Bale Wrapper Roller Assemblies for Stable Wide Film Wrapping
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Solution Overview
Problem
Existing bale wrapper machines face challenges in wrapping rectangular bales efficiently, as they require narrower films to maintain stability, leading to longer wrapping times and increased film usage, while attempting to use wider films results in film breakage and instability.
Innovation Solution
The bale wrapper apparatus features roller assemblies with cantilevered outer portions and a support mechanism that allows for wider film usage without compromising stability, using shorter upper rollers and longer lower rollers, and a four-bar linkage for adjustable roller separation, enabling efficient wrapping and reduced apparatus height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If narrower film is used to maintain stability with traditional roller configurations, then bale stability is improved, but wrapping time increases and film consumption increases
Solution Approach 1:
The roller assembly is segmented into multiple rollers (first roller, second roller, third roller, fourth roller) arranged in pairs, with each roller independently controllable. This segmentation allows different portions of the bale to be supported with different forces, enabling wider film usage while maintaining stability through distributed support points rather than a single rigid support structure.
Solution Approach 2:
The roller assembly incorporates dynamic control through independent roller operation and adjustable positioning. The rollers can be independently actuated to adapt to the bale's shape and size changes during wrapping, allowing the system to maintain stability with wider film by dynamically adjusting support distribution as the wrapping progresses.
2Productivity
If wider film is used to reduce wrapping time and improve air-tightness, then productivity and sealing quality are improved, but film breakage occurs and stability deteriorates
Solution Approach 1:
By segmenting the support function across multiple independently controlled rollers, the system can distribute the load and support the wider film across multiple contact points. This prevents film breakage by avoiding concentration of stress at single points, allowing wider film to be used successfully for faster wrapping with maintained integrity.
Solution Approach 2:
The system changes the parameters of film application by controlling the position, speed, and force of individual rollers. This allows optimization of film tension and contact pressure to prevent breakage while using wider film, enabling faster wrapping speeds without compromising film integrity through dynamic parameter adjustment during the wrapping process.
3Manufacturing precision
If rollers are positioned closer together to lift bale higher for optimal film application, then film application quality is improved, but bale stability deteriorates
Solution Approach 1:
The roller assembly is divided into multiple segmented rollers that can be independently positioned and controlled. This allows the system to lift the bale for optimal film application while distributing support across multiple roller pairs, preventing instability by maintaining support at multiple points rather than concentrating all support force at a single lifted position.
Solution Approach 2:
The roller positioning and bale elevation are dynamically controlled during wrapping. The system can adjust roller positions and bale height in real-time to optimize film application quality while maintaining stability through dynamic redistribution of support forces, allowing precise control over both elevation and support distribution.
4Adaptability or versatility
If apparatus height is reduced for transit through narrow spaces, then adaptability is improved, but wrapping capability may be compromised
Solution Approach 1:
The roller assembly incorporates dynamic positioning mechanisms that allow the entire assembly to be lowered for transit through narrow spaces, then raised and positioned for wrapping operations. This dynamic adaptability enables the apparatus to compromise minimal height for transit while maintaining full wrapping capability when deployed, as the rollers can be positioned optimally during the wrapping process itself.
Data Source
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AI summary
A bale wrapper apparatus includes a bale support assembly (22) that includes means (42a,b) for rotating a bale (24) about a substantially horizontal axis, a film dispenser (50) for dispensing film onto the bale, and means (54) for causing relative rotation about a substantially vertical axis between the bale support assembly and the film dispenser. The bale support assembly (22) includes at least two roller assemblies (26) for supporting and rotating a bale. Each roller assembly (26) may include at least one roller (42a) having at least one cantilevered outer portion (43). Alternatively or in addition, each roller assembly (26) may include at least two rollers comprising in use an upper roller (42a) and a lower roller (42b), wherein the lower roller extends beyond the upper roller at least at one end thereof.