Bale Wrapper Dynamic Speed Control via Obstacle Sensing
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Solution Overview
Problem
Existing bale wrappers face limitations in rotational speed due to unreliable safety systems, which lead to increased wrapping time and potential damage from obstacles, as they often incorrectly detect non-threatening objects, causing unnecessary interruptions.
Innovation Solution
A bale wrapper with multiple arms and a drive arrangement that rotates around an axis, equipped with a sensing arrangement and obstacle sensors, allowing the arms to operate at high speed when no obstacles are detected and reducing speed to prevent damage when obstacles are sensed, using sensors like microwave, radar, ultrasonic, or camera systems to control the rotation speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the rotational speed of the arms is increased to improve productivity, then wrapping time is reduced, but the risk of damage from hitting obstacles increases and the mechanical sensing arrangement becomes unreliable
Solution Approach 1:
The patent replaces the unreliable mechanical sensing arrangement with optical sensors (infrared sensors, light barriers) and electronic detection systems. These sensors can reliably detect obstacles at a distance without mechanical contact, enabling the arms to operate at higher speeds while maintaining safety through electronic control and braking mechanisms.
Solution Approach 2:
The patent implements preliminary detection of obstacles using sensors positioned ahead of the rotating arms. The system detects obstacles before the arms reach them, allowing the control system to prepare and apply braking forces in advance, enabling higher operating speeds while ensuring safe stopping distances.
2Reliability
If the rotational speed is limited to ensure safety, then damage from obstacles is prevented, but wrapping time increases and productivity decreases
Solution Approach 1:
The patent implements dynamic speed control where the rotational speed of the arms is continuously adjusted based on real-time obstacle detection. When no obstacles are detected, the arms operate at high speed for maximum productivity. When obstacles are detected by sensors, the speed is automatically reduced or stopped to prevent damage, optimizing both safety and productivity throughout the wrapping process.
Solution Approach 2:
The patent employs feedback control systems where sensors continuously monitor the environment and provide real-time information to the control system. The control system processes this information and adjusts the arm speed accordingly, creating a closed-loop system that automatically optimizes the balance between safety and productivity without manual intervention.
3Reliability
If mechanical sensing arrangements are used to detect obstacles, then safety is provided, but the system is only reliable within a certain speed range and limits the rotational speed
Solution Approach 1:
The patent replaces mechanical sensing arrangements with non-contact optical and electronic sensing systems including infrared sensors, light barriers, and electronic detectors. These systems provide reliable obstacle detection independent of rotational speed, eliminating the speed limitations inherent in mechanical sensing systems while maintaining or improving detection reliability.
Solution Approach 2:
The patent introduces optical fields and electromagnetic radiation as intermediaries between the sensing system and obstacles. Instead of direct mechanical contact between sensors and obstacles, the system uses infrared radiation, light, and electronic signals to detect obstacles at a distance, enabling reliable detection across a wide range of rotational speeds without mechanical wear or contact.
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 enables high-speed bale wrapping while ensuring safety by preventing arm and film dispenser damage, reducing wrapping time without compromising safety, by dynamically adjusting the rotation speed based on obstacle detection.
Implementation Method 1
The obstacle sensor can be a distance sensor, in particular a microwave sensor
Implementation Method 2
The obstacle sensor can be a distance sensor, in particular a microwave sensor and/or radar sensor
Implementation Method 3
The obstacle sensor can be a distance sensor, in particular a microwave sensor and/or radar sensor and/or ultrasonic sensor
Implementation Method 4
The obstacle sensor can also be an infrared sensor
Data Source
AI summary
A bale wrapper is provided that comprises a rotating arm holding a film dispenser. The arm rotates around an axis thereby wrapping the film from the film dispenser around the bale. Rotation of the arm is stopped when a sensing arrangement mounted ahead of the arm senses an obstacle. The arm is driven with a first speed sufficiently slow to prevent any risk of injury and the arm and the film dispenser from being damaged by hitting an obstacle detected by the sensing arrangement when an obstacle sensor observing a sensitive range in the environment of the bale wrapper detects an obstacle. The arm rotates at a second speed faster than the first speed when the obstacle sensor detects no obstacle.