Electronic Feeder Control for Square Baler Reliability
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Solution Overview
Problem
The existing feeder system in large square balers is prone to malfunction due to dust and debris restricting the free movement of the push-pull cable, which affects the accurate measurement of crop material volume and proper activation of the feeder fork, leading to improper operation.
Innovation Solution
A baler implement with a crop sensor and a processor-controlled feeder system that uses a rotary position sensor and actuator to determine when the crop material reaches a set threshold, allowing the feeder fork to move from a retracted to an extended position electronically, eliminating the need for a push-pull cable and improving reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a push-pull cable is used to connect the plate and lock for automatic feed stroke operation, then the feeder fork can be controlled to move only when desired crop material quantity is accumulated, but dust and debris restrict free movement of the cable causing system malfunction
Solution Approach 1:
The patent replaces the mechanical push-pull cable system with an electronic sensing and control system. A crop sensor detects crop material quantity and sends signals to a controller, which then actuates the feeder fork electronically. This substitution eliminates the mechanical cable that was vulnerable to dust and debris interference, thereby improving reliability in harsh agricultural environments.
Solution Approach 2:
The patent introduces electronic sensors and controllers as intermediaries between the crop material measurement function and the feeder fork actuation. Instead of direct mechanical coupling via cable, the system uses electrical signals transmitted through protected conduits or wireless communication, isolating the control mechanism from environmental contaminants like dust and debris.
2Productivity
If the feeder fork moves with every plunger stroke (1:1 continuous feed mode), then crop material is continuously moved into compression chamber, but crop material volume measurement and controlled feeding cannot be achieved
Solution Approach 1:
The patent implements a feedback control system where a crop sensor continuously monitors the quantity of crop material accumulated in the pre-compression chamber. This measurement feedback is sent to a controller that decides when to actuate the feeder fork, enabling precise control over feeding timing and quantity while maintaining productivity through automated decision-making.
Solution Approach 2:
The patent makes the feeder fork operation dynamic and adaptive rather than fixed. The system can switch between different feed modes (continuous 1:1 or volume-controlled automatic feed) and adjusts feeder activation timing based on real-time crop material quantity measurements, optimizing both productivity and measurement precision for different operating conditions.
Data Source
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AI summary
The present invention relates to a baler implement (20) includes a crop sensor (58) operable to sense data related to a quantity of the crop material accumulated within a pre-compression chamber (36). A baler controller (60) is operable to execute a feeder control algorithm (82) to receive a quantity signal from the crop sensor. When the quantity signal indicates that the quantity of the crop material accumulated within the pre-compression chamber is equal to or greater than a quantity threshold, the baler controller may then signal an actuator (76) to release a lock (72), thereby allowing a feeder fork (40) to move from a retracted position to an extended position thereof to move the crop material from the pre-compression chamber to a compression chamber (32) for baling.