Segmented Press Chamber for High-Density Baling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Baling presses face challenges in producing high-density bales with reduced effort and technology expenditure, while avoiding deformation of the press shield and damage to hydraulic drive elements, especially under high surface pressures and uneven filling conditions.
Innovation Solution
The device features a pressing chamber with a cross-sectional area of A x C/n, where n is greater than or equal to 2, allowing for the production of partial bales that are then stacked and connected in a storage space with a connecting device, generating higher area pressure and achieving better compaction without straining the power drive or guides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If large-sized hydraulic cylinders are used to achieve high surface pressure and high bale density, then the compression force and bale density are improved, but the device complexity, energy consumption, and infrastructure requirements increase significantly
Solution Approach 1:
The press chamber is divided into multiple smaller pressing chambers arranged side by side, each with its own smaller hydraulic cylinder. This segmentation allows the system to achieve the same total pressing force as a single large cylinder but with reduced individual cylinder sizes, lower complexity, and reduced energy requirements. The multiple chambers work in parallel to compress material into a single bale.
2Force
If large-sized hydraulic cylinders are used to achieve high surface pressure, then the compression force is improved, but the risk of deformation of press shield and damage to drive elements increases
Solution Approach 1:
The total compression force is distributed across multiple smaller hydraulic cylinders acting on separate pressing chambers. This segmentation reduces the mechanical stress concentration on the press shield and drive elements, thereby reducing the risk of deformation and damage while maintaining the required total compression force.
Solution Approach 2:
Each pressing chamber applies compression force locally to a specific region of the material. This distributed local compression approach prevents excessive stress concentration at any single point on the press shield, improving reliability while achieving the required overall compression.
3Stress or pressure
If the press chamber cross-sectional area is reduced to increase surface pressure, then the area pressure is improved, but the volume of material that can be processed per cycle is reduced
Solution Approach 1:
Multiple smaller pressing chambers are arranged side by side, each providing high surface pressure over a smaller area. The combined effect of all chambers simultaneously processing material maintains high productivity while each individual chamber operates at optimal high pressure conditions for dense bale formation.
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 enables the production of high-density bales with reduced energy and infrastructure requirements, minimizing the risk of deformation and damage to the press shield and drive elements, while achieving short press cycle times and high surface pressures.
Implementation Method 1
the press shield moves towards a bottom of the press chamber which delimits the press chamber at the bottom... exert a large pressing force on the material to be pressed into a pressed bale
Implementation Method 2
the press shield is driven either by one or more hydraulic cylinders... large-sized hydraulic cylinders are used today, which, at the appropriate pressure, exert a large pressing force
Implementation Method 3
The pieces of pressed material to be pressed are introduced into the pressing chamber through the door opening below the pressing shield
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a device (1) for producing compressed balls (5) from compressible pressed product pieces (50), each compressed ball (5) produced having a cuboid form with edge lengths A, B and C. The device (1) comprises a press housing (10) having at least one press chamber (15) and a press shield (17) that can be moved in the press chamber in the press direction (71) and back by means of a mechanical drive (18, 18'). The press chamber (15) has a cross-sectional surface of A x C/n. In the press chamber (15), n partial compressed balls (5.1 - 5.n) can be produced in n first press steps, with a flat cuboid form with the edge lengths A, B and C/n. A storage space (20) is arranged downstream from the press chamber (15), n partial compressed balls (5.1 - 5.n) being transferable into said storage space. The partial compressed balls (5.1 - 5.n) can be joined in the storage space (20) to form the cuboid compressed balls (5) with the edge lengths A, B and C. The press chamber (15) is separated from the storage space (20) by a mobile partition (12), and an opening (12') that can be freed by the partition (12) has at least the dimension A x B in the opening position, such that a partial compressed ball (5.1 - 5.n) formed in the press chamber (15) can be transported into the storage space (20) through said opening (12').