Bale Wrapping Apparatus Segmented Dispensing for Material Reduction
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Solution Overview
Problem
Existing bale wrapping methods are wasteful as they apply excessive wrapping material, especially at the axial ends of cylindrical bales, due to the minimal number of layers required at the circumferential surface and corners, which are the least vulnerable to damage.
Innovation Solution
A baling apparatus and method that uses a combination of a first dispenser for circumferential wrapping and a second dispenser for axial wrapping, with the first dispenser providing sufficient layers around the bale's surface and corners, reducing the need for excessive material at the ends by using overlapping turns from the second dispenser.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional single-axis or two-axis wrapping methods are used, then the bale is adequately protected at the circumferential surface and corners, but excessive wrapping material is applied at the axial ends
Solution Approach 1:
The wrapping operation is divided into two distinct segments: a first wrapping operation that applies material circumferentially around the bale, and a second wrapping operation that applies material axially along the ends. This segmentation allows each wrapping zone to be treated independently with appropriate material application, preventing over-wrapping at the ends while ensuring adequate protection at the circumferential surface and corners.
Solution Approach 2:
Different wrapping characteristics are applied to different parts of the bale. The circumferential surface and corners receive wrapping primarily from the first dispenser to ensure protection against puncturing, while the axial ends receive wrapping from the second dispenser. This local differentiation of wrapping quality ensures that material is applied where needed without waste.
2Reliability
If multiple layers of wrapping material are applied to ensure adequate protection, then the bale is sufficiently protected during handling, but the cost and complexity of the wrapping process increases
Solution Approach 1:
The wrapping system is segmented into two independent dispensers with distinct functions. The first dispenser handles circumferential wrapping while the second dispenser handles axial end wrapping. This segmentation allows the system to achieve comprehensive protection without requiring excessive layers from a single dispenser, thereby reducing overall material usage and system complexity.
Solution Approach 2:
Each dispenser is designed to perform its specific wrapping function efficiently. The first dispenser is optimized for circumferential wrapping, while the second dispenser is optimized for axial end wrapping. This multi-functional approach allows the system to achieve comprehensive protection with appropriate material application at each zone without requiring a single complex dispenser to handle all wrapping requirements.
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
Significantly reduces the amount of wrapping material required while ensuring adequate protection on the bale's surface and corners, optimizing material usage and handling efficiency.
Implementation Method 1
One surface of the film material is provided with a self-adhesive coating so that as the bale is wrapped with each turn of the wrapping material overlapping a previous adjacent turn to form two or more layers of wrapping material, the overlapping layers are bonded to each other by the self-adhesive coating
Data Source
Figure 1
Figure 2~9
Figure 3
AI summary
Baling apparatus (1 ) for forming a bale (2) of grass, hay, straw or the like and for wrapping the bale (2) in non-perforated plastics sheet wrapping material (64, 71 ) comprises a chassis (10), a baler (16) mounted on the chassis (10) within which the bale (2) is formed, and a pair of bale supporting rollers (54, 55) on which the bale is supported and rotated during wrapping. An upper segment (21) and a lower segment (22) of the baler (16) are pivotal upwardly for transferring a bale from the baler (16) to the bale supporting rollers (54, 55). A first dispenser (63) and a holding mechanism (65) extend wrapping material (64) across a discharge opening (40) through which the bale (2) is transferred from the baler (16) so that as the bale is being transferred onto the bale supporting rollers (54, 55), wrapping sheet material (64) is drawn from the first dispenser (63) around approximately 180° of the circumferential surface (5) of the bale (2) and extends around corner edges (8) of the bale (2). The bale supporting rollers (54, 55) rotate the bale (2) for wrapping an appropriate number of turns of the wrapping material (64) around the circumferential surface (5) of the bale (2), and a carrier ring member (74) which carries second dispensers (72, 73) revolves the second dispensers (72, 73) about the bale (2) while the bale (2) is being rotated by the bale supporting rollers (54, 55) for wrapping of the bale (2) with wrapping material (71 ) from the second dispensers (72, 73). A bale wrapper is also disclosed.