Segmented Bale Wrapper for High-Pressure Fiber Bales
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Solution Overview
Problem
Existing packaging technologies for highly compacted synthetic fiber bales face challenges in stability, material efficiency, and adaptability to varying bale formats, as they often require complex control systems and generate waste.
Innovation Solution
A packaging device and process that uses a tube-like bale wrapper closed on all sides with axial ends welded shut, allowing for rapid, precise packaging with minimal material and control effort, capable of adapting to different bale formats and allowing for continuous or intermittent conveying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multipart bale wrapper is used with complex tightening straps during high-pressure pressing, then the pressed bale can be securely packaged, but the device complexity and control engineering effort increase significantly
Solution Approach 1:
The bale wrapper is divided into three separate components: a bottom wrapper applied to the bottom surface, a top wrapper applied to the top surface, and side wrappers applied to the lateral surfaces. This segmentation allows each wrapper to be independently applied and secured, simplifying the overall packaging system while maintaining reliability for highly compacted pressed bales.
2Ease of manufacture
If traditional bale wrapping methods are used, then packaging can be achieved, but material waste is generated and adaptability to different bale formats is limited
Solution Approach 1:
Instead of using a single wrapper that must accommodate all bale formats, the system applies bottom, top, and side wrappers with specific dimensions optimized for each orientation. This local quality approach reduces material waste by eliminating excess material while maintaining packaging effectiveness for various bale formats.
3Loss of substance
If a one-piece bale wrapper is used to save material, then material efficiency improves, but the ability to adapt to different bale formats and maintain stability under high pressure deteriorates
Solution Approach 1:
The wrapper system is segmented into bottom, top, and side components that can be independently sized and configured. This segmentation enables adaptation to different bale formats by adjusting the dimensions of each segment while using only the necessary amount of material, avoiding waste associated with one-piece wrappers.
Solution Approach 2:
The packaging system dynamically adapts to different bale formats by selecting appropriate wrapper dimensions and application sequences. The side wrappers, for example, can be applied in different configurations depending on the bale dimensions, providing versatility without requiring a single oversized wrapper for all formats.
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 solution enables high-performance packaging of up to 60 bales per hour with reduced material usage and design effort, flexibility in handling various bale formats, and efficient energy utilization, while maintaining bale stability through a fixing device like tightening straps.
Implementation Method 1
The preferably linear conveying motion can be used to pull the tube-shape envelope over the pressed bale. The energy necessary for pulling over can be applied by the conveying motion.
Implementation Method 2
a fixing device for applying a fixing element, especially a tightening strap, on the pressed bale
Implementation Method 3
each pressed bale is produced and compacted in a baling press between pressure rams under very high pressure
Data Source
AI summary
A method and a baling system includes at least one baler (14) for producing highly compressed bales (2) made of artificial fibers. The baler (14) includes a securing device for applying a securing device (3), in particular strapping, to the compressed bales (2). A packaging device (1) applies a bale casing (4) that is closed on all sides to the secured compressed bales (2). The packaging device (1) includes a production and application device (21) for producing a sleeve-type casing (5) and for the application thereof to the compressed bales (2), as well as a sealing device (22) for closing and sealing axial ends (6, 7) of the sleeve-type casing (5) on the uncovered sides of the bales.