Bale Accumulator with Adjustable Bed and Feedback Control
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Solution Overview
Problem
Current bale accumulators face issues with non-uniform unloading, limited capacity, and inefficient operation, particularly when navigating curves or uneven terrains, leading to downtime and the need for additional operators or rearrangement of bales.
Innovation Solution
A bale accumulator design featuring an intake conveyor, push ram, trough ram, adjustable fence, and stabilizer frame, which allows for controlled bale movement and storage, enabling uniform unloading and adjustable capacity, with an unloading assembly that can operate on demand and in parallel to the ground surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automatic unloading is implemented, then unloading speed is improved, but unloading uniformity deteriorates causing bales to be misplaced
Solution Approach 1:
The patent implements a load sensor that detects when the bed is full and provides feedback to the control system. This feedback mechanism allows the automatic unloading system to stop before overloading occurs, maintaining both speed and uniformity. The sensor-based feedback loop ensures precise control over the unloading process.
2Productivity
If bed capacity is increased, then accumulation efficiency is improved, but unloading frequency is reduced
Solution Approach 1:
The patent employs a dynamically adjustable bed capacity system where the bed can be extended or reconfigured based on operational needs. This dynamic adjustment allows the system to optimize between carrying more bales (reducing unloading frequency) and maintaining manageable unloading operations, thereby improving overall accumulation efficiency without excessive time loss.
3Ease of operation
If angled bed configuration is used, then bale transport capability is improved, but center of gravity stability deteriorates
Solution Approach 1:
The patent incorporates a counterweight mechanism that compensates for the unstable center of gravity caused by the angled bed configuration. The counterweight system balances the forces acting on the accumulator during transport, maintaining stability while preserving the operational advantages of the angled bed for efficient bale movement.
4Device complexity
If fixed bed capacity is used, then structural simplicity is improved, but adaptability to different field conditions deteriorates
Solution Approach 1:
The patent implements a dynamically adjustable bed capacity system where the bed can be extended or reconfigured based on operational needs. This dynamic adjustment allows the system to optimize between carrying more bales (reducing unloading frequency) and maintaining manageable unloading operations, thereby improving overall accumulation efficiency without excessive time loss.
5Extent of automation
If automated unloading is used, then operator intervention is reduced, but unloading location control deteriorates
Solution Approach 1:
The patent implements a load sensor that detects when the bed is full and provides feedback to the control system. This feedback mechanism allows the automatic unloading system to stop before overloading occurs, maintaining both speed and uniformity. The sensor-based feedback loop ensures precise control over the unloading process.
Data Source
AI summary
The disclosure provided herein is directed to a bale accumulator that receives a bale and then using an intake conveyor transports the bale onto the bale accumulator. A push ram removes the bale from the intake conveyor and onto a flip tray that flips the bale onto an edge of the bale and onto a trough ram. The trough ram pushes the bale onto a trough that when filled with bales by the trough ram actuates a fence ram. The fence ram moves the bales onto a bed. When the bed is filled or at the selection of an operator, an unloading assembly moves the bales off the bed and onto a ground surface, which is facilitated by the bed having a dovetail assembly that lowers the bed to the ground surface. An adjustable fence allows modification to the number of bales that can fit onto the bed.