Baling Chamber Sensor for Uniform Bale Density
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Solution Overview
Problem
Existing agricultural balers face challenges in achieving uniform top fill, leading to non-uniform bale density and shape, which results in unstable bales and excessive wear on the baler mechanism, due to variations in baling speed and crop material type.
Innovation Solution
The implementation of a system with first and second bale speed sensors in the baling chamber, connected to a controller, which adjusts the synchronization between the plunger movement and the slice pushing mechanism in the pre-compression chamber, allowing for real-time optimization of top fill by detecting density deviations and adjusting the timing of slice formation and pushing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the plunger movement is used as the dominant movement to drive the baling process, then the baling force and productivity are improved, but the top fill uniformity deteriorates due to variations in baling speed and crop material type
Solution Approach 1:
The patent applies feedback by using sensors to detect bale density and top fill conditions in real-time, then feeds this information back to the control system to adjust the slice pushing mechanism timing and positioning. This closed-loop control enables the system to compensate for variations in baling speed and crop material type, maintaining uniform top fill despite changes in productivity parameters.
Solution Approach 2:
The patent implements dynamics by making the slice pushing mechanism adjustable and adaptable rather than fixed. The pushing mechanism can be dynamically positioned and timed based on real-time sensor feedback about bale formation conditions, allowing the system to optimize top fill uniformity while maintaining high baling speeds and accommodating different crop material types.
2Reliability
If the slice pushing mechanism is mechanically linked to the plunger driving mechanism for synchronized movement, then the synchronization is ensured, but the adaptability to different crop material types and baling conditions deteriorates
Solution Approach 1:
The patent uses sensor feedback about actual bale density and top fill conditions to dynamically adjust the slice pushing mechanism timing and positioning. This feedback loop enables the system to adapt to different crop material types and baling conditions while maintaining proper synchronization, as the control system can modify pushing parameters based on real-time observations rather than relying solely on fixed mechanical linkage.
Solution Approach 2:
The patent makes the slice pushing mechanism dynamically adjustable through independent control capabilities, allowing it to adapt its timing and positioning based on real-time sensor data. This dynamic adjustment capability provides versatility across different crop material types while maintaining synchronization through coordinated control rather than rigid mechanical coupling.
3Manufacturing precision
If the top fill is controlled by adjusting the slice forming process in the pre-compression chamber, then the top fill uniformity is improved, but the complexity of the control system increases
Solution Approach 1:
The patent implements a feedback control system that uses sensors to detect top fill conditions and adjusts the slice pushing mechanism accordingly. This feedback approach provides precise control of top fill uniformity while keeping the control system relatively simple, as it directly addresses the problem at its source (the pushing mechanism timing and positioning) rather than requiring complex adjustments throughout the entire slice forming process.
Solution Approach 2:
The patent applies local quality control by focusing the adjustment mechanism specifically at the slice pushing stage in the baling chamber, rather than attempting to control top fill uniformly throughout the entire pre-compression and baling process. This localized approach to control simplifies the overall system complexity while achieving the desired top fill uniformity through targeted adjustments.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A first (71) and a second (72) bale speed sensor are provided in a segment (41) of the baling chamber (1) of an agricultural baler. The first sensor (71) is positioned at an upper part, while the second sensor (72) is positioned at a lower part of the baling chamber (1). Respective outputs of said bale speed sensors being operationally connected to a controller (9) which is adapted to adjust based on said outputs a synchronization between the periodically forming and pushing of a slice (3) of crop material and the reciprocal movement of the plunger (5).