U.S. patent number 10,385,605 [Application Number 15/352,910] was granted by the patent office on 2019-08-20 for tailgate sensor.
This patent grant is currently assigned to Vermeer Manufacturing Company. The grantee listed for this patent is Vermeer Manufacturing Company. Invention is credited to Ty Hartwick, Philip Robert Lane, Jacob Limke, Willem Jacobus Reijersen van Buuren, Kent Thoreson.
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United States Patent |
10,385,605 |
Limke , et al. |
August 20, 2019 |
Tailgate sensor
Abstract
The round baler includes a frame and a tailgate pivotally
mounted to the frame via a tailgate pivot axis. The tailgate is
movable along a path of travel range between an open position and a
closed position. When in the open position, a bale can be
discharged from the baler and, when in the closed position, a bale
is prevented from being discharged from the baler. The baler also
includes a sensor that has a sensor axis. This sensor is mounted to
the baler with the sensor axis approximately coaxial with the
tailgate pivot axis. An operating portion of the sensor is
operatively directly movable with the tailgate. The sensor has a
mechanical rotary range that is at least the travel range of the
tailgate; and an electrical sensing range. The electrical sensing
range is less than both the mechanical rotary range and the travel
range of the tailgate.
Inventors: |
Limke; Jacob (Pella, IA),
Reijersen van Buuren; Willem Jacobus (Dirksland, NL),
Hartwick; Ty (Pella, IA), Lane; Philip Robert (Pella,
IA), Thoreson; Kent (Bussey, IA) |
Applicant: |
Name |
City |
State |
Country |
Type |
Vermeer Manufacturing Company |
Pella |
IA |
US |
|
|
Assignee: |
Vermeer Manufacturing Company
(Pella, IA)
|
Family
ID: |
60661921 |
Appl.
No.: |
15/352,910 |
Filed: |
November 16, 2016 |
Prior Publication Data
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|
|
Document
Identifier |
Publication Date |
|
US 20180135345 A1 |
May 17, 2018 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E05F
15/70 (20150115); A01F 15/0875 (20130101); A01D
89/002 (20130101); E05Y 2400/45 (20130101); A01F
15/0715 (20130101); A01F 15/0883 (20130101); E05Y
2400/44 (20130101); E05Y 2900/518 (20130101) |
Current International
Class: |
A01F
15/08 (20060101); E05F 15/70 (20150101); A01F
15/07 (20060101); A01D 89/00 (20060101) |
Field of
Search: |
;49/31 ;701/49 ;56/341
;702/188 ;340/613 ;177/245 ;100/99,7,87 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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1 444 882 |
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Nov 2004 |
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EP |
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3 087 827 |
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Feb 2016 |
|
EP |
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Other References
International Search Report and Written Opinion for Application No.
PCT/US2017/062028 dated Feb. 26, 2018. cited by applicant.
|
Primary Examiner: Nguyen; Chi Q
Attorney, Agent or Firm: Merchant & Gould P.C.
Claims
We claim:
1. A round baler comprising: a frame; a tailgate including a
tailgate pivot axis, the tailgate being pivotally mounted to the
frame about the tailgate pivot axis, the tailgate being movable
along a path of travel range between an open position and a closed
position, wherein, when in the open position, a bale can be
discharged from the round baler, and wherein, when in the closed
position, the bale is prevented from being discharged from the
round baler; and a sensor having a sensor axis mounted to the baler
such that the sensor axis is approximately coaxial with the
tailgate pivot axis, and wherein an operating portion of the sensor
is operatively connected with the tailgate, the operating portion
of the sensor being configured for direct movement with the
tailgate, wherein the sensor has a mechanical rotary range and an
electrical sensing range, the mechanical rotary range being at
least the path of travel range of the tailgate, the electrical
sensing range being less than the mechanical rotary range and
including only a portion of the path of travel range of the
tailgate.
2. The round baler of claim 1, wherein the tailgate defines a path
of travel angle that is defined by the open position and the closed
position, the path of travel angle being greater than or equal to
90 degrees.
3. The round baler of claim 2, wherein the sensor has a sensing
range defined along the path of travel of the tailgate, wherein the
sensing range has a sensing angle of less than or equal to 90
degrees.
4. The round baler of claim 1, wherein the sensor has a sensing
range that coincides with an upper portion of the tailgate path of
travel range and does not include a lower portion of the tailgate
path of travel range.
