Baler Controller Object Detection for Safe Bale Ejection
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Solution Overview
Problem
Baler implements often eject bales into an unloading zone that may be obstructed by objects, posing a risk of damage to both the bale and the object, due to the operator's limited visibility of the zone.
Innovation Solution
A baler implement equipped with an object detection sensor, such as a Terahertz sensor, and a controller that communicates with the sensor to determine if the unloading zone is clear before initiating bale ejection, using a processor to execute an unloading algorithm that prevents ejection if an object is detected and alerts the operator if necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the operator relies on direct visibility to monitor the unloading zone, then operational simplicity is maintained, but safety and damage prevention are compromised due to blocked view
Solution Approach 1:
An object detection sensor system acts as an intermediary between the operator and the unloading zone, detecting objects that would otherwise be invisible to the operator. The sensor system includes sensors positioned on the baler to detect objects in the unloading zone, and a display device that presents this information to the operator, enabling indirect monitoring of the zone without requiring direct line of sight.
Solution Approach 2:
The system implements feedback by continuously monitoring the unloading zone with object detection sensors and providing real-time information to the operator through a display device. The system can detect objects in the unloading zone and alert the operator, enabling informed decision-making about bale ejection timing and preventing damage from undetected objects.
2Productivity
If the operator ejects bales without verifying the unloading zone is clear, then productivity is maintained, but risk of bale and object damage increases
Solution Approach 1:
The system performs preliminary detection of objects in the unloading zone before bale ejection occurs. The object detection sensors continuously scan the unloading zone and the system can alert the operator or automatically delay ejection until the zone is clear, preventing damage before it occurs while maintaining productivity by enabling faster, more confident ejection decisions.
3Measurement precision
If object detection sensors are installed to monitor the unloading zone, then detection accuracy improves, but device complexity and cost increase
Solution Approach 1:
The object detection sensor system is designed to perform multiple functions: detecting objects in the unloading zone, determining their presence or absence, classifying objects as animals or non-animals, and providing information to the operator through the display device. This multi-functionality justifies the added complexity by delivering comprehensive safety and operational information from a single integrated system.
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 damage-free ejection of bales by preventing ejection when objects are present in the unloading zone, protecting both the bale and any obstructing objects from potential damage.
Implementation Method 1
The Terahertz sensor may be defined as a sensor operable to emit and detect electromagnetic radiation with a frequency between 0.1 Terahertz and 10 terahertz. Terahertz radiation provides the advantage of at least partial penetration into objects
Data Source
AI summary
A baler implement includes a bale formation system operable to form crop material into a bale and eject the bale into an unloading zone. An object detection sensor is positioned to detect data related to the unloading zone. A baler controller is operable to determine if an object is present in the unloading zone or if an object is not present in the unloading zone based on a data signal from the object detection sensor. When an object is not present in the unloading zone, the controller may initiate the bale ejection sequence to eject the bale. When an object is present in the unloading zone, the controller may prevent initiation of the bale ejection sequence to prevent ejection of the bale onto the object.