Note: Descriptions are shown in the official language in which they were submitted.
CA 02548635 1998-12-03
-1-
APPARATUS FOR WRAPPING STRAPPING ABOUT AN ARTICLE
Related Apulication
This application claims the benefit of U.S. Patent No. 6,182,563 issued on
February 6, 2001.
Field of the Invention
This invention relates generally to the handling of bales of hay and is
particularly directed to apparatus for stacking bales of hay into a large,
matrix-like
bundle to form a solid, rigid, self-supporting package which is easily handled
and
o stored without cutting or otherwise damaging the hay bales.
Background of the Invention
Cut hay is collected in the form of bales which are typically 14 inches by 18
inches by three and one half feet and are bound by twine or wire. The hay
baler
compresses the bale prior to applying the twine. The twine is of limited
strength,
15 limiting the extent to which the hay can be compressed and the density of
the hay
bale. This generally results in a rather loose bale.
Attempts have been made to stack hay bales to form a large bundle of hay
without success. A bundle of hay weighing many hundreds of pounds is more
easily
stored and affords economic advantages in handling, shipping and in feeding
livestock
20 over individual bales. However, these large bundles cannot be moved by hand
and
thus require mechanical means for moving and storing the bundles. If the
individual
bales are rather loosely bound such as by twine or are damaged by cutting or
shredding, the resultant large bundle of bales is even more loosely
constrained
rendering handling of the bundle difficult even by a machine and frequently
resulting
25 in loss and waste of hay.
The present invention addresses the aforementioned problems encountered in
the prior art by providing a hay bale stacking apparatus which under the
control of a
computer receives individual hay bales, stacks the bales in a large bundle,
tightly
bounds the bundle, and discharges the banded bundle from the aft of the
apparatus as
30 it traverses a field. The bundles are configured to facilitate handling
such as by pallet
forks, the individual bales are positioned and oriented in the bundle in a
manner
which enhances hay storage, and the bundle itself is a solid, rigid and self-
supporting
package with minimum damage to the hay.
CA 02548635 1998-12-03
2
Objects and Summary of the Invention
Accordingly, it is an object of the present invention to stack a plurality of
small
hay bales, into a large bundle which is securely banded in a manner which
avoids
severing the binding of the individual bales as well as cutting or shredding
the hay
during banding or during subsequent handling of the bundle.
It is another object of the present invention to provide for the automatic
stacking of individual bales of hay into large banded bundles in a computer
controlled
apparatus capable of operating in "on the go" as it traverses a field.
Yet another object of the present invention is to provide apparatus for the
stacking of hay bales into a large matrix-like bundle of hay bales which is
solid, rigid
and self supporting.
A further object of the present invention is to stack bales of hay in a large
securely banded bundle which can be lifted and moved by means of pallet forks
without damaging or severing the bundle's banding or the binding of the
individual
bales.
A still further object of the present invention is to bundle and store a
plurality
of hay bales in a manner which avoids contact of the bundle banding or the
individual
bale's binding with the ground and eliminates the damage and deterioration of
the
banding/binding associated therewith.
Another object of the present invention is to incorporate banding zones
extending inwardly into the bales in a large bundle of hay to permit a
restraining band
to be wrapped around the bundle without application of great tension to the
band to
avoid damage to the hay by the restraining band during banding or during
subsequent
handling of the bundle.
Brief Descn_ption of the DrawinE~
The appended claims set forth those novel features which characterize the
invention. However, the invention itself, as well as further objects and
advantages
thereof, will best be understood by reference to the following detailed
description of a
preferred embodiment taken in conjunction with the accompanying drawings,
where
CA 02548635 1998-12-03
3
like reference characters identify like elements throughout the various
figures, in
which:
FIGS. 1 and 2 are perspective views of a hay bale showing the manner in
which it is bound such as by wiz~c oz twee;
FIG. 3 is a side elevation view of a bundle or stack of hay bales fonm~ed in
accoz'danee with the present invention;
FIGS. 4 and 5 are side elevation views of a bundle of hay bales cor~taitning a
plurality of banding nines in accordance with one aspect of the present
invention;
FIG. 6 is a simplified schematic diagram showing the manner in which the
lU banding zones are formed in the bundle of hay bales;
FIGS, 7-21 are a series of side elevation views in simplified schematic
diagram
form illustrating the manner in which a bundle of hay bales is formed art
accordance
with the present invendon; and
FIG. 22 is a side view of the hay bale stacking apparatus of the present
invention;
FIG. 23 is a perspective view of the front portion of the hay bale staCkirlg .
apparatus shown in FIG. 22;
FIG. 24 is a perspective view of an upper, front portion of the hay bale
stacking apparatus of FIG_ 22 showing the pivoting arms of the verzica~.
plunger in the
upzaised position; .
