Bale Wrapper Control for Adaptive Film Application and Compression

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Solution Overview

Problem

Current bale wrapping devices lack adaptability to actual bale parameters and storage conditions, leading to inefficient use of wrapping material, labor-intensive operations, and inadequate compression, resulting in reduced storage quality.

Innovation Solution

A control system for a bale wrapping device that automatically adjusts the ratio of bale pushing device speed to wrapping hoop rotation based on sensor feedback, monitors wrapping material presence, and adjusts wrapping material application based on bale moisture, position, and expected storage time, while providing real-time alerts and automated material replenishment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If wrapping material is applied according to fixed mechanical or programmed settings, then the wrapping process is simple to operate, but the wrapping material usage becomes inefficient and wasteful

Engineering Contradiction:

Improvewrapping process simplicityVSAvoidwrapping material waste

Core Design Contradiction:

Ease of operationVSLoss of substance

Solution Approach 1:

The system incorporates sensors that detect actual bale parameters (moisture content, dimensions, weight) and provide real-time feedback to the control system. The control system then adjusts wrapping material application rates and compression forces dynamically based on this feedback, eliminating waste while maintaining operational simplicity through automated closed-loop control.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The wrapping device transitions from static, pre-programmed settings to dynamic adjustment capabilities. The control system continuously modifies wrapping material dispensing rates, bale pushing speed, and hoop rotation speed based on real-time sensor data about each bale's characteristics, optimizing material usage for each individual bale.

Inventive Principle:

Principle #15Dynamics

2Device complexity

If wrapping parameters are updated manually by operator, then the device complexity remains low, but the adaptability to changing bale parameters deteriorates

Engineering Contradiction:

Improvecontrol system simplicityVSAvoidresponse to bale parameter changes

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The system performs self-adjustment of wrapping parameters without requiring manual operator intervention. Sensors automatically detect bale characteristics and the control system independently modifies wrapping material application, compression forces, and processing speeds, enabling the device to adapt to varying bale conditions while maintaining simple operation.

Inventive Principle:

Principle #25Self-service

3Reliability

If overapplication of wrapping material is used to ensure adequate protection, then the reliability of bale protection is improved, but the loss of substance increases

Engineering Contradiction:

Improvebale protection adequacyVSAvoidwrapping material overuse

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The system dynamically changes wrapping material application parameters (quantity, layers, tightness) based on detected bale characteristics such as moisture content, size, and weight. This ensures adequate protection reliability for each bale's specific needs while preventing material overuse on bales requiring less protection.

Inventive Principle:

Principle #35Parameter changes

4Ease of operation

If manual monitoring and intervention is performed during wrapping operation, then the ease of operation is maintained, but the productivity decreases

Engineering Contradiction:

Improveoperational simplicityVSAvoidwrapping speed and efficiency

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

Real-time sensor feedback enables automated monitoring of wrapping material levels, bale processing status, and equipment operation. The control system responds automatically to these inputs, eliminating the need for manual monitoring while maintaining operational simplicity and significantly increasing productivity through continuous, uninterrupted operation.

Inventive Principle:

Principle #23Feedback

5Device complexity

If compression settings are adjusted manually, then the device complexity remains low, but the manufacturing precision of bale density deteriorates

Engineering Contradiction:

Improvecontrol system simplicityVSAvoidbale compression consistency

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

Sensors detect actual bale density and compression levels during the wrapping process, providing feedback to the control system. The system automatically adjusts compression forces to achieve target density specifications, ensuring consistent manufacturing precision while keeping the overall device complexity low through automated control.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS20250338798A1Control system for a bale wrapping device

Publication Date: 2025.11.06 KUHN NORTH AMERICA INC

AI summary

A system and method for automatic wrapping a row of bales in a bale wrapper, including placing a first bale on a loading table. The wrapping cycle including rotating a wrapping hoop to apply a wrapping material to a bale surface, moving a bale pushing device from a first position toward a second position to push the first bale through the wrapping hoop, dispensing from a first material applicator and a second material applicator, changing a wrapping application parameter for applying the wrapping material based on an intermediate position within the row of bales, continuing to move the bale pushing device until the second position is reached, stopping the rotation of the wrapping hoop, and moving the bale pushing device to the first position.