Round Baler Tailgate Pressure Feedback for Bale Density Control
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Solution Overview
Problem
Existing balers connected to tractors lack 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 system with a cylinder-piston actuator connected to a pressure sensor and control unit, which generates an alert signal when the bale reaches a desired density, allowing for precise control of the tailgate movement based on the bale's pressure, enabling the user to stop the baling process and discharge the bale at optimal density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a cylinder piston actuator is used to open and close the tailgate based on sensor feedback, then the tailgate can be controlled to open at specific positions or bale sizes, but the user cannot control the bale density
Solution Approach 1:
The patent introduces a pressure sensor that provides feedback on the actual bale density during the baling process. This feedback loop allows the control unit to monitor bale density in real-time and trigger tailgate opening at the desired density threshold, enabling precise density control that was previously unavailable in conventional balers
Solution Approach 2:
The patent replaces traditional mechanical control methods (based on bale size or position sensors) with a pressure-based sensing system. The pressure sensor directly measures bale density through the tailgate, substituting mechanical dimension-based control with a more direct physical property measurement that enables density-based control
2Extent of automation
If the tailgate opening is based on bale size or position sensors, then the baling process can be automated, but the density of the formed bale cannot be controlled
Solution Approach 1:
The pressure sensor provides continuous feedback on bale density during the automated baling process. The control unit receives this feedback and automatically triggers the tailgate opening mechanism when the desired density is reached, maintaining automation while adding precise density control capability
Solution Approach 2:
The patent changes the control parameter from mechanical dimensions (bale size or position) to a physical property parameter (bale density measured by pressure). This parameter change enables the automated system to control bale density precisely, transforming the automation system from size-based to density-based control
3Device complexity
If no pressure sensor is used, then the system remains simple, but the user has limited control over the baling process
Solution Approach 1:
The pressure sensor introduces minimal complexity by adding a single sensing element that provides critical feedback on bale density. This simple addition enables comprehensive control over the baling process, allowing users to specify and achieve target density values without significantly complicating the overall system architecture
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
This solution allows for precise control over bale density, ensuring that bales are formed and discharged at the desired level, enhancing the efficiency and quality of the baling process.
Implementation Method 1
A pressure sensor, connected to the control unit, is configured for detecting a control signal representative of a pressure inside the closing chamber
Data Source
AI summary
A baler connectable to a tractor for providing round bales comprises: a frame supported on a wheel axle; a chamber, for receiving crops and for housing a formed bale, the chamber having a fixed, predetermined size; a tailgate connected to the frame and movable between a closed position and an open position; a conveying assembly which has a first portion provided in the frame and a second portion provided in the tailgate; a cylinder-piston actuator, which includes a closing chamber and moves the tailgate from the open position to the closed position; a binder, configured for binding the formed bale with a fastening element; a pressure sensor for detecting a control signal representative of a pressure inside the closing chamber of the cylinder-piston actuator; a control unit, configured to generate an alert signal as a function of the control signal.