Adjustable Baler Chamber Wall for Twine Breakage Prevention
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Solution Overview
Problem
Baling machines using the twin spool process face challenges in maintaining high compression pressure without twine breakage, especially when handling elastic materials, leading to reduced bale density and increased risk of twine failure during ejection.
Innovation Solution
A baler apparatus with an adjustable baling chamber wall that reduces pressure during the final stage of bale formation, allowing controlled tension in binding twines and optimizing compression for various materials, thereby minimizing twine breakage and maintaining bale density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If high compression pressure is applied during the entire bale forming process, then bale density is improved, but the risk of twine breakage increases
Solution Approach 1:
The baling chamber wall is made adjustable to dynamically change the compression pressure during the baling process. The wall can be positioned in different locations to provide high compression during most of the bale formation and reduced compression during the final stage, allowing the system to adapt to different process requirements without manual intervention.
Solution Approach 2:
The adjustable wall is positioned to provide high compression pressure during the majority of the bale formation process (70-90% of bale length) to achieve high density. The wall position is then changed before the final stage to reduce compression pressure, preparing the bale for binding without over-compression that would cause twine breakage.
2Reliability
If compression pressure is reduced to prevent twine breakage, then twine reliability is improved, but bale density decreases
Solution Approach 1:
The baling process is divided into two distinct stages: a first stage with high compression pressure (6-10 bar) for the majority of bale formation to achieve high density, and a second final stage with reduced compression pressure (20-50% reduction) for the last 10-30% of bale length to prevent twine breakage. The adjustable wall enables this segmentation of the compression process.
3Adaptability or versatility
If the adjustable wall position is changed frequently, then adaptation to material elasticity is improved, but device complexity increases
Solution Approach 1:
Instead of continuously adjusting the wall position or using complex active control systems, the invention uses a simplified approach with one or two fixed adjustable wall positions. The wall is adjusted only once or twice during the baling process - once to set the initial high compression position, and once more before the final stage to reduce compression. This partial adjustment approach provides sufficient adaptation to material elasticity without excessive device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively reduces the risk of twine breakage while maintaining high bale density and compression levels, adapting to the elasticity of different materials by adjusting the compression pressure only during the final bale forming stage, ensuring the bale can withstand expansion without bursting.
Implementation Method 1
a reciprocating plunger adjacent the inlet end of the baling chamber that is operable to compress a body of bale material within the baling chamber
Implementation Method 2
The friction of the compressed material with the walls of the baling chamber provides a resistive force allowing for compression of the new material that is introduced into the baling chamber in front of the plunger
Implementation Method 3
The ends of the twine are then knotted together... the binding device including two spools that are configured to supply binding twine on opposite sides of the baling chamber
Data Source
AI summary
A baler apparatus includes a baling chamber (2) comprising a channel having an inlet end (6) and an outlet end (8), a reciprocating plunger (10) adjacent the inlet end of the baling chamber that is operable to compress a body (18) of bale material within the baling chamber, and a binding device (17) for binding the compressed body of bale material to form a bale (20). The baling chamber (2) has at least one adjustable wall (4) for adjusting the compression of the bale material during formation of a bale.