Baler Drive Chain Tension Sensing for Bale Chamber Power Tracking
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Solution Overview
Problem
Existing balers lack affordable and accurate methods for monitoring power consumption and material quantity in real-time, leading to inefficient operation and premature wear of components, and there is a need for optimizing ground speed to balance material delivery and power usage.
Innovation Solution
A method and system that monitor tension in an endless drive transmission element to determine power drawn by the baler's pressing means and material quantity, using sensors to track elastic stretch and displacement, and calculate the optimum ground speed based on power and material delivery rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If torque measuring instruments are used to monitor power drawn by the bale chamber, then power monitoring accuracy is improved, but device cost increases significantly
Solution Approach 1:
The patent introduces an intermediary element (the drive belt) that transmits mechanical power from the bale chamber to the monitoring system. By measuring tension in this intermediary belt rather than directly measuring torque at the power source, the system achieves power monitoring capability through a simpler, more cost-effective mechanism that avoids expensive torque sensors while maintaining measurement functionality.
2Measurement precision
If existing material quantity determination methods are used, then material quantity information is obtained, but measurement accuracy is poor or the system is cumbersome and expensive
Solution Approach 1:
The patent makes the drive belt tension monitoring system multi-functional by using it for both power consumption monitoring and material quantity determination. The same tension measurements that indicate power drawn by the bale chamber also correlate with material quantity, eliminating the need for separate sensing systems and reducing overall device complexity while maintaining measurement accuracy for both parameters.
3Productivity
If baler operates at high power levels to increase productivity, then bale formation speed is improved, but component wear increases and working life decreases
Solution Approach 1:
The patent implements a feedback mechanism that continuously monitors drive belt tension to determine real-time power consumption levels. This information can be used to optimize operating conditions, alert operators to excessive power draw that indicates component issues, and prevent operation in regimes that would cause premature wear, thereby extending component life while maintaining productivity when appropriate.
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 provides real-time monitoring of power consumption and material quantity, optimizing baler operation to extend component life, improve efficiency, and ensure proper bale formation, while allowing for automatic adjustment of ground speed for optimal performance.
Implementation Method 1
monitors a value of a characteristic indicative of tension in an endless drive transmission element through which power is being drawn by the pressing means
Data Source
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AI summary
A fixed chamber baler (2) comprises a bale chamber (10) defined by bale rotating rollers (17) driven by a drive transmission system (49) comprising a driven sprocket (50) driving first and second driven sprockets (52, 54) by a main drive chain (53). A tensioning sprocket (80) carried on a pivotally mounted carrier arm (83) is urged by a tension spring (95) into engagement with a slack leg (84) of a main drive chain (53). An angle sensor (105) coupled by a link member (107) to the carrier arm (83) monitors the angular displacement of the carrier arm (83) from a datum position and produces a signal indicative of the angular displacement of the carrier arm (83) from the datum position. The microcontroller is programmed to determine the power being drawn by the bale rotating rollers (17) to rotate the material in the bale chamber (10) from the degree of elastic stretch in the main drive chain (53) from an equation y = m1x + c1 where y is the value of the power and x is the value of the signal read from the angle sensor (105) and m1 and c1 are constants determined empirically. The current quantity of material in the bale chamber (10) is determined from a linear equation, a power law equation or a polynomial equation. The optimum ground speed of the baler is determined by multiplying the current ground speed by the optimum rate at which crop material should be delivered into the bale chamber (10), and dividing the product by the current rate at which the crop material is being delivered into the bale chamber (10).