Flat Wrapping Material Stack for Bale Handling
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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 wrapping system using flat, folded stacks of wrapping material, where a feed plate system with a serrated edge and independently movable cutting knife applies varying tension to cut the material, allowing for efficient dispensing and cutting of wrapping material without the need for heavy rolls.
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 into multiple individual sheets stacked together, replacing the single large cylindrical roll. Each sheet can be independently handled and positioned, dramatically reducing the weight and difficulty of maneuvering while maintaining continuous wrapping capability through the stacked arrangement.
Solution Approach 2:
The wrapping material is reconfigured from a three-dimensional cylindrical roll to a two-dimensional stacked arrangement of flat sheets. This dimensional change allows the material to be stored horizontally in a tray rather than vertically in a roll, reducing the height and weight that operators must handle while increasing storage capacity.
2Productivity
If cylindrical wrapping material rolls are used, then wrapping material can be fed continuously, but storage capacity is limited and downtime for reloading increases
Solution Approach 1:
The wrapping material is segmented into multiple individual sheets stacked together, replacing the single large cylindrical roll. Each sheet can be independently handled and positioned, dramatically reducing the weight and difficulty of maneuvering while maintaining continuous wrapping capability through the stacked arrangement.
Solution Approach 2:
The wrapping material is reconfigured from a three-dimensional cylindrical roll to a two-dimensional stacked arrangement of flat sheets. This dimensional change allows the material to be stored horizontally in a tray rather than vertically in a roll, reducing the height and weight that operators must handle while increasing storage capacity.
3Use of energy by moving object
If cylindrical wrapping material rolls are used, then wrapping material can be fed continuously, but power is required to overcome roll inertia to pull material off
Solution Approach 1:
The wrapping material is segmented into multiple individual sheets stacked together, replacing the single large cylindrical roll. Each sheet can be independently handled and positioned, dramatically reducing the weight and difficulty of maneuvering while maintaining continuous wrapping capability through the stacked arrangement.
Solution Approach 2:
The wrapping material is reconfigured from a three-dimensional cylindrical roll to a two-dimensional stacked arrangement of flat sheets. This dimensional change allows the material to be stored horizontally in a tray rather than vertically in a roll, reducing the height and weight that operators must handle while increasing storage capacity.
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 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
The upper plate is positioned within the wrapping material channel and comprises a serrated edge
Implementation Method 2
the upper plate is capable of creating a first angle in the wrapping material at the line of inflection between a trailing section of the wrapping material a leading section of the wrapping material
Implementation Method 3
the feed roll rotates within in the wrapping material channel in operable contact with at least a portion of the wrapping material such that at least a portion of the wrapping material is capable of being passed in the wrapping material channel
Data Source
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AI summary
The disclosure relates to a system and method for wrapping bales in a harvester (200) that uses wrapping material (606) stored in flat, folded layers instead of conventional round tubes or rolls, and specifically to a system for positioning and cutting the wrapping material during and after the process of wrapping a bale, the system comprising: a first feed roll (220), configured for dispensing a portion of wrapping material from a bundle (230); a feed plate system (500), configured to receive wrapping material and capable of applying a first amount of tension to the portion of wrapping material; and at least one cutting knife (604), positioned between the feed plate system and the bale chamber, such cutting knife independently movable from a first position to a second position; and a wrapping material channel positioned in operable communication with the bundle of wrapping material, the wrapping mechanism and the bale chamber.