Patent Description:
Round balers are typically equipped with a wrap system for wrapping a bale with a wrap material secure the bale in a cylindrical shape for storage and transport. The wrap material may include, but is not limited to, a net material or a solid sheet material. Some wrap systems are configured with a pair of spool rollers that are positioned to form a nip therebetween, and which inject the wrap material through an access and into a baling chamber. The wrap material is a very flexible material and can be difficult to control, especially when starting the wrapping cycle in which a leading edge of the wrap material must be inserted through the access and into the baling chamber.

One challenge with these types of systems is the lack of control of the mesh trajectory as the wrap material is ejected from the nip between the pair of spool rollers. There are many variables that can cause undesirable trajectories on the wrap material and result in the wrap material not aligning with the access and being blocked from the entering the baling chamber.

A round baler is provided. The round baler includes a baling system defining a baling chamber. The baling chamber includes an inlet providing entrance into the baling chamber. The baling system is operable to receive crop material into the baling chamber through the inlet and form the crop material into a bale within the baling chamber. The round baler further includes a wrap system. The wrap system is operable to insert a wrap material through an access and into the baling chamber to wrap the bale. The access may include the inlet through which the crop material is moved through and into the baling chamber, or may include a separate opening into the baling chamber. The wrap system includes a pair of spool rollers forming a nip therebetween. The pair of spool rollers are configured to rotate about respective axes of rotation in opposite rotational directions relative to each other and receive a wrap material from a supply roll through the nip. A driver is coupled to the pair of spool rollers and operable to transmit torque to the pair of spool rollers to rotate the pair of spool rollers about their respective axes of rotation. A torque controller is coupled to the driver. The torque controller is configured to control torque transmitted to the pair of spool rollers based on a current characteristic of the supply roll related to a current weight of the supply roll of the wrap material. The torque transmitted to the pair of spool rollers is controlled to achieve a desired acceleration rate of the spool rollers, such that a leading edge of the wrap material is ejected from the nip at an ejection trajectory that is within an allowable angular range relative to a tangent of the nip. When the ejection trajectory is within the allowable angular range, the leading edge of the wrap material is aligned with and may pass through the access and into the baling chamber.

In one aspect of the disclosure, the pair of spool rollers includes a first roller and a second roller. The first roller includes an elastomer defining a cylindrical outer elastomer surface of the first roller. The second roller may also include an elastomer defining a cylindrical outer elastomer surface of the second roller.

In one aspect of the disclosure, a support structure is configured to support the supply roll of the wrap material relative to the pair of spool rollers. The support structure supports the supply roll of the wrap material such that the supply roll of the wrap material rests against the cylindrical outer elastomer surface of the first roller along a contact region.

In one aspect of the disclosure, the round baler may include a sensor operable to sense data related to a weight of the supply roll of the wrap material. In one implementation, the sensor may include an electronic sensor such as but not limited to a potentiometer, an optical sensor, etc. In other implementations, the sensor may be configured as a mechanical sensor that is sensitive to and/or reacts to a physical property and/or movement of the supply roll of the wrap material, in which case the sensor may include a spring, a lever, cam and follower structure, combinations thereof, etc. The sensor may be configured to sense a characteristic of the supply roll of the wrap material that is related to a weight of the supply roll of the wrap material. For example, the sensor may be configured to sense data related to a force, a radial size, a diametric size, a volume, etc..

In one aspect of the disclosure, the driver may include a belt coupled to one or both of the pair of spool rollers. A tensioner is coupled to the blet and is operable to tension the belt. The torque controller is configured to selectively control the tensioner to adjust the tension of the belt to vary the torque supplied to the pair of spool rollers based on the current weight of the supply roll of the wrap material.

In one implementation of the round baler, the torque controller may include a computing device having a processor and a memory having a wrap feed control algorithm stored thereon. The processor is operable to execute the wrap feed control algorithm to receive data related to a weight of the supply roll of the wrap material from the sensor, and control the driver to adjust torque transmitted to the pair of rollers. The torque is controlled to achieve the desired acceleration rate of the pair of rollers. The torque from the driver may be decreased as the weight of the supply roll of the wrap material decreases. The computing device of the torque controller may be coupled to and in communication with the tensioner, and operable to communicate a control signal to the tensioner. For example, the computing device may communicate a signal to the tensioner, causing one an actuator of the tensioner to move, thereby adjusting the tension of the belt.

