Baler Flywheel Gear Shifting for PTO Start-Up and Acceleration

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Solution Overview

Problem

Large square balers are limited by the size of flywheels due to constraints in engine power and PTO clutch capacity, which restricts the ability to achieve higher bale density and efficiency.

Innovation Solution

A baler system with a cardan coupling connecting a flywheel to a tractor's PTO, featuring a displaceable geared collar that shifts between lower and higher gear ratios to optimize mechanical advantage, allowing for efficient acceleration and operation of the flywheel.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a larger flywheel is used to increase bale density and efficiency, then the energy storage and release capability is improved, but the ability to accelerate the flywheel to desired operating speed deteriorates due to limited engine power and PTO clutch capacity

Engineering Contradiction:

Improveenergy storage and release capabilityVSAvoidacceleration capability

Core Design Contradiction:

PowerVSSpeed

Solution Approach 1:

The patent applies a variable ratio drivetrain that dynamically changes the gear ratio between the PTO and flywheel during operation. The system transitions from a lower gear ratio during acceleration to a higher gear ratio during steady-state operation, allowing the flywheel to be accelerated effectively while maintaining optimal operating speed and energy storage capability.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent changes the transmission parameter (gear ratio) as a function of operating conditions. By using a displaceable geared collar that can engage different gear ratios, the system optimizes the power transfer characteristics to match the acceleration requirements and steady-state performance needs of the flywheel.

Inventive Principle:

Principle #35Parameter changes

2Device complexity

If a direct connection between PTO and flywheel is used, then the mechanical structure is simplified, but the mechanical advantage is insufficient to accelerate the flywheel effectively

Engineering Contradiction:

Improvemechanical structureVSAvoidmechanical advantage

Core Design Contradiction:

Device complexityVSForce

Solution Approach 1:

The patent introduces an intermediate variable ratio transmission mechanism between the PTO and flywheel. This intermediary component provides the necessary mechanical advantage during acceleration while maintaining a relatively simple overall structure through the use of a displaceable geared collar and fixed gears.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Speed

If a fixed high gear ratio is used to achieve desired operating speed, then the final speed is achieved, but the ability to start and accelerate the flywheel deteriorates

Engineering Contradiction:

Improveoperating speedVSAvoidstart-up capability

Core Design Contradiction:

SpeedVSEase of operation

Solution Approach 1:

The system dynamically adjusts the gear ratio based on the operational phase. During start-up and acceleration, the lower gear ratio provides higher torque for easier starting. Once the flywheel reaches a certain speed, the system shifts to the higher gear ratio to achieve and maintain the desired operating speed.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The displaceable geared collar is designed to automatically engage the appropriate gear ratio based on the flywheel's speed. The lower gear ratio is engaged preliminarily during start-up, and the system transitions to the higher gear ratio when acceleration is complete, ensuring optimal performance at each phase.

Inventive Principle:

Principle #10Preliminary 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 solution enhances the mechanical advantage of the PTO, enabling easier start-up and reduced wear on the PTO clutch, while allowing the flywheel to reach higher operating speeds, thereby improving bale density and efficiency without the need for larger flywheels.

Implementation Method 1

an intermediate gear being mounted for rotation in the housing between the input shaft and the output shaft, the intermediate gear being disposed parallel to the input shaft and adapted to drive the output shaft

Methodology Applied

Scientific EffectGear: Gear

Implementation Method 2

the input shaft is provided with a displaceable geared collar adapted to engage the intermediate gear with either a first lower gear ratio or a second higher gear ratio

Methodology Applied

Scientific EffectMechanical Advantage: Mechanical Advantage

Implementation Method 3

a flywheel connected by a cardan coupling to a connector to be connected to a PTO of a tractor

Methodology Applied

Scientific EffectCardan coupling:

Implementation Method 4

the output shaft is connected to the cardan coupling by way of a directional clutch

Methodology Applied

Scientific EffectClutch:

Data Source

PatentUS12185671B2Baling apparatus

Publication Date: 2025.01.07 AGCO CORP

AI summary

A baler including a flywheel driven by a PTO of a tractor, an input shaft which connects to the PTO, an output shaft which connects to the flywheel, an intermediate gear mounted for rotation between the input shaft and the output shaft, the intermediate gear being parallel to the input shaft and adapted to drive the output shaft, wherein the input shaft includes a displaceable geared collar adapted to engage the intermediate gear with either a first lower gear ratio or a second higher gear ratio. This allows the tractor PTO a lower ratio (speed) range to start the flywheel and then accelerate the flywheel to an intermediate speed before shifting and accelerating to the final desired operating speed.