Automatic Sensor Calibration in Baler Measurement Systems
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Solution Overview
Problem
Existing baler systems require laborious mechanical calibration of electro-mechanical sensors to accurately measure bale size and shape, which is cumbersome and often results in improper calibration due to mechanical and electrical tolerances.
Innovation Solution
A sensor arrangement with a control unit that automatically calibrates signals based on known states, converting them to be independent of mechanical and electrical tolerances, allowing for accurate measurement without manual calibration, using sensors that interact mechanically or contactlessly with the bale or conveying elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual mechanical calibration of electro-mechanical sensors is performed, then measurement accuracy can be improved, but the calibration process becomes laborious and time-consuming
Solution Approach 1:
The sensor system performs automatic self-calibration by utilizing the known geometric relationships within the baling chamber. The control unit automatically determines sensor calibration parameters by processing signals from multiple sensors during normal operation, eliminating the need for manual calibration while maintaining measurement accuracy.
Solution Approach 2:
The control unit continuously receives signals from multiple sensors and uses feedback algorithms to automatically adjust and refine calibration parameters. The system compares sensor readings with expected geometric relationships and automatically corrects calibration deviations, ensuring ongoing measurement accuracy without manual intervention.
2Measurement precision
If manual calibration is performed during assembly or service, then initial sensor accuracy can be established, but improper calibration often occurs due to mechanical and electrical tolerances
Solution Approach 1:
The system automatically performs calibration using the inherent geometric constraints of the baling chamber and known relationships between sensors. This self-calibration process eliminates human error and variability, ensuring consistent and reliable calibration results every time the system operates.
Solution Approach 2:
The patent replaces manual mechanical calibration procedures with an automated electronic calibration system. The control unit uses electronic signal processing and mathematical algorithms to determine calibration parameters, substituting the manual mechanical adjustment process with an automated electronic system that is more precise and consistent.
3Adaptability or versatility
If multiple sensors are distributed over the width of the baling chamber to measure bale properties, then comprehensive measurement capability is improved, but the complexity of calibrating each sensor increases
Solution Approach 1:
The calibration processes for multiple sensors are merged into a single unified automatic calibration routine executed by the control unit. The system simultaneously processes signals from all sensors and determines calibration parameters for each sensor based on their known geometric relationships to the baling chamber, reducing overall calibration complexity while maintaining comprehensive measurement capability.
Solution Approach 2:
The control unit performs multiple functions including signal acquisition, calibration parameter determination, and measurement processing for all sensors through a single integrated system. This universal approach allows the same control unit to handle calibration for all sensors distributed across the baling chamber, simplifying the overall calibration process despite the multiple sensors involved.
Data Source
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Figure 3
AI summary
A baler (10) comprises a baling chamber (24) and a sensor arrangement. The sensor arrangement comprises at least one sensor (34) arranged to provide information about a mechanical property of a bale (32) built in the baling chamber (24) and a control unit (50) receiving signals from the sensor (34). The control unit (50) is operable to automatically calibrate the signals from the sensor (34) based upon at least one signal from the sensor (34) received in at least one known state of the sensor (34).