Press-wrapper with dual-level wrapping stations
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Solution Overview
Problem
Existing square baler-wrapper combinations are inefficient due to the difficulty in evenly distributing film on cuboid bales and longer cycle times compared to round balers, making it challenging to achieve airtight wrapping with compact dimensions and within road traffic regulations.
Innovation Solution
A press-wrapper combination with a unique frame geometry that includes two independent wrapping stations, one horizontal and one vertical, allowing simultaneous wrapping at different levels, and a conveying system that enables efficient transfer and placement of bales, optimizing film distribution and reducing overall machine length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single wrapping station is used for square bales, then the machine structure is simpler, but the wrapping time exceeds the bale production cycle time
Solution Approach 1:
The wrapping process is divided into two independent wrapping stations (first and second wrapping stations) that operate simultaneously at different heights. The first wrapping station wraps the lower portion of the bale while the second wrapping station wraps the upper portion, allowing parallel processing that reduces total wrapping time to within the bale production cycle time.
Solution Approach 2:
The patent introduces a vertical dimension to the wrapping process by arranging wrapping stations at different heights (first wrapping station at lower level, second wrapping station at upper level). This three-dimensional arrangement allows simultaneous wrapping operations that would be impossible in a single-plane configuration, effectively doubling the wrapping capacity.
2Length of stationary object
If the press channel outlet is positioned close to the ground, then the machine is more compact, but it is impossible to accommodate multiple wrapping stations at different heights
Solution Approach 1:
The press channel is designed with a vertical rise towards the rear, creating height variation along the longitudinal axis of the machine. This allows the press channel outlet to be positioned at a higher elevation at the rear, providing the necessary vertical space for the second wrapping station while keeping the front of the machine relatively compact for road transport.
Solution Approach 2:
The press channel geometry is optimized to dynamically accommodate bales of varying lengths. The rising channel design allows shorter bales to be processed at lower heights while longer bales utilize the full vertical rise, providing flexible accommodation for different bale dimensions without compromising the multi-level wrapping capability.
3Device complexity
If wrapping film is applied to cuboid bales using conventional methods, then the application process is simple, but the film distribution is uneven on the bale surface
Solution Approach 1:
The second wrapping station is positioned at an upper level and applies wrapping film to the upper portion of the bale from above, while the first wrapping station applies film to the lower portion from below. This vertical separation of wrapping operations ensures even film distribution across the entire bale surface, including the top surface which would be difficult to reach from ground level.
Solution Approach 2:
The wrapping process is segmented into two distinct stages: the first wrapping station handles the lower portion and initial film application, while the second wrapping station handles the upper portion and completes the film distribution. This segmentation allows each station to optimize its film application for its specific zone, ensuring uniform coverage across the entire bale.
4Adaptability or versatility
If an additional tractor and driver are used for separate wrapping operations, then the wrapping process is more flexible, but the operational cost and time consumption increase significantly
Solution Approach 1:
The patent combines the pressing function and wrapping function into a single integrated machine. The press unit produces bales while the first and second wrapping stations simultaneously wrap them, eliminating the need for separate wrapping operations with additional tractors and drivers. This integration reduces operational costs and eliminates the time loss associated with transferring bales between separate machines.
Solution Approach 2:
The integrated design allows continuous operation where bales are pressed and wrapped in an uninterrupted sequence. The dual wrapping stations operate continuously as bales pass through, eliminating idle time and waiting periods that would occur with separate batch operations using multiple tractors.
Data Source
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AI summary
Press-wrapping combination (1), in particular as an agricultural machine pulled and driven by a tractor for collecting, pressing and wrapping agricultural crops, wherein the resulting cuboid bales (6) are completely wrapped with wrapping material directly after pressing in at least two independent, successive wrapping stations (11, 14) of the bale wrapping device (7) of the press-wrapping combination (1), wherein the bales (6) located in the first wrapping station (11) and in the second wrapping station (14) are positioned in spaced-apart, at least approximately horizontal planes to each other and the vertical distance between the planes to each other corresponds at least to the bale height.