Baler Ramp Sensor for Timed Bale Release Detection
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Solution Overview
Problem
Existing balers face challenges in accurately determining bale weight and density, particularly due to field inclinations, and in ensuring proper ejection and wrapping of bales, leading to potential inaccuracies and inefficiencies.
Innovation Solution
A baler system equipped with a weighing system, inclinometer, and control unit that calculates corrected bale weight in real time, adjusts density based on humidity, and ensures precise ejection and wrapping through sensors and a control unit that monitors ramp position and film application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a weighting system is used to detect bale weight, then weight measurement capability is provided, but measurement precision deteriorates due to field inclination effects
Solution Approach 1:
An inclinometer is introduced as an intermediary device to measure the inclination angle of the baler. The control unit uses this inclination data to calculate a correction factor that compensates for the gravitational component affecting the weight sensors, thereby eliminating the harmful effect of field inclination on weight measurement precision.
Solution Approach 2:
The system changes the measurement parameter from raw weight sensor output to corrected weight by applying a mathematical transformation. The control unit processes the weight data through a correction algorithm that accounts for inclination angle, converting the affected measurement into an accurate representation of actual bale weight.
2Measurement precision
If bale weight is detected after ejection using existing methods, then weight information is obtained, but productivity is reduced due to inability to adjust bale weight in real-time
Solution Approach 1:
The weight sensors and control unit continuously monitor the weight of crops in the forming chamber during the baling process, before the bale is ejected. This preliminary weight detection enables the operator to assess whether the bale is approaching the target weight and make timely decisions about when to open the tailgate, ensuring consistent bale weights without delaying the ejection cycle.
3Ease of operation
If a sensor on the ramp is used to detect bale ejection position, then ejection monitoring is provided, but reliability deteriorates due to false measurements
Solution Approach 1:
The control unit continuously receives feedback from the ramp sensor regarding the position of the ramp and the presence of the bale. By monitoring the temporal sequence of sensor signals and correlating them with the known motion cycle of the ramp, the system can distinguish between genuine bale ejection events and false triggers caused by ramp movement alone, thereby improving detection reliability.
4Measurement precision
If humidity sensors are mounted on the baler to detect bale humidity, then humidity control capability is provided, but device complexity increases due to mounting and maintenance difficulties
Solution Approach 1:
The humidity sensor is positioned to contact the bale directly during the wrapping process, allowing the bale itself to present the measurement target to the sensor. This self-service arrangement eliminates the need for complex mounting structures and facilitates easy maintenance, as the sensor naturally interfaces with the bale during normal operation without requiring additional adjustment mechanisms.
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 accurate, real-time bale weight and density control, ensuring consistent bale quality and reducing the risk of mis-ejection and disintegration, enhancing operational efficiency and reliability.
Implementation Method 1
a weighing system, configured to detect weight data representative of a weight of the forming chamber
Implementation Method 2
an inclinometer, configured to detect inclination data representative of an inclination angle of the baler with respect to a horizontal plane
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
A baler (1) comprises: a frame (10), including a forming chamber (101), configured to receive crops and to form a bale; a feeding assembly (11), configured to collect the crops form the ground and to feed the crops into the forming chamber (101); a tailgate (12), movable between a closed position, wherein the forming chamber (101) is closed, and an open position, wherein the forming chamber (101) is open to an external environment for discharging the bale; a control unit (16); a ramp (13), configured to lay down the bale on the ground and movable between a raised position and a discharge position, for allowing a release of the bale; a ramp sensor (21), responsive to a change of position of the ramp (13) from the raised position to the discharge position and vice versa. The control unit (16) is connected to the ramp sensor (21) for assessing a release of the bale, responsive to a change of the ramp position from the raised position to the discharge position and, in succession, from the discharge position to the raised position. The control unit comprises a timer.