In other implementations, the torque controller may include mechanical linkages, connections, pivots, levers, cams, followers, etc., that are coupled to the supply roll of the wrap material. The mechanic linkages may be configured to transmit forces and/or movements of the supply roll to the tensioner, whereby the tensioner is response to the movements in order to adjust tension in the belt.

Referring to <FIG>, a round baler is generally shown at <NUM>. The round baler <NUM> includes a frame <NUM>. One or more ground engaging elements <NUM>, such as but not limited to one or more wheels and/or tracks, are attached to and rotatably supported by the frame <NUM>. A tongue <NUM> may be coupled to the frame <NUM> at a forward end of the frame <NUM>. A hitch arrangement <NUM> may be included with the tongue <NUM>. The hitch arrangement <NUM> may be used to attach the round baler <NUM> to a traction unit, such as but not limited to an agricultural tractor. In other embodiments, the round baler <NUM> may be self-propelled, in which case the traction unit and the round baler <NUM> are configured as a single, self-propelled vehicle.

The round baler <NUM> includes a baling system <NUM>. The baling system <NUM> forms a baling chamber <NUM>. The baling system <NUM> is attached to and supported by the frame <NUM>. The baling system <NUM> may include one or more walls or panels that at least partially enclose and/or define the baling chamber <NUM>. In the example implementation shown in the Figures and described herein, the round baler <NUM> further includes a gate <NUM>. The gate <NUM> is attached to and rotatably supported by the frame <NUM>. The gate <NUM> is positioned adjacent a rearward end of the frame <NUM> and is pivotably moveable about a gate axis <NUM>. The gate axis <NUM> is generally horizontal and perpendicular to a central longitudinal axis <NUM> of the frame <NUM>. The gate <NUM> is moveable between a closed position for forming a bale within the baling chamber <NUM>, and an open position for discharging the bale from the baling chamber <NUM>.

The round baler <NUM> includes a pick-up <NUM> disposed proximate the forward end of the frame <NUM>. The pickup gathers crop material from a ground surface <NUM> and directs the gathered crop material toward and into an inlet <NUM> of the baling chamber <NUM>. The pickup may include, but is not limited to tines, forks, augers, conveyors, baffles, etc., for gathering and moving the crop material. The round baler <NUM> may be equipped with a pre-cutter, disposed between the pickup and the inlet <NUM>. As such, the pre-cutter is disposed downstream of the pickup and upstream of the inlet <NUM> relative to a direction of travel of the crop material. The pre-cutter cuts or chops the crop material into smaller pieces.

The round baler <NUM> may be configured as a variable chamber baler, or as a fixed chamber baler. The round baler <NUM> shown in the Figures and described herein is depicted and described as a variable chamber baler. As is understood by those skilled in the art, the variable chamber baler includes a plurality of longitudinally extending side-by-side forming belts <NUM> that are supported by a plurality of rollers. The bale is formed by the forming belts <NUM> and one or more side walls of the housing.

The crop material is directed through the inlet <NUM> and into the baling chamber <NUM>, whereby the forming belts <NUM> roll the crop material in a spiral fashion into the bale having a cylindrical shape. The forming belts <NUM> apply a constant pressure to the crop material as the crop material is formed into the bale. A forming belt tensioner continuously moves the forming belts <NUM> radially outward relative to a center of the cylindrical bale as the diameter of the bale increases. The forming belt tensioner maintains the appropriate tension in the forming belts <NUM> to obtain the desired density of the crop material.

The round baler <NUM> includes a wrap system <NUM>. The wrap system <NUM> is operable to wrap the bale with a wrap material <NUM> inside the baling chamber <NUM>. Once the bale is formed to a desired size, the wrap system <NUM> is initiated to begin a wrap cycle. Referring to <FIG>, when a wrap cycle is initiated the wrap system <NUM> feeds or inserts the wrap material <NUM> through an access <NUM> and into the baling chamber <NUM> to wrap the bale and thereby secure the crop material in a tight package and maintain the desired shape of the bale. In one implementation, the access <NUM> may include the inlet <NUM>, through which the crop material moves into the baling chamber <NUM>. In another implementation, the access <NUM> may include an opening into the baling chamber <NUM> that is separate from the inlet <NUM>. The wrap material <NUM> may include, but is not limited to, a net mesh or a solid plastic wrap. Movement of the gate <NUM> into the open position simultaneously moves the forming belts <NUM> clear of the formed bale, and allows the formed and wrapped bale to be discharged through the rear of the baling chamber <NUM>.

