High-Density Round Bale Compression via Pre-Compression and Press Belt
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Solution Overview
Problem
Existing round bale production methods result in low-density bales unsuitable for smaller formats, such as pet use, due to inadequate compression during the winding process.
Innovation Solution
A device comprising a feed station for forming a material web, a compression station with pressure elements to pre-compress the material, and a winding station with a rotating press belt to form high-density round bales, allowing for two-stage compression and controlled wrapping to achieve a compact, high-density bale.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If crop material is wound up in a baling chamber with a looped baling belt, then round bales are produced continuously, but the bales have low density due to low compression during winding
Solution Approach 1:
The material web is pre-compressed in a compression station before being fed into the baling chamber for winding. This preliminary compression increases the density of the material before it is formed into round bales, resolving the contradiction between continuous production and low density by preparing the material in advance with higher compression forces.
2Quantity of substance
If material is compressed strongly during winding to increase density, then compact high-density bales are produced, but the device complexity increases
Solution Approach 1:
The compression process is divided into two separate stages: a compression station with pressure elements that pre-compress the material web, and a baling chamber that winds the pre-compressed material into round bales. This segmentation allows high-density compression to be achieved without overly complicating the winding system, as the compression function is separated and optimized independently.
3Quantity of substance
If a two-stage compression process is implemented to achieve high density, then compact round bales are produced, but the device complexity increases
Solution Approach 1:
The compression station and baling chamber are integrated into a single continuous processing line where the material web flows sequentially through both stages without interruption. This merging of functions in a streamlined sequence achieves high-density compression while minimizing the complexity that would arise from separate, disconnected processing stages.
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 method produces round bales with a density of at least 180 kg/m³, suitable for compact storage and use in smaller formats like pet food, with a volume of 0.5 to 20 liters, ensuring effective transportation and handling.
Implementation Method 1
The web-shaped crop, hay and/or straw can thus be loosely placed on the conveyor belt and then guided through the compression station by this conveyor belt
Implementation Method 2
the material web is passed between at least two pressure elements and compressed. In the compression station, not only is the height of the material web reduced, but the material is also pre-creased by a wave-like passage between the rollers
Implementation Method 3
The forming of the material web behind the metering device can thus be achieved by gravity
Implementation Method 4
the baler belt applies a pressure of preferably 2,000 N to 3,000 N to the bale at the end of the wrapping process. This allows for the production of a high-density round bale
Data Source
Figure 1
Figure 2~4
AI summary
A device (1) for producing a round bale (20) comprises a feeding station (I) in which stalk-shaped crop material, hay and/or straw can be deposited onto a conveying means (41) as a material web (40), a compression station (II, III) in which the material web (40) can be passed between at least two pressure elements (52, 53) and compressed, a wrapping station (IV) with at least one circumferential press belt (43) around a press chamber (15) into which the compressed material web (40) can be inserted to form the compressed material web (40) into a round bale (20), and a fixing device by means of which a holding element can be wrapped around the round bale (20). The invention further relates to a method for producing a round bale (20) and a particularly compact round bale with a density of at least 180 kg/m³.