Baler Brake Device Tension Control via Dynamic Profile
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Solution Overview
Problem
Conventional round balers lack precise control over wrapping material tension, leading to issues such as tearing, recoil, poor spread, and uneven cuts due to manual adjustment of mechanical brake mechanisms, which are complex and time-consuming.
Innovation Solution
A computer-controlled brake device that automatically adjusts tension based on discrete wrapping phases and wrapping material characteristics, using a braking force profile that accounts for the type and amount of wrapping material, with a sensor and input device to input material characteristics and access stored profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment of mechanical brake mechanisms is used, then the device complexity is reduced, but the manufacturing precision of wrapping material tension is insufficient
Solution Approach 1:
The patent replaces manual mechanical brake adjustment with an automated electronic control system that uses a brake actuator controlled by a processor. The processor receives signals from sensors and automatically adjusts the brake force applied to the wrapping material roll, eliminating the need for manual mechanical adjustment while achieving precise tension control.
Solution Approach 2:
The system enables self-adjusting brake mechanism where the brake force is automatically controlled based on sensor feedback and pre-programmed parameters. The processor continuously monitors wrapping material characteristics and adjusts the brake actuator accordingly, allowing the system to self-regulate tension without operator intervention.
2Productivity
If manual adjustment of brake mechanisms is used, then the ease of operation is improved, but the productivity is reduced due to time-consuming adjustments
Solution Approach 1:
The patent replaces manual brake adjustment operations with an automated electronic control system. The processor receives input from sensors about wrapping material characteristics and automatically controls the brake actuator, eliminating time-consuming manual adjustments and significantly improving wrapping process efficiency.
Solution Approach 2:
The system incorporates sensors that continuously monitor wrapping material characteristics and provide feedback to the processor. The processor uses this feedback to automatically adjust brake force in real-time, ensuring optimal tension control without requiring operator intervention or time-consuming manual adjustments.
3Adaptability or versatility
If fixed brake force is applied, then the device complexity is reduced, but the adaptability to different wrapping material characteristics is insufficient
Solution Approach 1:
The patent implements a dynamic brake control system where the brake force is not fixed but continuously adjusted based on wrapping material characteristics. The processor modifies brake actuator commands in real-time according to sensor input about material type, roll diameter, and other variables, enabling adaptation to different materials while managing complexity through software control.
Solution Approach 2:
The system changes brake force parameters dynamically based on wrapping material characteristics. The processor adjusts brake actuator commands according to material type, roll diameter, and other parameters detected by sensors, allowing the same brake mechanism to optimize performance across different wrapping materials without physical reconfiguration.
4Reliability
If high tension is applied to wrapping material, then the reliability of bale confinement is improved, but the manufacturing precision is reduced due to material tearing and recoil
Solution Approach 1:
The system uses sensors to monitor wrapping material characteristics and provides feedback to the processor, which automatically adjusts brake force to optimal levels. This feedback control prevents excessive tension that could cause tearing or recoil while maintaining sufficient tension for reliable bale confinement, achieving both reliability and precision through closed-loop control.
Solution Approach 2:
The patent implements dynamic tension control where brake force is continuously adjusted during the wrapping process based on real-time sensor data. The system transitions from static fixed brake force to dynamic adaptive braking, allowing tension to be optimized for each specific wrapping scenario, preventing material damage while ensuring reliable confinement.
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
Enables precise and consistent tension control throughout the wrapping process, reducing operator frustration and improving the quality of bale wrapping by customizing tension according to material type and availability, resulting in a tighter, more even wrap with reduced assembly time.
Implementation Method 1
a brake device (60) supplying an opposing drag force to the wrapping material roll (31)
Data Source
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AI summary
A method for controlling a brake device (60) of a wrapping material dispensing system (30), further comprising wrapping material roll (31) with wrapping material (41), of a baler (1) whereby the brake device (60) is controlled according to a braking force profile (80, 80', 80") with different levels of braking force in function of the discrete wrapping phases. According to the invention the braking force profile (80, 80', 80") is a function of at least one wrapping material characteristic that is the type of wrapping material (41).