Abstract
An agricultural baler. The agricultural baler includes a baling chamber including a first segment, a plunger, and a baling chamber. The agricultural baler further includes a controller and a pre-compression chamber configured for gathering crop material, periodically forming a slice of the crop material, and pushing the slice towards the baling chamber into the first segment of the baling chamber. The agricultural baler further includes a slice-presence-detecting sensor disposed in an upper region of the first segment of the baling chamber, the slice-presence-detecting sensor comprising an output operationally connected to the controller. The plunger is configured for reciprocally moving in the baling chamber to compress slices of crop material into a bale. The controller is configured for adjusting a synchronization between the periodically forming and pushing of the slice in the pre-compression chamber and the reciprocally moving of the plunger.
Claims
1. An agricultural baler comprising: a baling chamber comprising a first segment and a plunger; a pre-compression chamber configured for gathering crop material, periodically forming a slice of the crop material, and pushing the slice towards the baling chamber into the first segment of the baling chamber; a controller; and a slice-presence-detecting sensor disposed in an upper region of the first segment of the baling chamber, the slice-presence-detecting sensor comprising an output operationally connected to the controller, wherein the plunger is configured for reciprocally moving in the baling chamber to compress slices of crop material into a bale, and wherein the controller is configured for adjusting a synchronization between the periodically forming and pushing of the slice in the pre-compression chamber and the reciprocally moving of the plunger.
2. The agricultural baler of claim 1, wherein the controller is further configured for adjusting a synchronization timing of the periodically forming and pushing of the slice in the pre-compression chamber with respect to the reciprocally moving of the plunger.
3. The agricultural baler of claim 1, wherein the slice-presence-detecting sensor is mounted at a top surface of the first segment of the baling chamber to detect arrival of the slice at the top surface.
4. The agricultural baler of claim 1, further comprising a plurality of slice-presence-detecting sensors mounted at different heights in the first segment of the baling chamber.
5. The agricultural baler of claim 1, wherein the slice-presence-detecting sensor is a force-sensor configured for measuring a force of contact between the slice and the first segment of the balling chamber.
6. The agricultural baler of claim 1, wherein the pre-compression chamber comprises an inlet and an outlet, wherein the outlet opens towards the first segment of the baling chamber, the pre-compression chamber comprising a pushing mechanism for pushing the slice through the outlet into the baling chamber, and wherein the controller is further configured for controlling a timing of the pushing mechanism.
7. The agricultural baler of claim 6, wherein the pre-compression chamber comprises two conveyors defining a channel between the inlet and the outlet, the two conveyors configured for forming the slice and for acting as a pushing mechanism.
8. The agricultural baler of claim 6, wherein the pushing mechanism comprises a set of fingers for grasping behind the slice of crop material at the inlet of the pre-compression chamber and for pushing the slice through the outlet.
9. The agricultural baler of claim 1, further comprising a plunger driving mechanism, a slice pushing driving mechanism, and an intermediary coupling element steerable via the controller, the plunger driving mechanism mechanically connected to the slice pushing driving mechanism via the intermediary coupling element to synchronize the slice pushing driving mechanism.
10. The agricultural baler of claim 9, wherein the intermediary coupling element is a planetary gearbox.
11. The agricultural baler of claim 9, wherein the intermediary coupling element is a two-part gearbox comprising a first part and a second part, the first part connecting one end via a straight gear coupling, the second part connecting another other end via a helical gear coupling.
12. The agricultural baler of claim 9, wherein the intermediary coupling element is configured for adjusting a relative position of the plunger driving mechanism and the slice pushing driving mechanism.
13. The agricultural baler of claim 9, further comprising an actuator connected to the intermediary coupling element to control the intermediary coupling element.
14. An agricultural baler comprising: a baling chamber comprising a first segment and a plunger; a pre-compression chamber configured for gathering crop material, periodically forming a slice of the crop material, and pushing the slice towards the baling chamber into the first segment of the baling chamber; a controller; a slice-presence-detecting sensor disposed in an upper region of the first segment of the baling chamber, the slice-presence-detecting sensor comprising an output operationally connected to the controller; a plunger driving mechanism; a slice pushing driving mechanism; and an intermediary coupling element controllable by the controller, the plunger driving mechanism mechanically connected to the slice pushing driving mechanism via the intermediary coupling element, wherein the plunger is configured for reciprocally moving in the baling chamber to compress slices of crop material into a bale, and wherein the controller is configured for adjusting a synchronization between the plunger driving mechanism and the slice pushing mechanism.