F1G. 25 is a perspective view of the upper portion of the hay bale stackinE
apparatus as shown in PIG_ 2~ showing the pivoting arms of the veztical
plunger in the
lowered position;
FIG. 26 is a top plan view of the vertical and horizontal plunger portions of
the
hay bale stacking apparatus of the present invention;
);~G. 27 is a front view of a lower portion of the hay bale stacking apparatus
of
FIG. 22;
FIG. 28 is a front view of the hay bale stacking apparatus illustrating the
chamber in wbitch a bundle of hay bales is formed;
FIG. 29 is a pcrspeciive view of one of the strap guides stto~ng ttae strap
guide hinge in two different orientations;
CA 02548635 1998-12-03
4
FIG. 30 is an aft view of the hay bale stacking apparatus of the present
invention showing the back gates in the open position;
FIG. 31 is an aft view of the hay bale stacking apparatus showing the back
gates in the closed position;
FIG. 32 is a side view of the hay bale stacking apparatus illustrating the
manner
in which a large bundle of hay bales is discharged from the apparatus;
FIG. 33 is a perspective view of a proportion of the hay bale stacking
apparatus
illustrating the hay bale inlet or receiving conveyor;
FIG. 34 is a partial perspective view of the hay bale stacking apparatus of
the
present invention illustrating details of the hydraulic control system;
FIG. 35 is a partial perspective view of the inventive hay bale stacking
apparatus shown partially cutaway illustrating the hay bale elevator portion
thereof;
FIGS. 36-39 are perspective views of the banding mechanism used in the hay
bale stacking apparatus of the present invention;
FIGS. 40-50 are a sequence of side views showing details of the manner in
which one section of strapping is manipulated in the banding apparatus of the
hay bale
stacking apparatus of the present invention;
FIG. 51 is a simplified block diagram showing the various inputs to and
outputs
from the computer which automatically controls the operation of the inventive
hay bale
stacking apparatus;
FIGS. 52-55 are simplified schematic diagrams showing hydraulic circuitry of
manifolds and complex hydraulic circuits;
FIGS. 56-61 are a series of side elevation views in simplified schematic
diagram form illustrating the manner in which strapping is mechanically pulled
from
the banding dispenser for forming a curved edge on the strapping sides; and
FIG. 62 is a partial perspective view of the lower banding troughs.
Detailed Description of the Preferred Embodiments
Referring to FIGS. 1 and 2, there are shown perspective views of a hay bale
10. In the following description, the terms "banding" and "strapping," or
"straps," are
inter-changeable. Hay bale 10 is generally rectangular in shape and is held
together by
CA 02548635 1998-12-03
means of first and second bindings 12a and 12b which are typically wire or
twine.
The directions of the forces employed to compress and form bale 10 are shown
by
direction arrows 14a and 14b. Direction arrows 14a, 14b thus show the
direction that
the hay bale 10 was compressed when formed in a hay baler. When the hay bale
10
5 exits the hay baler, bindings 12a and 12b are positioned on the top, bottom
and ends of
hay bale 10 as shown in FIG. 1. In this orientation, the hay bale is described
as being
in the "flat" position. FIG. 2 shows hay bale 10 rotated 90° from its
orientation in
FIG. 1, where the hay bale has been rotated about a horizontal axis extending
along
the lengthwise dimension of the hay bale. The direction arrows 14a and 14b of
hay
.bale compression are oriented horizontally in this orientation of the hay
bale 10 as
shown in FIG. 2. In this orientation, bindings 12a and 12b are now disposed on
the
sides and ends of the hay bale 10 which is described as being in the "on edge"
position. Hay quality is maintained better when stored on edge as shown in
FIG. 2
than when stored in the flat position as shown in FIG. 1. Moreover, bindings
12a and
12b are removed from the support surface which may be the ground or a floor of
a
storage building. When oriented on edge as shown in FIG. 2, bindings 12a, 12b
are
less likely to be damaged or destroyed by rodents or the elements as compared
with
the flat position shown in FIG. 1 where the bindings are in contact with the
hay bale
support surface. The hay bale stacking apparatus of the present invention
stores the
hay bales in the on end position as shown in FIG. 2 as described in detail
below.
