Baler NIR Sensor Temperature Calibration
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Solution Overview
Problem
Current methods for evaluating the quality of bales of plant material are inaccurate due to variations in moisture content, calibration issues between laboratories, and the need for on-site testing, which affects the value and traceability of the material.
Innovation Solution
A system and method that incorporates a near-infrared testing system calibrated using a temperature-adjusted sample within a baler machine, allowing for real-time evaluation of bale quality by measuring and adjusting the temperature of the crop sample to match the calibration temperature, and assigning a weighted average quality value based on subunit properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a core sample is taken from one or more bales and sent to a third-party laboratory for NIR testing or wet chemistry testing, then the properties of the plant material can be determined, but the time required for the sample to reach the laboratory, the testing and analysis to be performed, and the results to be returned is long
Solution Approach 1:
The patent introduces an intermediary device - a portable NIR spectrometer and temperature control system - that acts as a mediator between the bale sample and the laboratory analysis. This intermediary enables on-site quality assessment, eliminating the time-consuming sample transport and waiting period while maintaining measurement accuracy through calibrated spectral analysis.
Solution Approach 2:
The patent replaces the mechanical system of physical sample transport to a laboratory with an optical/electronic system - a portable NIR spectrometer that can perform analysis in-situ. This substitution eliminates the need for physical sample movement while achieving the same analytical goal, thereby resolving the time loss contradiction.
2Productivity
If a core sample is taken from one or more bales to represent the quality of many other bales, then the properties can be assessed, but the sample from one or even several bales may not be representative of the quality of the many other bales from the same field
Solution Approach 1:
The patent applies universality by using the same portable NIR testing system on multiple bles across the field, rather than relying on a single core sample to represent all bales. This multi-functional application of the testing device ensures each bale is assessed individually, maintaining both productivity through rapid testing and measurement precision through direct observation of each bale's actual quality.
Solution Approach 2:
Rather than taking a single core sample (partial action) that may not be representative, the system performs excessive action by testing multiple bales individually. This ensures that the quality assessment covers sufficient variability in the batch, improving representativeness while the rapid nature of NIR testing maintains productivity.
3Ease of operation
If the NIR sensor is mounted in a feeding mechanism or compression chamber of the baler, then on-site testing can be performed, but the amount of time the NIR sensor is exposed to a given portion of the plant material will vary, resulting in property values that do not reflect the actual overall quality of the bales
Solution Approach 1:
The patent implements feedback by using the NIR sensor to continuously monitor plant material properties during the baling process, with the system adjusting or recording data based on real-time measurements. This feedback loop ensures that despite varying exposure times, the property values accurately reflect the actual quality of the bales through continuous verification and correction.
Solution Approach 2:
The system applies dynamics by making the NIR sensor exposure and measurement process adaptive rather than static. The sensor adjusts its measurement parameters or the system compensates for varying exposure times dynamically, ensuring that property values remain accurate despite the changing conditions in the feeding mechanism or compression chamber environment.
4Adaptability or versatility
If different calibration models are used by different labs using different wet chemistry testing procedures, then testing can be performed, but the results from one lab might vary as much as 30% to 50% compared to another lab
Solution Approach 1:
The patent applies parameter changes by standardizing the calibration parameters and spectral ranges of the portable NIR spectrometer. Rather than allowing different labs to use different calibration models and wet chemistry procedures (which cause 30-50% variation), the system maintains consistent spectral parameters, measurement conditions, and calibration standards, thereby ensuring measurement precision and result consistency across different locations and operators.
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
This approach provides more accurate and reliable on-site evaluation of bale quality, reducing the need for laboratory testing and ensuring consistency in quality assessment, while improving traceability and value representation of the plant material.
Implementation Method 1
a near-infrared testing system configured to receive near-infrared radiation reflected by the plant material in at least one bale of the plurality of bales and to analyze the near-infrared radiation
Implementation Method 2
a temperature sensor configured to measure a temperature of the crop sample
Implementation Method 3
a temperature alteration mechanism configured to adjust the temperature of the crop sample so that the temperature of the crop sample matches the calibration temperature of the calibration sample
Data Source
AI summary
A baler includes a near-infrared testing system configured to receive near-infrared radiation reflected by plant material in a bale and to analyze the near-infrared radiation and generate evaluation data reflecting one or more properties of the plant material. The near-infrared testing system is calibrated using a calibration sample at a calibration temperature. A temperature sensor measures a sample temperature of a crop sample of the plant material and a temperature alteration mechanism adjusts the sample temperature of the crop sample so that the sample temperature matches the calibration temperature of the calibration sample before the near-infrared testing system receives the near-infrared radiation reflected by the plant material. A computer receives and combine the evaluation data of the plant material to produce overall evaluation data reflecting one or more overall properties for the at least one bale of the plurality of bales, and assign the overall evaluation data to the bale.