Referring to <FIG>, the wrap system <NUM> includes a pair of spool rollers <NUM>, <NUM>. The pair of spool rollers <NUM>, <NUM> includes a first roller <NUM> and a second roller <NUM>. The first roller <NUM> and the second roller <NUM> are arranged in a parallel relationship, and extend transversely across a width of the frame <NUM> in a horizontal orientation, generally perpendicular to the central longitudinal axis <NUM> of the frame <NUM>. The first roller <NUM> includes a cylindrical shape having a respective centerline <NUM>, about which the first roller <NUM> rotates. As such, the respective centerline <NUM> of the first roller <NUM> is an axis of rotation of the first roller <NUM>. The second roller <NUM> includes a cylindrical shape having a respective centerline <NUM>, about which the second roller <NUM> rotates. As such, the respective centerline <NUM> of the second roller <NUM> is an axis of rotation of the second roller <NUM>. The first roller <NUM> and the second roller <NUM> are arranged such that a circumferential surface of the first roller <NUM> and a circumferential surface of the second roller <NUM> are disposed in contacting or abutting engagement, and form a nip <NUM> therebetween where their respective circumferential surfaces come together and meet. As used herein, the term "nip" may be defined as, but is not limited to, the region where the first roller <NUM> and the second roller <NUM> come together and contact each other.

As described above, the pair of spool rollers <NUM>, <NUM> are configured to rotate about their respective axes of rotation <NUM>, <NUM>. The first roller <NUM> and the second roller <NUM> rotate in opposite rotational directions relative to each other and receive the wrap material <NUM> from a supply roll <NUM> through the nip <NUM>. As shown in the example implementation of the Figures, the first roller <NUM> is rotatable about its' respective axis of rotation <NUM> in a counter-clockwise direction as viewed on the page of the drawing, and the second roller <NUM> is rotatable about its' respective axis of rotation <NUM> in a clockwise direction as viewed on the page of the drawing. As such, the first roller <NUM> and the second roller <NUM> cooperate to feed the wrap material <NUM> through the nip <NUM>, from left to right as viewed on the page of the drawing.

The first roller <NUM> includes an elastomer defining a cylindrical outer elastomer surface <NUM> of the first roller <NUM>. The elastomer exhibits static adhesion or "sticky" properties which limits movement of the wrap material <NUM> relative to the cylindrical outer elastomer surface <NUM> of the first roller <NUM>. The elastomer may include for example, but is not limited to, a natural or synthetic rubber material, or some other material having similar static adhesion properties.

The second roller <NUM> may also include an elastomer defining a cylindrical outer elastomer surface <NUM> of the second roller <NUM>. The elastomer exhibits static adhesion or "sticky" properties which limits movement of the wrap material <NUM> relative to the cylindrical outer elastomer surface <NUM> of the second roller <NUM>. The elastomer may include for example, but is not limited to, a natural or synthetic rubber material, or some other material having similar static adhesion properties.

The round baler <NUM> further includes a support structure <NUM>. The support structure <NUM> is configured to support the supply roll <NUM> of the wrap material <NUM> relative to the pair of spool rollers <NUM>, <NUM>. The support structure <NUM> supports the supply roll <NUM> such that the supply roll <NUM> of the wrap material <NUM> rests against the cylindrical outer elastomer surface <NUM> of the first roller <NUM> along a contact region <NUM>. Because the supply roll <NUM> of the wrap material <NUM> rests against the cylindrical outer elastomer surface <NUM> of the first roller <NUM>, it should be appreciated that the support structure <NUM> must allow the supply roll <NUM> of the wrap material <NUM> to move relative to the frame <NUM> of the round baler <NUM> as the wrap material <NUM> is dispensed to maintain contact between the wrap material <NUM> on the supply roll <NUM> and the cylindrical outer elastomer surface <NUM> of the first roller <NUM>. The support structure <NUM> may include, but is not limited to, wall portions of a housing of the round baler <NUM>, various guides, pins, grooves, etc. The specific construction of the support structure <NUM> in which the supply roll <NUM> of the wrap material <NUM> is supported understood by those skilled in the art, is not pertinent to the teachings of this disclosure, and is therefore not described in greater detail herein.

