Variable Friction Conveyor for Square Baler Pre-Compression
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Solution Overview
Problem
Existing agricultural square baler systems face mechanical complexity and inefficiencies at high production speeds, particularly with rotating fork/blade arrangements and conveyor-based systems, which lead to incomplete emptying of the pre-compression chamber and material entanglement.
Innovation Solution
A conveyor-based stuffer arrangement with alternating high and low friction portions on the conveyor belt, synchronized with the baling plunger movement, to efficiently propel pre-compressed crop material into the baling chamber, preventing premature filling or emptying and reducing material entanglement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a conveyor-based system is used to advance crops towards the baling chamber, then the system is simpler than rotating fork/blade arrangements, but material may be forwarded prematurely before the plunger is in the correctly retracted position
Solution Approach 1:
The conveyor belt speed is made variable rather than constant, allowing it to be adjusted dynamically based on the plunger position and baling chamber status. The control system modifies the conveyor speed in real-time to prevent premature material transfer while ensuring complete emptying when appropriate.
Solution Approach 2:
The system incorporates feedback from sensors that monitor plunger position and baling chamber fill status. This feedback is used by the control system to adjust conveyor belt operation, ensuring material is only transferred when the plunger is correctly retracted and the chamber is ready, thereby preventing timing errors.
2Device complexity
If a conveyor-based system is used to advance crops towards the baling chamber, then the system is simpler than rotating fork/blade arrangements, but the force exerted by the conveyor may be insufficient to quickly propel the batch into the baling chamber
Solution Approach 1:
The conveyor belt speed is dynamically increased during the emptying phase to provide sufficient propelling force. The control system detects when the pre-compression chamber contains a ready batch and accelerates the conveyor belt to quickly propel the material into the baling chamber, thereby maintaining high productivity.
Solution Approach 2:
The conveyor belt operates in periodic cycles of high speed and reduced speed, synchronized with the plunger movement and baling chamber status. During the emptying phase, the belt runs at high speed to quickly transfer material; during other phases, it operates at reduced speed or remains stationary, providing periodic bursts of force when needed.
3Force
If the conveyor belt exerts high friction force on crop material, then the batch can be gripped and moved into the baling chamber, but material may become entangled in the conveyor surface
Solution Approach 1:
The conveyor belt surface has different friction characteristics in different zones. The zone that contacts the crop batch during gripping and transfer has higher friction to ensure effective gripping, while other zones have lower friction to prevent entanglement. This local differentiation of surface properties allows the system to achieve both gripping force and reduced entanglement.
Solution Approach 2:
The conveyor belt is divided into functional segments with different friction properties. One segment provides high friction for gripping the crop batch, while another segment provides low friction to allow smooth release and prevent entanglement. This segmentation of the conveyor belt into zones with different surface characteristics resolves the contradiction between gripping force and entanglement prevention.
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 a technically straightforward and high-speed operation of the square baler, ensuring complete emptying of the pre-compression chamber without material entanglement, by utilizing the high friction portion to propel pre-compressed material into the baling chamber and the low friction portion to prevent premature movement.
Implementation Method 1
The high friction portion is configured to be able to exert a sufficient force on a batch of crop material present in the pre-compression chamber, to grip said batch and move it into the baling chamber
Implementation Method 2
The low friction portion is configured to exert a force on the crop material that is insufficient to move a batch of crop material present in the pre-compression chamber into the baling chamber
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 2~3
AI summary
The present invention is related to an agricultural square baler equipped with a pre-compression chamber (1 ) supplied with crop material by a suitable supply means, and configured to guide crop material from said supply means towards and into the baling chamber (2) where the rectangular bales are formed. At least one of the upper and lower walls (7,6) of the pre-compression chamber is formed by a conveyor belt (10), arranged to move from the supply means towards said baling chamber. The conveyor belt comprises at least two portions (15,16) configured to exert different friction forces on a batch of crop material, so that the high friction portion (16) is capable of moving the batch into the baling chamber, whereas the low friction portion (15) exerts a low force on said batch, thereby preventing material to be prematurely moved towards said baling chamber. The invention is equally related to methods for providing crop material to the pre-compression chamber of a square baler according to the invention.