Baler Knotter Control Assembly Feedback Reset

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional balers face issues with the knotter device failing to reset promptly, leading to malfunctions and reduced productivity, especially at higher production rates.

Innovation Solution

The baler incorporates a knotter control assembly with a drive sprocket, clutch plate, and actuation subassembly that ensures timely and consistent resetting of the knotter mechanism, even at high production rates.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the production rate is increased, then productivity is improved, but the knotter shaft may overshoot and fail to reset promptly

Engineering Contradiction:

Improveproduction rateVSAvoidknotter reset timing

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent employs a feedback mechanism through the trip arm and control roller that monitors the knotter shaft's rotation position. When the knotter shaft completes its rotation, the trip arm engages with the control roller to disengage the clutch plate, creating a closed-loop control system that adjusts the clutch engagement based on real-time shaft position, preventing overshoot even at high production rates

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The clutch plate is designed with dynamic engagement characteristics, allowing it to engage and disengage based on the knotter shaft's rotational position. The clutch plate can slip or disengage automatically when the shaft overshoots, providing adaptive control that maintains reliable resetting across varying production rates without requiring abrupt stops

Inventive Principle:

Principle #15Dynamics

2Reliability

If the production rate is reduced, then knotter reset reliability is improved, but significant sudden stresses are imposed on components

Engineering Contradiction:

Improveknotter reset timingVSAvoidsudden stresses on components

Core Design Contradiction:

ReliabilityVSStress or pressure

Solution Approach 1:

The clutch plate provides dynamic, progressive disengagement rather than abrupt stopping. When the knotter shaft completes rotation, the trip arm gradually disengages the clutch plate, allowing the shaft to coast to a stop. This dynamic disengagement distributes stress over time rather than imposing sudden shocks on the knotter shaft and related components

Inventive Principle:

Principle #15Dynamics

3Productivity

If the knotter shaft continues rotating after knotting, then productivity is maintained, but the knotter fails to reset properly

Engineering Contradiction:

Improveproduction rateVSAvoidknotter resetting

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The trip arm serves as a feedback mechanism that detects when the knotter shaft has completed its rotation and automatically triggers clutch disengagement. This closed-loop control ensures the knotter resets reliably even when operating at high speeds, eliminating the need to reduce production rate for proper resetting

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The trip arm acts as an intermediary between the knotter shaft and the clutch plate. It translates the shaft's rotational completion into a disengagement signal for the clutch plate, mediating the transition from active knotting to reset mode and ensuring proper timing regardless of operational speed

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS20250113777A1Baler

Publication Date: 2025.04.10 MARCREST MFG

AI summary

A baler for forming crop material into bales. The baler includes a plunger moved by a plunger subassembly to form the bale, a knotter mechanism for knotting twine that is pulled onto the bale, and a knotter control assembly for controlling the knotter mechanism. The knotter control assembly includes a drive sprocket rotatable about its axis in timed relationship with movement of the plunger, a clutch plate mounted to the drive sprocket, and a knotter shaft positioned coaxially with the clutch plate. The knotter control assembly includes an actuation subassembly for engaging and disengaging the clutch plate with the knotter shaft. Upon activation, the actuation subassembly engages the clutch plate with the knotter shaft to activate the knotter mechanism, for knotting the twine on the bale. The actuation subassembly subsequently disengages the knotter shaft and the clutch plate.