Baler Belt Tensioner for Controlled Bale Ejection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Baling presses with variable bale chambers face issues with bale unloading, where the bale can fall out or be delayed due to belt tension and deflection roller arrangements, especially on uneven terrain, and existing solutions complicate the design with additional mobility requirements.
Innovation Solution
The baler utilizes the existing mobility of the variable bale forming chamber by keeping the belt tensioned and using an unloading control device to press the bale out through the open unloading door, with coordinated movement between the belt tensioner and unloading door to ensure controlled ejection without slippage or delay.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the belt is relaxed to enable bale discharge, then the bale can be discharged more easily, but significant slippage occurs between the belt and belt drive roller
Solution Approach 1:
The belt tensioner is activated before the unloading door opens to pre-relax the belt, and remains active during the unloading process to maintain controlled tension. This preliminary action prevents sudden slippage when the door opens while still enabling bale discharge.
Solution Approach 2:
The system dynamically adjusts belt tension during different operational phases: high tension during bale formation, reduced tension during unloading. The belt tensioner provides continuous variable tension control rather than a fixed state, optimizing performance for each operational phase.
2Reliability
If the belt is kept tensioned to prevent slippage, then belt drive reliability is maintained, but the bale may be held in the bale forming chamber delaying unloading
Solution Approach 1:
The belt tensioner is activated in advance before the unloading door opens, creating a controlled tension reduction phase. This allows the belt to gradually relax and release the bale without sudden slippage, preventing both belt drive failure and unloading delays.
Solution Approach 2:
The belt tensioner operates continuously throughout the unloading process, maintaining optimized tension levels. This continuous control ensures the belt remains engaged with the drive roller while simultaneously allowing bale discharge, eliminating gaps in useful action.
3Ease of operation
If deflection rollers are moved to push the bale out, then unloading is improved, but complex movable suspension and drive systems are required
Solution Approach 1:
The belt tensioner, originally designed for a single function (maintaining belt tension), is made multi-functional by enabling it to also perform bale pushing during unloading. This eliminates the need for separate movable deflection rollers while achieving the same unloading effect.
Solution Approach 2:
The functions of belt tensioning and bale discharge are merged into a single device - the belt tensioner. By coordinating the tensioner's movement with the unloading door operation, one component performs multiple critical functions, simplifying the overall system.
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 method ensures reliable and controlled bale unloading on uneven terrain without complex roller arrangements, maintaining belt tension to prevent slippage and delay, and avoids cross-slip by maintaining contact between the bale and unloading door.
Implementation Method 1
it can lead to significant slippage between the belt and the belt drive roller
Implementation Method 2
The unloading door (9) is moved by a hydraulic cylinder (17)
Implementation Method 3
a first hydraulic cylinder (13) is provided for moving the belt tensioner (7)
Data Source
Figure 1
AI summary
The present invention relates to a baler with a partially or fully variable bale forming chamber (2) in which stalk- and/or leaf-like harvested material or similar material can be formed and/or pressed into bales, wherein the bale forming chamber (2) has at least one belt element (3) rotating around deflection rollers (4), to which at least one adjustable belt tensioner (7, 8) is assigned, wherein the bale forming chamber (2) has a drive-on unloading door (9), and wherein an unloading control device (12) is provided for controlling the unloading door (9) and/or the deflection rollers (4) and/or the belt tensioner (7, 8) during the unloading of a bale. The invention further relates to a method for unloading a bale from a baler.According to the invention, the unloading control device (12) is designed to press the belt tensioner (7) against the bale when the unloading door (9) is opened and to push the bale out of the bale forming chamber (2) through the belt tensioner (7) while the belt element (3) remains taut.