Square Baler Rotor Load Sensing for Crop Density Control

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Solution Overview

Problem

Existing square balers face challenges in achieving uniform bale density due to unpredictable crop density levels in the pre-compression chamber, which can lead to either excessive density or insufficient density when transferring crop to the baling chamber.

Innovation Solution

A load-sensing transducer and processing circuit analyze the fluctuating load on the rotor during a complete filling and emptying cycle of the pre-compression chamber to estimate crop flow rate, using parameters like peak load, load difference, and average load increase to synchronize the stuffer cycle with the plunger movement, and adjust baler speed or pre-compression chamber volume to maintain desired density.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a stuffer cycle is performed every three cycles of the plunger in the baling chamber, then the baling chamber can be filled with crop, but the crop density in the pre-compression chamber becomes unpredictable and may be too great or the stuffer cycle may be delayed

Engineering Contradiction:

Improvebaling rateVSAvoidcrop density uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system uses a load sensing transducer to continuously monitor the load on the rotor during pre-compression chamber filling and emptying cycles. This feedback signal is processed to estimate crop flow rate, which then controls the stuffer cycle timing to ensure accurate crop density control in the baling chamber.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces mechanical timing methods with an electronic sensing and processing system. The load sensing transducer converts mechanical load variations into electrical signals, which are then processed to estimate crop flow rate and control the stuffer cycle, replacing purely mechanical timing mechanisms.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If the load on the rotor is not monitored, then the system is simpler, but the crop density in the pre-compression chamber cannot be controlled

Engineering Contradiction:

Improvecrop density controlVSAvoidsystem complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The load sensing transducer provides continuous feedback on rotor load during pre-compression chamber operation. This feedback is processed to estimate crop flow rate, enabling real-time control of crop density in the baling chamber while maintaining relatively simple system architecture.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system uses the rotor's own load variations during normal operation to estimate crop flow rate. The transducer monitors the rotor's load changes during filling and emptying cycles, and the processing circuit derives crop flow information from these inherent variations without requiring separate measurement systems.

Inventive Principle:

Principle #25Self-service

3Productivity

If the stuffer cycle is synchronized with plunger movement, then the baling process is efficient, but the crop density in the pre-compression chamber becomes unpredictable

Engineering Contradiction:

Improvebaling efficiencyVSAvoidcrop density uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system maintains synchronization between stuffer cycle and plunger movement while using load sensing feedback to control the timing. The processing circuit analyzes the load signal to determine the optimal moment to initiate the stuffer cycle, ensuring both efficiency and predictable crop density.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system performs preliminary analysis of the load signal during the pre-compression chamber filling cycle to predict when the optimal stuffer cycle initiation point will occur. This preliminary estimation allows the stuffer cycle to be synchronized with plunger movement while ensuring predictable crop density in the baling chamber.

Inventive Principle:

Principle #10Preliminary action

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 ensures consistent crop density in the baling chamber, allowing for well-formed bales by accurately estimating crop flow rate and providing real-time feedback to operators for speed adjustments and chamber volume modifications, thereby improving bale quality.

Implementation Method 1

a load-sensing transducer for measuring the load on the rotor

Methodology Applied

Scientific EffectLoad sensing:

Data Source

PatentUS10130040B2Square balers

Publication Date: 2018.11.20 BLUE LEAF I P INC

AI summary

A square baler having a baling chamber, a plunger reciprocable at one end of the baling chamber, a pre-compression chamber where charges of crop are amassed and pre-compressed by a rotor prior to transfer into the baling chamber. A transducer is provided for producing an electrical output signal indicative of the load on the rotor and a processing circuit is operative to estimate the rate of crop flow into the pre-compression chamber by analyzing the output signal of the transducer over a complete filling and emptying cycle of the pre-compression chamber.