Bale Press Secondary Spring System for Density Control
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Solution Overview
Problem
Existing roller balers lack precise control over bale formation, leading to incomplete bales being towed further, resulting in increased bale density and diameter, which is undesirable for maintaining selected bale specifications.
Innovation Solution
A bale press with a primary urging means and a secondary urging means, where the secondary urging means allows limited relative movement between the primary urging means and the corresponding part, enabling monitoring of this movement to produce signals indicative of bale formation status, thus allowing for precise control over bale formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the baler continues to tow at normal speed after bale formation signal, then productivity is maintained, but bale density and diameter increase beyond specifications
Solution Approach 1:
The secondary urging means (pre-load springs) is pre-configured to provide a initial urging force that creates a detectable movement signal before the primary urging means (hydraulic ram) completes its full stroke. This preliminary action allows the monitoring means to detect when the bale is nearing completion and trigger an early warning signal to the driver, enabling them to slow down before over-formation occurs.
Solution Approach 2:
The monitoring means continuously monitors the position/movement of the secondary urging means relative to the primary urging means. When the bale material exerts enough force to overcome the pre-load spring force, the closure segment moves slightly, changing the compression on the pre-load springs. This movement is detected by the monitoring means and converted into an electrical signal that provides feedback to the driver about bale formation status.
2Measurement precision
If the secondary urging means allows limited relative movement, then monitoring precision is improved, but device complexity increases
Solution Approach 1:
The secondary urging means acts as an intermediary mechanical element between the closure segment and the fixed segment. The pre-load springs provide a mechanical linkage that translates the force exerted by the bale material into measurable displacement. This intermediary mechanism converts the complex physical state of bale formation into a simple positional change that can be easily monitored by sensors.
Solution Approach 2:
The system utilizes changes in mechanical parameters (force and position) of the secondary urging means to detect bale formation status. The pre-load springs are designed with specific force characteristics that allow them to remain relatively compressed during normal operation but undergo detectable displacement when the bale reaches a critical density threshold. This parameter change approach converts a complex material formation process into a measurable mechanical parameter change.
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
This solution enables the formation of bales with precise control over density and diameter, preventing overformation and maintaining selected specifications, which reduces wear on baler components and minimizes the risk of blockages.
Implementation Method 1
A bale press with a primary urging means and a secondary urging means, where the secondary urging means allows limited relative movement between the primary urging means and the corresponding part
Data Source
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AI summary
A roller baler (3) comprising a fixed segment (22), a discharge segment (24) and a closure segment (30) carrying a plurality of bale rotating rollers (17) defining a bale chamber (20) within which crop material is formed into a bale (2). First and second main rams (37, 38) act between a chassis (7) of the baler (3) and the closure segment (30) for pivoting the closure segment (30) about a main pivot axis (15) between a bale forming state and an open state and for urging the closure segment (30) into the bale forming state with a first urging force of a first force value. The first main ram (37) is connected to the closure segment (30) through a secondary spring system (54) by a first connector (56) and a second connector (57). The secondary spring system (54) comprises disc springs (55) configured to act between the first and second connectors (56, 57) with a second urging force of a second force value less than the first force value of the first urging force. This permits limited pivoting of the closure segment (30) about the first pivot axis (15) from the bale forming state thereof when the radial outward force of the bale in the bale chamber (20) on the closure segment (30) exceeds the second force value. This limited movement of the closure segment (30) enables detection of the bale being in a nearing completion state prior to completion of the formation of the bale.