Windguard Sensor Control for Baler Plug Detection and Mitigation
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Solution Overview
Problem
Agricultural implements such as balers can become plugged due to sudden increases in crop volume or foreign objects, leading to incorrect operation and potential damage, which is difficult to detect and time-consuming to resolve.
Innovation Solution
A system with sensors to monitor windguard displacement, roller speed, and PTO shaft speed to determine plug conditions, adjusting parameters like travel speed or bale chamber pressure to mitigate the plug.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the operator manually monitors and responds to plug conditions, then the implement can be stopped and plugs removed, but the operator cannot know when a plug is present and it is time-consuming to resolve
Solution Approach 1:
The system continuously monitors windguard displacement, roller speed, and PTO shaft speed, comparing actual values against expected values to provide real-time feedback on plug conditions. This automated feedback loop eliminates the need for manual monitoring and enables rapid detection and response to plugs.
Solution Approach 2:
The patent replaces manual mechanical monitoring with an automated electronic detection system using sensors and a controller. The windguard displacement sensor, roller speed sensor, and PTO shaft speed sensor electronically monitor system parameters, substituting the operator's manual inspection process.
2Measurement precision
If multiple sensors are added to detect plug conditions, then detection accuracy improves, but device complexity increases
Solution Approach 1:
The controller serves multiple functions: it receives signals from multiple sensors (windguard displacement sensor, roller speed sensor, PTO shaft speed sensor), processes these signals, compares actual values against expected values, and controls mitigation actions. This multi-functionality reduces the need for separate dedicated components for each detection task.
Solution Approach 2:
The patent combines multiple sensor functions into a unified detection system where the controller integrates signals from the windguard displacement sensor, roller speed sensor, and PTO shaft speed sensor. By merging these functions into a single control unit, the system achieves high measurement precision without proportionally increasing overall system complexity.
3Difficulty of detecting and measuring
If the windguard is made movable to detect displacement, then plug detection capability is improved, but the device complexity and potential for false positives increase
Solution Approach 1:
The system uses feedback from multiple sensors (windguard displacement sensor, roller speed sensor, PTO shaft speed sensor) to continuously monitor and compare actual values against expected values. This feedback mechanism allows the system to distinguish between normal windguard movement and actual plug conditions, reducing false positives while maintaining high detection capability.
Solution Approach 2:
The windguard is designed as a movable component that can dynamically respond to various conditions. By making the windguard movable rather than fixed, the system can detect displacement caused by plugs while accommodating normal operational variations, improving detection capability without significantly increasing false positive rates.
Data Source
AI summary
An agricultural implement system includes an agricultural implement and a controller. The agricultural implement includes: a chassis, a rotatable power take off (PTO) shaft, a pickup, a movable windguard having a roller, a windguard displacement sensor, a roller speed sensor, a PTO shaft speed sensor, and a ground speed sensor. The controller is configured to: calculate a difference between the rotational speed of the roller and either the rotational speed of the PTO shaft or the ground speed of the agricultural implement; determine a plug condition exists when the displacement of the windguard exceeds a defined displacement and the calculated difference exceeds a predetermined threshold value; and output at least one plug condition mitigation signal to adjust at least one parameter of the agricultural implement system and mitigate the plug condition responsively to determining the plug condition exists.