Bale Stacker Sequencing for Faster Bundle Compression and Tying

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Solution Overview

Problem

Existing bale stacker machines require a long time to form bale bundles, which is inefficient for economical handling and transportation of forage.

Innovation Solution

A system comprising an injector and plunger assembly that moves bales in a predetermined sequence into a loading chamber, compresses them, and ties them together to form a bale bundle efficiently.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional bale stacker machines are used to form bale bundles, then the bales can be stacked and tied together, but the process takes a long time and is inefficient

Engineering Contradiction:

Improvespeed of bale bundle formationVSAvoidtime required to form bale bundles

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The injector assembly pre-positions bales in a chute before they enter the loading chamber, and the plunger assembly pre-compresses bales before tying. This preliminary arrangement and compression of bales in specific sequences reduces the overall time required for bundle formation by preparing components before final assembly.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses continuous cyclic operation where the injector and plunger assemblies operate in overlapping sequences. While the plunger is compressing one set of bales, the injector is simultaneously positioning the next set of bales. This continuous, overlapping action eliminates idle time and significantly increases productivity.

Inventive Principle:

Principle #20Continuity of useful action

2Manufacturing precision

If bales are moved into the loading chamber and compressed to form bundles, then bale bundles with predetermined dimensions are achieved, but the process is time-consuming

Engineering Contradiction:

Improvedimensional accuracy of bale bundlesVSAvoidtime required for compression and tying

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The plunger assembly performs preliminary compression of bales in the loading chamber before the knotter assembly ties them together. This pre-compression ensures the bales are properly dimensioned and compacted in advance, allowing the tying operation to proceed quickly without requiring additional compression time after bundle formation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The compression and tying operations are performed in continuous overlapping cycles. While the plunger is compressing bales, the knotter is simultaneously positioning and tying previous bundles. This continuous coordination ensures dimensional precision is maintained while minimizing total processing time.

Inventive Principle:

Principle #20Continuity of useful action

Data Source

PatentUS20260007107A1Bale stacker system

Publication Date: 2026.01.08 MARCREST MFG

AI summary

A system for forming a bale bundle that includes a preselected number of columns of bales, each column including a predetermined number of the bales. The system includes an injector for moving the predetermined number of the bales in a predetermined injection sequence into a loading chamber. In the predetermined injection sequence, the injector moves a preselected number of the bales into the chute and subsequently moves the predetermined number of the bales into the loading chamber. The system also includes a plunger assembly for moving columns of the bales positioned in succession in the loading chamber into the compression chamber in a predetermined assembly sequence, until the preselected number of the columns is in the compression chamber. The plunger assembly compresses the preselected number of columns while a knotter assembly ties the columns together to form the bale bundle, and the injector recommences the predetermined injection sequence.