Posted by NCWayne on March 13, 2012 at 23:28:47 from (69.40.232.132):
Been talking to a customer about this for several years and I don't remember if I ever posted about this or not. If I did it was way to long ago to remember anything. Anyway the project has come back up once again and they are wanting to get something started ASAP.
Basically I've got a customer that wants to be able to break up large bales of wheat straw in order to rebail them into smaller bails. I know how things often get off track on here, so let me say this from the get go. I won't get into the logistics of the whole deal but believe me if they are wanting it done, they have looked into the financial side of things and wouldn't be doing it if it wasn't profitable to them, so that's not an issue.
That said I have looked at commmercial bail busters online and the problem with them is that they rip the bail up. In this case my customer markets the small bails to various major retailers and as such need them to be in good shape. In other words the straw needs to be 'whole' and look like it was bailed once, not ripped up into pieces and rebailed.
They tried to get one going before with limited success. The problem they ran into was getting the flakes in the big bail to break up properly and get "fluffed up" enough to feed into the small bailer. I know they said it's particularly bad if there is a bit of moisture in the bale as it really causes to individual straws to clump together into large pieces instead of breaking up as easy as the dry stuff does.
I've got ideas in my mind of the material being carried down a conveyor into a set or two of counter rotating fingers. They would pick the material up and flip it over into the second set of fingers, and so on, and so on for as many times as it took to get things completely 'fluffed' That's what I have in my mind at the moment, or something along those lines anyway. Based on what they had before I believe what I've got in mind, in combination with what they had origionally, and possibly with a few other modifications, can be made to work.
Now, what I'm trying to figure out is what could I use for the 'fingers' that would have the strengh to pick and flip the material, as well as the spring/resiliance to handle a clod, etc that doesn't break up, without breaking. Whatever is used needs to be readily obtainable to buy a new one to replace any that do break, and better yet to even be a part that would be found on anther piece of equipment they already have. By that I mean things like a windrow machine, bailer tines, etc, etc. Basically pieces that already do nearly the same job on a smaller scale as they are needing to be done on a larger scale.
In the end I'm just a glorified mechanic/fabricator. Other than buying a bale here and there for ground cover, dog bedding, etc, etc I'm not in the hay business. So, without the knowledge that only comes with working with the stuff day in and day out, like many of you do, I'm her today looking for any ideas ya'll might have to throw into the mix if you were to build something like this for yourself.
Thanks for any tips, suggestions, ideas, wild a$$ guesses, or anything else that might even be the slightest bit relevant and help me figure out the best route to take here. THANKS WAYNE
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