Round Baler Wrap Quantity Indicator Using Microprocessor

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Solution Overview

Problem

Existing systems for round balers do not provide a clear indication of the number of bales that can be wrapped with the remaining wrap material, failing to accommodate variations in bale size and requiring operators to constantly monitor the wrap supply, leading to inefficient operation and potential improper wrapping.

Innovation Solution

A computer-based method using an on-board microprocessor in the baler to measure wrap usage per bale, calculate the remaining wrap quantity, and generate warnings when the supply is low, allowing for advance planning and automatic stopping of the wrapping process if insufficient wrap is detected.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If color change indicator is used to show remaining wrap, then the operator can detect when wrap is running out, but the information provided is indefinite and does not indicate how many more bales can be wrapped

Engineering Contradiction:

Improvewrap depletion detectionVSAvoidquantity of wrap information

Core Design Contradiction:

ReliabilityVSLoss of information

Solution Approach 1:

The patent replaces the mechanical/optical color change indicator system with an electronic measurement and calculation system. A sensor measures the diameter of the wrap roll, and a microprocessor calculates the remaining bale count based on this measurement and stored bale dimensions, providing precise digital information instead of vague color indicators.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a microprocessor as an intermediary between the physical wrap roll and the operator. The microprocessor receives sensor data about roll diameter, retrieves bale dimension data from memory, performs calculations to determine remaining bale count, and presents this processed information to the operator, transforming raw measurements into meaningful operational data.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If optical sensor is used to detect color change near core of roll, then electronic signal can be generated to indicate approach to end of roll, but the system does not provide definite number of remaining bales

Engineering Contradiction:

Improvewrap quantity detectionVSAvoidoperator decision making

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The patent implements a feedback system where the microprocessor continuously monitors the wrap roll diameter via sensor, compares the calculated remaining bale count against operator needs, and provides real-time information feedback. This allows the operator to make informed decisions about when to replace rolls based on actual remaining capacity rather than vague indicators.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent transitions from one-dimensional color change detection to a system that measures physical dimensions (roll diameter) and transforms this into quantitative information (remaining bale count). By adding the dimension of calculated bale quantity, the system provides comprehensive information that enables better operational planning.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Productivity

If wrap roll revolutions are measured and compared to material length, then microprocessor can determine length dispensed and wrap remaining, but the system does not accommodate variations in bale size

Engineering Contradiction:

Improvewrap monitoring efficiencyVSAvoidbale size variation

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent makes the system dynamic by storing multiple bale dimension profiles in the microprocessor memory and allowing selection of different bale sizes. The system adapts to varying bale dimensions by retrieving appropriate measurement data from memory and using it in calculations, enabling flexible operation across different bale types while maintaining accurate monitoring.

Inventive Principle:

Principle #15Dynamics

4Reliability

If sensor measures speed of moving wrap material, then visual indication can be provided of wrap movement speed to determine malfunction, but the system does not provide information about number of remaining bales

Engineering Contradiction:

Improvewrapping system monitoringVSAvoidremaining bale quantity

Core Design Contradiction:

ReliabilityVSLoss of information

Solution Approach 1:

The patent creates a multi-functional system where the microprocessor performs both wrap speed monitoring (for malfunction detection) and remaining bale calculation. The same sensor and processing unit that monitor wrap movement speed also measure roll diameter changes and calculate remaining bale count, eliminating the need for separate systems and providing comprehensive operational information.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS7295895B2Method of indicating remaining wrap

Publication Date: 2007.11.13 BLUE LEAF I P INC

AI summary

A method of measuring the quantity of wrap remaining on a round baler supply roll uses the existing wrap measuring apparatus of a round baler. An on-board microprocessor is programmed to calculate the minimum amount of wrap required for each bale, subtract the amount of wrap used to wrap a bale from the amount of wrap on the supply roll before wrapping the bale, and signal the operator if the amount on the roll is insufficient to wrap a bale. The microprocessor can also be programmed to signal the operator if the amount of wrap on the roll is insufficient to wrap a number of bales specified by the operator.