Baler Plunger Load Estimation via Drive Element Speed
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing baler systems face challenges in accurately measuring plunger load due to high loads and complex calibration requirements, making them expensive and difficult to control effectively.
Innovation Solution
A method and system that estimate plunger load by using the speed of a drive element, with predetermined relationships based on agricultural material characteristics and operational cycles, allowing for indirect measurement and accurate load determination without direct sensors, and using a flywheel for reliable speed measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If load sensors or deformation sensors are used to measure plunger load, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses the drive element as an intermediary component to indirectly measure plunger load. Instead of placing sensors directly on the plunger or bale chamber, the system measures parameters (speed, position, acceleration) of the drive element that is mechanically coupled to the plunger through the flywheel and linkage mechanism. This intermediary approach allows load determination without direct sensor contact with high-load zones, reducing complexity while maintaining measurement accuracy through mathematical relationships between drive element motion and plunger load.
Solution Approach 2:
The patent replaces direct mechanical sensor measurement systems with a computational approach. Instead of using load cells or strain gauge sensors that directly measure force, the system uses sensors to measure drive element motion parameters and then calculates plunger load through predetermined mathematical relationships. This substitution of mechanical measurement with computational analysis reduces device complexity and calibration requirements while maintaining measurement precision.
2Measurement precision
If direct load measurement is implemented, then measurement precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
The drive element serves as an accessible intermediary that is already part of the baler's mechanical structure. By measuring parameters of this existing component rather than installing new sensors in difficult-to-reach locations on the plunger or bale chamber, the system maintains measurement precision while significantly improving ease of manufacture and installation.
Solution Approach 2:
The system uses the baler's own drive element and its inherent motion characteristics to provide the measurement function. The drive element's speed, position, and acceleration naturally correlate with plunger load, so the system leverages the existing mechanical service of the drive element rather than requiring separate measurement infrastructure, thereby simplifying manufacture and installation.
3Measurement precision
If high accuracy measurements are implemented, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex sensor calibration procedures with a computational calibration approach. Instead of calibrating load sensors against known weights or forces, the system establishes predetermined mathematical relationships between drive element motion parameters and plunger load through controlled testing and data collection. This substitution eliminates the need for complex mechanical calibration setups while maintaining high measurement accuracy.
Solution Approach 2:
The system changes the measurement parameters from direct force measurement to motion parameter measurement (speed, position, acceleration). This parameter transformation allows the use of simpler sensors with less stringent calibration requirements while achieving equivalent or superior measurement precision through the mathematical relationships inherent in the baler's mechanics.
4Ease of manufacture
If simple measurement methods are used, then ease of manufacture is improved, but measurement precision deteriorates
Solution Approach 1:
The patent uses simple motion sensors to measure drive element parameters and replaces complex force measurement with computational analysis. This substitution maintains ease of manufacture through simple sensor installation while achieving high measurement precision through predetermined mathematical relationships that account for the mechanical system's dynamics.
Solution Approach 2:
The drive element acts as an intermediary that translates plunger load into measurable motion parameters. This intermediary relationship allows simple sensors to capture information that, when processed through mathematical relationships, yields accurate load measurements, thereby maintaining both simplicity and precision.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Methods and systems for determining the plunger load and use of such methods and systems for controlling such balers are provided. A method and adapted electronic systems for determining a value representative for or an estimate of the load on a plunger (410) of a baler for harvested agricultural material are provided. The method comprises of a step of obtaining (10) the speed of movement of a drive element (403) for the plunger (410), followed by determining (20) the estimate of or value representative for the load on the plunger (410) based upon the obtained speed of movement of the drive element (403).