Camera-Based Baler Monitoring System for Ejection and Wrapping
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Solution Overview
Problem
Agricultural round balers face challenges such as bale ejection issues on uneven terrain, mis-feeds in net or twine systems, and the need for rear visibility during backing, which existing solutions like bale push bars and ramps do not adequately address, requiring operators to manually manage multiple functions and risk obstacles.
Innovation Solution
Integration of cameras and sensors in the baler that automatically switch video feeds on a display to monitor bale ejection, net or twine wrapping, crop feeding, and rear visibility, allowing operators to manage these functions without manual intervention while facing forward, using existing equipment and software.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a bale push bar is used to push the bale away from the baler, then the bale can be cleared from the gate, but the bale may roll on uneven terrain and cause problems
Solution Approach 1:
The patent uses a camera to create a visual copy (video feed) of the bale ejection process and displays it on a monitor, allowing the operator to see the bale's position and movement without physically interacting with it. This eliminates the need for mechanical push bars that cause rolling issues on uneven terrain.
Solution Approach 2:
The patent replaces the mechanical bale push bar system with an optical monitoring system consisting of a camera and display. This substitution eliminates the mechanical interaction that causes bales to roll on uneven terrain while providing the operator with visual feedback about ejection status.
2Loss of information
If operators position the tractor perpendicular to the baler to see the bale ejection, then they can monitor the bale, but this reduces operational efficiency and increases workload
Solution Approach 1:
The patent introduces a camera as an intermediary device that captures visual information about the bale ejection process and transmits it to a monitor. This allows the operator to view bale ejection from the normal operating position without needing to reposition the tractor perpendicular to the baler.
Solution Approach 2:
The patent adds a visual dimension to the operator's monitoring capability by providing a video feed on a monitor. This allows the operator to see the bale ejection from the side or rear without physically repositioning the tractor, effectively adding a new dimension to the observation capability.
3Reliability
If net or twine feeding systems are used for wrapping, then bales can be secured, but mis-feeds occur from time-to-time that are difficult to detect
Solution Approach 1:
The patent implements a visual feedback system where a camera monitors the net or twine feeding process and displays the feed on a monitor. This allows the operator to immediately see if a mis-feed occurs, providing real-time feedback that enables quick correction before the problem affects bale wrapping quality.
4Ease of operation
If bale ramps are used to create momentum for bale ejection, then bales can roll clear of the baler, but the bale may roll back into the path on hills
Solution Approach 1:
The patent uses a camera to create a visual record of the bale ejection process, allowing the operator to monitor whether the bale has successfully cleared the gate and is not rolling back into the path, especially on hillside terrain where gravity may cause the bale to return.
5Loss of information
If traditional monitoring methods are used, then operators can see bale ejection, but they cannot simultaneously monitor crop feeding and wrapping systems
Solution Approach 1:
The patent employs a single camera system that can monitor multiple functions including bale ejection, crop feeding, and net/twine wrapping by positioning the camera to capture all these areas. The same display unit shows different views as needed, providing universal monitoring capability without requiring separate systems for each function.
Data Source
AI summary
A system is provided to utilize one or more video cameras placed proximal to one or more operating systems of a round baler and one or more signals on the baler to switch screens on a display to display video during bale ejection, crop feeding, twine or net wrapping and back up. The display switches screens back to other baler application when for example the ejection cycle is completed, the wrapping cycle is completed etc. This allows an operator to visually monitor various baler functions while facing forward and without the need to manually change setting on the display.