Baler Needle Rocker Coupling Device Kinematics
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Solution Overview
Problem
Existing balers in agriculture lack high-performance, high-compression, and high-throughput capabilities with high reliability and availability, particularly in terms of bale density and binding efficiency.
Innovation Solution
The baler incorporates a coupling device in the drive arrangement of the needle rocker, allowing for enhanced kinematics and faster movement of binding needles through the baling channel, combined with a band-shaped binding material connected by a material connection generator for increased tensile strength and efficient binding, and a band accumulator system for continuous unwinding and loading of binding material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a conventional drive arrangement with a single crank arm and pull rod is used, then the structure is simple, but the binding needle movement speed through the press channel is insufficient
Solution Approach 1:
The drive arrangement is segmented into multiple independent components: a first crank arm, a second crank arm, a coupling rod, and a pull rod. Each component performs a specific function in the motion transmission chain, allowing the system to achieve higher speeds through coordinated action while maintaining reasonable structural complexity through functional decomposition.
Solution Approach 2:
The invention introduces dynamic motion characteristics by using two crank arms with different rotation speeds (first crank arm rotates once per binding cycle, second crank arm rotates twice per binding cycle) and a coupling rod that translates rotational motion into linear reciprocating motion. This dynamic configuration optimizes the binding needle's acceleration and velocity profile through the press channel.
2Productivity
If the needle arm moves quickly through the press channel, then binding efficiency improves, but the binding needle has less time in the binding unit for proper binding
Solution Approach 1:
The motion profile of the binding needle is dynamically optimized through the two-crank mechanism. The first crank arm provides the primary driving motion for rapid transit, while the second crank arm, rotating at double speed, fine-tunes the timing and duration of the needle's presence in the binding unit. This dynamic coordination allows fast movement through the press channel while maintaining adequate binding time.
Solution Approach 2:
The binding cycle utilizes periodic rotational actions of the two crank arms to create a rhythmized motion pattern. The first crank arm completes one rotation per binding cycle, establishing the fundamental period, while the second crank arm completes two rotations per cycle, creating sub-periods that synchronize with the binding operations. This periodic action ensures consistent timing for needle insertion, binding, and withdrawal.
3Productivity
If binding material is fed rapidly to the binding unit, then throughput increases, but the feeding mechanism becomes more complex
Solution Approach 1:
The feeding mechanism merges the functions of material storage, controlled release, and rapid feeding into an integrated system. The binding material is stored in a accumulator that is mechanically coupled to the drive arrangement, combining the functions of the crank arms, coupling rod, and material feed mechanism into a coordinated system that achieves rapid feeding without separate complex control systems.
Solution Approach 2:
The binding material feeding mechanism is designed to be self-regulating through the mechanical coupling of the accumulator to the crank arm system. As the crank arms rotate and the coupling rod moves, the accumulator automatically releases binding material in response to the mechanical motion, without requiring separate sensors, motors, or control systems. The feeding rate is self-adjusted by the kinematics of the drive mechanism.
Data Source
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AI summary
Baler 2 for agricultural crops with a press channel 4 and with a needle rocker 12 pivotally mounted about a rocker pivot axis 8, which is arranged in a rocker pivot axis plane orthogonal to a longitudinal center axis of the press channel 60, and driven by at least one drive arrangement 10, which has at least one binding needle 14 movable by pivoting the needle rocker 12 through the press channel 4, wherein the drive arrangement 10 comprises a drive element 18 rotatably mounted about a drive axis 16 and a drive lever 20 arranged eccentrically thereon.The drive arrangement 10 has a coupling device 22 which is pivotably arranged about a coupling pivot axis 24 which is fixedly positioned relative to the press channel 4, wherein the coupling device 22 is spaced apart from the pivot axis 8 of the needle rocker 12 and is arranged on the needle rocker 12 and wherein the drive lever 20 is arranged on the coupling device 22.