Agricultural Baler Roll Assembly with Overlapping Extensions

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Solution Overview

Problem

Agricultural balers face the challenge of crop material loss due to uncontrollable migration of material during the bale formation process, which reduces efficiency and increases wear on components.

Innovation Solution

A roll assembly with rolls configured to rotate in the same direction and having overlapping extensions that do not collide, enhancing bale core formation and reducing gaps between rolls to minimize crop material escape.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If rolls with extensions are used to increase bale formation aggressiveness, then bale formation efficiency is improved, but crop material loss increases due to uncontrollable material migration

Engineering Contradiction:

Improvebale formation efficiencyVSAvoidcrop material loss

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The roll assembly is segmented into multiple rolls (first roll, second roll, third roll) with extensions that create multiple compression zones. This segmentation allows controlled compression at different stages, preventing material migration while maintaining formation efficiency

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple rolls with extensions are combined in close proximity to create overlapping rotation paths. This merging of compression zones provides continuous control over crop material, preventing uncontrollable migration while maintaining aggressive bale formation

Inventive Principle:

Principle #5Merging (Combining)

2Loss of substance

If rolls are positioned closer together to reduce gaps and prevent material escape, then crop material loss is reduced, but the risk of extension collision increases

Engineering Contradiction:

Improvecrop material lossVSAvoidrisk of extension collision

Core Design Contradiction:

Loss of substanceVSReliability

Solution Approach 1:

The rolls are configured with asymmetric positioning and different rotation directions. The first and second rolls rotate in one direction while the third roll rotates in the opposite direction, creating an asymmetric pattern that prevents extension collision while maintaining close spacing

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The third roll is configured to rotate in the opposite direction to the first and second rolls. This inversion of rotation direction allows the roll to be positioned closer to the other rolls without causing extension collision, as the extensions move in opposite directions during rotation

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS11576308B2Agricultural baler with rolls having overlapping extensions

Publication Date: 2023.02.14 BLUE LEAF I P INC

AI summary

A roll assembly, which may be included in an agricultural baler, includes: a first roll having a first roll surface with a plurality of first extensions extending therefrom, the first extensions defining a first rotation path when rotated; and a second roll having a second roll surface with a plurality of second extensions extending therefrom, the second extensions defining a second rotation path when rotated. The first roll and the second roll are disposed adjacent to one another such that the first rotation path and the second rotation path partially overlap. At least one roll driver is coupled to at least one of the first roll or the second roll and configured to rotate the first roll and the second roll in the rotation direction such that the first extensions and the second extensions do not collide with each other during rotation of the first roll and the second roll.