Bale Unroller Control for Jam-Free Unrolling and Discharge
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Solution Overview
Problem
Bale unwinders experience jams, blockages, and mechanical complexity, leading to increased costs, wear, and susceptibility to malfunctions.
Innovation Solution
A bale unroller with support devices, unrolling devices, and control devices that utilize sensors to prevent or rectify jams and blockages by controlling feed and unrolling drive systems, incorporating bottleneck structures and dust removal mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional bale unwinding mechanisms are used, then bales can be processed, but mechanical complexity increases leading to higher costs, wear, and susceptibility to malfunctions
Solution Approach 1:
The patent replaces complex mechanical unwinding mechanisms with a controlled falling system. The bale is positioned above the processing area and allowed to fall under gravity onto the processing mechanism, eliminating the need for complex mechanical unwinding devices. This substitution significantly reduces device complexity and manufacturing costs while maintaining processing capability.
2Productivity
If traditional bale unwinding mechanisms are used, then bales can be processed, but jams and blockages occur frequently
Solution Approach 1:
The patent applies preliminary anti-action by positioning the bale above the processing area before it enters the processing zone. This pre-positioning ensures the bale is correctly oriented and ready to fall onto the processing mechanism, preventing jams and blockages before they can occur. The controlled falling mechanism ensures smooth material flow without the need for complex mechanical unwinding that is prone to jamming.
3Productivity
If mechanical unwinding devices are used, then bales can be processed, but wear and tear increases leading to higher maintenance requirements
Solution Approach 1:
The patent replaces mechanical unwinding devices with a gravity-based falling system. The bale is positioned above the processing area and allowed to fall under gravity onto the processing mechanism. This substitution eliminates the need for complex mechanical unwinding components that are subject to wear and tear, significantly reducing maintenance requirements while maintaining processing capability.
4Reliability
If control devices are added to prevent jams, then operational reliability improves, but device complexity increases
Solution Approach 1:
The patent employs a self-service approach where the bale itself is used to trigger the processing sequence. The bale is positioned above the processing area and its own weight and position automatically initiate the falling and processing action. This self-triggering mechanism improves operational reliability by ensuring the bale is ready for processing without requiring complex control systems to detect and respond to jam conditions.
Data Source
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AI summary
The invention relates to a bale unroller (1) for a bale (2) of hay, straw, bedding and/or fodder, with support devices (3) for the bale (2) and unrolling devices (4) designed to release hay, straw, bedding and/or fodder from a bale (2) provided on the support devices (3) and to transport it to discharge devices (5) located downstream of the unrolling devices (4), wherein the support devices (3) are associated with feed devices (6) for feeding a bale (2) provided on the support devices (3) in a feed direction (Z) towards the unrolling devices (4), and wherein feed drive devices (7) for driving the feed devices (6) and unrolling drive devices (8) for driving the unrolling devices (4) are further provided.wherein the feed drive devices (7) and/or the unbundling drive devices (8) and/or the dispensing devices (5) are associated with control devices (9) which are designed to control the feed drive devices (7) and/or the unbundling drive devices (8) and/or the dispensing devices (5) in such a way that a malfunction or disturbance, such as in particular a jam or blockage caused by the bale (2), especially at the unbundling devices (4) and/or the dispensing devices (5), is avoided or rectified. Furthermore, the invention relates to a bale unbundling method in which a bale (2) of hay, straw, bedding and/or fodder is transported onto support devices (3) by means of the feed devices (6) driven by feed drive devices (7) to unbundling devices (4) driven by unbundling drive devices (8), which unbundle the hay, straw, bedding and/or fodder from the bale (2) and transport it to dispensing devices (5).wherein the feed drive devices (7) and/or the dissolving 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 blockage by the bale (2) especially at the dissolving devices (4) and/or the dispensing devices (5), is avoided or rectified.