As described above, the supply roll <NUM> of the wrap material <NUM> rests against the cylindrical outer elastomer surface <NUM> of the first roller <NUM> along the contact region <NUM> and is continuously pressed against the cylindrical outer elastomer surface <NUM> of the first roller <NUM> as a radial or diametric size <NUM> of the supply roll <NUM> of the wrap material <NUM> decreases. The contact region <NUM> is the common contact surface area between the supply roll <NUM> of the wrap material <NUM> and the fist roller. It should be appreciated that the contact region <NUM> extends generally parallel with a centerline <NUM> of the supply roll <NUM> and the centerline <NUM> of the first roller <NUM>, across a width of the supply roll <NUM> of the wrap material <NUM>.

The wrap material <NUM> follows a routing path that partially encircles the first roller <NUM>, between the contact region <NUM> and the nip <NUM> and about the axis of rotation <NUM> of the first roller <NUM>. The routing path follows a counter-clockwise path around the cylindrical outer elastomer surface <NUM> of the first roller <NUM> as viewed on the page of the drawing. The wrap material <NUM> enters the nip <NUM> moving from left to right as viewed on the page of the drawing, whereby the wrap material <NUM> is grasped between the first roller <NUM> and the second roller <NUM> at the nip <NUM>. During a wrap cycle, the first roller <NUM> and the second roller <NUM> are counter rotated bout their respective axes of rotation <NUM>, <NUM> to eject the wrap material <NUM> from the nip <NUM> toward and through the access <NUM> and into the baling chamber <NUM>.

Referring to <FIG>, the wrap system <NUM> includes a driver <NUM> that is coupled to the pair of spool rollers <NUM>, <NUM>. The driver <NUM> is operable to transmit torque to the pair of spool rollers <NUM>, <NUM> to rotate the pair of spool rollers <NUM>, <NUM> about their respective axes of rotation <NUM>, <NUM>. The driver <NUM> may be configured in any suitable manner, and include a device, system, or mechanism capable rotating the pair of spool rollers <NUM>, <NUM> about their respective axes of rotation <NUM>, <NUM>. In one implementation, the driver <NUM> includes a belt <NUM> coupled to at least one of the pair of spool rollers <NUM>, <NUM> and a tensioner <NUM> operable to tension the belt <NUM>. The belt <NUM> may be coupled to a rotating element <NUM>, such as but not limited to a driven roller of the baling system <NUM>, to receive torque therefrom. When the belt <NUM> is sufficiently tensioned by the tensioner <NUM>, the belt <NUM> transmits torque from the rotating element <NUM> to the pair of spool rollers <NUM>, <NUM>, thereby rotating the pair of spool rollers <NUM>, <NUM> about their respective axes of rotation <NUM>, <NUM>. When tension in the belt <NUM> is reduced by the tensioner <NUM>, the belt <NUM> slips relative to the rotating element <NUM> and/or at least one of the pair of spool rollers <NUM>, <NUM>, such that the pair of spool rollers <NUM>, <NUM> do not rotate. Accordingly, it should be appreciated that the amount of torque applied to the pair of spool rollers <NUM>, <NUM> is proportional to and/or controlled by the tension in the belt <NUM>. It should be appreciated the torque transfer to the pair of spool rollers <NUM>, <NUM> may be controlled via other systems and/or components of the round baler <NUM>, other than the example implementation described herein, such as but not limited to, an adjustable flywheel, braking system, electrically actuated components, hydraulically actuated components, etc..

Observations demonstrate that as the supply roll <NUM> of the wrap material <NUM> decreases in weight, such as may occur with a smaller diameter <NUM> of the supply roll <NUM> shown in <FIG> the angular acceleration rate of the pair of spool rollers <NUM>, <NUM> from rest when beginning the wrap cycle increases. The higher acceleration rate of the pair of spool rollers <NUM>, <NUM> that occurs when the weight of the supply roll <NUM> of the wrap material <NUM> decreases may result in a less desirable e.g., higher, ejection trajectory <NUM> toward the access <NUM> in the baling chamber <NUM>. This is believed to occur because the supply roll <NUM> of the wrap material <NUM> is "coupled" to the first roller <NUM> via the static adhesion of the elastomer forming the outer surface of the first roller <NUM>, thereby causing a "flywheel effect" in which the higher acceleration rate causes the centrifugal forces acting on the wrap material <NUM> to eject the wrap material <NUM> at a higher ejection trajectory <NUM> than occurs with a heavier supply roll <NUM> of the wrap material <NUM>. If the ejection trajectory <NUM> of the wrap material <NUM> from the nip <NUM> is not aligned with the access <NUM> into the baling chamber <NUM>, the wrap material <NUM> may contact other elements and fail to pass through the access <NUM>.

