Variable Speed Bale Wrapping Film Consumption
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Solution Overview
Problem
Existing bale wrapper technologies consume excessive stretch film while attempting to achieve adequate coverage and prevent air/water leakage, particularly in wrapping densely packed dry matter like hay or straw, as they often require constant relative speeds and multiple overlapping windings to ensure effective sealing.
Innovation Solution
A bale wrapper apparatus that varies the relative speeds of rotation about two axes during the wrapping cycle, allowing for different overlap ratios between successive windings, with an initial stage of high overlap (e.g., 2/3) for initial coverage and a subsequent stage of lower overlap (e.g., 50%) to optimize film usage and achieve satisfactory wrapping with fewer layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If constant relative speeds are used during wrapping, then the wrapping process is simple to control, but excessive film is consumed to achieve adequate coverage and prevent air/water leakage
Solution Approach 1:
The patent applies dynamics by varying the relative speeds of rotation between the bale and film dispenser during different stages of the wrapping cycle. The system transitions from a first relative speed during an initial wrapping stage to a second relative speed during a subsequent wrapping stage, allowing optimized film consumption at each phase while maintaining effective coverage and sealing.
2Reliability
If multiple overlapping windings are applied to ensure effective sealing, then air/water leakage is prevented, but film consumption increases significantly
Solution Approach 1:
The patent changes the parameter of relative speed during the wrapping process. By using a first relative speed for initial windings and a second relative speed for subsequent windings, the system achieves different overlap ratios that optimize both sealing effectiveness and film consumption, reducing the total number of windings needed while maintaining reliable sealing.
3Quantity of substance
If high overlap ratio is maintained throughout wrapping, then coverage is ensured, but film usage is excessive
Solution Approach 1:
The patent segments the wrapping process into distinct stages with different overlap requirements. The initial wrapping stage uses a first relative speed to create high overlap for comprehensive coverage, while the subsequent stage uses a second relative speed to create lower overlap, reducing film consumption while maintaining adequate coverage throughout the wrapping cycle.
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
This approach reduces film consumption by up to 33% compared to traditional methods while maintaining effective coverage, ensuring the bale is adequately sealed and minimizing gas exchange, thus preventing mold growth and nutritional loss in silage.
Implementation Method 1
a so-called satellite machine... apply stretch film wrapping to the outer surface of an agricultural bale
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
A bale wrapper apparatus (10) which comprises: a table for supporting an agricultural bale (20) with its longitudinal axis X extending substantially parallel to the ground and forming a first axis (13) about which the bale (20) is rotatable during a wrapping cycle; a holder (11) for a dispenser reel (12) of stretch film from which a strip of film (f) can be withdrawn in order to form successive overlapping windings (a, b) which wrap the outer surface and the end faces of the bale during the wrapping cycle; and means for applying relative rotation between the table and the holder (11) about a second axis (14) extending substantially perpendicular to the longitudinal axis X of the bale (20): in which the operation of the apparatus is controllable so that the relative speeds of rotation about the first and second axes (13, 14) can be varied during each wrapping cycle to obtain required variation in winding overlap coverage of the bale (20).