Split Roller Configuration for Round Baler Width and Stress
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Solution Overview
Problem
The existing round module builders or balers face limitations in the width of the round bale or module due to stress tolerances of rollers, which restrict the width and stability of the formed cylindrical shape, as increased width leads to higher bending loads on the rollers.
Innovation Solution
A split roller configuration where multiple rollers are positioned between the first and second walls of the module builder, with some rollers rotationally coupled between supports, allowing for adjustable alignment and offset axes to span the module width, thereby distributing belt forces and accommodating wider bales without exceeding roller stress tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the width of the round module or bale is increased, then the productivity and output size are improved, but the bending loads on the rollers increase beyond stress tolerances
Solution Approach 1:
The patent divides a single wide roller into multiple narrower roller segments arranged side-by-side. Each roller segment has a width of approximately 6 to 12 inches, while collectively they span the full module width of 48 to 72 inches. This segmentation allows the system to achieve wide bale formation capability without subjecting individual rollers to excessive bending loads, as each segment only supports a portion of the total width.
2Stress or pressure
If multiple rollers are used to span the module width, then the roller stress is reduced, but the device complexity increases
Solution Approach 1:
The patent designs roller segments with universal mounting capabilities that allow them to be installed in various positions and configurations within the forming chamber. The segments can serve multiple functions: forming the cylindrical shape, supporting the belts, and accommodating different module widths. This multi-functionality reduces the need for specialized components for each roller, thereby managing complexity despite using multiple rollers.
Solution Approach 2:
The patent combines multiple roller segments into a unified forming system where they work together as an integrated assembly. The rollers are positioned in parallel and collectively support the belts and harvested material, merging their individual functions into a coordinated system that achieves the desired wide bale formation while distributing loads effectively.
3Productivity
If the roller width is increased to accommodate wider bales, then the productivity is improved, but the stability of the roller structure decreases
Solution Approach 1:
By segmenting the roller structure into multiple narrower units, each segment maintains its structural stability and rigidity. The shorter span of each individual roller segment prevents excessive deflection and bending, ensuring stability. When assembled in parallel, these stable segments collectively provide the support needed for wide bale formation without compromising individual roller stability.
Data Source
AI summary
A round bale or module building assembly with a frame having a first wall and a second wall separated from one another by a module width and a plurality of rollers positioned between the first wall and the second wall, the plurality of rollers defining at least one belt path. Wherein, at least two rollers of the plurality of rollers have a combined width configured to substantially span the module width.