Vertical Stacking Bale Accumulator with Adjustable Lift Arms
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Solution Overview
Problem
Existing bale accumulators for vertical stacking of rectangular bales lack efficiency and adaptability, as they often require manual intervention and are not designed to handle varying bale lengths and sizes effectively, leading to inefficiencies in stacking and discharge processes.
Innovation Solution
A vertical stacking bale accumulator with a trailer frame, non-powered rollers, a bale stacking mechanism, and a control system that automatically lifts and positions bales into a stacked configuration, featuring adjustable components for accommodating different bale sizes and lengths, and a rear gate that opens automatically upon reaching a predetermined number of stacked bales for gravitational discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual intervention is used in bale stacking, then device complexity is reduced, but productivity and stacking efficiency deteriorate
Solution Approach 1:
The bale stacking mechanism is designed to automatically lift bales using a lift arm with hydraulic actuation, and the rear gate opens automatically when a predetermined number of bales are stacked. The system serves itself without requiring manual intervention to stack bales or control gate operation, thereby improving productivity while managing complexity through self-regulating mechanisms.
Solution Approach 2:
The control system monitors the stacking process and automatically opens the rear gate when a predetermined number of bales are accumulated. This feedback mechanism ensures proper stacking efficiency while automating the discharge process, reducing the need for manual monitoring and intervention.
2Adaptability or versatility
If fixed bale handling components are used, then device complexity is reduced, but adaptability to varying bale sizes deteriorates
Solution Approach 1:
The lift arm and bale engaging devices are designed with adjustable components that can adapt to varying bale lengths and sizes. The hydraulic actuation system allows dynamic adjustment of lifting height and engagement position, enabling the accumulator to handle different bale dimensions without requiring multiple fixed configurations, thus improving adaptability while managing complexity through a single adjustable mechanism.
3Productivity
If automated bale lifting is implemented, then productivity is improved, but use of energy deteriorates
Solution Approach 1:
The hydraulic actuation system for the lift arm is designed to automatically lift bales using energy stored in the hydraulic system, which is recharged during the lowering phase. The system serves itself by using the weight of the bales and hydraulic pressure to perform the lifting function, improving stacking speed while minimizing continuous energy consumption through efficient hydraulic cycling.
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 efficient, automated vertical stacking and discharge of bales, improving handling and storage efficiency by accommodating varying bale sizes and lengths, and reducing manual intervention through automated processes.
Implementation Method 1
a series of non-powered rollers lying transversely of the trailer frame and spaced apart from one another along the longitudinal direction from adjacent the front end of the trailer frame to adjacent the rear end of the trailer frame
Implementation Method 2
a bale stacking mechanism installed on the trailer frame and arranged to automatically maneuver sequentially-received individual bales into a stacked configuration atop the rear rollers
Implementation Method 3
a rear gate movably carried on the trailer frame proximate the rear end thereof for movement between a closed position obstructing deployment of the bales from the rear end of the trailer frame and an open position allowing deployment of the bales from the rear end of the trailer frame
Data Source
AI summary
A towable vertical stacking bale accumulator features angle-adjustable roller beds on an obliquely oriented trailer frame whereby a rearwardly declining slope of the rollers gravitationally conveys individual bales from the baler to a stacking station at the rear of the trailer frame, where an automatically controlled gate provides a stop for retaining the bales until either a full stack is compiled or an error is detected. Spring loaded bale lifters feature concave undersides to encourage retraction of same as they are lowered down the sides of a newly arrived bale, and carry hanging bale guides that prevent the incoming bales from overshooting sides of the roller bed. Lift frames on which the bale lifters are carried are raised and lowered by hydraulically driven lift arms, and are further stabilized by engagement of lift frame followers with guide members of upright support structures provided on opposing sides of the roller bed.