Round Baler Wrap Roll Sensor for Remaining Material Count
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Solution Overview
Problem
Existing round balers face challenges in accurately determining the remaining amount of wrap material on a net roll, especially when reloading a partially used roll, due to operator estimation and lack of precise measurement techniques.
Innovation Solution
A method involving a sensor system and a controller to detect the supply roll of wrap material, determine if it is partially used, and calculate the remaining length of wrap material based on sensor characteristics and calibration tables, thereby providing an accurate bale remaining count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If operator estimation method is used to determine remaining wrap material, then ease of operation is improved, but measurement precision deteriorates
Solution Approach 1:
The patent replaces the manual operator estimation method with an automated sensor-based detection system. The sensor system automatically measures the supply roll characteristics and the controller calculates the remaining wrap material length, eliminating the need for operator judgment while providing precise measurements through automated detection and calculation.
2Measurement precision
If sensor-based detection system is implemented, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The sensor system and controller are integrated into the existing round baler structure, allowing the system to self-monitor and self-calculate the remaining wrap material without requiring external intervention. The controller automatically processes sensor data and provides bale remaining count information, making the precision measurement capability inherent to the system rather than an added complexity.
3Loss of substance
If accurate determination of remaining wrap material is achieved, then loss of substance is reduced, but measurement precision requirements increase
Solution Approach 1:
The sensor system continuously monitors the supply roll characteristics and provides feedback to the controller, which calculates and displays the remaining bale count. This feedback mechanism allows for real-time adjustment and accurate determination of remaining wrap material, reducing waste by preventing premature roll replacement while maintaining manageable measurement precision requirements through iterative calculation.
Data Source
AI summary
A round baler having a baling system defining a baling chamber having an access into the baling chamber to receive crop therein and form the crop into a bale within the baling chamber. A wrap system operable to insert a wrap material into the baling chamber to wrap the bale. The wrap system includes a supply roll having wrapping material thereon, the supply roll rotatingly connected to the housing, and a support structure to support the supply roll of the wrap material relative to a pair of spool rollers. A sensor near the supply roll senses the supply roll of the wrap material and generates a sensor characteristic relative to a length portion of the wrap material remaining on the supply roll and a controller operably coupled to the sensor to receive the sensor characteristic. The controller determines when a partial net roll is loaded and remaining number of bales.