5. The round baler of claim 1, further comprising a second sensor
attached to the tailgate, wherein the second sensor has a
mechanical rotary range and an electrical sensing range, wherein
the electrical sensing range is less that the mechanical rotary
range of the second sensor and also less than the path of travel
range of the tailgate, wherein the second sensor has a sensing
range that includes a lower portion of the tailgate path of travel
range and does not include an upper portion of the tailgate path of
travel range.
6. The round baler of claim 1, wherein the sensor has a sensing
range that includes a lower portion of the tailgate path of travel
range and does not include an upper portion of the tailgate path of
travel range.
7. The round baler of claim 1, further comprising a tailgate latch
for selectively coupling the tailgate to the frame, the tailgate
latch having a latched position and an unlatched position, wherein,
when in the latched position, the latch secures the tailgate to the
frame of the round baler when the tailgate is in the closed
position, and wherein, when in the unlatched position, the tailgate
is in the open position.
8. The round baler of claim 7, further comprising a position sensor
in communication with the tailgate latch and a control system,
wherein the position sensor communicates to the control system when
the tailgate is in the latched position.
9. The round baler of claim 8, wherein the control system controls
the process of closing the tailgate by: reducing a speed of the
movement of the tailgate as the tailgate approaches the closed
position; increasing the speed of the movement of the tailgate as
the tailgate reaches the closed position; and stopping the movement
of the tailgate when the position sensor communicates that the
tailgate latch is in the latched position.
10. A system for controlling a tailgate comprising: a tailgate
including a tailgate pivot, the tailgate being pivotally mounted to
a frame of a round baler about the tailgate pivot, the tailgate
being pivotally mounted for movement through a path of travel range
defined by a closed position at a first angular position and a
fully open position at a second angular position, the second
angular position being spaced from the first angular position; a
sensor being mounted to the tailgate at the tailgate pivot, the
sensor having a sensing range including only a portion of the
tailgate path of travel range; an actuator for moving the tailgate
between the closed position and the open position; and a control
system in communication with the sensor, the control system having
logic to control the movement of the tailgate based on a sensor
measurement.
11. The system of claim 10, wherein the control system uses
closed-loop positional feedback from the sensor when the tailgate
is moved from the closed position towards the fully open position,
and wherein the control system receives open-loop positional
feedback from the sensor when the tailgate is moved from the open
position to the closed position.
12. The system of claim 10, wherein the sensor has a mechanical
rotary range and an electrical sensing range, the mechanical rotary
range being at least the path of travel range of the tailgate, the
electrical sensing range being less that the mechanical rotary
range and also less than the path of travel range of the
tailgate.
13. The system of claim 12, wherein the mechanical rotary range of
the sensor is more than the tailgate path of travel range.
14. The system of claim 10, wherein the sensor has a sensing range
that includes a lower portion of the tailgate path of travel range
and does not include an upper portion of the tailgate path of
travel range.
15. The system of claim 10, wherein the sensor has a sensing range
that includes an upper portion of the tailgate path of travel range
and does not include a lower portion of the tailgate path of travel
range.
16. The system of claim 10, wherein the sensor measurement of the
sensor is a linear change in voltage.
17. The system of claim 10, further comprising a tailgate latch for
selectively coupling the tailgate to the frame of the round baler,
the tailgate latch having a latched position and an unlatched
position, wherein, when in the latched position, the latch secures
the tailgate to the frame of the round baler when the tailgate is
in the closed position, and wherein, when in the unlatched
position, the tailgate is in the open position.
18. The system of claim 17, further comprising a position sensor in
communication with the tailgate latch and the control system,
wherein the position sensor communicates to the control system when
the tailgate is in the latched position.
19. The system of claim 17, wherein the control system controls the
process of closing tailgate by: reducing a speed of the movement of
the tailgate as the tailgate approaches the closed position;
increasing the speed of the movement of the tailgate as the
tailgate reaches the closed position; and stopping the movement of
the tailgate when the latch sensor communicates that the tailgate
is in a latched position.
