Regenerative Bale Handler Cylinder for Low-Power Raise and Gravity Lower

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Solution Overview

Problem

Cotton harvesters face peak power demands when multiple systems require power simultaneously, leading to excessive engine power usage and heat rejection, particularly during handler operations like lowering and raising, which is costly and inefficient.

Innovation Solution

Implementing a bale handler system with a regenerative valve for raising and a float/gravity lower mode that reduces hydraulic power requirements by utilizing gravity and diverting oil flow pressure, thereby minimizing auxiliary pump usage during these operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a larger engine is provided to meet peak power demands during handler operations, then power availability is improved, but cost increases

Engineering Contradiction:

Improvepeak power availabilityVSAvoidcost

Core Design Contradiction:

PowerVSEase of manufacture

Solution Approach 1:

The system dynamically switches between different hydraulic circuit modes (regenerative mode and gravity lower mode) based on operational requirements. The regenerative circuit recovers energy during handler lowering, while the gravity lower mode utilizes gravitational force to assist lowering operations, eliminating the need for continuous high-power pump operation and reducing peak engine power requirements

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes hydraulic circuit configuration parameters dynamically - switching between regenerative circuit configuration (with energy recovery) and gravity lower circuit configuration (with pump disconnection). This parameter change allows the same hydraulic system to meet varying power demands without requiring a larger engine

Inventive Principle:

Principle #35Parameter changes

2Speed

If auxiliary pump operates at full compensation pressure to lower the handler, then lowering speed is improved, but power consumption increases

Engineering Contradiction:

Improvehandler lowering speedVSAvoidpower consumption

Core Design Contradiction:

SpeedVSUse of energy by moving object

Solution Approach 1:

The system converts the gravitational force that causes uncontrolled handler descent into a beneficial resource. By using gravity lower mode, the system allows the handler weight to assist the lowering operation, converting what would be a harmful uncontrolled drop into a controlled, energy-efficient lowering process that reduces pump power requirements

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The handler system serves itself during lowering operations by utilizing its own weight to drive the lowering process. In gravity lower mode, the handler's gravitational force automatically drives the lowering action without requiring continuous external power input from the auxiliary pump, reducing energy consumption

Inventive Principle:

Principle #25Self-service

3Ease of operation

If pressure compensated pump operates at high standby pressure to extend the handler cylinder, then handler raising is improved, but excessive power is consumed and heat is rejected

Engineering Contradiction:

Improvehandler raising capabilityVSAvoidexcessive power consumption and heat rejection

Core Design Contradiction:

Ease of operationVSLoss of energy

Solution Approach 1:

The system applies partial action by using only the necessary pressure and flow required for handler raising operations. The regenerative circuit provides just enough pressure to extend the handler cylinder without maintaining excessive standby pressure, eliminating the waste of energy that occurs when pumps operate at high pressure regardless of actual demand

Inventive Principle:

Principle #16Partial or excessive action

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

This approach reduces peak power needs, conserves energy, and allows power to be redirected to other critical systems, potentially enabling the use of a smaller, less expensive engine while minimizing hydraulic heat rejection and maintaining operational efficiency.

Implementation Method 1

actuating the regenerative valve to regulate an oil flow pressure to the handler cylinder

Methodology Applied

Scientific EffectHydraulic pressure: Hydraulic Press

Implementation Method 2

a float/gravity lower mode that reduces hydraulic power requirements by utilizing gravity

Methodology Applied

Scientific EffectGravity: Gravitation

Data Source

PatentUS11903343B2Regenerative handler raise and gravity lower cylinder

Publication Date: 2024.02.20 DEERE & CO

AI summary

Hydraulic power savings for a rear module handler cylinder of a round module cotton harvester is possible by using a regenerative hydraulic arrangement for raising an empty handler and using gravity to lower the handler. A bale handler system for a cotton picker baler includes a handler for receiving a round module that is movable between upright and lowered positions and a handler cylinder operably connected to the handler. The handler cylinder system includes a regenerative valve. The regenerative valve is engaged when the handler moves to the upright position during regenerative handler raise mode of operation, the regenerative valve is not engaged when the handler moves to the lowered position during float handler lower mode of operation. While in the float handler lower mode of operation, the handler cylinder retracts and diverts an oil flow pressure from a base end to a rod end of the handler cylinder.