Auxiliary Power System for Agricultural Baler Flywheel Braking
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Solution Overview
Problem
Agricultural balers face challenges with peak loads on the plunger during compression strokes, leading to high stress on the driveline and flywheel, which can result in inefficient braking and increased operator effort, especially with larger machines where manual brakes are ineffective and require more horsepower.
Innovation Solution
An auxiliary power system (APS) is integrated with the driveline to brake the flywheel rotation, storing energy during braking for later use and reducing peak loads, featuring a power generation device, storage device, and feedback device controlled by an electrical processing circuit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a larger flywheel is used to compensate for higher peak loads during compression strokes, then the momentum helps carry the plunger through peak loads more effectively, but it requires a base unit with a larger horsepower rating to start and drive the flywheel
Solution Approach 1:
The system performs preliminary energy storage during low-load phases (return stroke, pickup, packing) by accumulating energy in the capacitive storage device, preparing energy reserves before the high-demand compression stroke occurs. This allows the flywheel to be smaller while still meeting peak power demands.
Solution Approach 2:
The system changes the operational parameters by using an electric motor with variable speed capability and a capacitive storage device that can rapidly discharge energy. This allows the flywheel to operate at optimized speeds and the motor to adjust its output dynamically, reducing the need for excessive horsepower rating.
2Ease of operation
If a manually operated mechanical brake is used to stop the hood latch, then the brake can stop the flywheel rotation, but it requires a lot of operator effort and is ineffective with larger flywheels
Solution Approach 1:
The system uses the flywheel's own kinetic energy to brake itself through electromagnetic braking. The motor/generator converts the flywheel's rotational energy into electrical energy stored in the capacitive device, simultaneously providing braking action without requiring external manual effort. The system serves itself by using its stored energy to perform the braking function.
Solution Approach 2:
The patent replaces the manual mechanical brake system with an electromagnetic braking system. Instead of using mechanical friction brakes that require manual operation, the system uses the motor/generator to create electromagnetic resistance that brakes the flywheel while converting its energy to electrical form for storage.
3Ease of operation
If the flywheel is made heavier to reduce peak impulse loads on the driveline, then operator comfort is improved, but more horsepower is required to start and drive the flywheel
Solution Approach 1:
The system accumulates energy during low-demand phases in the capacitive storage device, preparing energy reserves before compression strokes. This preliminary energy preparation allows the use of a smaller, lighter flywheel that still provides sufficient momentum during compression, reducing the horsepower requirement while maintaining operator comfort.
Solution Approach 2:
The system uses a variable speed electric motor that can dynamically adjust its output characteristics. The motor can provide high torque at low speeds for starting the flywheel, then operate at optimized speeds during operation. This dynamic control allows a smaller flywheel to achieve the same comfort benefits without requiring excessive horsepower.
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 APS effectively brakes the flywheel without manual operator effort, reduces fuel consumption, and enhances operator comfort by minimizing peak impulse loads transferred to the driveline, allowing safer access for maintenance and utilizing stored energy for auxiliary functions.
Implementation Method 1
an auxiliary power system (APS) is integrated with the driveline to brake the flywheel rotation, storing energy during braking for later use
Implementation Method 2
storing the power
Data Source
AI summary
An agricultural baler includes a plunger reciprocally movable within a main bale chamber during a compression stroke and a return stroke, a flywheel associated with the plunger, and a driveline associated with the flywheel and couplable with a power take-off (PTO) of a traction unit. The baler further includes an APS coupled with the driveline and configured for receiving power from the driveline and storing the power. A PTO indicator provides an output signal indicative of an engagement of the PTO. An electrical processing circuit is coupled with the APS and the PTO indicator, and controls operation of the APS, dependent on the output signal from the PTO indicator.