Automated Baler Ejection via Sensor-Controlled Teeth
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Solution Overview
Problem
The manual ejection process of bales in large square balers requires operators to exit their tractors, leading to inefficiency, increased training time, and potential damage due to incorrect sequence execution or selection of ejector teeth.
Innovation Solution
A substantially automated baling system that uses sensors and remote operator input to control the ejection procedure, including determining bale length and selecting the correct ejector teeth, allowing for remote operation and reducing manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual ejection procedure is used, then operator can control the process, but operator must exit tractor and perform multiple manual steps which reduces efficiency and increases training time
Solution Approach 1:
The system allows the operator to initiate the ejection process from the tractor seat, and the baler automatically performs the sequence of operations (positioning chamber door, selecting ejector teeth, actuating hydraulic cylinder) without requiring continuous manual intervention. The system serves itself by using sensors to detect bale position and automatically control the ejection sequence.
Solution Approach 2:
The patent replaces the manual mechanical operation system with an automated control system that uses electronic control units, sensors, and hydraulic actuators. The operator's manual actions are substituted by an automated sequence controlled by the ECU, which receives input from sensors and sends commands to hydraulic components.
2Reliability
If manual ejection procedure is used, then operator can inspect and adjust, but operator must remember complex sequence and select correct ejector teeth which increases risk of mistakes and damage
Solution Approach 1:
The system uses sensors to detect the position of the bale and the state of various components, feeding this information back to the ECU. The ECU uses this feedback to automatically adjust the ejection sequence, select the appropriate ejector teeth, and control the hydraulic cylinder actuation, eliminating the need for the operator to remember complex sequences.
Solution Approach 2:
The ECU acts as an intermediary between the operator and the complex ejection mechanism. The operator simply initiates the process, and the ECU mediates by automatically managing the sequence of operations, selecting ejector teeth based on sensor input, and controlling the hydraulic system, thereby shielding the operator from complexity.
3Productivity
If automated ejection is implemented, then efficiency and accuracy improve, but system complexity increases with sensors and control units
Solution Approach 1:
The ECU serves multiple functions: it controls the chamber door positioning, selects the appropriate ejector teeth based on bale position, actuates the hydraulic cylinder, and monitors the ejection process through sensor feedback. This multi-functionality consolidates what would otherwise require separate control systems into a single integrated unit.
Solution Approach 2:
The patent merges the control of multiple ejection components (chamber door, ejector tooth selection, hydraulic cylinder) into a single automated sequence managed by the ECU. The sensor system, control unit, and actuator systems are combined into an integrated automated ejection system that operates as a unified whole.
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
The automated system improves efficiency by eliminating the need for physical inspection and manual selection, minimizing the risk of damage to finished bales and reducing training requirements, while ensuring accurate ejection of bales without engaging unfinished ones.
Implementation Method 1
The ejector teeth are secured to a carriage that is moveable in both the forward direction (i.e., away from the discharge outlet) and the rearward direction (i.e., toward the discharge outlet) within the forming chamber by a hydraulic cylinder.
Implementation Method 2
An ejector system may also be used to eject the finished bale. The ejector system includes ejector teeth that can be manually selected to project into the forming chamber to engage the finished bale.
Implementation Method 3
The growth of the unfinished bale provides a force that pushes the finished bale toward the discharge outlet.
Data Source
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AI summary
A system for ejecting a bale from a baler, wherein the ejection process is controlled by a control unit (58) with input from various sensors and from a remote operator located on a tractor. The control unit automatically positions a chute (44), controls a power take-off from the tractor, depressurizes and opens a chamber door 72), ties the bale, selects and causes ejector teeth (40) to project into a forming chamber to engage the bale, causes the ejector teeth to move toward a discharge outlet (70) such that the engaged bale moves with them toward and through the discharge outlet, and determines when the bale has fully ejected from the baler. The remote operator may choose to eject only the bale or to eject the entire contents of the forming chamber, and if the former, the control unit determines the bale's length and selects a subset of the ejector teeth that corresponds to that length.