Positive Drive Wrap Delivery System for Round Module Builders
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Solution Overview
Problem
Existing wrap delivery systems for round module builders face issues with force requirements for belt movement, leading to mis-feeds and damage to belt sheaves, which affects wrap economy and reliability.
Innovation Solution
A module builder with a wrap floor system and drive systems that include a main drive belt and a rear lower gate roller, friction wheel, or gears to engage and drive the belts, ensuring consistent rotation and reducing friction-related damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If friction-based belt drive is used, then device complexity is reduced, but reliability deteriorates due to mis-feeds and belt damage
Solution Approach 1:
The patent replaces the friction-based mechanical belt drive system with a positive drive system using a drive chain and sprocket mechanism. This substitution eliminates the reliability issues of friction-based drives while maintaining acceptable system complexity. The positive drive ensures consistent belt movement without mis-feeds or damage from belt joint laces.
Solution Approach 2:
The patent introduces a drive chain as an intermediary element between the drive sprocket and the belt system. This intermediary positive drive mechanism transfers power reliably without the belt-to-belt friction problems, ensuring consistent wrap delivery while managing system complexity through modular chain and sprocket design.
2Productivity
If force is applied to drive belts, then productivity is improved, but object-generated harmful factors worsen due to sheave damage from belt joint laces
Solution Approach 1:
The patent replaces the direct friction-based belt drive with a positive drive system using a chain and sprocket. This eliminates the harmful interaction between belt joint laces and sheaves, allowing high productivity wrap delivery without sheave damage. The positive drive transmits force through engaged teeth rather than friction, preventing the lace damage issue.
3Ease of operation
If friction-based drive is used, then ease of operation is improved, but manufacturing precision deteriorates due to mis-feeds
Solution Approach 1:
The patent substitutes the friction-based belt drive with a positive chain drive system. This provides both ease of operation and manufacturing precision by eliminating mis-feeds. The chain and sprocket engagement ensures consistent, accurate belt positioning while maintaining simple operation through automatic engagement and disengagement mechanisms.
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 enhances wrap delivery efficiency by maintaining consistent belt rotation and reducing damage to sheaves, thereby improving wrap economy and reliability.
Implementation Method 1
A common problem with this system is that it requires a certain force to generate movement, and if that force is too low, the belts will not turn
Implementation Method 2
a rear lower gate roller configured to engage and drive the main drive belt
Implementation Method 3
a friction wheel configured to engage and drive the main drive belt
Data Source
AI summary
A module builder includes a wrap floor system including a wrap floor belt wrapped around a front belt sheave and a first drive system coupled to the wrap floor system. The first drive system includes a main drive belt coupled to a rear belt sheave and the front belt sheave, wherein in an engagement mode of operation the main drive belt is tensioned to rotate the rear belt sheave, and in a disengagement mode of operation the main drive belt loses tension to cease rotation of the rear belt sheave. The builder includes a second drive system coupled to a baler belt to drive the baler belt into a module forming chamber. The first drive system further includes one or more of a rear lower gate roller, friction wheel, wrap box roller, electric clutch, or motor to engage and drive the main drive belt.