Variable-Length Connecting Rod for Baler Plunger Force Control
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Solution Overview
Problem
Current agricultural baler designs require increasingly expensive components in the drive train to handle higher plunger forces for denser bales, leading to higher shipping and storage costs.
Innovation Solution
The use of variable-length connecting rods in the baler's compression system, which allows for larger compression forces at the plunger face while limiting the forces experienced by the gearbox, enabling the production of denser bales with a given gearbox design and increasing plunger throw for a given crank arm dimension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If higher plunger forces are applied to create denser bales, then bale density is improved, but the load on drive train components increases requiring more expensive components
Solution Approach 1:
The connecting rod is designed with variable length that changes during the compression stroke. The rod transitions from a first length during the approach phase to a second length during the compression phase, dynamically adjusting the mechanical advantage to achieve high plunger forces without requiring equally high forces throughout the entire stroke, thereby reducing drive train component requirements
Solution Approach 2:
The patent changes the geometric parameter of the connecting rod length during operation. By varying the connecting rod length from an initial value to a final value, the system optimizes the force multiplication effect at different stages of compression, allowing high bale density while reducing peak forces on the drive train
2Manufacturing precision
If higher plunger forces are applied to create denser bales, then bale density is improved, but the stress on gearbox increases
Solution Approach 1:
The variable-length connecting rod dynamically adjusts the mechanical advantage ratio during the compression stroke. The rod is shorter during the high-force compression phase, reducing the torque requirement on the gearbox while still achieving high plunger forces through the optimized lever arm geometry
Solution Approach 2:
The connecting rod is pre-configured with variable length characteristics before the compression stroke begins. This preliminary geometric arrangement allows the system to achieve high compression forces without requiring proportionally high drive train forces, thereby protecting the gearbox from excessive stress
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 enables the production of denser bales while reducing the stress on the gearbox, allowing for finer tuning of the plunger stroke and reducing the need for expensive drive train components, thus lowering costs and improving efficiency.
Implementation Method 1
a sensor in fluid communication with and configured to send signals indicating the fluid pressure within the fluid volume of the connecting rod
Data Source
AI summary
A baler including a frame, a feed system coupled to the frame, a baling chamber, a plunger at least partially positioned within and reciprocally movable with respect to the baling chamber, a connecting rod coupled to the plunger, where the connecting rod defines a fluid volume therein, a sensor in fluid communication with and configured to send signals indicating the fluid pressure within the fluid volume of the connecting rod, and a controller in operable communication with the sensor and configured to determine the magnitude of a force being applied to the plunger at least partially based on a signal received from the sensor.