Agricultural Baler Load Sensing for Component Life Estimation
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Solution Overview
Problem
Conventional agricultural balers lack a method to accurately assess the remaining life of their components, making it difficult for users to determine the consumed life or remaining life, especially when baling different crops or at varying densities.
Innovation Solution
A system that includes sensors to measure loads applied to the plunger and associated components, a controller to estimate life states, and generate output signals regarding life consumed or remaining, considering factors like bale density, crop type, and operating conditions, with optional graphical user interfaces for displaying life state information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional agricultural balers are used without load monitoring systems, then the device complexity is low, but the ability to assess component life and reliability is insufficient
Solution Approach 1:
The patent replaces manual inspection and estimation methods with automated sensor-based load measurement systems. Load cells and sensors electronically measure forces applied to the plunger and transmit data to a controller, substituting mechanical judgment with precise electronic measurement to assess component life
Solution Approach 2:
The patent introduces a controller as an intermediary that receives load data from sensors, processes the information, and generates life state estimates. This intermediary component bridges the gap between raw sensor data and meaningful reliability assessments, enabling automated decision-making about component condition
2Measurement precision
If load sensors and life estimation systems are added to balers, then the reliability and measurement precision improve, but the device complexity increases
Solution Approach 1:
The controller serves multiple functions: it monitors load forces, counts crank arm revolutions, determines life states, and can interface with graphical user interfaces. By making the controller a multi-functional component, the system achieves high measurement precision without proportionally increasing overall system complexity
Solution Approach 2:
The system automatically monitors its own operational parameters and assesses component life without requiring external intervention. The load sensors continuously measure forces, and the controller autonomously processes this data to provide real-time feedback on component condition, enabling self-diagnosis and self-monitoring
3Loss of information
If the baler operates with different crops and densities without monitoring, then the productivity is high, but the loss of information regarding life consumption occurs
Solution Approach 1:
The patent implements a feedback system where load sensors continuously measure forces during baling operations, and the controller processes this data to provide real-time information about life consumption. This feedback loop allows operators to see the impact of different crops and densities on component life without slowing down production, enabling informed decisions while maintaining productivity
Solution Approach 2:
The system performs preliminary assessment of life consumption during the baling process itself, rather than requiring post-operation analysis. By continuously monitoring loads and calculating life state changes in real-time, the system provides advance warning about component condition before failure occurs, allowing proactive maintenance scheduling
Data Source
AI summary
Systems and methods for estimating remaining life in an agricultural baler comprise a reciprocating plunger for compressing gathered agricultural material into bales. A first sensor generates signals corresponding to force applied to the reciprocating plunger and any baling components configured to at least partially carry forces applied to the plunger. Based on input signals from at least the first sensor, forces associated with a load are recorded and a life state is estimated for the reciprocating plunger and/or at least one associated baler component. An output signal is then generated corresponding to the one or more estimated life states. In an embodiment, an input signal from a second sensor indicates completion of a bale, wherein an amount of life consumed from the plunger and/or baling components is determined in association with the bale, based at least in part on operating conditions of the baled material.