Flat Stacked Wrapping Material Dispensing for Agricultural Baler
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Solution Overview
Problem
Conventional agricultural balers face challenges with heavy wrapping material rolls that are difficult to maneuver, limit storage capacity, and require power to feed wrapping material, leading to inefficiencies in bale wrapping processes.
Innovation Solution
A harvester system utilizing a material support tray for flat, folded stacks of wrapping material with a feed roll and tensioning elements to manage and dispense the material efficiently, allowing for controlled tension and easy loading/unloading of wrapping material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional cylindrical wrapping material rolls are used, then wrapping material can be fed continuously, but the rolls are heavy and difficult to maneuver by operators
Solution Approach 1:
The wrapping material is segmented from a continuous heavy roll into multiple flat sheets stacked together. Each sheet can be individually handled and loaded, transforming one heavy moving object into multiple lighter objects that are easier to maneuver and replace.
2Productivity
If cylindrical wrapping material rolls are used, then wrapping material is available for feeding, but storage capacity is limited and reloading frequency increases
Solution Approach 1:
The wrapping material storage transitions from a horizontal cylindrical roll configuration to a vertical stacked sheet configuration. This dimensional change allows multiple sheets to be stacked one on top of another, significantly increasing the storage capacity within the same space and reducing reloading frequency.
3Use of energy by moving object
If cylindrical wrapping material rolls are used, then wrapping material can be fed into the mechanism, but power is required to overcome the inertia of the roll
Solution Approach 1:
The feed roll is extracted from the heavy cylindrical roll configuration and applied directly to the flat stacked sheets. This removes the inertial resistance of the large roll, allowing the feed roll to easily dispense wrapping material without requiring significant power to overcome inertia, thereby reducing energy consumption.
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
The system enhances baling efficiency by reducing operator effort, increasing storage capacity, and eliminating the need for power to feed wrapping material, enabling smoother and more efficient bale wrapping operations.
Implementation Method 1
at least a first tensioning element, positioned adjacent to or in the material support tray and in operable contact with at least one stack of wrapping material, each tensioning element capable of applying at least a first amount of tension to the wrapping material
Implementation Method 2
The at least one feed roll is configured for dispensing at least one vertically stacked portion of the sheet from at least one of the stacks
Data Source
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AI summary
The disclosure relates to a system and methods for wrapping bales in a harvester (200) that uses wrapping material stored in flat, folded layers instead of conventional round tubes or rolls, the system comprising: a material support tray (210), capable of supporting at least one bundle of wrapping material (233), at least one feed roll (220), and at least a first tensioning element, positioned adjacent to or in the material support tray and in operable contact with at least one bundle of wrapping material.