Baler Wrap Stretch Sensing for Real-Time Tension Control
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Solution Overview
Problem
Existing baler systems require manual inspection of bale wrap stretch, disrupting operation and lacking real-time feedback for optimal tension adjustment.
Innovation Solution
A baler implement with a wrap sensor, bale size sensor, and controller that calculates and adjusts wrap stretch in real-time, providing on-the-go feedback and automatic tension control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection of wrap stretch is performed, then wrap stretch can be evaluated, but operational continuity is disrupted and real-time feedback is lost
Solution Approach 1:
The system continuously monitors wrap stretch in real-time and provides immediate feedback to the operator through the display device. The processor compares measured stretch values against target values and can automatically adjust wrap tension, eliminating the need for manual inspection while maintaining measurement accuracy and operational continuity.
Solution Approach 2:
The patent replaces the manual mechanical inspection process with an automated sensor-based measurement system. Sensors continuously measure wrap stretch and transmit data to the processor, which then controls the wrap tension mechanism, substituting human observation and manual measurement with an automated control loop.
2Measurement precision
If manual inspection of wrap stretch is performed, then wrap stretch can be evaluated, but real-time adjustment capability is lost
Solution Approach 1:
The system provides continuous real-time feedback on wrap stretch measurements to the operator and control system. The processor receives sensor data immediately, compares it against target values, and can trigger automatic adjustments during the wrap cycle, eliminating delays associated with manual inspection and enabling timely corrections.
Solution Approach 2:
The wrap stretch measurement and adjustment process continues uninterrupted throughout the baling operation. Sensors continuously monitor stretch during the wrap cycle, and the control system maintains continuous adjustment capability, ensuring that wrap tension remains optimal without stopping the baling process for inspection.
3Shape
If wrap material is tightly tensioned, then bale shape is maintained, but wrap material stretch exceeds desired amount
Solution Approach 1:
The system continuously measures wrap stretch and provides feedback to the control system, which automatically adjusts tension to maintain the optimal stretch range. This closed-loop control ensures that the wrap material provides sufficient tension to maintain bale shape while avoiding excessive stretch that would compromise bale integrity or wrap material performance.
Solution Approach 2:
The wrap tension system dynamically adjusts tension levels during the wrap cycle based on real-time stretch measurements. The processor modifies wrap material tensioning on-the-fly to accommodate variations in bale size, wrap layer count, and material properties, maintaining optimal stretch conditions throughout the wrapping process.
Data Source
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AI summary
A baler implement includes a baler controller configured to determine an unstretched length of wrap material dispensed by a wrap system during a wrap cycle, and determine a circumference of a bale in a baling chamber. The baler controller may then determine a stretched length of the wrap material as applied onto the bale during the wrap cycle from the circumference of the bale and a number of wrap layers of the wrap material wrapped around the circumference of the bale. The baler controller may then compare the stretched length of the wrap material as applied onto the bale to the unstretched length of the wrap material dispensed by the wrap system during the wrap cycle to determine an applied wrap stretch factor. The applied wrap stretch factor may be communicated to an operator, or used to control the wrap system to achieve a desired wrap stretch.