Round baler layer thickness sensing via drive shaft speed
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Solution Overview
Problem
Operators of variable chamber round balers face difficulties in determining the density of bales, particularly the change in density of each layer, leading to inefficient operation.
Innovation Solution
A system that includes sensors to detect the diameter of the bale and calculate the thickness of each layer, with data processed by a controller to display the information to the operator, allowing for adjustments to optimize bale density, comprising a display unit, sensors on the tensioning arm or fixed locations, and a processor to derive the time interval for bale rotation and layer thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the operator adjusts the speed of the towing vehicle to optimize bale density, then bale density can be improved, but the operator cannot determine the density of the bales, particularly the change in density of each layer
Solution Approach 1:
The patent implements a feedback system where sensors detect bale diameter and layer thickness, the controller processes this information to calculate density parameters, and the display unit presents real-time density information to the operator. This closed-loop feedback enables the operator to monitor bale density and adjust operations accordingly.
Solution Approach 2:
The patent replaces manual mechanical measurement methods with an automated sensor-based system. Sensors mounted on the tensioning arm or at fixed locations electronically detect bale dimensions, substituting the need for physical measurement and manual calculation with automated electronic detection and processing.
2Loss of information
If sensors are installed on the tensioning arm or at fixed locations to detect bale diameter, then layer thickness information can be obtained, but the device complexity increases
Solution Approach 1:
The tensioning arm, which already exists in the baler system to maintain belt tension, is given an additional function by mounting sensors on it to detect bale diameter. This multi-functional approach allows the system to gain new measurement capabilities without adding completely separate measurement apparatus.
Solution Approach 2:
The existing tensioning arm structure is utilized to serve dual purposes: maintaining belt tension and providing a mounting platform for diameter detection sensors. This approach leverages the self-service capability of existing components to perform additional functions without requiring entirely new dedicated structures.
Data Source
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AI summary
A round baler (12) comprises a baling chamber (16) and a press means (20) mounted therewithin. A first sensor (S1) is disposed within said baler (12) to determine a diameter change of a bale (15). A second sensor (S2) is configured to detect a speed of a drive shaft (14). The speed of the drive shaft (14) and the diameter change after each rotation of the bale (15) processed to determine a thickness (Th) of a layer of said crop material. The thickness (Th) is indicated in a display unit (22).