The hay bale stacking apparatus of the present invention arranges a number of
hay bales as shown in FIGS. 1 and 2 in a matrix-like bundle 16 of hay bales as
shown
in FIG. 3. The hay bale bundle 16 shown in the figure includes twenty-one hay
bales
which are stacked three bales high and seven bales wide. Hay bale 10 is in the
upper
left-half corner of the bundle 16 and is tied by bindings 12a and 12b, as
previously
described. Arrows 18a and 18b represent the direction of bundle compression as
the
bundle is formed by application of opposing compression forces by the hay bale
stacking apparatus of the present invention. Comparing the direction of
compression
forces in FIG. 3 with the compression forces applied to an individual bale in
FIGS. 1
and 2, it can be seen that the bundle compression forces are applied to the
same
opposed lateral surfaces of the hay bale as are the compression forces applied
in
CA 02548635 1998-12-03
6
initially forming the hay bale. When a hay bale exits the baler chamber of the
baling
apparatus, it expands outwardly in directions opposite to the direction of the
compression forces used in forming the bale. To form a solid, rigid, self
supporting
large package of hay in the form of bundle 16 shown in FIG. 3, the individual
hay
bales must again be compressed in the same direction with greater force than
they were
originally compressed during formation. This is a key aspect of the present
invention
and represents a fundamental departure from the prior art.
Referring to FIG. 4, there is shown another view of the bundle lb of hay bales
illustrating the position of one of the bands 20a (shown in dotted line form)
disposed
about the bundle. FIG. 5 is another side view of the bundle 16 of hay bales
illustrating additional details of the manner in which the bundle is securely
held
together by means of first and second bands 20a and 20b disposed about the hay
bales.
As previously described, the compression force applied to the bundle 16 of
hale bales
is in the opposed directions of arrows 18a and 18b, which are in the same
directions as
the forces used to initially compress the individual hay bales during
formation. In
FIG. 4, the first band 20a is shown disposed on the outer lateral surfaces of
the bundle
16, but is positioned within the individual hay bales at the top and bottom of
the
bundle. This is more clearly shown in the side elevation view of FIG. 5, where
the
first band 20a is shown disposed within an upper recessed banding zone 22a as
well as
in a lower recessed banding zone 22c. Similarly, second band 20b is disposed
within
an upper recessed banding zone 22b and a lower recessed banding zone 22d. The
bindings 12a and 12b of the top hay bale 24 are shown in dotted line form in
FIG. 5.
It can be seen from these figures that while the bundle bands 20a and 20b may
contact
the bindings of the individual hay bales along opposed lateral surfaces of the
bundle 16
of hay bales, the bundle bands do not engage the bindings of the top and
bottom rows
of hay bales. In other words, the bundle bands 20a, 20b do not engage the
bindings of
the hay bales in the top and bottom rows where the individual hay bale
bindings are
more likely to be damaged or severed. This essentially eliminates the
possibility of the
bundle bands severing the bindings of the upper and lower row of hay bales so
as to
maintain the bundle tightly bound without the damaging the hay.
CA 02548635 1998-12-03
7
Also in accordance with the present invention, the recessed banding zones 22a-
22d in the upper and lower rows of hale bales permit the first and second
bundle bands
20a, 20b to be wrapped around the bundle of hay bales 16 without applying
tension to
the bands while still pernutting the bands to securely maintain the hay in a
solid, rigid,
self supporting large package. It is not possible to maintain the hay in a
tightly bound
bundle by applying a high tension and pulling the banding tight, as in prior
art
approaches, because this will result in severing the bindings of the corner
hay bales
resulting in cutting and shredding of the hay and a general loosening of the
bundle of
hay bales. In accordance with another aspect of the present invention and as
described
in detail below, the bundle 16 of hay bales is tightly compressed by
mechanical
apparatus at high pressure, permitting the bundle bands 20a and 20b to be
wrapped
around the bundle without the application of high tension to the hands. As the
bundle
16 of hay bales is compressed by the mechanical apparatus, the four banding
zones
22a-22d are formed in the upper and lower surfaces of the bundle for receiving
the
first and second bands 20a, 20b. After bands 20a, 20b are secured, the
mechanical
compression apparatus is released and the bales of hay expand outwardly
against the
bands, while maintaining high compression, without cutting the binding of the
individual hay bales or shredding the hay in the outermost bales.
