bale press maintenance and bale shape
TRANSCRIPT
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 1/38
Bale PressBale Press Maintenance Maintenanceand Bale Shapeand Bale Shape
UniformityUniformity Joe W. Thomas – Vice President of Technology – Lummus Corporation – Savannah, GA USA
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 2/38
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 3/38
Effects of Poorly Shaped BalesEffects of Poorly Shaped Bales
Difficult or impossible to stack bales properly
Increased handling time per bale
Loss/Decrease of available storage space
Safety Concerns associated with bales
potentially falling
Increased storage costs
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 4/38
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 5/38
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 6/38
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 7/38
Factors that can influence bale shapeFactors that can influence bale shape
Non-uniform feed to Battery Condenser
Non-uniform feed to Press Box by Lint FeederMoisture content of the lint cotton
Press Dog maintenance Compression Chamber shape/maintenance
Floor Sleeve vs. no Floor Sleeve Extrude Pressure (Door-Less Presses)
Follow Block Clearance, Platens and Guides
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 8/38
NonNon--Uniform FeedUniform Feed
Uneven spread of lint in lint flue riser and acrossBattery Condenser Drum can result in a “bigended” bale at the press.
Uneven distribution of lint in the charging box bythe lint feed device can result in a “rolling,” orheavy sided bale.
Follow block guides help mitigate impact of“rolling” bale although accelerated guide wearmay result.
Uneven feed creates excessive side loading onpress boxes, floor sleeves and hydraulic cylinderbearings resulting in premature failure and/or bedsill shift.
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 9/38
Big Ended Bale Rolling Bale
Source: USDA-ARS Agricultural Handbook 503, “Cotton Ginner’s Handbook,” U.S Government Printing Office, 1977, pg. 45
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 10/38
Lint Moisture ContentLint Moisture Content –– Too LowToo Low
Increases wear on press hydraulics, boxes and
floor sleeves due to higher pressures. Causes lint to roll out from under Tramper and
causes Press Dogs to malfunction.
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 11/38
Lint Moisture ContentLint Moisture Content –– Too HighToo High
Increases wear on press hydraulics and press
boxes due to “Stiction.”
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 12/38
Press DogsPress Dogs
Press dogs are a necessary evil on short box
presses.
Not unusual to see Dogs missing or inoperable due
to lint accumulation or missing components.
Unrestrained lint cotton tends to “boil” out of thepress box creating tags and wads which can
ultimately affect final bale shape. This is especially true when processing low
moisture cottons.
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 13/38
LINT WADS BEGINNING TO FORM
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 14/38
DOG STUCK IN DOWN POSITION
WADS FORMING
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 15/38
Compression Chamber Shape/MaintenanceCompression Chamber Shape/Maintenance
Compression Chamber geometry has the greatest
impact on final bale shape.
Worn or Distorted Press Doors and worn Door
Linkages are the cause of “wedge” shaped bales in
Door type Presses.
Oversized Floor Sleeves and “Lint Extrusion” are
the causes of “wedge” shaped bales in Door-Lesstype Presses.
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 16/38
END DOOR AND LINKAGES
SIDE DOORS
INSIDE DOOR AND LINKAGES
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 17/38
Floor SleevesFloor Sleeves
Floor Sleeves are an extension of the CompressionChamber on up-packing door-less type Presses.
The function of a floor sleeve is to accommodate
automatic and semi-automatic tying systems on up-packing door-less Presses.
Mis-alignment between the Press Box and Floor
Sleeve can result in poorly shaped bales. Lint under compression “extrudes” through the gap
between the top of the Compression Chamber andthe bottom of the Floor Sleeve creating exaggeratedfolds at top of bale.
Align inside of Floor Sleeve as close as possible withPress Box.
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 18/38
ALIGN SIDE WALLS AS CLOSE
AS POSSIBLE
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 19/38
LINT EXTRUSION DURING
COMPRESSION TAKES PLACEIN THIS GAP
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 20/38
EXAGERRATEDFOLDS
FLOOR SLEEVE
SLIGHT BULGE
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 21/38
EXAGERRATED FOLDSFLOOR SLEEVE
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 22/38
BALE WITH SHARP CORNERS AND NO FOLDSOR BULGES
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 23/38
FOLDSFLOOR SLEEVE BULGE
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 24/38
SLIGHT BULGE
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 25/38
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 26/38
NO FOLDS
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 27/38
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 28/38
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 29/38
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 30/38
BULGE AT FULL COMPRESSION
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 31/38
SLIGHT BULGE
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 32/38
Extrude Pressure (door Extrude Pressure (door --less)less)
Extrude pressure for down-packing presses is
the pressure on the “blind” end of the Top
Ram at which the Press Box is stripped off ofthe bale during compression.
Extrude pressure for up-packing presses isthe pressure on the “blind” end of the Top
(opposing) Ram at which the Top Ram backsaway from the Compression Chamber
allowing the semi-formed bale to extrude
from the Press Box.
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 33/38
Extrude Pressure (door Extrude Pressure (door --less)less)
Extrude pressure that is too low can lead to
mis-shaped bales.
Extrude pressure that is too high creates undo
wear and tear on the press box, floor sleeve
and hydraulic system.
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 34/38
Compression Chamber SchematicCompression Chamber Schematic
STRAIN GAGE LOCATIONAT CENTER
INITIAL FAILURE OCCURSAT CORNERS
Sources: Blodgett, Omer W., “Design of Welded Structures,” James F. Lincoln Arc Welding Foundation, Cleveland, OH, 1976, pp. 6.5-1 – 6.5-6EU Mechanical Standard EN 13445 “Unfired Pressure Vessels,” Guy Baylac and Daneille Koplewicz editors, August 2004, pp. 47-52
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 35/38
Compression Chamber Corner StressesCompression Chamber Corner Stresses
Source: Culler, Barry, MCAE Technologies - 108 Little Ridge - Duluth, Georgia 30096
MaximumStress
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 36/38
Bottom Ram Pressure vs. Box StressBottom Ram Pressure vs. Box Stress
Stress
BR Pressure
Extrude
Final Compression
TR ReachesTop Sill
S t r e s s
( i n v e r
t e d )
P
r e s s u r e
Time
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 37/38
Follow Block ConfigurationFollow Block Configuration
Missing, Worn or Improper fitting Follow
Block Guides lead to mis-shaped bales.
Turn-ups on the ends of Platen Bars help
keep strapping guide tracks clear but
contribute to poor bale shape.Excess clearance between edge of Follow
Block and Press Box allow Follow Block tomove causing poor bale shape during
compression. (¼” is adequate clearance)
8/7/2019 Bale Press Maintenance and Bale Shape
http://slidepdf.com/reader/full/bale-press-maintenance-and-bale-shape 38/38
Thank YouThank You