Round Baler Bale Unloading Timing and Placement
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Solution Overview
Problem
Existing methods for unloading bales from round balers result in scattered bale placement on the field, leading to inefficient collection due to dependency on various variables and frequent stopping and starting of the baler, which can cause operational challenges and increased risk of damage.
Innovation Solution
A method where the first bale is carried by a bale holder while the second bale is growing, allowing the first bale to be unloaded just before the second bale is finished, ensuring they are placed close together on the field, reducing collection effort and minimizing field displacements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If bales are unloaded immediately after growing using conventional methods, then the baler operates continuously, but bales are scattered all over the field making collection inefficient
Solution Approach 1:
The system calculates and positions the bale drop location in advance based on the baler's current position, speed, and the distance required to complete bale growth. This preliminary positioning ensures that when the bale is unloaded, it lands at the optimal location for efficient collection, rather than being scattered randomly across the field.
Solution Approach 2:
The control system continuously monitors the baler's position, speed, and bale growth status, using this feedback to dynamically calculate the optimal unloading timing and location. This closed-loop control ensures that bales are consistently positioned for efficient collection while maintaining continuous baler operation.
2Manufacturing precision
If the baler stops frequently to unload bales at optimal positions, then bale placement precision is improved, but operational efficiency decreases and damage risk increases
Solution Approach 1:
The system performs preliminary calculations of the optimal unloading position based on current baler state parameters. This allows the baler to maintain continuous operation while knowing in advance where the bale will land, eliminating the need for frequent stops to position bales optimally.
Solution Approach 2:
The patent replaces the mechanical approach of stopping and positioning the baler physically with a control system that uses mathematical calculations and timing to achieve precise bale placement. This substitution allows continuous mechanical operation while maintaining placement precision through intelligent control rather than mechanical stopping.
3Loss of time
If bales are unloaded close together to reduce collection effort, then collection efficiency is improved, but the baler must be stopped more frequently
Solution Approach 1:
The control system calculates the exact timing for bale unloading based on the baler's current speed and position, ensuring that bales are dropped close together without requiring the baler to stop. This preliminary timing calculation allows the baler to maintain continuous operation while achieving the desired bale clustering for efficient collection.
Solution Approach 2:
The system dynamically adjusts the unloading timing based on real-time baler speed and position data. This dynamic control allows the baler to maintain varying speeds and continue operating continuously while still positioning bales to land close together, rather than requiring fixed stopping intervals.
Data Source
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Figure 3
AI summary
Method for unloading a first (12) and a second (13) bale from a round baler (1) onto a field (11), the round baler comprising a bale chamber (5) and a bale holder (2), the method successively comprising the steps of: - growing (M7) the second bale in the bale chamber, while the first bale is carried by the bale holder; - unloading (M8) the first bale from the bale holder onto the field a period of time before finishing growing the second bale, the first bale defining a first position (P1) on the field; - finishing (M9) growing the second bale, transporting the second bale to the bale holder, and unloading the second bale onto the field, the second bale defining a second position (P2) on the field; the period of time is related to a distance (d3) between the first position (P1) and the second position (P2), which distance (d3) will be covered by the baler on the field for finishing the second bale, and wherein said period of time is determined such that the distance (d3) is smaller than a sum of the diameters (dl, d2) of the first bale and second bale.