The wrap system <NUM> includes a torque controller <NUM>. The torque controller <NUM> is coupled to the driver <NUM>, and is configured to selectively control the driver <NUM>, e.g., the tensioner <NUM>, to adjust torque transfer through the driver <NUM>, e.g., the tension of the belt <NUM>, at the start or initiation of a wrap cycle. The tension in the belt <NUM> is controlled during initiation of the wrap cycle to vary the torque supplied to the pair of spool rollers <NUM>, <NUM> based on a current characteristic of the supply roll related to the current weight of the supply roll <NUM> of the wrap material <NUM> to achieve a desired acceleration rate of the spool rollers <NUM>, <NUM>. When the acceleration rate of the pair of spool rollers <NUM>, <NUM> is controlled to the desired acceleration rate during initiation of a wrap cycle, a leading edge <NUM> of the wrap material <NUM> is ejected from the nip <NUM> at the ejection trajectory <NUM> that is within an allowable angular range <NUM> relative to a tangent <NUM> of the nip <NUM>, such that the leading edge <NUM> of the wrap material <NUM> passes through the access <NUM> and into the baling chamber <NUM>.

The ejection trajectory <NUM> is the trajectory or path that the leading edge <NUM> of the wrap material <NUM> follows when ejected from the nip <NUM> and prior to entering or passing through the access <NUM> into the baling chamber <NUM>. The ejection trajectory <NUM> may be described relative to the tangent <NUM> of the nip <NUM>. As described above, the nip <NUM> is the contact location where the circular, circumferential exterior surface of the first roller <NUM> contacts the circular, circumferential exterior surface of the second roller <NUM>. The tangent <NUM> of the nip <NUM> is therefore the tangent <NUM> of the circumferential exterior surface of the first roller <NUM> and the second roller <NUM> at the nip <NUM>, and generally extends along the central longitudinal axis <NUM> of the frame <NUM>.

The allowable angular range <NUM> is an angle measured relative to the tangent <NUM> of the nip <NUM>. The allowable angular range <NUM> may include an angular range above and/or below the tangent <NUM> of the nip <NUM>, and corresponds with alignment with the access <NUM> into the baling chamber <NUM>. The allowable angular range <NUM> may be defined to include all angles relative to the tangent <NUM> of the nip <NUM> in which the leading edge <NUM> of the wrap material <NUM> will pass through the access <NUM> and enter the baling chamber <NUM>. It should be appreciated that the allowable angular range <NUM> may vary with the specific size, shape, orientation, and positioning of the components of the round baler <NUM>, and may vary with different implementations and/or configurations of the round baler <NUM>.

The wrap system <NUM> may further include a sensor <NUM> that is operable to sense data related to the characteristic of the supply roll related to the weight of the supply roll <NUM> of the wrap material <NUM>. It should be appreciated that the weight of the supply roll <NUM> of the wrap material <NUM> decreases as the wrap material <NUM> is dispensed from the supply roll <NUM>. The sensor <NUM> may include, but is not limited to, an electronic sensor the generates and communicates an electronic signal to the torque controller <NUM>, or a mechanical sensor that generates and communicates movement and/or force to the torque controller <NUM>. The sensor <NUM> may be configured to sense a mass, a force or a weight of the supply roll <NUM>, a radial or diametric size <NUM> of the supply roll <NUM>, a volume of the supply roll <NUM>, a rotational inertia of the supply roll, or some other type of data related to the weight of the supply roll <NUM>. If the sensor <NUM> is implemented as an electronic sensor, the sensor <NUM> may include, but is not limited to, an optical sensor, a potentiometer, a resistance sensor, or some other implementation that is capable of generating an electronic signal representing and/or associated with the data related to the weight of the supply roll <NUM>. If the sensor <NUM> is implemented as a mechanical sensor, the sensor <NUM> may include levers, springs, cam and follower assemblies, linkages, etc., necessary to sense and communicate mechanical forces and/or mechanical movement associated with the weight of the supply roll <NUM> to the torque controller <NUM>.