15. The agricultural baler of claim 14, wherein the slice-presence-detecting sensor is mounted at a top surface of the first segment of the baling chamber to detect arrival of the slice at the top surface.
16. The agricultural baler of claim 14, further comprising a plurality slice-presence-detecting sensors mounted at different heights in the first segment of the baling chamber.
17. The agricultural baler of claim 14, wherein the intermediary coupling element is a planetary gearbox.
18. The agricultural baler of claim 14, wherein the intermediary coupling element is a two-part gearbox comprising a first part and a second part, the first part connecting one end via a straight gear coupling, the second part connecting another other end via a helical gear coupling.
19. The agricultural baler of claim 14, wherein the intermediary coupling element is configured for adjusting a relative position of the plunger driving mechanism and the slice pushing driving mechanism.
20. The agricultural baler of claim 14, further comprising an actuator connected to the intermediary coupling element to control the intermediary coupling element.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] For the purpose of illustration, there are shown in the drawings certain embodiments of the present invention. In the drawings, like numerals indicate like elements throughout. It should be understood, however, that the invention is not limited to the precise arrangements, dimensions, and instruments shown. In the drawings:
[0027] FIG. 1 shows a schematic representation of a baling chamber and a pre-compression chamber, in accordance with an exemplary embodiment of the present invention;
[0028] FIG. 2 shows top-fill possibilities;
[0029] FIG. 3 shows an alternative schematic representation of a baling chamber and a pre-compression chamber, in accordance with an exemplary embodiment of the present invention;
[0030] FIG. 4 shows a gearbox suitable for coupling a movement of the baling chamber and a movement of the pre-compression chamber of FIG. 1, in accordance with an exemplary embodiment of the present invention; and
[0031] FIG. 5 shows influence of a gearbox in the movement of the elements of the pre-compression chamber of FIG. 1, in accordance with an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0032] FIG. 1 shows a schematic representation of main inside elements of an agricultural baler 100, in accordance with an exemplary embodiment of the present invention. FIG. 2 shows a baling chamber 1 and a pre-compression chamber 2, in accordance with an exemplary embodiment of the present invention. The pre-compression chamber 2 opens in the baling chamber 1 to push a slice of crop material 3 in a first segment 4 of the baling chamber 1.
[0033] The baling chamber comprises a plunger 5 which is provided for reciprocally moving in the baling chamber 1. The reciprocal movement is indicated by arrow 6. To this end, the plunger 5 is driven by a plunger driving mechanism 13. The connection between the plunger driving mechanism 13 and the plunger 5 is schematically represented by a pair of arms, although other driving mechanisms can be used as well for driving the plunger 5 in the reciprocal movement 6.
[0034] The pre-compression chamber 2 comprises a slice pushing mechanism 12. The slice pushing mechanism 12 is driven by a slice pushing driving mechanism 14. Desirably, the slice pushing driving mechanism 14 is mechanically connected to the plunger driving mechanism 13. Such mechanical connection ensures a synchronized movement between the plunger 5 and the slice pushing mechanism 12.
[0035] It will be clear that synchronization between the slice pushing mechanism 12 of the pre-compression chamber 2, and the reciprocal movement 6 of the plunger 5 is important for a correct operation of the baler 100. In the reciprocal movement of the plunger 5, the plunger 5 moves over at least a part of the first segment 4 of the baling chamber 1. Therefore, for being able to push a slice of crop material 3 into the baling chamber 1, the plunger 5 is desirably somewhere in a withdrawn position in the reciprocal movement 6. Otherwise, the first segment 4 is not open for receiving a slice of crop material 3.
[0036] The pre-compression chamber 2 desirably comprises an inlet 10 and an outlet 11. The outlet 11 opens toward the first segment 4 of the baling chamber 1, so that a slice of crop material 3 formed in the pre-compression chamber 2 can be pushed through the outlet 11 into the baling chamber 1. The inlet 10 of the pre-compression chamber 2 is desirably connected to crop gathering means (not shown) provided for gathering crop material and pushing the gathered crop material into the pre-compression chamber 2 via the inlet 10.
[0037] The mechanical connection between the plunger driving mechanism 13 and the slice pushing driving mechanism 14 is schematically represented by the elements 15, 16 and 17 in FIG. 1.
