Baler Binding Device Needle Guide Load Management
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Solution Overview
Problem
The high load on binding needles in balers due to the moment of inertia of the binder roll and the sudden release of tension in the binder strand, leading to slippage and increased force requirements for unwinding, is not efficiently managed by existing systems, resulting in instability and inefficiency in the binding process.
Innovation Solution
A binding device with a needle rocker and additional guide elements that adjust to balance the load during insertion and retraction movements, using a second needle guide element to release binder during insertion and maintain tension during retraction, along with a buffer element to manage the binder roll's rotation and prevent slippage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single elastically deflectable guide element is used to temporarily store binding agent strand, then binding agent can be quickly made available during needle swing arm movement, but the binding needle experiences high load against the restoring force and the needle swing arm becomes unstable and heavy
Solution Approach 1:
The single guide element is divided into multiple guide elements (first guide element, second guide element, third guide element) distributed along the guide path. Each guide element provides a portion of the buffering function, distributing the load and restoring force across multiple points rather than concentrating it on the needle swing arm, enabling high-speed operation without excessive needle load.
Solution Approach 2:
The guide elements are arranged in a spatial sequence along the guide path from the binder roll toward the needle. This spatial distribution transforms the buffering function from a single-point elastic storage to a distributed system where the binding agent strand is temporarily stored along the path, reducing the force concentration on the needle swing arm while maintaining quick feed capability.
2Reliability
If the guide element is made heavy and stable to withstand high loads, then the needle can work against restoring force, but the acceleration and deceleration forces required to move the needle swing arm increase
Solution Approach 1:
The buffering function is segmented across multiple guide elements rather than concentrated in one heavy element. This distribution allows each guide element to be lighter while collectively providing the necessary stability and load-bearing capacity, reducing the total mass of the needle swing arm and associated acceleration forces.
Solution Approach 2:
Multiple guide elements act as intermediaries between the binding agent roll and the needle swing arm. These intermediaries provide the necessary restoring force and stability without requiring the needle swing arm itself to be heavily constructed, as the guide elements absorb and manage the forces independently.
3Speed
If the guide element suddenly stops at its starting position, then the binder roller can stop quickly, but the tension in the binder strand is suddenly released causing the binder to slacken and jump out of the guide
Solution Approach 1:
The buffering function is distributed across multiple guide elements along the guide path. When the binder roll stops, the binding agent strand can be gradually absorbed by the sequence of guide elements rather than all buffering occurring at a single point. This gradual absorption maintains continuous tension in the binder strand, preventing sudden slackening and instability.
Solution Approach 2:
The guide elements are positioned at different locations along the guide path, creating a spatial distribution of buffering capacity. This allows the system to manage the stopping process progressively as the binding agent strand passes through each guide element in sequence, maintaining tension stability while enabling quick roller cessation.
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 solution reduces the load on the needle rocker during high-speed operations, prevents binder slippage, and maintains consistent tension, enhancing the efficiency and reliability of the binding process by balancing the guide path lengths and using elastic deflection to manage the binder roll's rotation.
Implementation Method 1
the binding agent strand is deflected over at least one elastically deflectable guide element, usually a guide roller. If tension is exerted by the binding needle, the guide element can yield to this tension, thereby quickly making binding agent available. If the tension by the binding needle decreases, the guide element elastically returns to its original position
Data Source
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AI summary
The invention relates to a binding device (10) for a baler (1), comprising a needle arm (11) adjustable relative to a frame (2) of the baler (1) with a plurality of binding needles (12) for feeding a strand of binding agent (55) into a press channel (3), wherein the binding device (10) defines a guide path for each strand of binding agent (55) extending from a roll of binding agent (50) by means of a plurality of guide elements (17-19, 20-23, 31, 41), wherein each binding needle (12) extends from a base (13) to a tip (14) on which a first needle guide element (17) is arranged, and wherein the needle arm (11) is adjustable by an insertion movement from a first position in which the binding needles (12) are arranged outside the press channel (3) to a second position in which the binding needles (12) are at least partially inserted into the press channel (3). are,and is adjustable back to the first position by a retraction movement, and further comprising an additional guide element (19) independent of the needle arm (11), to which the first needle guide element (17) is subordinate in the guide path. In order to enable reliable and efficient guidance of a binder strand, the invention provides that the needle arm (11) has a second needle guide element (18), which is arranged closer to the base (13) than the first needle guide element (17) and is positioned in the guide path between the additional guide element (19) and the first needle guide element (17), wherein the second needle guide element (18) approaches the additional guide element (19) by the insertion movement and moves away from it by the retraction movement.