As described above, the torque controller <NUM> is coupled to the driver <NUM>, and is configured to selectively control the tensioner <NUM> to adjust the tension of the belt <NUM> at the start or initiation of a wrap cycle. The torque controller <NUM> may be implemented as a mechanical device responsive to force or movement communicated from the sensor <NUM>. As such, in one implementation, the mechanical based sensor <NUM> may detect a force or movement, which is communicated to the mechanical based torque controller <NUM>, which in turn controls the tensioner <NUM>.

In other implementations, the torque controller <NUM> may include an electronic torque controller <NUM>. The torque controller <NUM> may be disposed in communication with the sensor <NUM>, and the tensioner <NUM>. The torque controller <NUM> is operable to receive data from the sensor <NUM> related to the weight of the supply roll <NUM> of the wrap material <NUM>, and comminate a control signal to the tensioner <NUM>. While the torque controller <NUM> is generally described herein as a singular device, it should be appreciated that the torque controller <NUM> may include multiple devices linked together to share and/or communicate information therebetween. Furthermore, it should be appreciated that the torque controller <NUM> may be located on the round baler <NUM> or located remotely from the round baler <NUM>.

The torque controller <NUM> may alternatively be referred to as a computing device, a computer, a controller, a control unit, a control module, a module, etc. The torque controller <NUM> includes a processor <NUM>, a memory <NUM>, and all software, hardware, algorithms, connections, sensors, etc., necessary to manage and control the operation of the driver <NUM> and/or tensioner <NUM>. As such, a method may be embodied as a program or algorithm operable on the torque controller <NUM>. It should be appreciated that the torque controller <NUM> may include any device capable of analyzing data from various sensors, comparing data, making decisions, and executing the required tasks.

As used herein, "torque controller <NUM>" is intended to be used consistent with how the term is used by a person of skill in the art, and refers to a computing component with processing, memory, and communication capabilities, which is utilized to execute instructions (i.e., stored on the memory <NUM> or received via the communication capabilities) to control or communicate with one or more other components. In certain embodiments, the torque controller <NUM> may be configured to receive input signals in various formats (e.g., hydraulic signals, voltage signals, current signals, CAN messages, optical signals, radio signals), and to output command or communication signals in various formats (e.g., hydraulic signals, voltage signals, current signals, CAN messages, optical signals, radio signals).

The torque controller <NUM> may be in communication with other components on the round baler <NUM>, such as hydraulic components, electrical components, and operator inputs within an operator station of an associated work vehicle. The torque controller <NUM> may be electrically connected to these other components by a wiring harness such that messages, commands, and electrical power may be transmitted between the torque controller <NUM> and the other components. Although the torque controller <NUM> is referenced in the singular, in alternative embodiments the configuration and functionality described herein can be split across multiple devices using techniques known to a person of ordinary skill in the art.

The torque controller <NUM> may be embodied as one or multiple digital computers or host machines each having one or more processors, read only memory (ROM), random access memory (RAM), electrically-programmable read only memory (EPROM), optical drives, magnetic drives, etc., a high-speed clock, analog-to-digital (A/D) circuitry, digital-to-analog (D/A) circuitry, and any required input/output (I/O) circuitry, I/O devices, and communication interfaces, as well as signal conditioning and buffer electronics.

The computer-readable memory <NUM> may include any non-transitory/tangible medium which participates in providing data or computer-readable instructions. The memory <NUM> may be non-volatile or volatile. Non-volatile media may include, for example, optical or magnetic disks and other persistent memory. Example volatile media may include dynamic random access memory (DRAM), which may constitute a main memory. Other examples of embodiments for memory <NUM> include a floppy, flexible disk, or hard disk, magnetic tape or other magnetic medium, a CD-ROM, DVD, and/or any other optical medium, as well as other possible memory devices such as flash memory.

The torque controller <NUM> includes the tangible, non-transitory memory <NUM> on which are recorded computer-executable instructions, including a wrap feed control algorithm <NUM>. The processor <NUM> of the torque controller <NUM> is configured for executing the wrap feed control algorithm <NUM>. The wrap feed control algorithm <NUM> implements a method of controlling the wrap system <NUM>, described in detail below.

As described above, the first roller <NUM> and the second roller <NUM> may include an elastomer defining the cylindrical outer elastomer surface <NUM> of the first roller <NUM> and the second roller <NUM> respectively. It has been observed that when the elastomer of the first roller <NUM> and the second roller <NUM> are new, the static adhesion characteristics of the elastomer tend to be higher, and may increase the ejection trajectory <NUM> relative to used elastomer, in which the static adhesion decreases. In other words, when the first roll and the second roll are new, the elastomer has a higher degree or amount of static adhesion, and the amount of static adhesion decreases with usage and stabilizes at a lower, more consistent level. The higher static adhesion that occurs when the first roller <NUM> and the second roller <NUM> are new may affect the ejection trajectory <NUM>.

