Bale Wrapping Sensor Detecting Crop Protrusions

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Solution Overview

Problem

Existing baling machines lack the ability to effectively detect whether a bale is properly wrapped, as they only monitor the wrapping web's deployment and not the integrity of the wrap, leading to potential damage or rotting of crops due to improper or damaged wrapping.

Innovation Solution

A sensor system is integrated into the baling machine that monitors the presence of crop material outside the bale's circumference to ensure all material is contained within a defined diameter, detecting protrusions or loose material to indicate proper wrapping, using an emitter and detector to send and receive light signals.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If optical sensors are used to detect wrapping web deployment, then the wrapping process can be interrupted when web is not properly fed, but the sensors cannot detect whether the wrapping web is damaged or whether the bale is properly wrapped

Engineering Contradiction:

Improvewrapping integrityVSAvoidsensor system capability

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Instead of directly sensing the wrapping web to detect its presence and integrity, the patent inverts the approach by sensing the crop material itself. The sensor detects whether crop material is properly contained within the bale, which indirectly indicates whether the wrapping web is intact and properly deployed. This inversion allows detection of wrapping integrity without directly monitoring the web.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent introduces crop material as an intermediary object for detection. Rather than placing sensors to directly monitor the wrapping web (which would require complex sensor systems), the sensor monitors the position and containment of crop material within the bale. The crop material serves as a mediator that provides information about wrapping integrity indirectly.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If sensors monitor only the wrapping web deployment, then the wrapping process can be suspended when web is not properly advanced, but the integrity of the wrapped bale cannot be ensured

Engineering Contradiction:

Improvebale wrapping integrityVSAvoidwrapping defect detection

Core Design Contradiction:

ReliabilityVSLoss of information

Solution Approach 1:

The patent inverts the detection approach by monitoring what is contained (crop material) rather than what contains (wrapping web). By sensing whether crop material remains within the defined bale diameter, the system infers wrapping integrity without directly observing the web, thereby preventing loss of information about wrapping defects.

Inventive Principle:

Principle #13The other way round (Inversion)

3Measurement precision

If the sensor system detects only web presence, then malfunction can be identified, but damage to wrapping web or improper wrapping cannot be sensed

Engineering Contradiction:

Improvewrapping status detectionVSAvoidwrapping defect detection

Core Design Contradiction:

Measurement precisionVSDifficulty of detecting and measuring

Solution Approach 1:

The patent resolves the detection difficulty by inverting the measurement target. Instead of attempting to directly measure wrapping web integrity (which is difficult), the sensor measures the position of crop material relative to the bale circumference. This provides precise indirect measurement of wrapping status without the technical challenges of direct web monitoring.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The crop material acts as an intermediary that makes wrapping defects detectable. By monitoring whether crop material protrudes beyond the bale circumference, the system converts the difficult-to-detect wrapping web defects into easily measurable positions of crop material, thereby improving measurement precision while reducing detection difficulty.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 ensures that each bale is properly wrapped by detecting any material protrusions or defects in the wrapping web, preventing damage and rotting, and providing an operator alert for remedial action, thereby maintaining bale integrity and crop quality.

Implementation Method 1

a sensor arranged within the baling chamber; characterised by the sensor sensing the presence of crop material in a region close to and outside the circumference of the bale

Methodology Applied

Scientific EffectLight detection: Photoelectric Effect

Data Source

PatentEP2250875B1Sensor for detection of wrapping on bale

Publication Date: 2019.05.01 CNH IND BELGIUM NV

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AI summary

A baling machine and method for forming a bale is disclosed. A sensor 82 is positioned in the baling chamber and is positioned to sense a region proximate the perimeter of the bale to determine if material is present, thereby determining if the bale is properly wrapped or not. When the bale is not properly wrapped, material is present in the region proximate the perimeter in which the sensor is active, causing the sensor to send a signal indicating that the bale is not properly wrapped.