Round Baler Pressure Feedback for Bale Density Control

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Solution Overview

Problem

Existing balers lack effective control over bale density, as the opening of the tailgate is not dependent on the bale's density, limiting user control over the baling process.

Innovation Solution

A baler connected to a tractor with a cylinder-piston actuator and a pressure sensor that monitors the pressure inside the closing chamber, generating an alert signal when the bale reaches a desired density, allowing for precise control over the tailgate's movement and bale formation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If a cylinder piston actuator is used to open and close the tailgate based on sensor feedback of tailgate position or actuator orientation, then the tailgate can be automatically controlled, but the user has limited control on the whole process as the opening does not depend on bale density

Engineering Contradiction:

Improveautomatic tailgate controlVSAvoiduser control on baling process

Core Design Contradiction:

Extent of automationVSEase of operation

Solution Approach 1:

The patent introduces a pressure sensor that provides feedback on the actual pressure inside the closing chamber, which correlates with bale density. This feedback loop allows the control unit to compare actual pressure with target pressure and automatically adjust the baling process, achieving both automation and density control without requiring manual user intervention.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system enables the baler to automatically regulate its own operation by using the pressure sensor to monitor bale density in real-time and automatically controlling the tailgate opening/closing cycle based on whether target density is reached, making the system self-regulating without continuous user input.

Inventive Principle:

Principle #25Self-service

2Device complexity

If the tailgate opening is controlled only by tailgate position sensors or actuator orientation sensors, then the control system is simple, but the bale density cannot be controlled or monitored

Engineering Contradiction:

Improvecontrol system simplicityVSAvoidbale density control

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent uses a pressure sensor to measure the actual pressure inside the closing chamber, which is directly related to bale density. This pneumatic/hydraulic approach allows density measurement through pressure monitoring, adding precise density control capability while maintaining relatively simple system architecture by utilizing the existing hydraulic/closed-chamber mechanism.

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Device complexity

If no pressure monitoring is implemented, then the device structure remains simple, but the user cannot determine when the bale reaches desired density

Engineering Contradiction:

Improvedevice structureVSAvoidbale density measurement

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent replaces complex mechanical density measurement mechanisms with a simple pressure sensor that electronically measures pressure inside the closing chamber. This substitution achieves precise density measurement (since pressure correlates with density) while keeping the device structure relatively simple by using electronic sensing rather than mechanical measurement apparatus.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 precise control over bale density by alerting the user to stop the baling process when the desired density is reached, ensuring consistent bale quality and user intervention for optimal bale formation.

Implementation Method 1

A pressure sensor may be provided in the baler. The pressure sensor is connected to the control unit. The pressure sensor is configured for detecting a control signal. The control signal is representative of a pressure inside the closing chamber of the cylinder-piston actuator.

Methodology Applied

Scientific EffectPressure detection:

Data Source

PatentEP3664596B1Baler connectable to a tractor for providing round bales and method for producing round bales

Publication Date: 2023.11.08 KVERNELAND GRP RAVENNA

Figure 1
Figure 2

AI summary

A baler (1) connectable to a tractor (2) for providing round bales comprises: a frame (3) supported on a wheel (4) axle; a chamber (5), for receiving crops and for housing a formed bale, the chamber having a fixed, predetermined size; a tailgate (6) connected to the frame and movable between a closed position, for cooperating with the frame (3) to delimit the chamber (5), and an open position, for discharging the formed bale; a conveying assembly, which delimits the chamber (5) for imparting a rotating movement to the crops contained in the chamber (5), and has a first portion provided in the frame (3) and a second portion provided in the tailgate (6); a cylinder-piston actuator (7), which includes a closing chamber (701) and is connected to the frame (3) and to the tailgate (6) to move the tailgate (6) from the open position to the closed position, upon receiving an actuating fluid in the closing chamber (701); a binder (12), configured for binding the formed bale with a fastening element; a pressure sensor (P1) for detecting a control signal representative of a pressure inside the closing chamber (701) of the cylinder-piston actuator (7); a control unit, configured to generate an alert signal as a function of the control signal.