Location: Cotton Ginning Research
Project Number: 6066-30600-001-002-S
Project Type: Non-Assistance Cooperative Agreement
Start Date: Sep 1, 2026
End Date: Sep 30, 2028
Objective:
The overall objective of this work is address the critical issue of plastic contamination which is costing the cotton industry millions of dollars per year. Successfully meeting the objectives of this work will reduce claims of plastic contamination and address labor shortages which, in turn, will increase the profitability of cotton production in the United States, in keeping with the research priorities of the Secretary of Agriculture. The objective of this research is to develop, integrate, and evaluate a next-generation mechanized system for handling, unwrapping, cutting, and retrieving plastic wrap from modern high-density round cotton modules. Specifically, the project will (1) fully assemble and mechanize a base conceptual prototype round cotton module handling system derived from a rotational-style unwrapping mechanism which can accommodate the increased module weight and volume of the latest generation of cotton harvesters; (2) conduct full-scale prototype testing to identify structural, mechanical, and operational deficiencies requiring engineering redesign; (3) expand testing and optimization of an integrated, modular two-stage wrap cutting system to evaluate cutting performance across material types, blade geometries, and operating conditions and establish engineering redesign criteria; and (4) design, fabricate, and evaluate a conveyor-based automated module wrap retrieval system capable of removing polyethylene wrap post-cutting to minimize contamination and labor requirements. These objectives collectively support the development of a reliable, scalable, and automation-ready system to improve cotton gin efficiency, safety, and product quality.
Approach:
To accomplish the objectives of this project the work has been broken down into component tasks.
Task A – Structural Redesign of Major Components. The project will iteratively redesign rollers, arms, trolleys, and the frame using load analyses, CAD modeling, and finite element evaluation. Roller designs will be optimized for improved stress distribution through revised shaft geometry and hollow tube construction, while grabber arms will be reinforced to prevent stress concentration in hook regions. Trolley designs will be reconfigured to reduce weight while providing stable linear motion on reduced beam configurations. Frame members will be redesigned for adequate rigidity and simplified fabrication.
Task B – Prototype Fabrication and Mechanical Verification. Full scale components will be fabricated following completion of analytical validation. Test setups will simulate module loads up to and exceeding expected operating conditions. Verification milestones include: static load testing of grabber arms, roller compression tests under elevated loads, alignment testing of trolleys and rails, and structural performance checks on the frame under representative distributed loads.
Task C – Integration and Testing of Wrap Cutting Mechanism. A two stage cutting system, comprising a roller chain traverse and rack and pinion extension, will be incorporated into the upgraded handling frame. Programmable height positioning using screw jacks will allow precise cutter alignment. Bench testing will evaluate cutter performance across wrap materials at varying blade angles and speeds prior to full integration. Module level testing will confirm durability, smooth tool travel, and mechanical compatibility with the rotational unwrapping system.
Task D – System Level Performance Trials. Following integration, the complete round module handling and unwrapping system will undergo initial, in-lab time and motion studies, repeatability assessments, and extended stress cycle testing. Operational metrics include module pickup stability, rotation uniformity, mechanical reliability under repeated loading, and total unwrapping duration compared to legacy systems. Results will guide refinements to geometry, material thicknesses, and component interfaces.