20. A baler comprising: a frame and a tailgate for allowing bales
to be discharged from the baler, the tailgate being adapted to
pivot about a tailgate pivot axis relative to the frame, the
tailgate being able to pivot through a tailgate range of pivotal
movement; a rotary sensor including a sensor housing and a sensor
rotary member, the sensor rotary member being mounted within the
sensor housing, the sensor housing and the sensor rotary member
being rotatable relative to one another about a sensor axis of
rotation, the rotary sensor having a mechanical range of rotary
movement between the sensor housing and the sensor rotary member,
the rotary sensor having a sensed range of rotary movement between
the sensor housing and the sensor rotary member, the mechanical
range of rotary movement being greater than the sensed range of
rotary movement, the mechanical range of rotary movement being
equal to or greater than the tailgate range of pivotal movement,
and the sensed range of rotary movement including only a portion of
the tailgate range of pivotal movement; and the rotary sensor being
mounted with the sensor axis of rotation generally coaxially
aligned with the tailgate pivot axis, the sensor housing being
coupled to one of the frame and the tailgate and the sensor rotary
member being coupled to the other of the frame and the tailgate,
the rotary sensor being mounted such that the rotary sensor and the
tailgate rotate together at a one-to-one ratio as the tailgate
moves through the tailgate range of pivotal movement, the rotary
sensor mechanically rotating with the tailgate throughout the
entire tailgate range of pivotal movement.
21. The baler of claim 20, wherein the sensed range includes an
upper portion of the tailgate path of travel range and does not
include a lower portion of the tailgate path of travel range.
22. The baler of claim 20, wherein the mechanical rotary range of
the sensor is more than the path of travel range of the
tailgate.
23. The baler of claim 20, wherein the tailgate is movable along
the tailgate range between an open position and a closed position,
the baler further comprising: a tailgate latch for selectively
coupling the tailgate to the frame of the baler, the tailgate latch
having a latched position and an unlatched position, wherein, when
in the latched position, the latch secures the tailgate to the
frame of the baler when the tailgate is in the closed position, and
wherein, when in the unlatched position, the tailgate is in the
open position; and an actuator for moving the tailgate between the
closed position and the open position; a control system in
communication with the rotary sensor, the control system having
logic to control movement of the tailgate based on a rotary sensor
measurement; a position sensor in communication with the tailgate
latch and the control system, wherein the position sensor
communicates to the control system when the tailgate is in the
latched position, wherein the control system controls the process
of closing the tailgate by: reducing a speed of the movement of the
actuator as the tailgate approaches the closed position; increasing
the speed of the movement of the actuator as the tailgate reaches
the closed position; and stopping the movement of the tailgate when
the position sensor communicates that the latch is in the latched
position.
24. A system for controlling a tailgate comprising: a tailgate
including a tailgate pivot, the tailgate being pivotally mounted to
a frame of a round baler about the tailgate pivot, the tailgate
being pivotally mounted for movement through a path of travel range
defined by a closed position at a first angular position and a
fully open position at a second angular position, the second
angular position being spaced from the first angular position; a
tailgate sensor being mounted to the tailgate at the tailgate
pivot; a tailgate latch for selectively coupling the tailgate to
the frame of the round baler, the tailgate latch having a latched
position and an unlatched position, wherein, when in the latched
position, the latch secures the tailgate to the frame of the round
baler when the tailgate is in the closed position, and wherein,
when in the unlatched position, the tailgate is in the open
position; an actuator for moving the tailgate between the closed
position and the open position and for moving the tailgate latch
between the latched position and the unlatched position; a control
system in communication with the tailgate sensor, the control
system having logic to control the movement of the tailgate based
on a sensor measurement; and a latch sensor in communication with
the tailgate latch and the control system, wherein the latch sensor
communicates to the control system when the tailgate is in the
latched position, wherein the control system controls the process
of closing the tailgate by: reducing a speed of the movement of the
actuator as the tailgate approaches the closed position; increasing
the speed of the movement of the actuator as the tailgate reaches
the closed position; and stopping the movement of the tailgate when
the latch sensor communicates that the latch is in the latched
position.
25. The system of claim 24, wherein the tailgate sensor senses
movement along a portion of the tailgate path of travel between the
open position and the closed position.
26. The system of claim 24, wherein the tailgate sensor has a
sensing range of less than the tailgate path of travel range.
27. The system of claim 24, wherein the latch sensor is at least
one of a proximity sensor and a contact sensor.
28. The system of claim 24, wherein the control system uses
closed-loop positional feedback from the sensor when the tailgate
is moved from the closed position towards the fully open position,
and wherein the control system receives open-loop positional
feedback from the sensor when the tailgate is moved from the open
position to the closed position.
