Baler Bale Engagement Roller for Density Control
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Solution Overview
Problem
Existing balers are limited in increasing bale density due to mechanical constraints such as bearing loading limits, baling belt limitations, and cost and weight factors, restricting the tension that can be applied to the baling belt.
Innovation Solution
A baler design featuring a drive roller, idler rollers, and a bale engagement roller with an actuator that moves perpendicular to its axis to directly engage and locally depress the bale, forming concentric layers and increasing bale density through differential rotational speeds and localized compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If tension is increased on the baling belt to increase bale density, then bale density improves, but mechanical component loading limits are exceeded
Solution Approach 1:
The patent introduces a bale engagement roller that applies localized compression to specific regions of the bale rather than uniformly increasing tension across the entire baling belt. This allows density improvement in targeted areas without subjecting all mechanical components to increased loading stresses.
Solution Approach 2:
The compression function is segmented into multiple components: the bale engagement roller provides localized compression while the baling belt maintains its tensioning function. This segmentation allows each component to operate within its design limits while achieving overall density improvement.
2Quantity of substance
If more tension rollers are added to increase bale density, then compression capability improves, but device complexity and cost increase
Solution Approach 1:
The bale engagement roller serves multiple functions: it provides localized compression, engages directly with crop material, and works in conjunction with the existing baling belt system. This multi-functionality achieves density improvement without requiring additional dedicated tension rollers.
Solution Approach 2:
The bale engagement roller acts as an intermediary component between the crop material and the baling system, providing the necessary compression through direct engagement rather than relying on increased baling belt tension or additional tension rollers.
3Quantity of substance
If baling belt tension is increased to improve packing efficiency, then bale density improves, but baling belt and bearing loading limits are exceeded
Solution Approach 1:
Compression is applied locally through the bale engagement roller rather than through increased uniform tension on the baling belt. This preserves the reliability of the baling belt and its bearings by keeping them within their loading limits while still achieving density improvement through localized action.
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
This design allows for increased bale density by enabling localized compression and entwinement of crop material, overcoming mechanical limitations and achieving higher packing efficiency without excessive component stress or cost.
Implementation Method 1
A bale engagement roller is rotatable about a bale engagement roller axis. The bale engagement roller is positioned to directly engage crop material in the bale chamber.
Implementation Method 2
An actuator is coupled to the bale engagement roller. The actuator translates the bale engagement roller in a direction perpendicular to the bale engagement roller axis.
Implementation Method 3
The density of a bale is controlled by the amount of tension placed on the baling belt. A taut baling belt compresses the bale along a majority of the perimeter of the bale as the bale is formed.
Data Source
AI summary
A baler for forming a bale of crop material includes a plurality of walls defining a bale chamber. A drive roller and a plurality of idler rollers are disposed in the bale chamber. At least one baling belt contacts the drive roller and the plurality of idler rollers. A bale engagement roller is rotatable about a bale engagement roller axis. The bale engagement roller is positioned to directly engage crop material in the bale chamber. An actuator is coupled to the bale engagement roller. The actuator translates the bale engagement roller in a direction perpendicular to the bale engagement roller axis.