In order to address the change in the static adhesion of the first roller <NUM> and the second roller <NUM> that occurs with usage, A desired acceleration rate of the pair of spool rollers <NUM>, <NUM> may be defined based on a usage of the pair of spool rollers <NUM>, <NUM>. For example, the desired acceleration rate of the pair of spool rollers <NUM>, <NUM> may be defined to include a first value for an initial usage period and a second value for a subsequent usage period. The initial usage period may be defined as a number of bales wrapped, a number of hours of operation, an estimated percent of life cycle, etc. The subsequent usage period may be defined as the remainder of the useful life of the pair of spool rollers <NUM>, <NUM>.

The usage of the round baler <NUM> may be monitored, for example, by the torque controller <NUM>. If the usage of the round baler <NUM> is within the initial usage period, then the torque controller <NUM> may define the desired acceleration rate to equal to the value. If the usage of the round baler <NUM> is not within the initial usage period, i.e., if the usage of the round baler <NUM> is within the subsequent usage period, then the torque controller <NUM> may define the desired acceleration rate to equal the second value. The torque controller <NUM> may be configured to automatically re-define the desired acceleration rate from the first value to the second value after the initial usage period ends.

A current characteristic of the supply roll <NUM> of the wrap material <NUM> related to a current weight of the supply roll <NUM> of the wrap material <NUM> is sensed or detected with the sensor <NUM>. The data related to the current weight of the supply roll <NUM> is then communicated to the torque controller <NUM>, which receives data related to the current weight of the supply roll <NUM> of the wrap material <NUM> from the sensor <NUM>. As described above, the sensor <NUM> may include an electronic sensor that communicates an electronic signal to the torque controller <NUM>, or may include a mechanical sensor that communicates a force or movement to the torque controller <NUM>, or may include a combination of both a mechanic signal and an electronic signal.

The torque controller <NUM> may then use the data related to the current characteristic related to the current weight of the supply roll <NUM> to calculate or otherwise determine the current weight of the supply roll <NUM> of the wrap material <NUM>. The manner in which the toque controller determines the current weight of the supply roll <NUM> is dependent upon the type of data sensed or detected by the sensor <NUM>. For example, if the sensor <NUM> detects a radial or diametric size <NUM>, then the torque controller <NUM> may correlate the radial or diametric size <NUM> to a weight based on look-up table or other similar process. If the sensor <NUM> detects a mass force, then the torque controller <NUM> may convert the mass force signal to the current weight. It should be appreciated that the torque controller <NUM> may determine the current weight of the supply roll <NUM> using many different processes, which are understood by those skilled in the art.

Upon initiation of a new wrap cycle to wrap a completed bale with the wrap material <NUM>, the torque controller <NUM> controls rotation of the pair of spool rollers <NUM>, <NUM> based on the current weight of the supply roll <NUM> of the wrap material <NUM>. The rotation of the pair of spool rollers <NUM>, <NUM> is controlled to achieve the desired acceleration rate of the spool rollers <NUM>, <NUM>. The desired acceleration rate of the spool rollers <NUM>, <NUM> ejects the leading edge <NUM> of the wrap material <NUM> from the nip <NUM> at an ejection trajectory <NUM> that is within the allowable angular range <NUM> relative to the tangent <NUM> of the nip <NUM>. By ejecting the wrap material <NUM> with the leading edge <NUM> thereof at the ejection trajectory <NUM> within the allowable angular range <NUM>, the leading edge <NUM> of the wrap material <NUM> may pass through the access <NUM> and into the baling chamber <NUM>.