Description
BACKGROUND
Round balers have become an integral part of the agricultural
industry and a variety of different types of balers are currently
in use. Balers can be either towed behind a tractor or be
self-propelled. Balers often either use a system of belts that
compress the bale or a system that includes a fixed chamber to form
the bale. A wrap material is then applied to the finished round
bale to aid in securing the bale. Typically after a bale is formed
and wrapped, a tailgate will be opened and the bale will be ejected
from the baler. During operation of the baler, it is desirable to
open and close the tailgate as fast as possible to minimize the
bale forming cycle time, thereby allowing the operator to become
more efficient. However, it is also undesirable to slam the
tailgate open and closed.
Therefore, improvements in tailgate sensing and operation are
needed.
SUMMARY
The present disclosure relates generally to sensing the rotary
position of a tailgate of a round baler as it rotates about its
tailgate pivot axis, with a specific sensor that is not developed
for this specific purpose, wherein the performance of that sensor
is not optimized for this purpose. The sensor has a sensing range
that is less than the complete rotary path of travel of the
tailgate, and thus it is not an obvious design choice for this
application. However, the sensor does have a mechanical rotary
range of movement that is more than the rotary movement of the
tailgate. Although this sensor is not able to measure the position
of the tailgate throughout the complete path of travel of the
tailgate, there is a motivation to utilize it for this purpose due
to significant advantages in its cost and reliability. The present
disclosure describes a method for utilizing this specific type of
sensor to produce acceptable results.
In one example, a round baler is disclosed. The round baler
includes a frame and a tailgate pivotally mounted to the frame with
a tailgate pivot axis. The tailgate is movable along a path of
travel range between an open position and a closed position. When
in the open position, a bale can be discharged from the round baler
and, when in the closed position, a bale is prevented from being
discharged from the round baler. The baler also includes a sensor
that has a sensor axis. This sensor is mounted to the baler with
the sensor axis approximately coaxial with the tailgate pivot axis.
An operating portion of the sensor is operatively connected for
direct movement with the tailgate. The sensor has a mechanical
rotary range that is more than the path of travel range of the
tailgate and an electrical sensing range. The electrical sensing
range is less than the mechanical rotary range and also less than
the path of travel range of the tailgate.
In another example, a round baler is disclosed. The round baler
includes a frame and a tailgate for allowing bales to be discharged
from the baler. The tailgate is adapted to pivot about a tailgate
pivot axis relative to the frame through a tailgate range of
pivotal movement. The round baler includes a rotary sensor that
includes a sensor housing and a sensor rotary member that is
mounted within the sensor housing. The sensor housing and the
sensor rotary member are rotatable relative to one another about a
sensor axis of rotation. The rotary sensor has a mechanical range
of rotary movement between the sensor housing and the sensor rotary
member. The rotary sensor has a sensed range of rotary movement
between the sensor housing and the sensor rotary member. The
mechanical range of rotary movement is greater than the sensed
range of rotary movement. The mechanical range of rotary movement
is equal to or greater than the tailgate range of pivotal movement.
The sensed range of rotary movement is less than the tailgate range
of pivotal movement. The rotary sensor is mounted with the sensor
axis of rotation generally coaxially aligned with the tailgate
pivot axis. The sensor housing is coupled to one of the frame and
the tailgate, and the sensor rotary member is coupled to the other
of the frame and the tailgate. The rotary sensor is mounted such
that the rotary sensor and the tailgate rotate together at a
one-to-one ratio as the tailgate moves through the tailgate range
of pivotal movement. The rotary sensor mechanically rotates with
the tailgate throughout the entire tailgate range of pivotal
movement.
In one example, the sensor is used to sense the position of the
tailgate along the lower portion of travel, but not the upper
portion of travel.
In one example, the sensor is used to sense the position of the
tailgate along the upper portion of travel, but not the lower
portion of travel.
A variety of additional aspects will be set forth in the
description that follows. The aspects can relate to individual
features and to combinations of features. It is to be understood
that both the foregoing general description and the following
detailed description are exemplary and explanatory only and are not
restrictive of the broad inventive concepts upon which the
embodiments disclosed herein are based.
BRIEF DESCRIPTION OF THE DRAWINGS
The following drawings are illustrative of particular embodiments
of the present disclosure and therefore do not limit the scope of
the present disclosure. The drawings are not to scale and are
intended for use in conjunction with the explanations in the
following detailed description. Embodiments of the present
disclosure will hereinafter be described in conjunction with the
appended drawings, wherein like numerals denote like elements.
FIG. 1 illustrates a schematic side view of an example round baler
with a tailgate in a closed position, according to one embodiment
of the present disclosure;
FIG. 2 illustrates a schematic side view of the round baler of FIG.
