Variable Speed Baler Chamber Control via Accumulator Sensor

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Solution Overview

Problem

Conventional round balers face challenges in controlling the feed rate of crop material, particularly when towed behind a combine, as varying the tractor's ground speed and engine speed is inadequate for minimizing cycle time and adjusting to different material types, leading to potential plugging or bale deterioration.

Innovation Solution

A variable speed baler system that uses sensors to detect accumulated crop material and bale growth rates, allowing for dynamic adjustment of the baling chamber speed based on user input and operational cycles, ensuring optimal bale formation and wrapping.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the baling chamber speed is increased to reduce bale wrapping time and minimize cycle time, then productivity is improved, but the feed rate control becomes inadequate leading to potential plugging or bale deterioration

Engineering Contradiction:

Improvebale wrapping speedVSAvoidfeed rate control stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The baling chamber speed is made dynamically adjustable rather than fixed. The system allows the baling chamber to rotate at different speeds depending on the operational phase (bale forming vs. bale wrapping) and material accumulation conditions, resolving the contradiction between high speed productivity and stable feed rate control

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The rotational speed parameter of the baling chamber is changed based on detected material characteristics and operational cycle phase. The system transitions between different speed regimes (higher speed for wrapping, lower speed for forming) to simultaneously achieve high productivity and reliable control

Inventive Principle:

Principle #35Parameter changes

2Reliability

If the baling chamber speed is decreased to improve feed rate control, then reliability is improved, but productivity and cycle time are reduced

Engineering Contradiction:

Improvefeed rate control precisionVSAvoidbale formation efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system implements periodic variation in baling chamber speed corresponding to the operational cycles (bale forming phase followed by bale wrapping phase). During forming, lower speed ensures reliable feed control; during wrapping, higher speed increases productivity, creating a rhythmic pattern that balances both requirements

Inventive Principle:

Principle #19Periodic action

3Adaptability or versatility

If the tractor ground speed is varied to control feed rate, then adaptability to different conditions is improved, but the ground speed is constrained by combine harvesting requirements

Engineering Contradiction:

Improvefeed rate adjustment capabilityVSAvoidindependence from combine speed

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The feed rate control function is extracted from the tractor ground speed control and transferred to the baling chamber rotational speed control. This allows the baler to independently adjust feed rate by controlling chamber rotation rather than requiring changes in tractor or combine ground speed, achieving operational independence

Inventive Principle:

Principle #2Taking out (Extraction)

4Device complexity

If the bale chamber operates at constant speed throughout the cycle, then device complexity is reduced, but the ability to optimize for different operational phases is limited

Engineering Contradiction:

Improvespeed control system simplicityVSAvoidcycle time optimization

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The system uses sensors to detect material accumulation characteristics and operational cycle phase, providing feedback that triggers appropriate speed adjustments. This feedback mechanism enables automated speed optimization without requiring complex manual control systems

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The baling chamber speed control system automatically adjusts itself based on detected conditions and operational phase, without requiring external intervention. The system self-regulates between forming and wrapping speeds to optimize productivity while maintaining simple control architecture

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS10188043B2Variable speed round bale chamber control with accumulator sensor

Publication Date: 2019.01.29 AGCO CORP

AI summary

A sensor detects a characteristic of accumulated crop material and a controller manipulates the speed of a baling chamber in response thereto. The speed of a baling chamber of a variable speed baler is manipulated in response to a characteristic of an accumulated crop material. For example, the height of accumulated crop material in an accumulation area may be detected and the speed of the baling chamber manipulated in response thereto. The rate of growth of the bale may also be determined and used in manipulating the speed of the baling chamber.