Round Baler Non-Contact Sensor for Accurate Bale Diameter Measurement
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Solution Overview
Problem
Conventional round balers determine the diameter of bales while they are still in the baling chamber, not accounting for expansion that occurs when the bale is placed on the ground, leading to deviations from the set diameter.
Innovation Solution
A round baler equipped with a non-contact sensor system positioned at the rear to measure the bale diameter after it has been ejected, allowing for accurate determination of the actual diameter on the ground, with a control unit processing these measurements to adjust parameters for consistent bale formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensor measures the bale diameter while the bale is still in the baling chamber, then the measurement can be taken during the baling process, but the measured diameter does not reflect the actual diameter the bale will have when placed on the field due to expansion
Solution Approach 1:
The patent applies preliminary action by positioning the sensor to measure the bale diameter after the bale has been ejected from the baling chamber and has settled on the ground. This timing allows the bale to complete its expansion process before measurement, ensuring the measured diameter reflects the actual field condition. The sensor is arranged to detect the bale at this specific stage in the process, rather than attempting to measure during compression.
2Measurement precision
If the sensor is positioned to measure the bale after ejection, then the actual field diameter can be measured, but the sensor must be arranged at the rear of the baler which increases device complexity
Solution Approach 1:
The patent uses the discharged bale itself as an intermediary element that carries the measurement information. The sensor is positioned to detect the bale's diameter as it passes through the discharge area, using the bale's physical presence and movement through the discharge flap area as the measurement medium. This approach simplifies the sensor arrangement by leveraging the existing bale discharge pathway rather than requiring complex positioning mechanisms.
3Device complexity
If conventional sensors are used inside the baling chamber, then the measurement system is simpler to integrate, but the measurement does not account for bale expansion when placed on the ground
Solution Approach 1:
The patent implements feedback by using the measured diameter information from the ejected bale to adjust and control the baling process parameters. The control unit receives the diameter measurement data and uses it to modify compression force, bale density, or other operational parameters to achieve the desired target diameter. This closed-loop feedback system ensures that subsequent bales are produced with accurate diameter control based on actual field conditions.
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 determination and adjustment of bale diameter, ensuring it matches the user-set size, improving operational accuracy and user feedback.
Implementation Method 1
the sensor device comprises at least one non-contact sensor for determining the diameter of the round bale formed in the baling chamber after it has left the baling chamber
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
The present invention relates to a round baler (1) comprising a baler housing (2) comprising at least one stationary housing part (3) and a discharge flap (4) pivotable relative to the stationary housing part (3) between a closing position and an opening position, as well as a baling chamber (5), a baling element (6) circumferentially delimiting the baling chamber (5), which is designed as a baling belt or is formed from a plurality of spaced-apart baling rollers, at least one device for encasing a round bale formed in the baling chamber (5) with a covering, and a sensor device. The round baler (1) is characterized in that the sensor device comprises at least one non-contact sensor (12) for determining a diameter (D1,...,n) of the round bale formed in the baling chamber (5) after it has left the baling chamber (5), which is arranged at the rear of the round baler (1).