1 with the tailgate in the open position;
FIG. 3 illustrates an example rotary sensor, according to one
embodiment of the present disclosure;
FIG. 4 illustrates a schematic representation of a tailgate pivot
arrangement including a shaft, according to one embodiment of the
present disclosure;
FIG. 5 illustrates a schematic representation of a tailgate pivot
arrangement, according to one embodiment of the present
disclosure;
FIG. 6 illustrates a schematic diagram of a portion of a path of
travel range and an example sensed range of the tailgate of the
round baler of FIG. 1, according to one embodiment of the present
disclosure;
FIG. 7 illustrates a schematic diagram of a portion of a path of
travel range and an example sensed range of the tailgate of the
round baler of FIG. 1, according to one embodiment of the present
disclosure; and
FIG. 8 illustrates a schematic diagram of a portion of a path of
travel range and an example sensed range of the tailgate of the
round baler of FIG. 1, according to one embodiment of the present
disclosure.
DETAILED DESCRIPTION
Various embodiments will be described in detail with reference to
the drawings, wherein like reference numerals represent like parts
and assemblies throughout the several views. Reference to various
embodiments does not limit the scope of the claims attached hereto.
Additionally, any examples set forth in this specification are not
intended to be limiting and merely set forth some of the many
possible embodiments for the appended claims.
The round baler disclosed herein has several advantages.
Specifically, the round baler uses a tailgate position sensor that
is cost effective and reliable. The tailgate sensor is produced in
mass quantities and has proven to have a long life span. The
tailgate position sensor allows the round baler to monitor the
position of the tailgate over a limited range of movement of the
tailgate so as to allow the round baler to more efficiently operate
(e.g., reducing baling cycle times).
FIGS. 1 and 2 show schematic side views of a round baler 100. In
accordance with the principles of the present disclosure, the round
baler 100 uses an expandable baling chamber 102 which operates by
utilizing a series of bale forming belts routed around a series of
rollers. Alternatively, a single bale forming belt may be utilized.
Further, a fixed baling chamber may also be utilized.
The baler 100 includes a driving means 109, a pick-up device 110,
and a tailgate 114. As material is picked up by the pick-up device
110 and deposited in the baling chamber 102, the material is
compressed into a bale. Once a full bale is formed, the bale is
wrapped by a wrapping device 118. The wrapping device 118 is
configured to apply a layer of wrap material to the outer
circumference of the full bale. Once the wrapping sequence is
completed, the operator ejects the full bale from the baling
chamber 102 by moving the tailgate 114 from a closed position, as
shown in FIG. 1, to an open position, as shown in FIG. 2. Further
details relating to the baling operation within the baling chamber
can be found in U.S. Pat. No. 7,181,900, which is hereby
incorporated by reference in its entirety.
In the depicted embodiment, the tailgate 114 is pivotally attached
to a main frame 120 of the baler 100 at a tailgate pivot 122 by way
of a pivot tube 104. In some embodiments, a linkage is connected
between the main frame 120 and the tailgate 114. Specifically, the
tailgate pivot 122 is shown to be positioned on the main frame 120.
When in the closed position, the tailgate 114 is latched to the
main frame 120 of the baler 100 via a latch 115. Movement of the
tailgate 114 is controlled by a tailgate actuator 124, such as a
hydraulic actuator. In some embodiments, the baler 100 includes a
plurality of tailgate actuators 124 for controlling the movement of
the tailgate 114. In some embodiments, the tailgate actuator(s) 124
is/are in communication with a controller 127 used to control the
operation of the baler 100.
Referring generally to the controller 127 and methods of
controlling, and referring in particular to computing systems
embodying the methods and systems of the present disclosure, it is
noted that various computing systems can be used to perform the
control processes disclosed herein. For example, embodiments of the
disclosure may be practiced in various types of electrical circuits
comprising discrete electronic elements, packaged or integrated
electronic chips containing logic gates, a circuit utilizing a
microprocessor, or on a single chip containing electronic elements
or microprocessors. Embodiments of the disclosure may also be
practiced using other technologies capable of performing logical
operations such as, for example, AND, OR, and NOT, including, but
not limited to, mechanical, optical, fluidic, and quantum
technologies. In addition, aspects of the methods described herein
can be practiced within a general purpose computer or in any other
circuits or systems.
As the tailgate 114 is rotated about the tailgate pivot 122, the
tailgate actuator 124 supports the weight of the tailgate 114.
