Agricultural Baler Bale Weight Estimation Without Load Cells

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Solution Overview

Problem

Existing crop bale weighing systems in agricultural balers are sensitive and expensive, and measurement errors occur when the baler is tilted or on a slope, requiring costly compensation measures for accurate weighing.

Innovation Solution

A method and device that estimate bale weight using existing sensors on the baler, such as moisture, bale density, and diameter, without a weighing system, by analyzing relationships between these parameters and actual weights during a training phase, allowing for precise weight determination in the operating phase without additional equipment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a weighing system with force measuring bolts or load cells is used to measure bale weight, then measurement accuracy is improved, but device cost and complexity increase significantly

Engineering Contradiction:

Improvebale weight measurement accuracyVSAvoidweighing system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical weighing system (force measuring bolts, load cells) with a computational model that uses sensor data from the existing baler system. The bale weight is calculated using the formula W = ρ × V × (1 - M/100) × C, where sensor measurements of crop density, bale volume, and moisture content substitute for direct mechanical weight measurement, eliminating the need for expensive weighing components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent creates a virtual model of the bale weight determination process that replicates the function of physical weighing systems. By using the relationship between crop parameters (density, volume, moisture) and weight, the system creates a computational copy of the weighing function that achieves similar accuracy without physical weighing equipment.

Inventive Principle:

Principle #26Copying

2Measurement precision

If weighing systems are installed on the baler to determine bale weight, then bale weight can be measured, but the system becomes sensitive to tilting and slope conditions requiring additional compensation measures

Engineering Contradiction:

Improvebale weight measurementVSAvoidoperation on slopes and inclines

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The patent replaces the mechanical weighing system that is sensitive to tilting with a computational calculation method. By using the formula W = ρ × V × (1 - M/100) × C based on crop parameters rather than direct force measurement, the system eliminates sensitivity to baler orientation and slope conditions, enabling accurate weight determination in varying terrain.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If expensive compensation measures are implemented to allow accurate weighing on tilted surfaces, then measurement accuracy is maintained, but device cost increases

Engineering Contradiction:

Improveweighing accuracy on slopesVSAvoidcompensation system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent eliminates the need for compensation systems by replacing mechanical weighing with computational calculation. The formula-based approach using crop parameters inherently compensates for tilting effects, as it does not rely on force measurements that are affected by gravity vector changes during operation on slopes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 approach achieves high accuracy in bale weight estimation with less than 10% deviation, eliminating the need for expensive weighing systems and compensation measures, and enabling cost-effective and robust bale weight determination even on slopes or inclines.

Implementation Method 1

a sensor system for detecting the moisture content of the crop stream received by the baler

Methodology Applied

Scientific EffectMoisture detection:

Implementation Method 2

for detecting the bale density of the crop bale in the bale forming chamber

Methodology Applied

Scientific EffectDensity measurement:

Implementation Method 3

for detecting the bale diameter

Methodology Applied

Scientific EffectDimensional measurement:

Data Source

PatentEP4494453A1Agricultural baler and method and apparatus for determining bale weight of a bale of crop formed therefrom

Publication Date: 2025.01.22 ALOIS POETTINGER MASCHFAB

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AI summary

The present invention relates to determining the bale weight of a crop bale formed by an agricultural baler. The invention relates, on the one hand, to a method and a device for determining the bale weight using various sensor signals from sensors located on the baler, and on the other hand, to the baler itself. According to the invention, the baler has sensors for detecting the moisture content of the crop flow taken in by the baler, for detecting the bale density of the crop bale in the baling chamber, and for detecting the bale diameter.