Moisture Sensor Array for Hay Bale Moisture Fraction Analysis

The patent divides the bale into multiple measurement zones using an array of moisture sensors positioned at different locations within the bale. Instead of taking a single average reading, the system segments the bale into distinct zones (e.g., center, perimeter, upper, lower sections) and measures moisture content in each zone separately. This segmentation allows the system to detect localized high moisture areas that would be masked in an average reading, while still providing a comprehensive assessment of overall bale moisture conditions.

The patent transitions from a one-dimensional average moisture measurement to a multi-dimensional assessment by measuring moisture content at multiple spatial locations and depths within the bale. The system uses an array of sensors positioned at different heights, radial distances, and axial positions to create a three-dimensional moisture distribution map. This dimensional expansion reveals moisture patterns and localized high moisture zones that cannot be detected through single-point or average measurements.

The patent designs the moisture sensor array system to serve multiple functions simultaneously. The same array of sensors used for measuring moisture content also serves as the basis for determining moisture distribution patterns, calculating moisture content ratios, identifying high moisture zones, and triggering warnings. The Electronic Control Unit performs multiple functions including data collection, processing, analysis, and operator notification. This multi-functionality reduces the need for separate specialized equipment for each measurement and control task, thereby managing system complexity while maintaining high measurement precision.

The patent implements a feedback mechanism where the Electronic Control Unit continuously monitors moisture sensor readings, compares them against predetermined thresholds, and provides real-time feedback to the operator through visual or audible warnings. The system feedbacks not only the current moisture status but also the calculated moisture content ratio and identified high moisture zones. This feedback loop enables the operator to take immediate action to prevent mold, spoilage, and fire risks, while the automated feedback reduces the need for complex manual monitoring and analysis systems.