Square Baler Plunger with Impulse Energy Storage
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Solution Overview
Problem
Conventional square hay balers apply high forces to the plunger, leading to excessive loading on the drive train and connecting rods, which can be inefficient and stressful on the baler components.
Innovation Solution
A powered square baler with a reciprocating plunger assembly that includes an impulse device or energy storage mechanism, such as a spring, to transmit energy and apply an impulse force to the loose material, reducing the peak torque required and distributing work over a larger range of motion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If high forces are applied to the plunger to complete the compaction stroke, then the compaction effectiveness is improved, but the loading on the drive train and connecting rods increases excessively
Solution Approach 1:
The patent employs a reciprocating plunger mechanism that alternates between forward compression strokes and backward recovery strokes. This periodic action allows the system to accumulate energy during the recovery phase and release it during the compression phase, reducing peak forces on the drive train and connecting rods while maintaining effective compaction.
Solution Approach 2:
The patent incorporates an impulse device that stores energy during the plunger's backward movement and releases it beforehand during the forward compression stroke. This preliminary energy storage and release reduces the peak torque requirements on the drive train and connecting rods, thereby improving component durability while maintaining compaction effectiveness.
2Force
If high forces are applied to the plunger to complete the compaction stroke, then the compaction effectiveness is improved, but the peak torque on the drive train increases
Solution Approach 1:
The reciprocating plunger mechanism creates periodic cycles of energy storage and release. During the recovery stroke, energy is stored in the impulse device, and during the compression stroke, this stored energy is released to assist the plunger, thereby reducing peak torque requirements on the drive train while maintaining effective compaction forces.
Solution Approach 2:
The impulse device performs preliminary energy storage during the plunger's backward movement and releases this energy before the forward compression stroke begins. This preliminary action reduces the peak torque burden on the drive train by providing an additional force source during the critical compression phase.
3Device complexity
If conventional connecting rods and drive train components are used, then the structural simplicity is maintained, but the component stress increases excessively
Solution Approach 1:
The impulse device stores energy during the plunger's recovery movement and releases it beforehand during the compression stroke. This preliminary energy storage reduces peak stresses on the connecting rods and drive train components by providing an additional force source that distributes the loading over a longer duration, thereby reducing stress concentrations.
Solution Approach 2:
The reciprocating mechanism creates periodic cycles that distribute stress over time. The impulse device enhances this by storing energy during the low-stress recovery phase and releasing it during the high-stress compression phase, thereby reducing peak stress levels on the connecting rods and drive train components while maintaining structural simplicity.
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 effectively compacts bale material while reducing the load on baler components, distributing work over a larger range of crank arm rotation and minimizing peak torque, thus enhancing the efficiency and durability of the baler.
Implementation Method 1
The reciprocating plunger assembly includes a plunger head and an energy storage device. The plunger head is slidably mounted relative to the frame and is operable to be driven by a power source to reciprocate into and out of the chamber and apply a compressive force against the loose material. The energy storage device stores energy from the power source and transmits the energy to the plunger head in response to the applied compressive force, with the transmitted energy causing an impulse force to be applied against the loose material by the plunger head.
Data Source
AI summary
A powered square baler is operable to form a bale by compressing loose material. The powered square baler broadly includes a chassis and a reciprocating plunger assembly. The chassis includes a baler frame that presents a baling chamber to receive the loose material. The reciprocating plunger assembly includes a plunger head and an energy storage device. The plunger head is slidably mounted relative to the frame and is operable to be driven by a power source to reciprocate into and out of the chamber and apply a compressive force against the loose material. The energy storage device stores energy from the power source and transmits the energy to the plunger head in response to the applied compressive force, with the transmitted energy causing an impulse force to be applied against the loose material by the plunger head.