Round Baler Belt Tension Control for Bale Weight Consistency

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Solution Overview

Problem

Existing round balers lack efficient methods for determining the weight and moisture content of bales, achieving consistent bale weight and size, and providing identification labels with location and historical data for each bale.

Innovation Solution

A cylindrical baler system that senses bale diameter, weight, and moisture content, using load cells and moisture sensors to calculate volume-averaged moisture and dry matter, and adjusts belt tension through a variable fluid pressure relief valve to achieve target bale weights and sizes, while incorporating identification methods such as RFID chips or transponders for data association.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If bale formation is terminated according to diameter criterion only, then bale size is consistent, but bale weight and dry matter content vary widely

Engineering Contradiction:

Improvebale diameterVSAvoidbale weight consistency

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The system incorporates load cells that continuously measure bale weight during formation and provide feedback to the control system. The control system uses this feedback to terminate baling when the target weight is achieved, rather than relying solely on diameter measurements. This closed-loop feedback mechanism ensures consistent bale weight despite variations in crop moisture and density.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system transitions from using only diameter as the termination parameter to using weight as the primary termination parameter. By changing the controlling parameter from dimensional (diameter) to physical (weight), the system directly addresses the variability in bale weight caused by moisture content differences in the crop.

Inventive Principle:

Principle #35Parameter changes

2Measurement precision

If multiple sensors are incorporated for comprehensive data collection, then measurement accuracy improves, but device complexity increases

Engineering Contradiction:

Improvebale weight and moisture measurementVSAvoidsensor system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The control system serves multiple functions: it processes data from diameter sensors, load cells, and moisture sensors; it determines when to terminate baling; it calculates volume-averaged moisture content; and it provides display outputs. By making the control system multi-functional, the patent avoids adding separate dedicated devices for each function, thereby improving measurement precision without proportionally increasing device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines multiple measurement functions (diameter measurement, weight measurement via load cells, and moisture sensing) into a single integrated baling system. The control system consolidates data from all sensors and performs unified processing, reducing the complexity that would arise from having separate independent systems for each measurement function.

Inventive Principle:

Principle #5Merging (Combining)

3Measurement precision

If volume-averaged moisture content is measured after predetermined diameter, then moisture measurement accuracy improves, but baling time increases

Engineering Contradiction:

Improvemoisture content measurementVSAvoidbaling cycle time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The system begins moisture measurements as soon as the bale reaches the predetermined diameter, rather than waiting until baling is complete. The control system continuously accumulates moisture readings and diameter data throughout the remaining baling process, calculating the volume-averaged moisture content in real-time. This preliminary and continuous measurement approach eliminates post-baling measurement delays.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The moisture measurement process is made continuous rather than discrete. The moisture sensor continuously monitors moisture content as the bale grows, and the control system continuously processes this data along with diameter measurements. This continuous measurement and calculation process ensures accurate volume-averaged moisture content is obtained without interrupting or extending the baling cycle.

Inventive Principle:

Principle #20Continuity of useful action

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 accurate data collection and display for decision-making, archival, and automatic control, ensuring consistent bale weights, sizes, and identification, improving bale density adjustment and data management.

Implementation Method 1

A load cell is provided in the tongue of the baler and axle load cells are provided at each end of the axle

Methodology Applied

Scientific EffectForce detection: Force

Implementation Method 2

A moisture sensor is mounted on the baler to sense the moisture content of the crop material

Methodology Applied

Scientific EffectElectromagnetic detection: Electromagnetic Induction

Data Source

PatentUS7703391B2Round baler with scale and moisture meter

Publication Date: 2010.04.27 VERMEER MFG CO

AI summary

A large round baler equipped with moisture sensing apparatus and a bale scale to improve information useful in baling and using bales. Moisture sensing begins after the bale reaches a predetermined diameter. A history of bale weights is used to estimate how much tension to apply to a belt tensioner to achieve both a target bale weight and a target bale size.