Plunger Face NIR Sensor for Baler Moisture Measurement
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Solution Overview
Problem
Existing baling systems inaccurately measure moisture content of crop material, leading to inefficient preservative application and potential bale deterioration.
Innovation Solution
A baling system with a moisture sensor integrated into the plunger face of the baler, capable of determining the moisture content of individual charges within the feeder chute, using near-infrared or microwave radiation to provide precise measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a moisture sensor is positioned to measure the entire bale, then the measurement covers the whole bale, but the measurement accuracy for individual charges is insufficient
Solution Approach 1:
The patent divides the measurement process into segments by measuring moisture content of individual charges as they are fed into the forming chamber, rather than measuring the entire bale as a whole. The sensor is positioned to detect moisture of each charge separately, enabling precise per-charge measurements that can then be aggregated for overall bale composition.
Solution Approach 2:
The moisture measurement is performed preliminarily on individual charges before they are compressed into the final bale. By measuring each charge's moisture content as it enters the forming chamber, the system establishes accurate baseline data that informs preservative application decisions before the charges are mixed and compressed together.
2Ease of operation
If preservative is applied based on average bale moisture, then the application process is simple, but the preservative amount is inaccurate leading to waste or insufficient protection
Solution Approach 1:
The system implements feedback control by using real-time moisture measurements of individual charges to dynamically adjust preservative application rates. The controller receives moisture data from the sensor and automatically modulates preservative delivery to match actual moisture needs, preventing both over-application (waste) and under-application (insufficient protection).
Solution Approach 2:
The system changes the operational parameter from fixed-rate preservative application to variable-rate application based on measured moisture content. By adjusting the preservative application rate according to actual moisture measurements of each charge, the system optimizes preservative usage while maintaining effective protection.
3Measurement precision
If the moisture sensor measures individual charges, then the measurement accuracy improves, but the device complexity increases
Solution Approach 1:
The patent integrates the moisture sensor into the existing plunger face structure, allowing the plunger to serve dual functions: mechanical compression of charges and as a mounting platform for the moisture detection sensor. This multi-functional integration reduces overall device complexity while maintaining precise measurement capability.
Solution Approach 2:
The plunger face structure serves itself by incorporating the moisture sensor directly into its design, eliminating the need for separate mounting mechanisms or additional structural components. The existing plunger infrastructure provides the mounting platform, reducing overall system complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables accurate moisture content measurement of each individual charge, optimizing preservative application and minimizing waste and deterioration risks.
Implementation Method 1
the moisture sensor is a near infra-red sensor operable to use near infra-red radiation to determine the moisture content
Data Source
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AI summary
A baling system operable to receive loose material, form the loose material into an individual charge, and compress the individual charge with one or more other charges to form a bale. The baling system includes a forming chamber and a plunger operable to move in a reciprocating manner within the forming chamber from a front-dead-center position in which a plunger face is furthest from the bale to a rear-dead-center position in which the plunger face contacts and compresses the bale. The system includes a feeder component operable to pre-compress the loose material to form the individual charge and then move the individual charge into the forming chamber, the feeder component including a feeder chute having a feeder chute outlet connected to the forming chamber. The feeder component is operable to pre-compress the loose material into the individual charge and then move the individual charge into the forming chamber for compression by the plunger into the bale. The system includes a moisture sensor operable to determine a moisture content of the individual charge in the feeder chute, wherein at least a portion of the moisture sensor is positioned in the plunger face. In one embodiment, the moisture sensor is a near infra-red sensor operable to use near infra-red radiation to determine the moisture content.