Baler Feedback Control Using Mat Thickness and Bale Growth Rate
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Solution Overview
Problem
Current balers lack real-time feedback on mat thickness and bale growth rate, making it difficult for operators to adjust operating parameters for optimal bale density and efficiency.
Innovation Solution
Implement sensors and a control system in balers to monitor mat thickness and bale growth rate, using these metrics as inputs for controlling ground speed and other operations, such as through-put control and indication systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the speed of the baler is increased to improve productivity, then the ground speed and bale generation rate increase, but the pickup headers become overloaded and pressure-exerting belts are overloaded resulting in clogs and unevenly distributed bale
Solution Approach 1:
The patent implements a feedback control system that monitors mat thickness and bale growth rate in real-time and uses this information to automatically adjust ground speed. Sensors measure the physical attributes of the mat and bale, and the control system processes this data to maintain optimal operating conditions, preventing overload while maximizing productivity.
Solution Approach 2:
The system dynamically adjusts the ground speed of the baler based on real-time monitoring of mat thickness and bale growth rate. Rather than operating at a fixed speed, the baler's ground speed varies automatically to match the actual baling conditions, allowing the system to adapt to changing crop density and maintain optimal performance throughout the field.
2Reliability
If the speed of the baler is decreased to avoid overload, then operational stability is maintained, but the productivity and efficiency of the baler decline
Solution Approach 1:
The feedback control system continuously monitors mat thickness and bale growth rate, and only reduces ground speed when sensors detect conditions that would lead to overload. This allows the baler to maintain high productivity during normal operation while automatically slowing down only when necessary to prevent clogs or uneven bales.
Solution Approach 2:
The system changes the ground speed parameter dynamically based on monitored physical attributes. Rather than operating at a conservative fixed speed, the ground speed is adjusted as a variable parameter that responds to actual baling conditions, allowing the system to achieve both high productivity and operational stability.
3Manufacturing precision
If real-time monitoring of mat thickness and bale growth rate is implemented, then operators can adjust operating parameters for optimal bale density, but the device complexity increases due to additional sensors and control systems
Solution Approach 1:
The patent employs feedback control where sensors monitor mat thickness and bale growth rate, and this information is fed back to automatically adjust ground speed. This closed-loop control system maintains consistent bale density without requiring complex manual intervention, as the system self-regulates based on sensor data.
Solution Approach 2:
The baler system serves itself by automatically adjusting its ground speed based on sensor feedback about mat thickness and bale growth rate. The system monitors its own performance and makes necessary adjustments without external intervention, reducing the need for complex operator input while maintaining precise control over bale density.
Data Source
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AI summary
Described herein are technologies for monitoring bale growth rate and mat thickness as well as technologies for controlling baler (310) operations according to the monitoring of bale growth rate and mat thickness. A baler (310) includes sensors (362,363,364,366) and a control system that uses sensor output as input for its processes. The controller is configured to determine a value of a physical attribute in an operation of a baler (310) based on data received from a sensor. Also, the controller is configured to estimate a mat thickness or a bale growth rate based on the determined value of the physical attribute. The controller is also configured to control an operation of the baler (310) or an operation of a tow vehicle, configured to tow the baler, based on the estimated mat thickness or bale growth rate.