Variable-Length Connecting Rod for Baler Plunger Force Control
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Solution Overview
Problem
Current agricultural balers require increasingly expensive components in the drive train to handle higher plunger forces for denser bales, leading to higher shipping and storage costs due to the limitations of existing baler designs.
Innovation Solution
The implementation of a baler with variable-length connecting rods that allow for larger compression forces at the plunger face while limiting the forces experienced by the gearbox, enabling the production of denser bales with a given gearbox design and increasing plunger throw, while also allowing for fine-tuning of the reciprocating motion within the baling chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If higher plunger forces are used to create denser bales, then bale density is improved, but the load on drive train components increases requiring more expensive components
Solution Approach 1:
The connecting rod length is made variable rather than fixed, allowing the system to dynamically adjust its mechanical characteristics. During the compression stroke, the connecting rod extends to increase plunger throw and compression force at the plunger face, while during the return stroke it retracts to reduce the arc and forces on the gearbox and crank arm. This dynamic adjustment enables higher bale density without proportionally increasing drive train loads.
Solution Approach 2:
The system changes the physical parameter of connecting rod length during operation. By extending the connecting rod length during compression, the plunger throw is increased, which directly increases the compression force and bale density. The hydraulic system enables this parameter change on-demand, allowing optimization of compression performance without permanently increasing the size and cost of drive train components.
2Productivity
If larger plunger forces are applied, then compression efficiency is improved, but stress on the gearbox increases
Solution Approach 1:
The variable connecting rod length dynamically changes the mechanical leverage and force distribution in the drive train. During compression, the extended connecting rod increases plunger force while the hydraulic system bears part of the load. During the return stroke, the retracted connecting rod reduces the arc traveled by the crank arm and gearbox, thereby reducing stress and wear on these components while maintaining compression efficiency.
Solution Approach 2:
The hydraulic system acts as an intermediary that enables the connecting rod to extend and retract. The hydraulic cylinder and fluid pressure system provide the force to change the connecting rod length, allowing the mechanical system to achieve higher compression forces without proportionally increasing the stress on the gearbox and other mechanical components.
3Device complexity
If fixed connecting rod length is used, then device complexity is reduced, but adaptability of plunger motion is limited
Solution Approach 1:
The connecting rod transitions from a static, fixed-length component to a dynamic, variable-length component. The hydraulic cylinder integrated into the connecting rod allows it to extend and retract based on operational needs, providing adaptability in plunger motion control. This enables fine-tuning of the reciprocating motion characteristics to optimize compression performance for different bale density requirements.
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 baler achieves higher bale density with reduced stress on the gearbox, allowing for more efficient production of denser bales using existing gearbox designs and enhancing the plunger throw, thus reducing material costs and improving operational efficiency.
Implementation Method 1
a first feed line extending between and in fluid communication with the fluid volume of the connecting rod and the pump
Implementation Method 2
a lockout valve adjustable between a first configuration in which the fluid volume is in fluid communication with the pump, and a second configuration in which the fluid volume is not in fluid communication with the pump
Data Source
AI summary
A baler including a frame, a feed system coupled to the frame, a baling chamber, a gearbox, a crank arm driven by the gearbox, a plunger at least partially positioned within and reciprocally movable with respect to the baling chamber, and a connecting rod extending between and coupled to both the crank arm and the plunger, where the connecting rod defines a connector length, and where the connecting rod defines a fluid volume therein. The baler also including a hydraulic system in operable communication with the connecting rod, a pump, a first feed line extending between and in fluid communication with the fluid volume of the connecting rod and the pump, and a lockout valve adjustable between a first configuration in which the fluid volume is in fluid communication with the pump, and a second configuration in which the fluid volume is not in fluid communication with the pump.