Baler Pickup Drive Clutch Control for Torque Overload Shutdown
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Solution Overview
Problem
Agricultural balers face challenges in protecting the pickup unit from torque overload, leading to potential damage and requiring time-consuming manual intervention for reset, with existing solutions like shear bolts being inefficient and posing safety concerns.
Innovation Solution
A drive system incorporating a PTO shaft, gearbox, pickup drive shaft, sensors, and an electrical processing circuit with a clutch and actuator to disconnect motive power to the reel upon overload, allowing manual rotation without automatic reengagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a radial pin, shear bolt, or overrunning clutch configuration is used to disconnect the driveline during torque overload, then the pickup unit is protected from damage, but the system requires time-consuming manual intervention to reset and reengage power
Solution Approach 1:
The patent replaces traditional mechanical disconnect mechanisms (radial pins, shear bolts, overrunning clutches) with an electrically controlled clutch system. The clutch is actuated by an electric motor that can be controlled through the vehicle's existing electrical system, allowing for automated or remotely controlled engagement and disengagement without manual intervention at the pickup unit.
Solution Approach 2:
The system enables self-service operation by automatically detecting torque overload conditions through sensors and autonomously actuating the clutch to disconnect the driveline. The system can also automatically reengage the clutch when appropriate, eliminating the need for manual reset operations and allowing the operator to continue working without stopping to service the pickup unit.
2Productivity
If operating power is automatically reapplied to the pickup unit after overload, then operational continuity is maintained, but safety concerns arise when the operator is still cleaning out or resetting the pickup unit
Solution Approach 1:
The system incorporates sensors that continuously monitor the operational state of the pickup unit and provide feedback to the control system. The operator can signal through the cab that they are actively working on the pickup unit, and the system responds by preventing automatic reengagement of the clutch. This creates a safe feedback loop where the system adapts its behavior based on real-time operator status.
Solution Approach 2:
The patent introduces an intermediary control system located in the vehicle cab that acts as a mediator between the automated clutch system and the operator. This intermediary allows the operator to communicate their status (working on pickup unit vs. ready for operation) without being physically present at the pickup unit, enabling safe automated operation while respecting operator safety needs.
3Reliability
If traditional disconnect mechanisms are used, then the driveline can be disconnected during overload, but replacing shear bolts and resetting the system is a time-consuming process
Solution Approach 1:
The patent replaces mechanical disconnect mechanisms (radial pins, shear bolts, overrunning clutches) with an electrically controlled clutch system. The clutch is actuated by an electric motor that can be controlled through the vehicle's existing electrical system, allowing for automated or remotely controlled engagement and disengagement without manual intervention at the pickup unit.
Solution Approach 2:
The system enables self-service operation by automatically detecting torque overload conditions through sensors and autonomously actuating the clutch to disconnect the driveline. The system can also automatically reengage the clutch when appropriate, eliminating the need for manual reset operations and allowing the operator to continue working without stopping to service the pickup unit.
Data Source
AI summary
A drive system for an agricultural baler that includes a power take off (PTO) shaft configured for being operably connected in between an agricultural vehicle and the agricultural baler and for supplying motive power to the agricultural baler, a gearbox configured for being mounted on the agricultural baler and connected to the PTO shaft for receiving motive power from the PTO shaft, a pickup drive shaft operably connected to the gearbox and configured for being operably connected to a reel of a pickup unit of the agricultural baler, at least one sensor associated with the pickup drive shaft and configured for sensing a rotational movement of the pickup drive shaft, and an electrical processing circuit operably connected to the at least one sensor. The electrical processing circuit is configured for disconnecting motive power to the reel.