weight set by a user. A processor compares stored actual weights to the target weight, and, based on a difference, adjusts the bale-forming process. The processor may calculate a load value for a connecting rod, measure an actual load value for the rod, and, based on a difference, set a new pressure value for the process, and then repeat these steps until the bale is fully formed. The processor may determine a first line relating a calculated load on the connecting rod to a current pressure, determine a second line relating a measured load on the rod to the current pressure, identify a pressure value at the intersection of the first and the second lines, and make this the new pressure value for the process, and then repeat these steps until the bale is fully formed.