Variable Speed Baler Chamber Control via Crop Sensor Feedback

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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 bale chamber speed, 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 rate, allowing for manipulation of the baling chamber speed based on user input and operational cycles, enabling precise control of the baling process.

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 timeVSAvoidfeed rate control

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The baling chamber speed is made dynamically adjustable rather than fixed, allowing the system to optimize speed based on real-time conditions. The variable speed drive enables the baling chamber to operate at different speeds during different operational phases, resolving the contradiction between high speed productivity and reliable feed rate control.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system incorporates feedback mechanisms that monitor operational conditions and automatically adjust the baling chamber speed accordingly. This closed-loop control ensures that the feed rate is properly controlled while maintaining high productivity, preventing both plugging and bale deterioration issues.

Inventive Principle:

Principle #23Feedback

2Reliability

If the baling chamber speed is varied to control feed rate, then feed rate control is improved, but the cycle time increases and accumulation area requirements increase

Engineering Contradiction:

Improvefeed rate controlVSAvoidcycle time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system applies periodic speed variations to the baling chamber, using controlled acceleration and deceleration phases. This periodic action pattern allows the chamber to move faster during productive phases while maintaining proper feed rate control during critical phases, minimizing overall cycle time while ensuring reliable operation.

Inventive Principle:

Principle #19Periodic action

3Productivity

If the baling chamber speed is increased to accommodate accumulated material feeding, then productivity is improved, but the system cannot sufficiently adjust speed when pulled by a combine

Engineering Contradiction:

Improvebaling chamber speedVSAvoidspeed adjustment capability

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The variable speed drive system provides universal speed control capability that works in multiple operational scenarios. Whether the baler is pulled by a tractor or a combine, the system can independently adjust the baling chamber speed to optimal levels, making the system adaptable to different towing vehicles and operational conditions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10098282B2Variable speed round bale chamber control using bale growth rate

Publication Date: 2018.10.16 AGCO CORP

AI summary

In an example embodiment, a sensor detects a characteristic of accumulated crop material and a controller manipulates the speed of a baling chamber in response thereto. In an example method, 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.