Referring to FIG. 6, there is shown a simplified schematic diagram of the
manner in which the banding zones 22a-22d are formed in the bundle 16 of hale
bales.
A vertical plunger applies a downwardly directed force in the direction of
arrow 30 to
the bundle 16 of hay bale which is disposed upon a support member 32. Shown in
FIG. 6 are first and second vertical plunger elements 26a, 26b which are part
of the
vertical plunger. Additional details of the vertical plunger are described in
detail
below. The first and second vertical plunger element 26a, 26b form the upper
banding
zones 22a and 22b in the upper row of hay bales. Attached to support member 32
are
a pair of spaced lower strap guides 28a and 286 which engage the lower row of
hale
bales and form the lower banding zones 22c and 22d therein. It is in this
manner that
the banding zones 22a-22d are formed in the upper and lower rows of hay bales
within
the bundle 16 of hay bales by the vertical plunger device. These banding zones
permit
the bundle 16 to be moved by pallet forks (not shown for simplicity), maintain
the
CA 02548635 1998-12-03
8
bundle, bands displaced from the support surface, and permit the bands to be
tightly
positioned about the bundle without the application of high tension to the
bands.
Referring to FIGS. 7-21, there is shown a series of simplified schematic
diagrams of the operation of a hay bale stacking apparatus 40 in accordance
with the
principles of the present invention. FIGS. 7-2l are in the form of side
elevation views
of the hay bale stacking apparatus 40 and omit many structural details of the
apparatus
in order to specifically illustrate the series of operations carried out by
the hay bale
stacking apparatus 40 in forming a bundle of hay bales in accordance with the
present
invention. These structural details of the hay bale stacling apparatus are
fully
described herein following the description of the operation of the apparatus
shown in
FIGS. 7-21.
The hey bale stacking apparatus 40 includes a pair of banding dispensers (only
one of which is shown as element 42 in FIGS. 7-21 for simplicity). Banding
dispenser
42 holds and dispenses banding 44 which is shown in the figures in dotted line
form.
There are two banding dispensers 42 disposed side by side each of which lets
out a
respective length of banding 44 although only one is shown in the figures for
simplicity. Banding 44 is tightly wrapped around a bundle of hay bales by the
hay
bale stacking apparatus 40 as described in the following paragraphs. One end
of
banding 44 is attached to a banding apparatus 56. The hay bale stacking
apparatus 40
further includes a banding clamp 46 through which the banding 44 passes and a
vertical plunger 48. Vertical plunger 48 includes a pair of pivoting arms
(only one of
which is shown in the figures as element 76). Vertical plunger 48 further
includes a
pair of strap guides 54 for supporting a hay bale SOa. Hay bale SOa is bound
together
by bake bindings 52a and 52b (also shown in dotted line form). Hay bale
stacking
apparatus 40 further includes a pair of upper banding troughs 58 and a pair of
lower
banding troughs 60.
Hay bale stacking apparatus 40 operates in the following manner to form a
large bound bundle of hay bales. Hay bale SOa is received by the hay bale
stacking
apparatus 40 and is positioned on the vertical plunger 48. Vertical plunger is
attached
to and supported by a support frame 49 and moves vertically both upwardly and
downwardly on the support frame. Vertical plunger 48 includes the
aforementioned
CA 02548635 1998-12-03
9
pivoting arms 76 and strap guides $4. Pivoting arms ?6 arc horizontally spaced
from
one another as are the strap guides 54. The pivoting arms and strap guides 76;
54
initially move as a single unit in forming a stack of hay bales, but later
separate to
accommodate a stank of two or more hay bales as described below. The pivoting
arms
~ and the strap guides 75, 54 as part of the vertical plunger 48 are
vertically displaced in
both directions along support frame 49.
