Frameless Weldless Baler Plunger Assembly

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Solution Overview

Problem

Agricultural balers face durability issues due to the constant reciprocating action of plungers, which leads to material weakness and potential fractures from welding, especially in tight spaces where welds are incomplete.

Innovation Solution

The plunger is formed by a plurality of sections held together with an interference fit using tubes and clamps, eliminating the need for a frame structure and welds, allowing for easier repair and replacement, and providing a stronger connection than traditional welds.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If plunger sections are welded to a frame to form the plunger, then the plunger sections are held together to form a complete plunger structure, but material weak spots are created that lead to durability issues and potential fractures

Engineering Contradiction:

Improveplunger structural strengthVSAvoidplunger durability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The plunger is divided into multiple plunger sections that can be assembled separately and then connected through tubes without welding. Each section remains structurally intact while the overall plunger function is maintained through the segmented design, eliminating weld-induced weak spots.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Tubes serve as intermediary components that connect the plunger sections together. These tubes act as mediators that join the sections without requiring direct welding between sections, thereby avoiding the creation of material weak spots while still providing structural integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If welds are used to connect plunger sections in tight spaces, then the plunger sections are joined together, but incomplete welds are created that reduce durability

Engineering Contradiction:

Improveplunger assembly feasibilityVSAvoidweld quality

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The tubes act as intermediary connectors that can be easily assembled in tight spaces without requiring complex welding operations. The tube connection system provides a manufacturable solution that avoids the quality issues associated with welding in confined areas.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The welding process is replaced with a mechanical connection system using tubes and clamps. This substitution eliminates the need for thermal processes and skilled welding in tight spaces, providing a more reliable and easier manufacturing method.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Stability of the object's composition

If a frame structure with welds is used to hold plunger sections together, then the plunger sections are securely connected, but material weak spots are created that reduce overall plunger strength

Engineering Contradiction:

Improveplunger section connection stabilityVSAvoidplunger material strength

Core Design Contradiction:

Stability of the object's compositionVSStrength

Solution Approach 1:

Tubes serve as intermediary connectors that provide stable connection between plunger sections without creating material weak spots. The tube connection maintains structural stability while preserving the full material strength of the plunger sections.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The plunger assembly uses a composite structure combining plunger sections with tube connectors. This composite design integrates different components (sections and tubes) in a way that maintains overall structural stability without compromising the material strength of individual components.

Inventive Principle:

Principle #40Composite materials

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 design enhances the durability of the plunger by reducing material weak spots and allowing for easy maintenance, while maintaining or improving the plunger's strength and operational efficiency.

Implementation Method 1

a tube placed within the tube opening of each tube holding portion such that an interference fit is formed between the tube and the at least one tube holding portion of each plunger section to hold the plunger sections together

Methodology Applied

Scientific EffectInterference fit: Friction

Data Source

PatentUS11793116B2Agricultural baler with frameless and weldless plunger

Publication Date: 2023.10.24 BLUE LEAF I P INC

AI summary

A plunger for an agricultural baler includes: a plurality of plunger sections held together to form the plunger, the plurality of plunger sections including a pair of plunger end sections, each of the plunger sections including at least one tube holding portion having a tube opening formed therein; at least one of at least one roller or at least one sliding block attached to and extending laterally from each of the plunger end sections; and a tube placed within the tube opening of each tube holding portion such that an interference fit is formed between the tube and the at least one tube holding portion of each plunger section to hold the plunger sections together.