In order to control the rotation of the pair of spool rollers <NUM>, <NUM>, the torque controller <NUM> selectively controls the driver <NUM> to vary the torque supplied to the pair of spool rollers <NUM>, <NUM>. Accordingly, the torque supplied to the pair of spool rollers <NUM>, <NUM> with the supply roll <NUM> having a smaller diameter <NUM> and therefore a lesser weight, such as shown in <FIG>, will be less than the torque supplied to the pair of spool rollers <NUM>, <NUM> with the supply roll <NUM> having a larger diameter <NUM> and therefore a greater weight, such as shown in <FIG>. The driver <NUM> is controlled based on the current weight of the supply roll <NUM> of the wrap material <NUM>. It should be appreciated that for a given current weight of the supply roll <NUM>, a higher applied torque will result in a faster or higher acceleration rate, whereas a lower applied torque will result in a slower or lesser accretion rate. In order to achieve the desired acceleration rate as the weight of the supply roll <NUM> decreases, the amount of torque transmitted from the driver <NUM> to the pair of spool rollers <NUM>, <NUM> may be decreased so that the consistent desired acceleration rate is achieved. As such, the torque from the driver <NUM> is decreased as the weight of the supply roll <NUM> of the wrap material <NUM> decreases.

As described above, in the example implementation shown in the Figures and described herein, the driver <NUM> includes the belt <NUM> coupled to one or both of the pair of spool rollers <NUM>, <NUM>, and the tensioner <NUM> operable to tension the belt <NUM>. Selectively controlling the drive to vary the torque supplied to the pair of spool rollers <NUM>, <NUM> based on the current weight of the supply roll <NUM> of the wrap material <NUM> may include selectively controlling the tensioner <NUM> to adjust the tension of the belt <NUM> based on the current weight of the supply roll <NUM> of the wrap material <NUM>. The tensioner <NUM> may be controlled via a signal from the torque controller <NUM>. For example, the tensioner <NUM> may include an actuator <NUM> coupled to a pulley <NUM> that is engaged with the belt <NUM>. The position of the pully relative to the belt <NUM> may affect the tension in the belt <NUM>. As such, engaging or moving the actuator <NUM> re-positions the pulley <NUM> and adjusts the tension in the belt <NUM>. The actuator <NUM> may include, but is not limited to, a hydraulic cylinder, an electric linear actuator, an electric rotary actuator, or some other similar device. The actuator <NUM> may be controlled via the signal from the torque controller <NUM>.

The pair of spool rollers <NUM>, <NUM> may be replaced at some point during the normal life cycle of the round baler <NUM>. As described above, the elastomer of the pair of spool rollers <NUM>, <NUM> exhibits a higher level of static adhesion when new. As such, in response to replacing the pair of spool rollers <NUM>, <NUM> with an un-used pair of spool rollers <NUM>, <NUM> after the subsequent usage period, the torque controller <NUM> may re-establish or re-define the desired acceleration rate of the pair of spool rollers <NUM>, <NUM> at the first value for the initial usage period.

Claim 1:
A round baler (<NUM>) comprising:
a baling system (<NUM>) defining a baling chamber (<NUM>) having an access (<NUM>) into the baling chamber (<NUM>), wherein the baling system (<NUM>) is operable to receive crop material into the baling chamber (<NUM>) through the access (<NUM>) and form the crop material into a bale within the baling chamber (<NUM>);
a wrap system (<NUM>) operable to insert a wrap material (<NUM>) through the access (<NUM>) and into the baling chamber (<NUM>) to wrap the bale, the wrap system (<NUM>) including:
a pair of spool rollers (<NUM>, <NUM>) forming a nip (<NUM>) therebetween, wherein the pair of spool rollers (<NUM>, <NUM>) are configured to rotate about respective axes of rotation (<NUM>, <NUM>) in opposite rotational directions relative to each other and receive a wrap material (<NUM>) from a supply roll (<NUM>) through the nip (<NUM>);
a driver (<NUM>) coupled to the pair of spool rollers (<NUM>, <NUM>) and operable to transmit torque to the pair of spool rollers (<NUM>, <NUM>) to rotate the pair of spool rollers (<NUM>, <NUM>) about their respective axes of rotation (<NUM>, <NUM>);
a torque controller (<NUM>) coupled to the driver (<NUM>), wherein the torque controller (<NUM>) is configured to control torque transmitted to the pair of spool rollers (<NUM>, <NUM>) based on a current characteristic of the supply roll (<NUM>) related to a current weight of the supply roll (<NUM>) of the wrap material (<NUM>) to achieve a desired acceleration rate of the spool rollers, such that a leading edge (<NUM>) of the wrap material (<NUM>) is ejected from the nip (<NUM>) at an ejection trajectory (<NUM>) that is within an allowable angular range (<NUM>) relative to a tangent (<NUM>) of the nip (<NUM>), such that the leading edge (<NUM>) of the wrap material (<NUM>) passes through the access (<NUM>) and into the baling chamber (<NUM>).