Inclined Milling Machine Pendulum Bale Transport
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Solution Overview
Problem
Inclined milling machines face challenges in efficiently adding new bales and working off the last remainder at the tip of the wedge-shaped bales, due to high complexity and laborious processes, as well as issues with residue removal and fiber suction.
Innovation Solution
A pendulum rising or sliding bed is used in conjunction with a cutter head that assumes a flat angle to the bale transport track at the wedge tip, allowing for efficient and stable operation, with a fork-lift truck for bale alignment and hydraulic movement, and light barriers for safety, enabling easy alignment and processing of bales.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conveyor belts are used with fast advance and return mechanisms, then new bales can be added when operatives are delayed, but the process becomes very laborious and leads to unstable bales falling over during fast advance and return
Solution Approach 1:
A loading carriage acts as an intermediary device between the bale storage area and the conveyor belt. The carriage moves back and forth on rails parallel to the conveyor, picking up bales from the storage area and delivering them to the conveyor belt at the appropriate position. This intermediary mechanism eliminates the need for complex fast advance and return mechanisms on the conveyor itself, reducing operational complexity and bale instability while maintaining the ability to add bales flexibly.
Solution Approach 2:
The bale handling system is segmented into distinct functional zones: a bale storage area, a loading carriage operating on parallel rails, and the main conveyor belt. This segmentation allows each component to perform its specific function independently - the carriage handles bale pickup and delivery, while the conveyor focuses on transporting bales to the cutter head, simplifying overall operation.
2Productivity
If the conveyor belt is extended beyond the cutter head path, then more bales can be processed, but the first cutter roller cannot get close to the conveyor belt due to grated hoop and covers, leaving residues that must be removed by hand
Solution Approach 1:
The conveyor belt system incorporates a localized extension at the discharge end that protrudes beyond the cutter head path. This local quality change allows the conveyor to deliver bales closer to the cutter without requiring the entire conveyor length to be extended, enabling the cutter rollers to effectively process the bale ends while minimizing residue.
Solution Approach 2:
The conveyor belt system is designed with dynamic adjustment capabilities at the discharge end, allowing the belt position to be optimized relative to the cutter head. This dynamic positioning ensures that the conveyor can adapt to different bale sizes and cutter positions, maintaining optimal cutting conditions and preventing residue accumulation.
3Use of energy by moving object
If the conveyor belt is shortened, then the suction stream works better, but the grated surface lies exposed and fibres are not sucked along, falling behind the conveyor belt onto the bed
Solution Approach 1:
The conveyor belt system incorporates a localized extension at the discharge end that protrudes beyond the cutter head path. This local quality change allows the conveyor to deliver bales closer to the cutter without requiring the entire conveyor length to be extended, enabling the cutter rollers to effectively process the bale ends while minimizing residue.
Solution Approach 2:
The exposed grated surface, which initially appears to be a problem causing fibre loss, is strategically positioned and designed to work with the suction stream. The grille structure creates turbulence in the air current that enhances fibre pickup, converting what seemed like a harmful exposure into a beneficial feature for fibre collection.
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 solution simplifies and economizes the bale milling process by allowing for efficient alignment and processing of bales, reducing labor and preventing bale instability, while ensuring complete fiber removal and efficient production.
Implementation Method 1
A pendulum bed (1) is installed on the factory floor and can be operated by means of a ramp (2) with a fork-lift truck. The bales are slowly moved by the pendulum bed forwards towards the wedge tip.
Implementation Method 2
The cutter head (3) with the cutter rollers moves over rollers (4) guided and quickly driven back and forth on a track (5) and (6).
Implementation Method 3
the worked off fibres are blown by a fan (10) to the next processing stage
Data Source
AI summary
A milling machine for working off several textile bales in a wedge shape includes a pendulum or a sliding bed for moving the bales forward in the cutting zone, wherein the bales are worked off in a wedge shape under at least two different angles. That is, the angle between the direction of the back and forth work off movement and the direction of the forward movement at the lowest work off zone is less than in the centre of the inclined work off path.