Agricultural Baler Auxiliary Power System Peak Load Management
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Solution Overview
Problem
Agricultural balers face challenges in managing large intermittent loads during operation, leading to increased peak loads on the plunger, which can result in engine lugging and the need for larger flywheels that require higher horsepower ratings.
Innovation Solution
An auxiliary power system (APS) is implemented that scavenges power from linearly movable components of the baler, storing it for subsequent use to flatten out load requirements and power auxiliary components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a larger flywheel is used to compensate for higher peak loads on the plunger, then the plunger can carry through peak loads more effectively, but the base unit requires a larger horsepower rating to start and drive the flywheel
Solution Approach 1:
The auxiliary power system performs preliminary action by storing energy in advance during low-load periods. The system captures and stores energy when the baler operates during non-peak phases, preparing energy reserves before peak load conditions occur, thereby enabling the plunger to carry through peak loads without requiring a larger base unit horsepower rating
Solution Approach 2:
The invention changes the energy storage parameter from traditional mechanical flywheel mass to an auxiliary power system with controllable energy storage capacity. This parameter change allows energy to be stored and released on demand, providing peak load compensation without the proportional increase in base unit horsepower that would be required by a larger mechanical flywheel
2Force
If a heavier flywheel is used to provide momentum during compression strokes, then peak loads are better managed, but the device complexity and size increase
Solution Approach 1:
The invention substitutes the traditional mechanical flywheel system with an auxiliary power system that uses energy storage and conversion mechanisms. Instead of relying on the mass and rotational inertia of a heavy mechanical flywheel, the system uses controllable energy storage devices to provide the necessary force and momentum during compression strokes, thereby reducing device complexity and size while maintaining force output
3Reliability
If the base unit engine is oversized to handle peak loads, then lugging is prevented, but energy efficiency decreases during normal operation
Solution Approach 1:
The auxiliary power system performs preliminary energy storage during low-load normal operation phases, capturing excess energy that would otherwise be wasted. This stored energy is then deployed during peak load conditions, allowing the base unit engine to operate at optimal efficiency levels during normal operation while still having sufficient power available during peak demands
Solution Approach 2:
The system implements periodic energy storage and release cycles that synchronize with the baler's operational pattern. During normal operation phases, energy is stored in the auxiliary system; during peak load phases, energy is released to supplement the base unit engine. This periodic action allows the engine to maintain high efficiency during normal operation while preventing lugging during peak loads
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 APS effectively manages peak loads by storing energy during off-peak periods and using it to reduce mechanical stress on the driveline, allowing for smaller flywheel sizes and more efficient operation, while also powering auxiliary systems without heat generation.
Implementation Method 1
an auxiliary power system (APS) is implemented that scavenges power from linearly movable components of the baler, storing it for subsequent use to flatten out load requirements
Data Source
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AI summary
An agricultural baler (10) includes a flywheel (44), a driveline (50) associated with the flywheel (44) and couplable with a power take-off (PTO) of a traction unit, and a movable component (100) which is driven directly or indirectly by the driveline (50) and movable in a linear and/or rotational manner. The baler is characterized by an auxiliary power system (52) coupled with the movable component (100). The auxiliary power system (52) is configured for receiving power from the movable component (100) and storing the power.