During a baling operation, it is desirable to open and close the
tailgate quickly to minimize the cycle time. This process includes
1) releasing the tailgate latch 115; 2) raising the tailgate 114
from the closed to the open position; 3) lowering the tailgate 114
from the open to the closed position; and 4) closing the tailgate
latch 115. The tailgate 114 includes a sensor 126 to measure a
position of the tailgate 114.
FIG. 3 shows a front view of an example sensor 126. The sensor 126
is a rotary sensor. In some embodiments, the sensor 126 is a rotary
transducer, such as a rotary potentiometer. The sensor 126 includes
a housing 106 and a rotatable member 108 mounted within the housing
106, wherein this assembly has a sensor axis of rotation R. The
rotatable member 108 is illustrated to have a drive slot 107. The
sensor 126 can be a non-contact angular position sensor, such as a
CHERRY AN1 sensor. An angular position sensor is described in U.S.
Pat. No. 6,960,973, which is hereby incorporated by reference in
its entirety. Such a sensor provides a linear change in voltage
output to the controller 127 that corresponds to an angular
rotation of the rotatable member 108. Common uses for the sensor
126 include, but are not limited to, throttle and valve position
sensing, pedal position sensing, joystick position sensing, and
gear position sensing.
As the rotatable member 108 rotates about the housing 106, the
sensor 126 senses the relative position of the rotatable member 108
with respect to the housing 106. The rotatable member 108 has a
mechanical travel range that rotatable member 108 can rotate within
the housing 106, represented by angle .beta.. In some embodiments,
the mechanical travel range is about 120 degrees with respect to
the housing 106. However, the sensor 126 is configured to only
sense the movement of the rotatable member 108 over a range that is
less than the mechanical travel range, angle .beta.. Angle .alpha.
represents the position of the rotatable member 108 within the
housing 106. The electrical sensing range for the sensor is
represented by the cross-hatched area between the angle .alpha.,min
in which the rotatable member 108 is moved a small amount from a
position where it is spring-biased against an internal stop to
define a starting angle, and the angle .alpha.,max.
FIG. 4 shows a schematic top view of a cross-section of the baler
100. FIG. 4 further shows the mounting of the sensor 126 to the
baler 100, according to one embodiment of the present disclosure.
As shown, the tailgate 114 is pivotally attached to the main frame
120 at the tailgate pivot 122. In the depicted embodiment, the
tailgate pivot 122 includes a shaft 123 that rotates with the
tailgate 114 about the main frame 120. The sensor 126 is positioned
at the tailgate pivot 122. Specifically, the housing 106 of the
sensor 126 is mounted to the main frame 120 in a position where the
sensor axis of rotation is generally aligned with the axis of
rotation of the shaft 123. The rotatable member 108 is drivably
engaged with the shaft 123. In the embodiment shown in FIG. 4,
drive adaptor 125 is configured with a tab that fits into the drive
slot 107 of the rotatable member 108. The housing 106 is set in a
rotational position where the tab of the drive adaptor will rotate
through its range of motion as the tailgate 114 moves between the
closed and open positions. That rotational position is within the
range of mechanical travel of the sensor 126. Therefore, as the
tailgate 114 moves between the open and closed positions, the shaft
123 rotates, which then rotates the rotatable member 108 of the
sensor 126.
The sensor 126 is configured to measure the angular position of the
tailgate 114 by sensing the position of the rotatable member 108
with respect to the housing 106, where the housing 106 is fixed to
the main frame 120. Then sensor 126 provides such measurements to
the controller 127. The controller 127 is configured to aid in
controlling the operation of the baler 100, specifically the
tailgate 114, using the measurements provided by the sensor 126.
While the rotatable member 108 of the sensor 126 is configured to
move with the tailgate 114 along the sensor's mechanical travel
range, the sensor 126 is capable of measuring the angular the
position of the tailgate 114 along only a portion of that movement.
Specifically, the sensor 126 can only sense the position of the
tailgate 114 when the angle .alpha. is within its electric sensing
range as shown in FIG. 3. This will be explained in more detail
with respect to FIGS. 6-8.
