Round Baler Pressing-Belt Sensing for Misalignment Detection

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Solution Overview

Problem

Existing round baler implements face issues with non-uniform feeding of baling material, leading to oblique running of pressing means, which can cause damage and inaccurate sensor feedback, resulting in inefficient bale formation and potential tearing of pressing components.

Innovation Solution

A round baler implement equipped with a sensor device having a pivoting device, pick-up, and deflector that adjusts based on pressing means tension, providing accurate feedback to correct non-uniform feeding and prevent oblique running, using a potentiometer to monitor pivoting movement and a spring element for preloading.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If sensors only detect pressing means tension, then they can monitor bale shape, but they fail to detect oblique running of pressing means

Engineering Contradiction:

Improvesensor detection accuracyVSAvoidsensor functionality under oblique running

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The sensor device is segmented into two independent detection components: a pick-up that detects pressing means tension and a deflector that detects oblique running. Each component monitors a specific parameter, allowing the system to detect both normal tension variations and abnormal oblique movements separately and accurately.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sensor device is designed with multi-functionality to detect both pressing means tension (through the pick-up) and oblique running (through the deflector). This universal detection capability ensures reliable operation under both normal and abnormal conditions, eliminating the limitation of single-function sensors.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Shape

If pressing means runs obliquely due to non-uniform feeding, then bale shape deteriorates, but pressing means may tear or cross

Engineering Contradiction:

Improveround bale uniformityVSAvoidpressing means integrity

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

The deflector is pre-positioned to detect oblique running of the pressing means before it causes severe damage such as tearing or crossing. By providing early warning through sensor signals, the system allows preliminary corrective actions to maintain bale shape uniformity and prevent pressing means failure.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The sensor device provides real-time feedback about pressing means position and tension to the operator or control system. This feedback loop enables continuous monitoring and adjustment of feeding uniformity, preventing oblique running that would deteriorate bale shape or damage the pressing means.

Inventive Principle:

Principle #23Feedback

3Shape

If operator manually adjusts feed distribution based on sensor feedback, then bale shape improves, but operational complexity increases

Engineering Contradiction:

Improvebale formation qualityVSAvoidoperator workload

Core Design Contradiction:

ShapeVSEase of operation

Solution Approach 1:

The sensor device with its deflector and pick-up components automatically monitors pressing means position and tension without requiring manual intervention. The system self-detects oblique running and tension variations, providing continuous feedback that reduces the need for operator observation and manual adjustment, thereby improving ease of operation while maintaining bale formation quality.

Inventive Principle:

Principle #25Self-service

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

The system ensures precise bale formation by adjusting material supply and preventing pressing means damage, enhancing operational efficiency and accuracy through real-time sensor feedback.

Implementation Method 1

a pick-up which is received on the pivoting device so as to be preloaded in the direction of the pressing means such that it is in contact with the pressing means, and a sensor for determining the position of the pivoting device. The information provided by the sensor may allow conclusions to be drawn about the shape of the bale formed

Methodology Applied

Scientific EffectTension: Tension

Implementation Method 2

a pick-up which is received on the pivoting device so as to be preloaded in the direction of the pressing means

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 3

The sensor device furthermore has a deflector which pivots the pivoting device upon contact with the pressing means independently of the tension of the pressing means

Methodology Applied

Scientific EffectImpact Force: Impact Force

Data Source

PatentUS12457942B2Round baler implement

Publication Date: 2025.11.04 DEERE & CO

AI summary

A round baler implement having a variable pressing chamber for producing cylindrical round bales, includes at least one circulating pressing belt and at least one sensor device for detecting tension in the pressing belt. The sensor device includes a pivoting device and a pick-up that is received on the pivoting device so as to be preloaded in the direction of the pressing belt such that it is in contact with the pressing belt. The sensor device further includes a deflector which pivots the pivoting device upon contact with the pressing means independently of the tension of the pressing means to detect a misalignment of the pressing belt and/or an unevenly forming bale.