Square Baler Pickup Roller Torque Sensor Crop Flow Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing square balers face challenges in achieving uniform bale density due to inconsistent crop density in the pre-compression chamber, which can lead to either over-compression or under-compression when transferring crop to the baling chamber.
Innovation Solution
A torque sensor connected to the pickup roller's tine bar generates an electrical output signal, allowing a processing circuit to estimate crop flow rate by analyzing torque only when the tines are horizontal, disregarding ground drag and crop pileup resistance, and providing feedback to adjust baler speed or pre-compression chamber volume for optimal density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If pressure sensors are used in the pre-compression chamber to detect crop density, then crop density can be monitored, but the measurement is affected by crop pileup resistance and inconsistent timing with plunger cycles
Solution Approach 1:
The invention extracts the measurement function from the pre-compression chamber environment (where crop pileup resistance interferes) and relocates it to the pickup roller tine bars. By measuring torque on the tine bars as they engage crop, the system obtains density information before crop enters the pre-compression chamber, eliminating interference from chamber fullness and enabling reliable timing synchronization with plunger cycles.
2Manufacturing precision
If the stuffer cycle is synchronized to initiate after three plunger cycles, then the baling chamber is ready for transfer, but crop density may be too great or the cycle may be delayed if density reaches desired level at non-integer plunger cycle points
Solution Approach 1:
The invention implements feedback control by continuously monitoring torque on pickup roller tine bars and using this information to determine when desired crop density is achieved. The stuffer cycle is then triggered based on this real-time density feedback rather than fixed timing, ensuring optimal density conditions are met while maintaining synchronization with plunger cycles. The system can adjust stuffer timing based on actual crop flow conditions.
Solution Approach 2:
The invention transitions from static, fixed-time stuffer cycle initiation to dynamic, condition-based initiation. The stuffer cycle timing becomes adaptable, changing based on real-time crop density measurements from torque sensors. This allows the system to optimize density uniformity while maintaining flexibility in timing to match actual crop flow rates and plunger cycle synchronization requirements.
3Productivity
If torque is measured continuously on the pickup roller, then crop flow rate information is available, but ground drag and crop pileup resistance contaminate the measurement
Solution Approach 1:
The invention applies local quality by measuring torque at specific locations and times on the pickup roller operation cycle. Torque is measured on individual tine bars at specific angular positions where ground drag is minimal and crop pileup resistance is absent. By selecting specific measurement points in the rotational cycle, the system obtains pure crop weight information without contamination from ground interaction forces or chamber resistance.
Solution Approach 2:
The invention uses periodic measurement action by sampling torque only at specific phases of the pickup roller rotation cycle. Rather than continuous measurement, torque is measured periodically at angular positions where tines are clearing ground contact and approaching the pre-compression chamber. This periodic sampling at optimized intervals captures crop flow information while excluding ground drag and pileup resistance from the measurement.
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
Ensures consistent crop density in the pre-compression chamber at the time of transfer, resulting in well-formed bales of uniform density by synchronizing the stuffer cycle with the plunger's movement, improving bale quality and operational efficiency.
Implementation Method 1
a torque sensor connected to at least one tine bar of the pickup roller to produce an electrical output signal indicative of the torque experienced by the at least one tine bar of the pickup roller
Data Source
Figure 1
Figure 2~3
AI summary
A square baler has a baling chamber, a plunger reciprocable at one end of the baling chamber, a pre-compression chamber within which charges of crop are amassed and pre-compressed by a rotor prior to transfer into the baling chamber, and a pickup roller having radially projecting tines for picking up crop from the ground and advancing the crop to the rotor. A torque sensor is connected to at least one tine of the pickup roller to produce an electrical output signal indicative of the torque experienced by the pickup roller, and a processing circuit is operative to estimate the rate of crop flow into the chute by analyzing the electrical output of the torque sensor only at times when the position of the tine lies within a predetermined angular position of the pickup roller.