FIG. 5 shows another schematic top view of an example cross-section
of the baler 100. In the depicted embodiment, the tailgate pivot
122 is fixed to the main frame 120 of the baler 100. As shown, the
sensor 126 is shown slightly separated from its permanent mounting
location, thereby showing a partially exploded view of its mounting
components. Specifically, the housing 106 of the sensor 126 is
configured to be attached to the main frame 120 by way of a bracket
128. The rotatable member 108 is configured to be drivably engaged
with the tailgate 114 by way of a sensor arm 130. The sensor 126 is
mounted so that the rotatable member 108 is generally aligned with
the axis of rotation of the tailgate pivot 122. The sensor arm 130
is configured to be effectively attached to the sensor 126 through
the engagement of a tab that engages with the drive slot 107 of the
rotatable member 108. The sensor arm 130 is engaged with the
tailgate 114 at a drive extension 132, which is fixed to the
tailgate 114 and with a slot in the sensor arm 130. Therefore, as
the tailgate 114 rotates between the open and closed positions, the
drive extension 132 rotates with the tailgate 114 about its axis of
rotation, causing the sensor arm 130 to rotate with the rotatable
member 108 of the sensor 126 about the sensor's axis of rotation R.
Because the housing 106 of the sensor 126 is fixed to the main
frame 120 by way of the bracket 128, the sensor 126 can sense the
relative position of the tailgate 114 with respect to the main
frame 120. The slot in the sensor arm 130 that is engaged with the
drive extension 132 of the tailgate 114 provides for some
misalignment between the tailgate axis of rotation and the sensor
axis of rotation.
In other embodiments, the tailgate pivot 122 is positioned on the
tailgate 114 and, therefore, the sensor 126 is positioned on the
tailgate 114. Specifically, the rotatable member 108 can be
attached to the main frame 120 by the sensor arm 130, and the
housing 106 of the sensor 126 can be mounted to the tailgate
114.
FIG. 6 shows a schematic diagram of the portion of a path of travel
range of the tailgate 114 that the sensor 126 is configured to
measure, according to one embodiment of the present disclosure. The
tailgate 114 is shown to move about the tailgate pivot 122, thereby
having a path of travel range that corresponds with an angular
position range represented by an angle .theta.. In some
embodiments, the angle .theta. is greater than 90 degrees. In some
embodiments, the angle .theta. is about 120 degrees.
The tailgate actuator 124 is shown to be positionable between
points A, B, and C. At point A, the tailgate 114 is in a latched,
closed position. At point B, the tailgate actuator 124 travels a
distance to disengage the tailgate latch 115, thereby positioning
the tailgate 114 in an unlatched, closed position. When extending
from point B to point C, the tailgate 114 rotates from the closed
position, corresponding to point B, to the open positon,
corresponding to point C.
The sensor 126 is shown with its axis coaxially aligned with the
tailgate pivot axis, and the sensor housing 106 rotated to a
position wherein its sensing range, which corresponds with the
shaded region, is positioned so that when the angle .alpha. is at
the smallest angle of 5 degrees as shown, it is positioned higher
than point C which represents the highest position of the tailgate.
Thus, the sensor 126 is capable of measuring the angular position
of the tailgate 114 at the open position, point C, but it is not
capable of measuring the angular positon of the tailgate 114 at the
closed position, point B. As the tailgate moves through its range
of motion represented by the angle .theta., the sensor will move
through that same range of travel, wherein the magnitude of that
angular travel will result in an angle .alpha. that is beyond the
sensing range of the sensor 126. The sensing range of sensor 126
overlaps or coincides with an upper portion of the tailgate path of
travel range and does not include a lower portion of the tailgate
path of travel range. The tailgate 114, therefore, has a sensed
range of movement where the angular position of the tailgate is
sensed; and a non-sensed range of movement where the angular
position of the tailgate 114 is not sensed. In one example, the
sensed range covers at least 45, 60, 75, or 90 degrees, and the
non-sensed range covers at least 10, 15, 20, or 25 degrees.
With this mounting arrangement, the lower portion of travel of the
tailgate 114 will not be detected by the sensor 126. The process
would include moving the tailgate 114 by extending the tailgate
actuator 124 at full speed from the closed position toward the open
position. The lower portion of that travel will be an open-loop
control and therefore no feedback will be provided by the sensor
126 until the tailgate 114 moves into the sensor 126's sensing
range. As the tailgate 114 approaches the open position, the speed
can be reduced before the tailgate 114 is stopped at any desired
position within the sensing range of the sensor 126.
When closing the tailgate 114 by retracting the tailgate actuator
124, the tailgate 114 moves from an open position toward the closed
position. A portion of closing movement is measurable by the sensor
126, corresponding to that portion where the measured angle .alpha.
is within the cross-hatched sensing range. However, as the tailgate
114 approaches the closed position, the sensor 126 would not be
capable of measuring that movement as the tailgate 114 will
eventually have an angular position outside of the sensing range.
