Chevron Rib Starter Roll for Baler Edge Wrapping
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Solution Overview
Problem
Existing round balers face difficulties in evenly wrapping bales due to lightweight and flimsy wrapping materials, which are prone to bunching and are affected by wind and static electricity, and prior starter rolls exacerbate this by biasing the wrapping material away from the bale edges.
Innovation Solution
A starter roll with a contact surface featuring a plurality of chevron-shaped ribs that guide the wrapping material laterally outward from the center to the edges of the bale, ensuring even coverage and preventing bunching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a smooth, spiral, or helical surface starter roll is used to engage crop material, then the roll can effectively roll up crop material into a bale, but the wrapping material becomes biased in the direction of the spiral and is moved away from one of the edges of the bale
Solution Approach 1:
The patent inverts the conventional spiral surface design by using a chevron pattern with V-shaped ribs that point in the direction of bale formation. This reversal of the spiral concept allows the ribs to guide wrapping material toward the bale edges rather than pushing it away, solving the contradiction between effective crop engagement and uniform wrapping material distribution.
Solution Approach 2:
The chevron-shaped ribs provide different local functions across the starter roll surface: the V-shaped ribs engage and guide wrapping material toward the edges, while the spaces between ribs allow material passage. This local differentiation enables simultaneous crop engagement and wrapping material distribution without requiring a completely different roll design.
2Quantity of substance
If lightweight and flimsy wrapping materials are used, then material consumption is reduced and cost is lowered, but the material is susceptible to bunching and is difficult to cover the edges of the bale
Solution Approach 1:
The chevron-shaped ribs act as an intermediary mechanism between the wrapping material and the bale edges. These ribs physically guide and spread the lightweight material laterally outward, preventing bunching and ensuring edge coverage without requiring heavier or stiffer wrapping materials.
3Manufacturing precision
If elastic ends are provided on wrapping material to cover bale edges, then edge coverage is improved, but the material still bunches toward the center making it difficult to cover edges and sidewalls
Solution Approach 1:
The chevron ribs perform preliminary action by guiding and spreading the wrapping material laterally outward before the material is fully applied to the bale. This pre-positioning prevents bunching toward the center and ensures uniform distribution across the bale surface, including proper edge coverage.
Data Source
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AI summary
In one embodiment, a starter roll for a baler includes a continuous chevron-shaped rib provided on a contact surface of the starter roll. The rib may include a center portion arranged generally parallel to the longitudinal axis of the starter roll and outwardly and rearwardly extending wings. A plurality of ribs may be provided to form guide channels for guiding wrapping material that is provided to the bale and engaged by the starter roll outward to cover the edges of a bale and distribute the wrapping material over the lateral surface of the bale.