Baler Pull-Off Feed Control for Tight Binding Without Film Blockages
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Solution Overview
Problem
Existing balers face issues with binding material springing back after cutting, leading to blockages and reduced reliability due to high tension, especially with stretch film, limiting the amount of stretching that can be applied for tight binding.
Innovation Solution
A baler with an actively driven pull-off device that adjusts feed speeds during the binding and cutting phases, allowing controlled stretching and reduced tension, reducing the risk of material springing back and improving reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high stretching is applied to stretch film binding material to achieve tight binding and economise on film usage, then binding tightness and film economy are improved, but the risk of blockage increases due to rapid contraction and springing back of the severed film
Solution Approach 1:
The patent applies preliminary action by increasing the feed speed of the pull-off device during the cutting phase before the binding material is severed. This preliminary increase in feed speed reduces the tension in the binding material before cutting, preventing rapid contraction and springing back that would cause blockages, while still allowing high stretching to be applied during the binding phase for tight binding
Solution Approach 2:
The patent applies dynamics by making the feed speed of the pull-off device variable rather than constant. The feed speed is increased during the cutting phase to prevent blockages, while maintaining appropriate speed during the binding phase to ensure tight binding. This dynamic adjustment of feed speed resolves the contradiction between achieving tight binding and preventing blockages
2Reliability
If the feed speed of the pull-off device is increased during the cutting phase to reduce material springing back, then blockage risk is reduced, but the complexity of controlling feed speeds during different phases increases
Solution Approach 1:
The patent applies periodic action by implementing distinct feed speed regimes for different phases of operation. During the binding phase, the pull-off device operates at a first feed speed appropriate for stretching and binding. During the cutting phase, the feed speed is increased to a second, higher speed to prevent blockages. This periodic variation of feed speed based on operational phase resolves the contradiction between blockage prevention and control complexity
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
Enhances the reliability of the baler by minimizing blockages and enabling increased stretching for tighter binding while reducing material consumption.
Implementation Method 1
Film binding material needs to be stretched before it is fed into the bale chamber to provide a tight binding on the bale... Additional stretching is usually provided between the feed mechanism and the bale chamber... As the film binding material is highly stretched during the binding phase, when the film is subsequently severed during the cutting phase the stretched film contracts and may spring back rapidly
Data Source
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AI summary
The present invention relates to a baler (2) for forming a round bale in a process that includes a bale forming phase, a binding phase wherein the bale is bound with a binding material, and a cutting phase wherein the binding material is cut. The baler includes a bale drive rotating the bale with a circumferential speed (SB), a cutter device (26) and binding mechanism (24) comprising a supply device (28) supplying binding material (F) and a feed mechanism (42) including a pull-off device (44) drawing binding material from the supply device and feeding it to the bale chamber (20). The pull-off device comprises a rotary drive element (46) and a rotary drive (68) for driving the rotary drive element. The pull-off device feeds the binding material at a first feed speed S1 during the binding phase and at a second feed speed S2 during the cutting phase, where S2 is greater than S1 and S2, during the cutting phase, is greater than SB.