The process can include moving the tailgate 114 at full speed from
the open position until the end of the sensing range of the sensor
126. The speed of movement of the tailgate 114 can be reduced at
the point in time when the tailgate 114 has an angular position
that corresponds to the end of the sensing range of the sensor 126.
As the tailgate 114 continues to move toward the closed position,
the system would be operating in an open-loop control. In some
embodiments, in order to ensure that the tailgate 114 is completely
closed, which is important for the operation of the baler 100, the
controller 127 could utilize a position sensor 116 (e.g., proximity
sensor, contact sensor, or other like sensor) for the tailgate
latch 115, to detect when the latch 115 is closed. In the some
embodiments, the tailgate latch 115 is operated by the tailgate
actuators 124 (as shown in FIGS. 1 and 2 for instance), so the
system can continue to retract the tailgate cylinder at the reduced
speed until the system detects that the latch 115 is in the locked
position.
FIG. 7 shows a schematic diagram of a portion of the path of travel
range of the tailgate 114 that the sensor 126 is capable of
measuring, according to one embodiment of the present disclosure.
The sensor 126 is illustrated to have a sensing range, which
corresponds with the angular position range represented between an
angle .alpha.,min and .alpha.,max, wherein the sensor 126 is
positioned so that this sensing range is capable of measuring the
angular position of the tailgate 114 at the closed position, point
B, but it is not capable of measuring the angular positon of the
tailgate 114 at the open position, point C. The sensing range of
the sensor 126 overlaps or coincides with a lower portion of the
path of travel range of the tailgate 114 and does not include an
upper portion of the path of travel range of the tailgate 114.
Therefore, the sensing range, corresponding to the angular position
range represented by the cross-hatched area between angle
.alpha.,min and .alpha.,max is oppositely shifted along the path of
travel range of the tailgate 114 as compared to the embodiment
discussed with relation to FIG. 6. The magnitude of angle .theta.
remains greater than the magnitude of angle .alpha.. In other
embodiments, the sensed range is offset from the upper portion of
the path of travel of the tailgate 114 and offset from the lower
portion of the path of travel of tailgate 114.
With this mounting arrangement, the last portion of travel of the
tailgate 114 when moving from the closed to the open position will
not be detected by the sensor 126. The process would include moving
the tailgate 114 by extending the tailgate actuator 124 at full
speed from the closed position toward the open position. The first
portion of that travel will be a closed-loop control, providing
position feedback to the sensor 126 until the tailgate 114 moves
out of the sensor 126's sensing range. As the tailgate 114
approaches the open position and moves to the range of travel
outside of the sensor's sensing range, the speed can be
reduced.
When closing the tailgate 114, the first portion of travel of the
tailgate 114 will not be detected by the sensor 126. The process
would include moving the tailgate 114 by retracting the tailgate
actuator 124 at full speed from the open position. The first
portion of that travel will be an open-loop control and therefore
no feedback will be provided by the sensor 126 until the tailgate
114 moves into the sensor 126's sensing range. As the tailgate 114
approaches the closed position, the speed can be reduced before the
tailgate 114 reaches the closed position, point B. When reaching
the closed position, point B, the tailgate 114 can again be moved
at full speed so as to allow the tailgate 114 to properly engage
and close the latch 115.
FIG. 8 shows a schematic isometric diagram of the path of travel
range of the tailgate 114 that would be moved with a first cylinder
124L on the left side of the baler 100 and a second cylinder 124R
on the right side, with a plurality of sensors 126L, 126R for
measuring the position of the tailgate 114, according to one
embodiment of the present disclosure. Because the sensors 126 have
a limited measuring range, a pair of identical sensors 126L,126R
can be utilized and positioned so as to be able to sense the
position of the tailgate 114 along a wider range of the path of
travel range of the tailgate 114. As illustrated, the sensors 126L,
126R are positioned such that their sensing ranges overlap. This
allows the sensor 126L to be capable of measuring the angular
position of the tailgate 114 at the open position, point C, and
sensor 126R to be capable of measuring the angular position of the
tailgate 114 at the closed position, point B. Therefore, the
sensing range is a combination of the embodiments described herein
with respect to FIGS. 6 and 7.
The various embodiments described above are provided by way of
illustration only and should not be construed to limit the claims
attached hereto. Those skilled in the art will readily recognize
various modifications and changes that may be made without
following the example embodiments and applications illustrated and
described herein, and without departing from the true spirit and
scope of the following claims.
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