Rotary Sensor Coaxial with Tailgate Pivot Axis
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Solution Overview
Problem
Existing tailgate sensors in round balers have a limited sensing range, which hinders efficient operation by not being able to monitor the tailgate position throughout its complete path of travel, leading to inefficiencies in bale forming cycle times.
Innovation Solution
A rotary sensor with a mechanical range greater than the tailgate's path of travel is used, with its sensing range aligned coaxially with the tailgate pivot axis, allowing for direct movement with the tailgate and providing position feedback within a specific range to optimize tailgate operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sensor with limited sensing range is used, then cost and reliability are improved, but the ability to monitor the complete tailgate path of travel deteriorates
Solution Approach 1:
The patent applies partial action by using a sensor with a sensing range that covers only the critical portion of the tailgate's path of travel (approximately 90 degrees) rather than the entire range. The sensor is positioned to monitor the tailgate from a specific angular position, providing sufficient information for safe operation without requiring complete path coverage. This resolves the contradiction by accepting partial monitoring in exchange for using a more reliable, cost-effective sensor.
2Productivity
If the tailgate is opened and closed quickly, then productivity is improved, but the risk of damage and safety issues worsens
Solution Approach 1:
The patent implements feedback by using a sensor to detect the tailgate's position and provide this information to the control system. The sensor monitors whether the tailgate has reached safe positions during opening and closing operations. This feedback enables the control system to manage the tailgate operation efficiently - allowing rapid movement when safe and providing position verification to prevent damage, thus resolving the contradiction between speed and safety.
Data Source
AI summary
The round baler includes a frame and a tailgate pivotally mounted to the frame via a tailgate pivot axis. The tailgate is movable along a path of travel range between an open position and a closed position. When in the open position, a bale can be discharged from the baler and, when in the closed position, a bale is prevented from being discharged from the baler. The baler also includes a sensor that has a sensor axis. This sensor is mounted to the baler with the sensor axis approximately coaxial with the tailgate pivot axis. An operating portion of the sensor is operatively directly movable with the tailgate. The sensor has a mechanical rotary range that is at least the travel range of the tailgate; and an electrical sensing range. The electrical sensing range is less than both the mechanical rotary range and the travel range of the tailgate.