Bale Wrapping Sensor Gap Detection for Wrap Integrity
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Solution Overview
Problem
Existing bale forming and wrapping technologies face challenges in ensuring that the bale surface is properly wrapped before ejection, leading to issues like the bale falling apart, and existing sensors may not accurately detect malfunctions in the wrapping process, such as the web being wrapped around rollers instead of the bale surface.
Innovation Solution
A bale forming apparatus with a moveable discharge gate and a web detecting sensor that senses segments of the bale surface through a gap between the discharge gate and the casing, allowing for contactless detection of wrapping material coverage and preventing the bale from being ejected if not properly wrapped, thereby avoiding the bale from falling apart.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a web detecting sensor is positioned inside the casing to directly monitor the bale surface, then the detection accuracy of wrapping material coverage is improved, but the sensor is exposed to debris and crop material that can damage it and complicate maintenance
Solution Approach 1:
The patent uses the gap between the discharge gate and casing as an intermediary space through which the sensor can detect the bale surface indirectly. The sensor is positioned outside the casing and detects wrapping material coverage through this gap, eliminating direct exposure to harmful debris while maintaining detection capability
Solution Approach 2:
The patent replaces direct mechanical contact between the sensor and bale surface with optical or electromagnetic detection through the gap. This substitution allows the sensor to monitor wrapping material coverage without physical contact, preventing damage from crop material and debris
2Productivity
If the discharge gate is moved into the bale ejecting position without proper wrapping detection, then the productivity and ejection speed are improved, but the bale may fall apart due to inadequate wrapping
Solution Approach 1:
The patent implements a feedback control system where the web detecting sensor continuously monitors wrapping material coverage and provides signals to the control unit. The control unit uses this feedback to determine whether the discharge gate should be moved to the ejection position, ensuring that only properly wrapped bales are ejected
Solution Approach 2:
The patent performs wrapping verification before the ejection action is executed. The sensor detects wrapping material coverage in advance, and the control unit decides on the discharge gate movement based on this preliminary detection, preventing premature ejection of improperly wrapped bales
3Measurement precision
If the web detecting sensor is positioned inside the casing in direct contact with the bale, then the detection of wrapping material coverage is improved, but the device complexity and maintenance difficulty increase
Solution Approach 1:
The gap between the discharge gate and casing serves as an intermediary that allows the sensor to be positioned outside the casing while still detecting the bale surface. This positioning makes the sensor easily accessible for maintenance without requiring disassembly of the casing or exposure to harmful internal conditions
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 solution effectively reduces the risk of the bale being ejected without proper wrapping, ensures accurate detection of wrapping material coverage, and maintains sensor reliability by positioning it outside the bale's direct contact, reducing the risk of damage from debris and allowing for easier maintenance.
Implementation Method 1
a web detecting sensor which senses segments of the bale surface visible through the gap between the discharge gate and the casing
Data Source
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AI summary
A bale forming apparatus (1) forms a round bale (B', B), wraps a surface of the bale (B), and ejects the bale (B). A discharge gate (11) of a casing (11, 15) is in a bale forming position while the bale (B') is formed. For wrapping the bale (B) the discharge gate (11) is pivoted into a bale wrapping position. A web detecting sensor (99) detects whether or not provided web is present on the surface of the bale (B) in the casing (11, 15). This web detecting sensor (99) senses a segment of the bale surface which is visible through a gap (N) between a stationary casing part (15) and the discharge gate (11) being in the bale wrapping position. The wrapped bale (B) is ejected.