Square Baler Control System for Bale Ejection and Quality
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Solution Overview
Problem
Square balers face difficulties in ejecting the last completed bale due to frictional forces and in forming solid bales when the bale in progress is too short, leading to issues with the bale ejection system and bale quality.
Innovation Solution
A control system that predicts the remaining crop and adjusts bale length to ensure all bales exceed a minimum length at job completion, allowing easy ejection by varying bale size at the end of a job, while maintaining acceptable bale quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the bale in progress is used to push the last completed bale out of the baling chamber, then the bale ejection function is achieved, but the bale in progress may be too short to form a sufficiently solid bale of acceptable quality
Solution Approach 1:
The control system receives a prediction signal from the operator about remaining crop before the job ends, and uses this information to proactively adjust bale formation in advance. This preliminary action allows the system to prepare appropriate bale lengths before the ejection problem occurs, rather than reacting too late.
Solution Approach 2:
The system dynamically adjusts bale length based on the prediction signal and current bale in progress length. When the prediction indicates insufficient crop remaining, the system varies the bale length to ensure the last completed bale is sufficiently long for easy ejection, while maintaining acceptable quality standards.
2Adaptability or versatility
If the discharge chute is raised to permit transportation, then the baler can be moved between fields, but the last completed bale cannot be ejected if it only sticks out slightly from the baling chamber
Solution Approach 1:
The control system uses the operator's prediction signal to proactively manage bale length before the discharge chute needs to be raised. By ensuring the last completed bale is sufficiently long in advance, the system prevents ejection difficulties that would otherwise occur when the chute is raised for transportation.
Solution Approach 2:
The system incorporates feedback from the bale length sensor and the operator's prediction signal to continuously monitor and adjust bale formation. This feedback loop ensures that the bale length is appropriate for both quality requirements and subsequent ejection needs, even when transportation operations are planned.
3Manufacturing precision
If the control system maintains standard bale length, then bale quality is consistent, but the last completed bale may be too short to overcome frictional forces during ejection
Solution Approach 1:
The system dynamically adjusts bale length based on real-time conditions (prediction signal and bale in progress length). When the prediction indicates the job is nearing completion, the system varies the bale length to ensure the last completed bale is sufficiently long to overcome frictional forces during ejection, while maintaining acceptable quality standards.
Solution Approach 2:
The control system changes the bale length parameter in response to the prediction signal. By adjusting this critical parameter based on remaining crop predictions, the system ensures that the last completed bale has sufficient length for reliable ejection while maintaining overall bale quality requirements.
Data Source
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AI summary
According to the invention there are provided means and a method for controlling a square baler, wherein: - the length of the bale (20) in progress is determined by a bale length sensor; - the crop remaining to be baled before completion of a job is predicted by the operator; and - depending on the prediction and the length of the bale (20) in progress, a control system ensures that all bales completed after the receipt of the prediction signal exceed a predetermined minimum length at the completion of the job.