Baler Infeed Blockage Clearance via Dynamic Pressure Reduction
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Solution Overview
Problem
Baler systems face difficulties in clearing blockages in the infeed system, especially when forming nearly complete bales, due to reduced power availability, leading to increased loading on drive transmissions and productivity losses.
Innovation Solution
The method involves reducing the pressure applied by the pressing means in the baler by a predefined amount, typically between 50% to 90% of the original pressure, to facilitate easier clearing of blockages in the infeed system, which can be automatically or manually controlled based on bale size or density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the baler continues to apply full pressing pressure during a blockage, then the bale density and compression are maintained, but the drive transmission system experiences increased loading and potential damage
Solution Approach 1:
The pressing pressure is dynamically adjusted based on operational conditions. When a blockage is detected, the control system automatically reduces the pressing pressure from full compression levels to a reduced level, allowing the baler to clear the blockage without damaging the drive transmission system. This dynamic pressure adjustment resolves the contradiction by adapting the pressing force to the current operational state.
Solution Approach 2:
The pressing pressure parameter is changed from its normal high value to a reduced value when a blockage occurs. This parameter change allows the system to clear blockages more easily while preventing excessive loading on the drive transmission. The control system monitors blockage conditions and adjusts the pressing pressure parameter accordingly, resolving the contradiction between maintaining reliability and improving blockage clearing efficiency.
2Productivity
If the baler reduces pressing pressure to clear a blockage, then the drive transmission loading is reduced, but the bale density and compression quality may be compromised
Solution Approach 1:
The pressing pressure is applied periodically in cycles. During normal operation, full pressing pressure is applied to achieve proper bale density. When a blockage is detected, the pressure is temporarily reduced to clear the blockage, then restored to full pressure to complete the bale with proper density. This periodic application of full pressure ensures that bale density consistency is maintained despite temporary pressure reductions during blockage clearing.
Solution Approach 2:
The control system detects the blockage condition and reduces pressing pressure as a preliminary action before the blockage causes severe loading issues. By proactively reducing pressure when a blockage is first detected, the system prevents excessive loading while minimizing the duration and impact on bale density. The pressure is then restored once the blockage is cleared, ensuring the remainder of the bale achieves proper density.
3Manufacturing precision
If the baler maintains full pressing pressure during blockage clearing attempts, then the bale formation quality is preserved, but the clearing process takes longer and causes more wear on components
Solution Approach 1:
The pressing pressure is dynamically adjusted based on real-time detection of blockage conditions. When a blockage is detected, the system automatically reduces pressure to facilitate quicker clearing. Once the blockage is cleared, the pressure is restored to full levels to complete the bale with proper formation quality. This dynamic adjustment reduces downtime while maintaining bale quality through selective pressure application.
Solution Approach 2:
The system temporarily skips the full pressing pressure application during the blockage clearing phase to rush through the clearing process quickly. By reducing pressure during this temporary period, the blockage is cleared faster, reducing downtime. The full pressing pressure is then resumed to ensure proper bale formation quality for the remainder of the bale, thus skipping the time-consuming full-pressure clearing phase.
Data Source
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AI summary
A roller baler (3) comprises a chassis (5) and a fixed segment (14) rigidly secured to the chassis (5), a tipping segment (15) and a closure segment (16), each of which carry a plurality of bale rotating rollers (17, 18, 19) which define a bale chamber (22), within which a bale is rotated, pressed and formed to a selectable bale density. The closure segment (16) is pivotal about a main pivot axis (35) from a closed state to an open state for accommodating a bale from the bale chamber (22). An infeed system (12) picks up crop material and feeds the crop material into the bale chamber (22). A pair of main double-acting hydraulic rams (40) acting between the chassis (5) and the closure segment (16) operate the closure segment (16) between the closed state and the open state, and apply pressure to the bale being formed in the bale chamber (22) for forming the bale to the selected bale density. A pressure regulator (54) controls the pressure of hydraulic fluid applied to the main rams (40) at a selectable density pressure for controlling the pressure applied by the main rams (40) to the closure segment (16). A microcontroller (50) controls the pressure regulator (54) to reduce the pressure of the hydraulic fluid applied to the main rams (40) in response to a blockage occurring in the infeed system (12), so that on restarting the baler, the power drawn by the baler to rotate the bale is reduced, thereby increasing the available power to the infeed system (12) to clear the blockage therein.