Bale Processor Fan Placement for Auger-Free Material Transfer
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Solution Overview
Problem
Existing bale processors using augers are prone to plugging due to materials like twine and netwrap, and eliminating the auger is complicated and expensive, making it difficult to efficiently transfer filamentary material from a shredder to a blower.
Innovation Solution
The solution involves covering the bale chamber with multiple fans placed close to the primary shredder flail rotor, eliminating the need for a secondary conveyance system like an auger, and optionally positioning blowers at an angle to reduce the distance between the shredder and fans, with discharge openings on both sides for improved efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If an auger is used to convey material from shredder to blower, then material transfer is achieved, but plugging occurs due to twine and netwrap wrapping around the auger
Solution Approach 1:
The patent removes the auger component entirely from the system. Instead of using an auger to convey material, the design allows material to be drawn directly from the shredder chamber to the blower through strategic fan placement, eliminating the plugging problem associated with augers while maintaining material transfer capability
Solution Approach 2:
The patent introduces air flow generated by strategically positioned fans as an intermediary medium to transfer material from the shredder to the blower. This air flow acts as a carrier that moves filamentary material without requiring mechanical contact, thereby preventing twine and netwrap from wrapping around conveyance components
2Reliability
If the auger is eliminated to prevent plugging, then clogging resistance improves, but the design becomes complicated and expensive
Solution Approach 1:
The patent makes the fans serve dual functions: they both process material (as part of the shredding system) and convey material (replacing the auger function). This multi-functionality eliminates the need for separate conveyance components, simplifying the overall system design while maintaining clogging resistance
Solution Approach 2:
The patent merges the material processing function and material conveyance function into a single integrated system. The fans are positioned to simultaneously perform shredding assistance and material transport, combining what were previously separate functions into one unified mechanism
3Area of stationary object
If a single large fan is used to cover the six foot bale processor, then material coverage is achieved, but the fan becomes too heavy and expensive to manufacture
Solution Approach 1:
The patent divides the fan system into multiple smaller fans distributed across the bale chamber rather than using one large fan. This segmentation reduces the size and weight of each individual fan, making them easier and less expensive to manufacture while collectively covering the entire six foot bale processor area
Solution Approach 2:
The patent transitions from a single large fan configuration to a distributed array of smaller fans across multiple dimensions within the bale chamber. This spatial distribution achieves comprehensive material coverage while using smaller, more manufacturable fan units
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 configuration reduces clogging risks, allows for simpler and cheaper fan design, and enhances the efficient transfer of filamentary material from the shredder to the blower, improving the overall processing efficiency.
Implementation Method 1
a rotor with flails that remove such filamentary portions of the bale
Implementation Method 2
a blower for blowing such filamentary material directly to and out of a delivery chute
Data Source
AI summary
A bale processor of a type for tearing apart a bale of forage material into filamentary material includes a shredder rotor with blades that remove filamentary portions of the bale and delivers such filamentary material directly to a multiple fan blower for blowing such filamentary material directly to and out of a delivery chute. An independent dual discharge feature permits discharge out of either side and/or one or more blowers placed closer to the shredder rotor can be used independently of the dual discharge feature and the multiple fan blower feature.