Baler Brake System for Flywheel Position Control
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Solution Overview
Problem
Large towable square balers with heavy flywheels face challenges in starting due to high inertia, leading to potential tractor engine stalling or safety mechanism deactivation, and when stopped, the flywheel can unintentionally rotate due to gravity, causing unsafe plunger movement.
Innovation Solution
A brake system with a sensor and control unit that stops the flywheel's crank in predefined positions based on crop material presence or absence, using a disc brake system to manage the braking force and prevent unintended plunger movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a heavy flywheel with high inertia is used to overcome peak loads during compression, then the baler can deliver high energy for peak loads, but the PTO shaft cannot provide sufficient torque to bring the flywheel up to steady speed during start-up
Solution Approach 1:
The brake system is activated before start-up to position the crank at a favorable launch position where the plunger is near the baling chamber entrance. This preliminary positioning ensures that when the flywheel starts rotating, it encounters minimal resistance during the first compression cycle, enabling successful start-up without requiring excessive starting torque from the PTO shaft
2Ease of operation
If the baler is stopped with the crank in a favorable position for restart, then start-up is easier, but gravity causes the crank to automatically rotate to an unfavorable position when the baling chamber is empty
Solution Approach 1:
A sensor detects the crank position and provides feedback to the control system. When the baling chamber is empty and the crank approaches a favorable position, the control system activates the brake to stop the crank precisely at the desired position, preventing gravity-induced rotation to unfavorable positions. This closed-loop control maintains position stability while preserving start-up ease
Solution Approach 2:
The brake system applies a counteracting force to gravity before the crank can rotate to an unfavorable position. By detecting the approaching favorable position and applying the brake in advance, the system prevents the harmful gravitational rotation that would occur if the crank were left unchecked
3Force
If the crank stops in a position where the plunger is at the distal position during compression, then compression force is maximized, but the plunger may unintentionally move when the baling chamber is empty
Solution Approach 1:
Different stop positions are defined based on the operational state of the baling chamber. When crop material is present, the crank stops at the distal position to maximize compression force. When the chamber is empty, the crank stops at a safe position that prevents unintentional plunger movement. This localized adaptation of stop positions resolves the contradiction between compression effectiveness and safety
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
Ensures safe and controlled operation by maintaining the flywheel in favorable positions, preventing unintentional plunger movement and reducing start-up issues, thus enhancing operational safety and reliability.
Implementation Method 1
a brake system adapted for providing a brake force for decelerating the flywheel
Implementation Method 2
the flywheel and crank tend to automatically rotate to an unfavorable condition because of the gravity force acting on the heavy crank
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention relates to an agricultural baler (2) comprising a shaft (14), a flywheel (16) connected to the shaft (14), a plunger (20) connected to the flywheel (16) via a crank (50), a brake system (60) adapted for providing a brake force for decelerating the flywheel (16) depending on a brake control signal (S), a sensor system (77) for providing first sensor data (T) indicative of presence of crop material in the baling chamber (6); and a brake control system (61) arranged for receiving the first sensor data (T), and connected to the brake system (60) for providing the brake control signal (S), the brake control system (61) comprising a control unit (80) provided with an algorithm for determining the brake control signal (S) for stopping the crank (50) in a either one of a plurality of predefined stop positions depending on the received first sensor data (T).