[0038] An important aspect in the formation of a nice square bale via the agricultural baler 100, is the top fill. FIG. 2 illustrates some possibilities regarding top fill. Top fill is defined as the distribution of crop material over the first segment 4 area at the moment that the plunger 5 hits the slice of crop material 3 in its forward movement. In an ideal situation, as is illustrated by slice 31, the crop material 3 is evenly distributed over the complete area of the first segment 4 of the baling chamber 1. However, this ideal situation cannot always be achieved. At a lower baling speed, it is possible that a slice of crop material 3 that is formed in the pre-compression chamber 2 has a density that is too low to keep the slice 3 in shape. The effect is that the slice of crop material 3 shrinks in the first segment 4 of the baling chamber 1, thereby resulting in a slice as is shown in FIG. 2 with reference number 32 or reference number 35. Pressing a bale with slices formed like that, results in an uneven distribution of load to the plunger 5 and results in bales having shapes that deviate from the ideal rectangular shape 31. In another case, a wrong synchronization between the slice pushing mechanism 14 and the plunger 5 could result in a slice 3 that is not yet completely pushed in the first segment 4 of the baling chamber 1 when the plunger 5 hits the slice 3, or has already fallen back (due to gravity) because the slice pushing mechanism 12 withdrew too early. In such situation, a slice 3 as is shown in FIG. 2 by reference number 33 is compressed by the plunger 5. Compressing such a slice 3 again results in the above described problems. In fast working balers, another problem might arise where the slice pushing mechanism 12 pushes the slice 3 in the first segment 4 of the baling chamber 1 with such force that the slice 3 deforms because it bumps into the top wall of the baling chamber 1. Such situation results in a slice 3 as is shown in FIG. 2 with reference number 34. Again, such slice 3 results in excessive wear of the baler elements because of unbalanced load, and results in bad bales.
[0039] FIG. 1 shows a sensor 7 that is placed in an upper region of the first segment 4 of the baling chamber 1. The sensor 7 is adapted to measure a presence of a slice 3 in the first segment 4 of the baling chamber 1. Therefore, this sensor 7 is referred to as slice presence detecting sensor. Such slice presence detecting sensor 7 can be formed in different manners such as ultrasonic sensor, infrared sensor, contact sensor, optical sensor, or other known sensors. Desirably, the slice presence detecting sensor 7 is formed as a force sensor adapted to measure a contact force. With such force sensor, not only the presence of the slice can be measured, but also the force with which the slice arrives at the sensor can be measured. Such force can be indicative for slice deformation (a slice arriving at the sensor with a high force undergoes a high acceleration which can result in a deformation of the slice).
[0040] The slice presence detecting sensor 7 is operationally coupled 8 to a controller 9. The controller 9 is adapted to adjust synchronization between the reciprocal plunger movement 6 and the slice pushing movement 12A of the pre-compression chamber 2. In the example of FIG. 1, a mechanical connection is established between plunger driving mechanism 13 and the slice pushing driving mechanism 14 via respective plunger shaft 15 and slice pushing mechanism shaft 16 which are connected via a gearbox 17. The gearbox 17 is adapted for adjusting the rotation ratio between the plunger shaft 15 and the slice pushing mechanism shaft 16, thereby adjusting synchronization between reciprocal plunger movement 6 and the slice pushing movement 12A of the pre-compression chamber 2. The controller 9 is adapted to control the gearbox 17 based on the input of the slice presence detecting sensor 7.
[0041] FIG. 4 shows an example of a gearbox 17 that is suitable for adjusting synchronization between a first and a second rotating shaft, in accordance with an exemplary embodiment of the present invention. The gearbox 17 comprises helical input gear 15 and a straight output gear 16. In the example of FIG. 4 and FIG. 1, the helical input gear 15 is coupled to the plunger shaft 15 and the straight output gear 16 is coupled to the slice pushing mechanism shaft 16. The input gear 15 and output gear 16 are connected via an intermediary gear 18 showing two parts. A first part comprises a helical gear 19 complementary to the helical input gear 15, and the second part shows a straight gear 20 complementary with the straight output gear 16. Thereby, in a fixed position, the intermediary gear 18 transmits the rotation of the input shaft 15 connected to the input gear 15 directly in a one-to-one ratio to the output shaft 16 connected to the output gear 16. The first part 19 and the second part 20 of the intermediary gear 18 are desirably integrally formed in such a matter that one end of the intermediary gear 18 comprises the helical gear 19 and the opposite end comprises the straight gear 20. The helical gear 19 and the straight gear 20 are formed around a single longitudinal axis 21 of the intermediary gear element 18. Desirably, the helical gear 19 diameter is larger than the straight gear diameter 20. More desirably, the helical gear 19 diameter is larger than two times the straight gear 20 diameter. The intermediary gear element 18 is provided to move along its longitudinal axis 21 between a first and a second position. In FIG. 4, the intermediary gear element 18 is shown in its most leftward position, and can be shifted to the right. By moving the intermediary gear element 18 along its longitudinal axis 21, the relative position of the input gear 15 and the output gear 16 changes. Thereby, synchronization between the input gear 15 and output gear 16 respectively coupled to the plunger driving mechanism 13 and the slice pushing driving mechanism 14 can be amended and fine-tuned while maintaining an overall synchronization (as the shafts are mechanically coupled). Such fine-tuning is achieved by moving the intermediary gear element 18 along its longitudinal axis 21. Such movement is indicated in FIG. 4 by the arrows on the longitudinal axis 21.
