Hay Bale Loader and Storage Assembly for Single-Vehicle Handling
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Solution Overview
Problem
Agricultural operations for loading and unloading hay bales are complex, requiring multiple vehicles and operators, which can compromise safety, efficiency, and accuracy, and may lead to issues with contaminated or harmful bales.
Innovation Solution
A hydraulic actuated lift system for trailers, comprising a loader assembly with a rotatable loader arm and spike, a storage assembly for hay bale conveyance, and an unloader assembly with a winch and unloader sled, controlled by a sensor and controller system, to automate and streamline the loading and unloading process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual loading and unloading operations are used, then operational flexibility is maintained, but operational complexity increases and safety is compromised
Solution Approach 1:
The patent combines multiple loading and unloading operations into a single integrated vehicle system. The loader assembly, storage assembly, and unloader assembly work together as one coordinated unit, eliminating the need for multiple separate vehicles and operators. This merging of functions reduces operational complexity while maintaining safety through automated coordination of all components.
Solution Approach 2:
The vehicle performs its own loading and unloading operations through automated sensor detection and hydraulic actuation. The system detects hay bales, positions itself, and executes loading/unloading sequences without requiring external assistance or complex manual coordination. This self-service capability simplifies operations while reducing the need for multiple operators.
2Reliability
If multiple vehicles and operators are used for loading and unloading, then operational flexibility is maintained, but safety is compromised
Solution Approach 1:
The patent incorporates sensor systems that continuously detect the presence, position, and status of hay bales and vehicle components. This feedback information is used by the control system to automatically adjust operations, ensuring safe execution of loading and unloading sequences. The feedback mechanism eliminates the need for multiple operators to coordinate manually, reducing safety risks while maintaining reliable operation.
Solution Approach 2:
The patent replaces manual mechanical operations with automated hydraulic and sensor-based systems. The hydraulic actuator assemblies automatically position loader arms and storage assemblies, while sensors detect hay bales and trigger appropriate responses. This substitution of mechanical coordination with automated control systems improves safety by eliminating human exposure to hazardous operations.
3Measurement precision
If automated sensor and controller systems are used, then delivery accuracy is enhanced, but device complexity increases
Solution Approach 1:
The patent employs sensor and controller systems that serve multiple functions: detecting hay bales, determining their position, triggering loading sequences, and monitoring operational status. This multi-functionality reduces the need for separate specialized components for each detection and control task, thereby enhancing delivery accuracy without proportionally increasing system complexity.
4Productivity
If manual operations are used, then device complexity is reduced, but productivity decreases
Solution Approach 1:
The patent enables continuous loading and unloading operations through automated sequences. While one hay bale is being processed, the system simultaneously positions components for the next bale, eliminating idle time and manual repositioning delays. This continuous operation significantly improves productivity compared to manual methods, where operations are interrupted by operator actions, despite the increased automation 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
Reduces operational complexity, improves safety and efficiency, enhances delivery accuracy, and detects and avoids contaminated bales, thereby improving livestock health and reducing fuel consumption.
Implementation Method 1
The loader assembly further includes a hydraulic cylinder coupled to the frame and the loader arm. The hydraulic cylinder is operable to move the loader arm between the retracted position and the extended position.
Implementation Method 2
In this position the spike is oriented to impale a hay bale as the vehicle moves in a forward direction.
Data Source
AI summary
A system and a method for loading a hay bale on a vehicle. The vehicle has a frame, a loader assembly mounted to the frame, and a storage assembly mounted to the frame and positioned relative to the loader assembly. The loader assembly has a loader arm rotatably coupled to the frame and a spike extending outwards and orthogonal to the loader arm. The loader arm can be manipulated between a retracted position and an extended position. When in the extended position, the loader arm extends outside the frame with the spike oriented parallel to the frame. The storage conveys a storage plate along a path relative to the loader assembly. The storage plate is arranged to remove the hay bale from the spike as the storage plate is conveyed along the path in a first direction and with the loader arm in the retracted position.