Bale Wrapping Control System for Consistent Stretch Ratio
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Solution Overview
Problem
Current bale wrapping technologies face limitations in achieving consistent stretch ratios and accurate wrapping due to acceleration and deceleration zones when wrapping non-uniform shapes, leading to inconsistent material thickness and air tightness, and are prone to overstretching at varying temperatures.
Innovation Solution
A bale wrapping apparatus with a control system that uses sensors to monitor rotational position and speed, generating control signals to adjust the dispensing rate and rotation of the wrapping material, ensuring a consistent stretch ratio through acceleration and deceleration zones by varying the powered dispensing and braking of the wrapping material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the dispenser means rotates around the bale at high speed, then productivity is improved, but the stretch ratio consistency deteriorates due to acceleration and deceleration zones
Solution Approach 1:
The patent applies dynamics by making the dispenser means powered and variable in speed, allowing it to adjust its rotational speed dynamically during operation. The controller varies the rotational speed of the dispenser means to compensate for acceleration and deceleration zones, maintaining consistent stretch ratio across different wrapping positions and speeds.
Solution Approach 2:
The patent implements feedback through sensors that detect the rotational position and speed of the dispenser means, feeding this information to the controller. The controller processes this feedback and adjusts the powered rollers' speed accordingly, creating a closed-loop control system that maintains consistent stretch ratio despite variations in rotational speed.
2Productivity
If the dispenser means rotates at high speed, then productivity is improved, but the wrapping material thickness consistency deteriorates
Solution Approach 1:
The powered rollers that draw wrapping material from the roll are made variable in speed, allowing dynamic adjustment during the wrapping cycle. The controller varies the rollers' rotational speed to compensate for acceleration and deceleration zones of the dispenser means, ensuring consistent material thickness is maintained regardless of wrapping speed.
Solution Approach 2:
Sensors detect the rotational position and speed of the dispenser means and feed this information to the controller, which adjusts the powered rollers' speed in real-time. This feedback mechanism ensures that wrapping material thickness remains consistent even when operating at high speeds.
3Productivity
If the dispenser means rotates faster, then productivity is improved, but the stretch ratio control precision deteriorates due to increased resistance from the wrapping material dispensing unit
Solution Approach 1:
The dispenser means is converted from an unpowered passive rotation to an actively powered system with variable speed control. The powered rollers can independently adjust their rotational speed to overcome resistance from the wrapping material dispensing unit, maintaining precise stretch ratio control even at higher wrapping speeds.
Solution Approach 2:
The sensor system monitors the rotational speed and position of the dispenser means, providing feedback to the controller. The controller uses this information to dynamically adjust the powered rollers' speed, compensating for increased resistance at higher speeds and maintaining accurate stretch ratio control.
4Productivity
If the wrapping material is overstretched due to acceleration zones, then productivity is improved through faster dispensing, but the wrapping material quality deteriorates as it enters plastic state
Solution Approach 1:
The powered rollers provide dynamic speed control during the dispensing process, allowing the system to accelerate faster dispensing while simultaneously preventing overstretching. The controller modulates the roller speed to keep the wrapping material within its elastic state, avoiding transition to plastic state even at high dispensing speeds.
Solution Approach 2:
Sensors detect the rotational position and speed of the dispenser means, providing real-time feedback to the controller. The controller adjusts the powered rollers' speed based on this feedback, preventing overstretching of the wrapping material during acceleration zones and maintaining material quality while enabling high-speed operation.
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
The system maintains a consistent stretch ratio and compacting pressure, preventing overstretching and ensuring the wrapping material's elastic properties are utilized effectively, resulting in improved air tightness and quality of the wrapped bale across varying temperatures and bale shapes.
Implementation Method 1
a first sensor component configured to sense first signals indicating rotational position and rotational speed for the material dispenser rotational support; a second sensor component configured to sense second signals indicating rotational speed for the material dispenser
Implementation Method 2
The controller is configured to receive the first and second signals; generate, in response to processing at least one of the first and second signals, first control signals; and provide the first control signals to at least one of the material dispenser for controlling a dispensing rate of the wrapping material
Implementation Method 3
a material dispenser rotational support configured to rotate the wrapping material dispensed around a central rotating axis... controlling rotation of the material dispenser rotational support
Data Source
AI summary
The application discloses a bale wrapping apparatus (100), comprising a wrapping table with bale rotating means (112, 122) to hold, control and rotate a bale for the application of a wrapping material, and dispenser means (300) configured to dispense the wrapping material from rolls, and a dispenser means rotational support (116) configured to rotate the dispensed wrapping material around a uniform and/or non-uniform bale of material around a central rotating axis, and a wrapping control system configured to power, control, adjust and/or regulate the dispensed wrapping material through the dispenser means (300) to a predefined stretch ratio within acceleration and/or deceleration zones within one or more 360 degree rotations of the dispenser means rotational support (116). Furthermore, the application discloses a method for wrapping a bale (200) made from a crop product by a bale wrapping apparatus (100).