Baler Piston Printed Sensors for Compaction Force Monitoring
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Solution Overview
Problem
Existing agricultural balers face high compaction forces that can cause damage due to uneven crop distribution, necessitating robust and expensive force sensors that are difficult to maintain.
Innovation Solution
Implementing printed sensors on the piston and channel walls to detect compaction forces, utilizing a non-conductive matrix with embedded conductive particles that change conductivity based on deformation, allowing for easy access and cost-effective monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If robust measuring bolts are used to detect pressing force, then measurement reliability is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces mechanical strain gauges (measuring bolts) with a printed sensor system that uses electrical conductivity changes in a printed conductive layer to detect deformation. This substitution eliminates the need for robust mechanical sensors while maintaining measurement capability through electrical signal detection.
Solution Approach 2:
The printed sensor is designed as a cost-effective, easily replaceable component that can be printed directly onto the piston or connecting rod. If damaged, the entire sensor can be replaced by reprinting, eliminating the need for expensive repairs of robust mechanical sensors.
2Reliability
If robust measuring bolts are used to detect pressing force, then measurement reliability is improved, but ease of repair deteriorates
Solution Approach 1:
The printed sensor is designed as a cost-effective, easily replaceable component that can be printed directly onto the piston or connecting rod. If damaged, the entire sensor can be replaced by reprinting, eliminating the need for expensive repairs of robust mechanical sensors.
Solution Approach 2:
The patent replaces mechanical strain gauges (measuring bolts) with a printed sensor system that uses electrical conductivity changes in a printed conductive layer to detect deformation. This substitution eliminates the need for robust mechanical sensors while maintaining measurement capability through electrical signal detection.
3Ease of operation
If surface mounting sensors are used, then ease of operation is improved, but measurement precision deteriorates
Solution Approach 1:
The patent changes the physical state of the sensor from a mechanical strain gauge to a printed conductive layer that detects deformation through electrical conductivity changes. This parameter change allows the sensor to be mounted on the surface for easy access while maintaining high measurement precision through electrical signal detection.
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
Enables simpler and more economical monitoring of compaction forces, reducing the risk of damage and facilitating easy sensor maintenance.
Implementation Method 1
A sensor with a printed layer comprising a non-conductive matrix and conductive particles embedded in the matrix is particularly suitable for the present invention. By making contact with each other at certain points, the conductive particles impart a finite electrical conductivity to the layer. The sensitivity of such a sensor to deformation is based on the fact that the contacts between the conductive particles become less tight when the layer is stretched and the particles within it are pulled apart, or that the particles are pressed against each other and the contacts become tighter when the layer is compressed.
Data Source
Figure 1
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AI summary
An agricultural baler (1) comprises a press channel (8), a piston (9) movable in the press channel (8) to exert a pressing force on material located in the press channel (8) and at least one sensor (20) for detecting a measured quantity associated with the exerted pressing force, which is designed as a printed sensor.