Baler Sensor Feedback for On-the-fly Quality Control
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Solution Overview
Problem
Current baling equipment requires manual adjustments based on bale characteristics, which is time-consuming and prone to errors, as operators must inspect and adjust settings after each bale is formed to ensure specifications are met.
Innovation Solution
Implementing a system with sensors to collect data on bale characteristics and actuators to automatically adjust baler settings in real-time, allowing for continuous formation of bales that meet predetermined specifications for shape, size, density, and twine control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual inspection and adjustment of bale settings is performed after each bale is formed, then bale quality specifications can be ensured, but time consumption and operational efficiency deteriorate
Solution Approach 1:
The system implements automatic feedback control by using sensors to detect bale characteristics (shape, size, density) and automatically adjusting baler settings based on the detected deviations from specifications. This closed-loop feedback mechanism eliminates manual inspection while maintaining quality compliance, thereby resolving the contradiction between manufacturing precision and productivity.
Solution Approach 2:
The patent replaces the manual mechanical inspection and adjustment process with an automated sensor-based detection and actuator-driven adjustment system. This substitution of mechanical human operations with automated systems eliminates time consumption associated with manual interventions while ensuring consistent bale quality, thus improving productivity without sacrificing manufacturing precision.
2Manufacturing precision
If manual inspection of each bale is performed to determine correct characteristics, then bale quality control is achieved, but time loss and operational delays increase
Solution Approach 1:
The baler system performs self-inspection and self-adjustment through integrated sensors and actuators that automatically detect bale characteristics and modify settings without external human intervention. This self-service capability eliminates the time loss associated with manual inspection while maintaining continuous operation, thereby resolving the contradiction between manufacturing precision and time loss.
Solution Approach 2:
The automated system enables continuous baling operation by eliminating the intermittent stoppages required for manual inspection and adjustment. The sensor-actuator system operates continuously to monitor and adjust bale characteristics, ensuring quality compliance without breaking the production flow, thus reducing time loss while maintaining manufacturing precision.
3Productivity
If automated sensors and actuators are implemented for real-time adjustment, then productivity and consistency are improved, but device complexity increases
Solution Approach 1:
The patent integrates multiple functions into the baler system by combining sensing, control, and actuation capabilities within the existing baler framework. The sensor array and actuator system serve multiple purposes including quality monitoring, automatic adjustment, and process optimization, thereby improving productivity without proportionally increasing device complexity through multi-functional integration.
Solution Approach 2:
The system introduces a control unit as an intermediary that processes sensor data and generates actuator commands, simplifying the overall system architecture. This intermediary layer coordinates between the sensor array and actuators, enabling automated real-time adjustment while managing system complexity through centralized control logic rather than direct point-to-point connections.
Data Source
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AI summary
One or more techniques and/or systems are disclosed for automatically adjusting settings on a baler based at least on the characteristics of a previously formed or forming bale. A baler collects a target crop and forms a bale. During or after formation of the bale, sensors collect data that is indicative of bale characteristics, including mass flow, shape, size, density, wrap and twine control, amongst other for the bale. A baler controller can use the identified bale characteristics to determine baler settings adjustments, for the baler, that can bring the bale, or subsequent bale, into specification based on predetermined thresholds for the bale characteristics. Further, actuators can operably adjust the baler settings on the fly.