[0042] Alternatively to the gearbox 17 as shown in FIG. 4, the gearbox 17 may be embodied as a planetary gearbox for adjusting synchronization between the plunger shaft 15 and the slice pushing driving mechanism shaft 16, in accordance with an exemplary embodiment of the present invention. A planetary gearbox connects three shafts. The center wheel, the ring wheel, and the planetary wheels form the shaft connecting elements. Thereby, the plunger shaft 15 and slice pushing driving mechanism 16 can each be connected to one of the three gear elements of the planetary gearbox. A controller can be connected to the third gear of the planetary gearbox. The gearbox can be so configured that a standing still controller results in a ratio between input axis and output axis (in the present case the plunger shaft 15 and slice pushing driving mechanism shaft 16) that is fixed and predetermined so that synchronization is achieved. A rotation of the controller, rotating the third gear of the planetary gearbox, amends the relative position of the input shaft and output shaft, thereby adjusting the synchronization. A skilled person, given the information above, can configure a planetary gearbox in different manners to serve the purpose of the present invention.
[0043] By adjusting synchronization between the reciprocal plunger movement 6 and the slice pushing movement 12A of the slice pushing mechanism 12, the timing of insertion of a slice 3 with respect to the plunger movement 6 can be adjusted and thereby optimized. Also the speed of pushing the slice into the first segment 4 of the baling chamber 1 can be adjusted and optimized.
[0044] FIG. 5 shows two graphical representations of the slice pushing movement 12A. The lower graph shows the movement that the slice pushing mechanism 12 tip makes in time, and shows on the horizontal axis the horizontal movement in millimeters and on the vertical axis the vertical movement in millimeters. Starting at point 28, the tip is displaced in the direction indicated by arrow 29 and grasps behind the slice 3 to push the slice 3 through the outlet 11 into the baling chamber 1. The pushing movement is indicated by reference number 27. In the rest of the movement 26, the tip withdraws, and in the withdrawn position, moves back to the starting point 28 where the tip can push a new slice 3 in a subsequent period. The upper part of FIG. 5 shows the transmission of rotational movement between the plunger shaft 15 and the slice pushing mechanism shaft 16 over the time. In the figure, as an example, the slice pushing period takes 1.2 seconds, meaning that every 1.2 second a new slice of crop material is pushed into the baling chamber 1. Using a fixed connection between the plunger shaft 15 and the slice pushing mechanism shaft 16, a rotation is transmitted from one to the other shaft in a flat manner as is indicated by reference number 24. This route results in a slice pushing mechanism tip moving along the path 26 with a constant speed (constant speed meaning that every period, in every sub-segment of the movement, the tip follows the path with an identical distance over time ratio). Thereby, the speed of the segment 27 of the path of movement 26 cannot be adjusted. Using a gearbox as described above to connect the plunger shaft 15 and the slice pushing driving mechanism shaft 16, the synchronization can be adjusted. An example of an adjusted synchronization is indicated with reference number 25. In this example, the first part of the period is speeded up with respect to the second part of the period. Thereby, the slice pushing mechanism tip moves faster over the segment 27 of the movement path 26 than over the rest of the movement path. As a result, the timing of arrival of the slice 3 in the first segment 4 of the baling chamber 1 is adjusted.
