Square Baler Knotting System with Selective Needle Control
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Solution Overview
Problem
Existing square balers require complex and costly modifications to form bales from multiple slices, necessitating special needle yokes and different needle lengths for separate pivotable groups, which complicates the knotting process.
Innovation Solution
A simplified knotting system where all needles are mounted on a common shaft, with a first set of knotters permanently operative for each slice and a second set that can be selectively disabled during slice formation, allowing all needles to pivot in unison, and only becoming operative at the end of the bale formation to tie all strands together.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate needle assemblies with different needle lengths are used for slice formation, then slice tying can be achieved, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
The knotting system is segmented into two distinct sets of knotters: a first set that is permanently operative for tying slices, and a second set that is selectively disabled during slice formation and only activated at the end of bale formation. This segmentation allows the same needle assembly to serve multiple functions without requiring separate assemblies for different operations.
Solution Approach 2:
The system employs dynamic control of the knotters through a control mechanism that can selectively enable or disable the second set of knotters based on the operational phase (slice formation vs. bale formation). This dynamic switching allows a single needle assembly to adapt its functionality without physical reconfiguration.
2Adaptability or versatility
If multiple separately movable groups of needles are provided for tying slices, then slice formation is enabled, but the device complexity and cost increase
Solution Approach 1:
A single needle assembly is designed to perform multiple functions: it ties slices during the slice formation phase and ties the final bale at the end of the bale formation phase. The universality is achieved through the selective disabling/ enabling of different knotters rather than requiring separate needle assemblies for each function.
Solution Approach 2:
The patent merges the slice-tying function and bale-tying function into a single integrated needle assembly system. By combining both functions in one assembly and using control mechanisms to manage their activation, the system eliminates the need for separate movable needle groups, thereby reducing manufacturing complexity.
3Device complexity
If a common shaft with all needles mounted is used, then device complexity is reduced, but the ability to selectively knot strands during slice formation is lost
Solution Approach 1:
The knotters are segmented into two functional groups: a first set that remains permanently operative for slice tying, and a second set that can be selectively disabled. This segmentation allows the simple common shaft configuration to maintain selective knotting capability through control of individual knotters rather than through complex needle arrangements.
Solution Approach 2:
A control mechanism acts as an intermediary between the operator and the knotters, enabling selective disabling of the second set of knotters during slice formation. This intermediary control system preserves the simplicity of the common shaft mounting while restoring the selective knotting capability that would otherwise be lost.
Data Source
AI summary
A baler is described for forming square bales made up of several separately tied slices. The baler has a bale chamber and a plurality of needles movable in unison through the bale chamber to pass respective strands of twine from one side of the bale chamber to associated knotters located on the opposite side of the bale chamber. A first set of permanently operative knotters knot strands of twine tied around individual slices on each occasion that the needles are moved through the bale chamber. A second set of knitters configured to be selectively disabled by movement of a frame carrying their twine engaging components to a position out of reach of the tip of the needles, knot the remaining strands of twine only at the end of the formation of a complete bale.