Baler Wrapping Brake Control Using Electronic Roll Identifiers
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Solution Overview
Problem
Existing agricultural balers struggle with precise control of wrapping material tension during the binding process, which is crucial for preventing material tear or recoil, and lack efficient systems to determine the remaining amount of wrapping material on the roll.
Innovation Solution
A control system that utilizes electronic identifiers on the wrapping material to monitor and adjust the braking force applied by an electrically controlled braking apparatus, determining the roll diameter and phase of the wrapping cycle to maintain optimal tension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a potentiometer is used to measure the angle of deflection of the lever to determine the diameter of the roll of wrapping material, then the amount of wrapping material remaining on the roll can be calculated and the braking force can be adjusted accordingly, but the potentiometer is expensive and may not withstand the operating environment of a baler
Solution Approach 1:
The patent replaces the mechanical potentiometer-based measurement system with an electronic identifier detection system. Electronic identifiers (such as RFID tags) are attached to the wrapping material, and a reader detects these identifiers as the material passes, providing information about the amount of material remaining without requiring mechanical contact or complex mechanical measurement components in the harsh baler environment.
Solution Approach 2:
The patent introduces electronic identifiers as an intermediary between the wrapping material and the control system. These identifiers serve as mediators that convey information about material quantity without requiring direct mechanical measurement of the roll diameter or lever deflection, thereby avoiding the reliability issues of mechanical sensors in the operating environment.
2Force
If the braking force is increased quickly to increase tension in the wrapping material, then the desired tension can be achieved, but the wrapping material may tear and/or recoil from the baling chamber
Solution Approach 1:
The patent implements dynamic control of the braking force based on real-time detection of electronic identifiers. The control system adjusts the braking force continuously throughout the wrapping cycle, applying different force levels at different stages: lower force when the roll diameter is large, increasing force as the roll diameter decreases and more material is consumed, thereby maintaining optimal tension without sudden increases that could cause tearing.
Solution Approach 2:
The system uses feedback from the electronic identifier reader to continuously monitor the amount of wrapping material remaining on the roll. This feedback information is used by the control system to adjust the braking force in real-time, ensuring that the tension in the wrapping material remains within optimal limits throughout the wrapping process and preventing both insufficient tension and excessive tension that could cause material failure.
3Force
If the braking force is increased too much at the beginning of the wrapping process, then tension can be established quickly, but the wrapping material cannot begin rotation and be fed to the baling chamber
Solution Approach 1:
The control system dynamically adjusts the braking force based on the phase of the wrapping cycle and the detected electronic identifiers. At the beginning of the wrapping process when the roll diameter is large, the braking force is kept low to allow the wrapping material to begin rotation and be fed smoothly into the baling chamber. As the wrapping progresses and the roll diameter decreases (detected through electronic identifier counting), the braking force is gradually increased to maintain proper tension.
Data Source
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AI summary
A control system for controlling a braking operation performed by one or more controllable components of an agricultural baler on a wrapping material incorporating a plurality of electronic identifiers is disclosed. The control system ensures that a desired braking force for a given wrapping material is applied to the wrapping material during each phase of the binding cycle.