Variable Geometry Conveyor for Continuous Round Baler
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Solution Overview
Problem
Conventional agricultural balers experience inefficiencies due to prolonged downtime for bale ejection and potential clogging issues, as well as operator error and silage pile-up, which affect bale formation and density during continuous harvesting operations.
Innovation Solution
A harvester system with two bale chambers and a conveyor system featuring movable rollers and variable geometry belts that facilitate synchronized transfer of bales from one chamber to another, maintaining bale shape and density while reducing transfer time and minimizing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional single bale chamber baler is used, then the structure is simple, but the downtime for bale ejection is prolonged (10-15 seconds) reducing productivity
Solution Approach 1:
The baler is divided into two separate bale chambers (first and second bale chambers) that operate independently and simultaneously. While one chamber is forming or ejecting a bale, the other chamber can be receiving crop or forming a bale, thereby eliminating idle downtime and continuous harvesting without interruption.
Solution Approach 2:
The dual chamber design enables continuous operation where crop pickup, bale formation, wrapping, and ejection occur in parallel across two chambers. The conveyor system continuously transfers crop material between chambers without interruption, maintaining continuous useful action throughout the harvesting process.
2Device complexity
If a back-feed mechanism with a single movable roller is used to transfer bales, then the device complexity is reduced, but the likelihood of clogging increases and reliability decreases
Solution Approach 1:
Different sections of the conveyor system have different roller configurations optimized for their specific functions. The entry point to the bale chamber has rollers positioned to guide crop smoothly, the transfer section has rollers for bale movement, and the ejection section has rollers for bale discharge, with each section having the specific quality needed for its local function.
Solution Approach 2:
The conveyor system acts as an intermediary mechanism between the two bale chambers, using multiple rollers as intermediate transfer points. These rollers mediate the transfer of bales and crop material between chambers, reducing direct contact and potential clogging points while maintaining reliable transfer.
3Manufacturing precision
If a long belt pathway is used in the bale chamber, then the bale can be fully formed, but silage pile-up and plugging occur due to insufficient tension
Solution Approach 1:
The belt tensioning system is made dynamic with adjustable tensioning mechanisms that can adapt to different operating conditions. The tension can be optimized during bale formation to prevent pile-up while allowing the long belt pathway to fully form the bale, resolving the conflict between bale quality and plugging prevention.
Solution Approach 2:
The belt tension, speed, and roller positions are adjustable parameters that can be optimized for different stages of bale formation. By changing these parameters dynamically during operation, the system prevents silage pile-up and plugging while still achieving proper bale formation through the long pathway.
4Ease of operation
If multiple movable rollers with independent movement are used for bale transfer, then the bale transfer control is improved, but the device complexity and operator error potential increase
Solution Approach 1:
Multiple roller control functions are merged into a single integrated conveyor system controlled by one operator station. The conveyor system combines crop pickup, bale formation, and ejection functions into a unified control mechanism, reducing the number of independent controls while maintaining operational flexibility and reducing operator error potential.
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A crop harvesting system (300) for continuous round baling is described that comprises a first and second bale chamber (310, 320) and a conveyor system (330) in operable communication with the first and second bale chambers. The conveyor system transfers harvested material (301) from a harvesting assembly (303) to one of the two bale chambers and assumes a variable geometry to facilitate movement of a bale (B1) still in formation from the first bale chamber to the second bale chamber. The crop harvesting system can comprise at least three bale carriers (350, 370, 380), at least two serpentine systems (340, 360) to facilitate movement of the bale (B1) into and out of the first and second bale chambers. The crop harvesting system can be integrated into an agricultural harvester such as a baler or combine.