Round Baler Net-Wrap Control Using Bale Growth Rate
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Solution Overview
Problem
Existing round balers experience inefficiencies in net wrapping bales, leading to increased idle time, inconsistent bale diameters, and trapped crop material between wrap layers, which decreases productivity and complicates bale handling.
Innovation Solution
A round baler equipped with an electronic controller that monitors bale growth and initiates net wrapping while the vehicle is moving, automatically disengaging the crop supply assembly upon reaching a full bale condition to prevent crop accumulation between wrap layers, and completes the wrapping process before ejecting the bale.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the operator stops forward motion of the vehicle to net wrap the bale, then the wrapping process can be completed properly, but productivity decreases due to increased idle time
Solution Approach 1:
The system initiates the net wrap dispensing process in advance while the vehicle is still moving and crop collection is ongoing. The electronic controller starts dispensing net wrap material before the vehicle comes to a complete stop, allowing the wrapping process to begin during the transition period and reducing the total idle time required for wrapping.
Solution Approach 2:
The system maintains continuous operation by overlapping the net wrap dispensing process with the vehicle deceleration and stopping process. Instead of completing all stopping actions before starting wrapping, the system continues useful actions (net wrap dispensing) during the transition period, eliminating gaps in productivity.
2Loss of time
If the operator uses a fixed time delay to stop forward motion, then the vehicle has time to stop, but bale diameter consistency decreases due to varying crop conditions
Solution Approach 1:
The system transitions from a static, fixed time delay approach to a dynamic, adaptive control system. The electronic controller continuously monitors bale diameter and adjusts the net wrap dispensing timing based on real-time bale growth rate, which varies with crop conditions. This dynamic adjustment ensures consistent bale diameter regardless of whether the crop is heavy or light volume.
Solution Approach 2:
The system uses feedback from bale diameter measurements to adjust the net wrap dispensing process. The electronic controller monitors the bale diameter and the rate at which the bale is growing, then adjusts when to start and stop net wrap dispensing to achieve the desired bale diameter, ensuring consistency across varying crop conditions.
3Productivity
If crop collection continues during net wrap dispensing, then productivity is maintained, but crop becomes trapped between net wrap layers
Solution Approach 1:
The system stops crop collection in advance before the net wrap dispensing is complete. The electronic controller monitors the dispensing process and automatically disengages the crop supply assembly (pick-up or rotor) at the appropriate time to prevent additional crop from being fed into the baling chamber during the final stages of net wrap application, thereby preventing crop entrapment.
Solution Approach 2:
The electronic controller acts as an intermediary that coordinates between the net wrap dispensing process and the crop collection process. It monitors both processes and automatically adjusts the crop supply assembly operation to ensure that crop collection is stopped at the optimal moment to prevent entrapment while minimizing productivity loss.
4Productivity
If the vehicle travels slower in heavy volume crop, then crop collection is more efficient, but the fixed time delay becomes too long for stopping
Solution Approach 1:
The system initiates net wrap dispensing in advance while the vehicle is still moving at reduced speed in heavy volume crop. This allows the wrapping process to begin during the deceleration period, so that by the time the vehicle comes to a complete stop, the net wrap dispensing is already underway or complete, eliminating the need for an excessively long fixed time delay.
Solution Approach 2:
The system adapts the net wrap dispensing timing dynamically based on vehicle speed and crop conditions. In heavy volume crop where the vehicle travels slower, the system adjusts the dispensing rate and timing to match the reduced speed, ensuring that the wrapping process completes in appropriate time without requiring the vehicle to stop for an excessively long period.
Data Source
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AI summary
A system, method, and apparatus includes management of a net wrap cycle of a cylindrical bale in a baling chamber (68) of a round baler (50). The baler includes a crop supply assembly (54) that passes crop material into the baling chamber (68) and a net wrap unit (67). An electronic controller (100) determines a net wrapping condition of the bale in the baling chamber (68) in response to operation of the crop supply assembly (54), initiates a net wrap start event to dispense a first portion of a net wrap material (71) from the net wrap unit (67) in response to the net wrapping condition being less than a full bale condition, and disengages a component from the crop supply assembly (54) to stop operation of the crop supply assembly (54) when the bale has satisfied the full bale condition. The net wrapping condition includes a diameter growth rate measurement being greater than a net wrap initiation threshold.