[0045] Desirably, the gearbox 17 comprises an actuator that is steerable via the controller 9. The controller 9 is operationally connected to the slice presence detecting sensor 7. The actuator is desirably coupled to the gearbox 17 in such a manner that the relative position of the plunger shaft 15 with respect to the slice pushing mechanism shaft 16 is adjustable. In the example of the gearbox 17 of FIG. 4, the actuator is coupled to the intermediary gear element 18 to move the intermediary gear element along it longitudinal axis 21. In the example of the planetary gearbox, the actuator is coupled to the third of the three gear elements, so that a rotation of the actuator changes the relative position of the plunger shaft 15 (connected to a first of the three gear elements) and the slice pushing mechanism shaft 16 (connected to a second of the three gear elements). The actuator is steerable by the controller, which thereby controls the relative position of the plunger shaft 15 with respect to the slice pushing mechanism shaft 16.
[0046] The controller comprises an electrical circuit or an electronic circuit or a programmable electronic circuit or a combination of the above, so that the connector can control the actuator based on the input of the slice presence detecting sensor 7. The controller can comprise an open control loop, or a closed control loop, or a control loop comprising feed forward control commands, or a combination of the above.
[0047] FIG. 3 shows an alternative configuration of a baling chamber 1 and a pre-compression chamber 2, in accordance with an exemplary embodiment of the present invention. In the example of FIG. 3, multiple slice presence detecting sensors 7 are provided in the first segment 4 of the baling chamber 1, each of the sensors 7 being mounted at a different height in the first segment 4 of the baling chamber 1. The slice presence detecting sensors 7 are desirably mounted in at least one of the side walls of the baling chamber 1. Having multiple slice presence detecting sensors 7 at different heights in the first segment 4 of the baling chamber 1 allows deducing not only an arrival of the slice 3, but also a speed of the slice 3, and where at least three sensors 7 are provided, an acceleration or deceleration of the slice 3 in the first segment 4 of the baling chamber 1. This speed and acceleration/deceleration information can be further used by the controller 9 to adjust the synchronization between the reciprocal movement of the plunger 5 and the slice pushing in the pre-compression chamber 2.
[0048] FIG. 3 also shows an alternative configuration of the pre-compression chamber 2. In the example of FIG. 3, the pre-compression chamber 2 is defined by two belt conveyers 22, 23 forming a channel between an inlet 10 and an outlet 11. The outlet 11 opens into the baling chamber 1. The inlet 10 is connected to crop gather means which are provided to introduce crop material into the channel defined by the belt conveyers 22 and 23. In such configuration, in the slice forming process, the belt conveyers 22, 23 rotate at a first (low) speed. Once the slice is formed, the belt conveyers 22, 23 accelerate to a second (high) speed thereby throwing the formed slice through the outlet 11 into the first segment 4 of the baling chamber 1. The second speed is higher than the first speed. The belt conveyers 22, 23 are driven by electric or hydraulic engines. These engines can be coupled to one another (for synchronization) or can be driven independently. These engines can be coupled to the plunger driving mechanism for synchronization or can be independent from the plunger driving mechanism. The controller 9 is provided to control the engines driving the belt conveyers 22, 23 so that the timing of arrival of the slice in the first segment 4 of the baling chamber 1 is adjustable. Therefore, the slice presence detecting sensors 7 are operationally connected 8 to the controller 9.
[0049] It will be clear that different combination can be made of baler elements which examples are given in the present description. Also alternative gearboxes could be developed, beside the gearboxes described above which allow to adjust synchronization. Therefore, it is emphasized that the examples described and the figures shown in support of the description are not intended to limit the invention. The scope of the invention shall be solely defined in claims.
[0050] In the above description, different embodiments have been described that allow to adjust the timing of arrival of a slice in the first segment 4 of the baling chamber. By adjusting the timing, referring back to FIG. 2, situations as indicated by reference number 33 can be avoided. Furthermore, deduction of the slice with respect to the ideal shape 31 (deduction such as indicated with reference number 32, 34 and 35) can be minimized. Adjusting the synchronization between the reciprocal plunger movement 6 and the slice pushing movement 12A of the pre-compression chamber 2 implies that at least one of the slice pushing speed and slice pushing timing is controllable and can be amended.
[0051] In the present description, crop gathering means or crop gathering mechanism or feeder for feeding crop material refer to the same or at least similar part of the baler.
[0052] These and other advantages of the present invention will be apparent to those skilled in the art from the foregoing specification. Accordingly, it is to be recognized by those skilled in the art that changes or modifications may be made to the above-described embodiments without departing from the broad inventive concepts of the invention. It is to be understood that this invention is not limited to the particular embodiments described herein, but is intended to include all changes and modifications that are within the scope and spirit of the invention.
