Bale Breaker Control System for Jam Prevention
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Solution Overview
Problem
Existing bale breakers often experience jams, blockages, and uneven shredding results due to their complex mechanical designs, leading to increased costs, wear, maintenance, and susceptibility to failure.
Innovation Solution
A bale breaker with support devices, opener devices, and control systems that include sensors to detect malfunctions and adjust operations to prevent or resolve jams, featuring a bottleneck for lump crushing and dedusting devices to separate unwanted materials, utilizing knife-, blade-, or rod-shaped carriers for efficient material processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If complex mechanical designs are used in bale breakers, then material processing capability is improved, but susceptibility to jams and blockages increases
Solution Approach 1:
The patent implements variable speed control of the rotor relative to the stator, allowing the system to adapt its processing intensity dynamically. This prevents overload conditions that cause jams while maintaining high processing capability when conditions are favorable
Solution Approach 2:
The patent incorporates sensors that detect jamming conditions and feed this information back to the control system, which then adjusts rotor speed or reverses rotation to eliminate jams, creating a self-regulating system that prevents reliability issues
2Productivity
If complex mechanical designs are used in bale breakers, then material processing capability is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical control mechanisms with an electronic control system that uses sensors and variable speed motors, simplifying the mechanical structure while maintaining or enhancing processing capability
Solution Approach 2:
The control system performs multiple functions including speed regulation, jam detection, reverse operation, and overload protection, replacing what would otherwise require multiple separate mechanical devices
3Productivity
If complex mechanical designs are used in bale breakers, then material processing capability is improved, but maintenance requirements increase
Solution Approach 1:
The patent replaces wear-prone mechanical control components with electronic controls and sensors that have fewer moving parts, reducing maintenance needs while preserving processing capability
Solution Approach 2:
The patent designs the rotor and stator as replaceable wear parts that can be easily removed and replaced when worn, simplifying maintenance of the high-wear processing components
4Productivity
If high processing intensity is applied to bales, then material processing efficiency is improved, but wear on components increases
Solution Approach 1:
The patent uses variable speed control to optimize the balance between processing intensity and component wear, operating at higher speeds for efficiency when conditions permit, and reducing speed to minimize wear during prolonged operation
Solution Approach 2:
The patent changes operational parameters such as rotor speed, feed rate, and gap between rotor-stator to optimize the balance between processing efficiency and wear, adjusting these parameters based on material type and processing conditions
Data Source
AI summary
The invention relates to a bale breaker (1) for a bale (2) of hay, straw, litter and/or fodder, comprising support means (3) for the bale (2) and breaker means (4) adapted to detach hay, straw, litter and/or fodder from a bale (2) provided on the support means (3) and to transport it to discharge means (5) arranged downstream of the breaker means (4), wherein feed means (6) for feeding a bale (2) provided on the support means (3) in a feed direction (Z) toward the disintegrating means (4) are associated with the support means (3), and wherein feed drive means (7) for driving the feed means (6) and disintegrating drive means (8) for driving the disintegrating means (4) are further provided, wherein control devices (9) are associated with the feed drive devices (7) and/or the opening drive devices (8) and/or the discharge devices (5), which are designed to control the feed drive devices (7) and/or the opening drive devices (8) and/or the discharge devices (5) in such a way that a malfunction or disturbance, such as in particular a jam or a blockage by the bale (2), in particular at the opening devices (4) and/or the discharge devices (5), is avoided or eliminated. Furthermore, the invention relates to a bale unraveling method in which a bale (2) of hay, straw, litter and/or fodder is transported on support devices (3) by means of their feed devices (6) driven by feed drive devices (7) to unraveling devices (4) driven by unraveling drive devices (8), which unravel hay, straw, litter and/or fodder from the bale (2) and transport it to output devices (5), wherein the feed drive devices (7) and/or the unraveling drive devices (8) and/or the dispensing devices (5) are controlled by means of control devices (9) in such a way that a malfunction or disturbance, such as in particular a jam or a blockage by the bale (2), in particular at the unraveling devices (4) and/or the dispensing devices (5), is avoided or eliminated.