Re-bale Feeder System for Hay Bale Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Large rectangular and round bales of hay and straw are inconvenient for manual handling due to their size, necessitating a solution for reprocessing them into smaller, more manageable bales for industries like equine and small holdings.
Innovation Solution
A re-bale feeder system comprising an open-topped box chamber with a conveyor that urges material longitudinally towards an exit, aligning with a bale former to form smaller bales, utilizing bale chain drives and optional bale separators to break up material efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If large bales are used for field scale and transportation, then transportation efficiency is improved, but manual handling becomes difficult
Solution Approach 1:
The patent divides large bales into smaller bales using a re-baling apparatus. The large bale is fed into a chamber where it is cut and reformed into multiple smaller bales that are easier to handle manually while maintaining efficient transportation of the original large bale structure.
Solution Approach 2:
The system performs preliminary processing of large bales by feeding them through a chamber with cutting mechanisms before reforming. This preliminary action of cutting and preparing the material allows for efficient re-baling into smaller units without manual intervention.
2Ease of operation
If bales are reduced to smaller size for manual handling, then ease of operation is improved, but processing complexity increases
Solution Approach 1:
The re-baling apparatus uses a nested structure where the chamber, conveyor systems, and cutting mechanisms are integrated within a compact frame. The radially extending members are received within the chamber, and the overall structure nests components efficiently to reduce complexity while maintaining functionality.
Solution Approach 2:
The chamber serves multiple functions: it contains the material, supports the conveyor system, accommodates the radially extending members for cutting, and facilitates the re-baling process. This multi-functionality reduces the need for separate components, thereby reducing overall system complexity.
3Productivity
If material is fed continuously to bale former, then productivity is improved, but material control becomes difficult
Solution Approach 1:
The conveyor system provides controlled feedback mechanisms to regulate material flow into the bale former. The system monitors and adjusts the feeding rate to match the baling capacity, ensuring continuous productivity while maintaining proper material control and preventing overfeeding or jams.
Solution Approach 2:
The feeding system uses dynamic adjustment capabilities where the conveyor speed and material flow can be varied based on operational conditions. This dynamic control allows the system to maintain optimal productivity while adapting material flow rates to ensure proper control during the baling process.
Data Source
AI summary
A re-bale feeder (10) comprising an open-topped box frame into which material is placed, a conveyor (12) within the box frame operative to urge the material in a longitudinal direction towards an exit end. Also disclosed is a bale former (30) comprising a rotating loading roller (31) with a plurality of radially extending members extending therefrom, a surround cage surrounding at least a forward side of the loading roller (31), the surround cage (33) having a plurality of opening therein to allow the radially extending members of the rotating loading roller (31) to extend therethrough during rotation of the loading roller (31), and a baling system to receive material loaded by the loading roller (31) and form the material into one or more bales and a bale assembly.