Baler Constituent Sensing for Bale Density and Wrap Control
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Solution Overview
Problem
Existing baler control systems primarily focus on moisture content and preservative additive adjustment, neglecting other constituent parameters and physical attributes of bales, which affect feeding quality.
Innovation Solution
A baler system equipped with sensors to detect properties like dry matter content, protein, starch, fiber, sugar, fat, and oil content, and a controller to adjust physical characteristics such as compaction, wrap tension, and preservative application based on these properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If only moisture content measurement and preservative adjustment are used, then the control system is simple, but the bale quality and feeding value cannot be fully optimized
Solution Approach 1:
The control system is segmented into multiple independent sensor modules (moisture sensor, protein sensor, fiber sensor, etc.) that detect different constituent properties separately. Each sensor type focuses on a specific parameter, allowing the system to handle complex quality optimization through modular detection rather than a monolithic approach.
Solution Approach 2:
The control system is designed with multi-functionality to handle various constituent properties (moisture content, protein, fiber, starch, sugar, fat, oil) through a unified controller that processes all sensor inputs. This universal approach allows a single control system to optimize multiple quality parameters simultaneously without requiring separate dedicated systems for each parameter.
2Measurement precision
If multiple constituent property sensors are added, then the measurement of bale quality parameters is improved, but the device complexity increases
Solution Approach 1:
The sensor system is divided into specialized modules, with each sensor type (moisture sensor, protein sensor, fiber sensor, starch sensor, sugar sensor, fat sensor, oil sensor) dedicated to detecting a specific constituent property. This segmentation allows for precise measurement of individual parameters while keeping each sensor module relatively simple and manageable.
Solution Approach 2:
The patent replaces complex mechanical analysis methods with optical and electrical sensing technologies. Instead of using mechanical separation or chemical analysis methods that would be physically complex, the system uses sensors that detect constituent properties through optical, electrical, or electromagnetic fields, thereby reducing mechanical complexity while maintaining high measurement precision.
3Manufacturing precision
If multiple bale forming actuators are used to adjust physical characteristics, then the bale quality is improved, but the control system complexity increases
Solution Approach 1:
The bale forming actuators are designed with dynamic adjustability, allowing their operation parameters (such as compression force, wrapping tension, and timing) to be changed in real-time based on sensor inputs. This dynamic control enables the system to optimize bale physical characteristics for different crop types and moisture levels without requiring multiple fixed actuators, thereby reducing overall system complexity.
Solution Approach 2:
The control system optimizes bale physical characteristics by changing operational parameters (compression force, wrapping tension, baling speed, moisture content thresholds) rather than requiring multiple different actuators. The same actuators can perform different functions by adjusting their parameters dynamically, which reduces the number of physical components needed while maintaining high control accuracy.
Data Source
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AI summary
A baler for forming a bale of crop material includes a bale chamber for forming the bale. One or more constituent property sensors are configured to detect one or more constituent properties other than moisture content of the crop material used to form the bale and to generate one or more sensor signals corresponding to the one or more constituent properties. One or more bale forming actuators are configured to adjust one or more physical characteristics of the bale as the bale is formed. A controller is configured to receive the sensor signals and to generate one or more control signals to the one or more bale forming actuators to adjust the one or more physical characteristics of the bale at least in part in response to the one or more sensor signals.