Baler Wrap Stretch Sensing for Real-Time Tension Adjustment
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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 adjusting wrap tension.
Innovation Solution
A baler implement with a wrap sensor and bale size sensor, controlled by a processor, determines the unstretched and stretched lengths of wrap material to calculate the applied wrap stretch factor, providing real-time feedback and automatic tension adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection of wrap stretch is used, then the operator can determine wrap material stretch, but the baling operation must be stopped and the operator must exit the tractor
Solution Approach 1:
The patent replaces the manual mechanical inspection method with an automated optical/electronic sensing system. The wrap sensor uses optical or electronic means to detect wrap material stretch automatically, eliminating the need for manual measurement and allowing continuous operation without stopping the baler or requiring operator intervention.
Solution Approach 2:
The wrap sensor system enables the baler to self-monitor and self-adjust wrap tension automatically. The system provides real-time feedback to the control system, which can automatically adjust wrap material tension without operator intervention, making the system self-sufficient and eliminating time loss associated with manual inspection.
2Loss of information
If manual inspection of wrap stretch is used, then the operator can examine the completed bale, but real-time feedback for adjusting wrap tension is not available
Solution Approach 1:
The patent implements a closed-loop feedback system where the wrap sensor continuously monitors wrap material stretch and provides real-time data to the control system. This feedback enables dynamic adjustment of wrap tension during the wrapping process, allowing the operator or automatic control system to optimize wrap application in real-time based on actual stretch conditions.
3Measurement precision
If the operator stops the baling operation to inspect wrap stretch, then accurate measurement can be made, but productivity is reduced
Solution Approach 1:
The wrap sensor system enables continuous monitoring of wrap stretch throughout the baling operation without interruption. The sensing system operates continuously as the baler runs, providing ongoing measurement and feedback that maintains measurement accuracy while eliminating stops and maintaining full productivity throughout the baling process.
Data Source
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.