Back Wrap Roll Net Wrapping Width Control
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Solution Overview
Problem
Conventional net wrapping systems in agricultural balers face difficulties in maintaining the width of the net wrapping as it traverses through the wrapper assembly, leading to incomplete wrapping of bales due to insufficient engagement with spreader rolls and changes in tension during the wrapping process.
Innovation Solution
A net wrapping system that includes a back wrap roll and an insertion assembly with spreader rolls, where the back wrap roll maintains engagement with the net wrapping along a fixed spreader roll surface, ensuring consistent width and length as the net wrapping traverses between the net roll and the bale, even when the insertion assembly moves between home and insert positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the brake roll is removed from the storage roll to allow free movement of the wrapping material, then the wrapping material can move freely towards the bale chamber, but the width of the wrapping material will not be maintained
Solution Approach 1:
A back wrap roll is introduced as an intermediary element between the fixed spreader roll and the insertion assembly spreader rolls. This back wrap roll maintains continuous contact with the wrapping material, serving as a mediator that preserves width consistency even when the insertion assembly moves between home and insert positions. The back wrap roll ensures the wrapping material maintains its width by providing stable engagement throughout the insertion cycle.
2Adaptability or versatility
If the insertion assembly moves between home and insert positions, then the net wrapping can be inserted onto the bale, but the engagement length with the fixed spreader roll changes causing width variation
Solution Approach 1:
The back wrap roll acts as a stable intermediary that remains engaged with the wrapping material throughout the insertion assembly's movement between home and insert positions. This intermediary element compensates for the changing engagement length with the fixed spreader roll, maintaining consistent wrapping material width despite the dynamic positioning requirements of the insertion assembly.
3Manufacturing precision
If conventional spreader rolls are used to maintain width, then width control is attempted, but engagement is insufficient leading to incomplete wrapping
Solution Approach 1:
The net wrapping system is segmented into multiple functional zones: the fixed spreader roll for initial width establishment, the back wrap roll for continuous width maintenance, and the insertion assembly spreader rolls for final positioning. This segmentation allows each component to perform its specific function optimally, ensuring both width control and reliable complete wrapping.
Solution Approach 2:
The back wrap roll serves as an intermediary between the fixed spreader roll and the insertion assembly, bridging the gap in engagement continuity. This intermediary ensures that width control is maintained throughout the entire wrapping process, preventing the engagement insufficiency that leads to incomplete wrapping.
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
A net wrapping system (200) includes an insertion assembly (206) configured to move between a home position and an insert position. The insertion assembly (206) has at least one insertion assembly spreader roll (208, 210) configured to engage net wrapping (202) from a net roll (204). The net wrapping system (200) also includes a fixed spreader roll (212) proximate to the net roll (204) and configured to engage the net wrapping (202) along a length of the fixed spreader roll circumferential surface (218) when the insertion assembly (206) is in the home position. The net wrapping system (200) further includes a back wrap roll (214) located along a net path between the fixed spreader roll (212) and the at least one insertion assembly spreader roll (208, 210) and configured to cause the net wrapping (202) to maintain engagement with substantially the same length of the fixed spreader roll circumferential surface (218) when the insertion assembly (206) is in the insert position.