Baler Sensor Placement for Density Measurement
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Solution Overview
Problem
Existing agricultural baler systems face challenges in accurately determining the density of forage material and load on the plunger, leading to inaccuracies in bale formation due to tolerance in gearbox alignment and varying wad sizes, which current sensor placements and systems fail to address effectively.
Innovation Solution
The placement of sensors on structural members within the bale chamber to detect deflection, providing signals that include load and density information, allowing for precise control of bale density through a control system that adjusts the positioning of these members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is placed on the plunger drive train to determine load and density, then load information can be obtained, but measurement precision deteriorates due to gearbox alignment tolerance and drive train losses
Solution Approach 1:
The invention extracts the measurement function from the plunger drive train and relocates it to the bale chamber walls. By placing sensors directly on the bale chamber walls to measure deflection caused by the bale, the system eliminates the intermediate drive train components (gearbox, belts, etc.) that introduce measurement errors, thereby improving both measurement precision and reliability
Solution Approach 2:
The invention introduces the bale chamber walls as an intermediary measurement element. Instead of measuring plunger load directly through the drive train, the system measures the deflection of the bale chamber walls caused by the bale pressure, providing a more direct and accurate measurement of bale density
2Measurement precision
If a sensor on the plunger is used to monitor load, then density information can be estimated, but measurement precision deteriorates due to varying wad sizes altering the signal
Solution Approach 1:
The invention removes the measurement function from the plunger system where it is affected by varying wad sizes and timing, and relocates it to the bale chamber walls. The wall deflection sensors provide a continuous measurement that is independent of wad size variations, improving measurement precision while maintaining adaptability to different baling conditions
Solution Approach 2:
The sensors on the bale chamber walls continuously monitor deflection throughout the entire baling cycle, providing preliminary and continuous data about bale formation. This allows for real-time adjustments and ensures accurate density measurement regardless of when during the cycle the measurement is taken
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
This approach enables accurate determination of bale density and load, allowing for improved precision in bale formation and easy configuration of bale density, overcoming previous inaccuracies and variability issues.
Implementation Method 1
The sensor is coupled to the bale chamber and produces a signal. The signal contains information that includes the load on the compressing device and/or the density of the crop material.
Data Source
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AI summary
An agricultural baler system (10) including a gathering device (12), a bale chamber (26), a compressing device (30) and at least one sensor (40). The gathering device (12) is configured to gather crop material. The bale chamber (26) is coupled to the gathering device (12), with at least some of the crop material being directed into the bale chamber (26). The compressing device (30) is coupled to the bale chamber (26). The compressing device (30) periodically compresses the crop material in the bale chamber (26). The sensor (40) is coupled to the bale chamber (26) and it produces a signal. The signal contains information that includes the load on the compressing device (30) and/or the density of the forming bale.