Bautding 44 which is let off from the banding dispenser 42 is connected at
otte
end thereof to a banding mechanism 57 within the banding apparatus 56. V~ith
hay
bale SOa positioned on the strap guides 54, the pivoting arms 76 are lowered
o»to the
upper surface of the hay bale as shown in FIG.' 8. Attached co the lower
surfaces of
the pivoting arms 76 are a pair of vertical compression members 76a for
foi~ning
upper banding zones within the hay bales as described below. With hay bale 50a
securely positioned between pivoting arms 76 and strap guides 54, the hay bale
is
lowered by the vertical plunger 48 as sDown in FIG. 9. As the vertical plunger
48
lowers hay bale 50a to form the first stack of three bales, banding 44 is let
out by the
banding clamp 46 and is maintained in contact with the lower surface of the
hay bale
SOa by means of the strap guides 54. With the strap guides 54 lowered a
distance
eq~ to the height of a hay bale, the upper portion of the vertical plunger 48
including
the pivoting arms ~6 is raised to receive a second hay bale SOb which is
positioned vn
~ the first hay bale SOa as shown in FIG. 10. Again, pivoting arms ?6 are
lowered to a
position in contact with the upper surface of the bay bale, as shown for the
case of hay
bale SOb in FIG. 11, and the vertical plunger 48 lowers the first and second
hay bales
50a, SOb a distance equal to the height of the second hay halt. A third hay
bale SOc is
then positioned on top of the second hay bale SOb as shown in FIG_ 12. The
three hay
bales SOa, SOb and SOc are thus supported by the strap guides S4 which have
been
separated from the upper portion of the vertical plunger 4$ to accommodate the
three
stacked hay bales. 'The vertical plunger 48 is then displaced downwardly in
the
direction of arrow 62 as shown in FIG. 13 letting out additional b2Utdirlg 44
from the
banding dispenser 42. During the stacking and lowering of the three hay bales,
the
end of banding 44 is securely clamped to the banding mechanism 57 within the
banding apparatus 56: As shown in FIG. I3, the strap guides 54 form a pair of
CA 02548635 1998-12-03
1~
spaced, parallel lower compressed banding zones 66, while the vertical
compression
members 76a on the pivoting arms 7b form a pair of parallel, spaced upper
compressed banding zones 64. As shown in FIG. 14, a first bundle 80 of three
stacks
of hay bales, each three bales high, has been formed by the hay bale stacking
apparatus 40 with each successive stack of three hay bales displaced in the
direction of
arrow 38 causing additional banding 44 to be withdrawn from the banding
dispenser 42
so that the banding is guided around three sides of the hay bale bundle and is
disposed
within the upper and lower compressed banding zones formed in the upper and
lower
rows of hay bales.
As each stack of three hay bales is displaced in the direction of arrow 38 so
as
to form a larger bundle of bales, the vertical plunger 48 returns to the
raised position
as shown in.FIG. 14 for receiving the first bale of another stack of bales. As
also
shown in FIG. 14, hay bale Sla is positioned in the vertical plunger 48 and is
disposed
upon the strap guides 54. After the first stack of three bales of a particular
bundle is
displaced, the banding clamp 46 clamps and holds banding 44a as the vertical
plunger
48 lowers hay bales Sla, Slb and Slc. This action pulls banding 44b through
strap
guides 54 to the position of banding 44a, removing the slack 44b that is
created by the
lowering of vertical plunger 48 in FIGS. 15, 16 and 17. In FIG. 15, pivoting
arms 76
of the vertical plunger 48 are placed over and in contact with hay bale Sla
and the hay
bale is lowered as previously described, In FIG. 16, the vertical plunger 48
has
received a second hay bale Slb which is disposed upon the lowered first hay
bale Sla.
In FIG. 17, the three stacked hay bales S la, S l b and S l c are shown in the
vertical
plunger 48. Pivoting arms 76 are lowered in the direction of arrow b2 so as to
form
the upper compressed banding zones in the top hay bale S l c while the strap
guides 54
form the lower compressed banding zones in the bottom hay bale Sla as
previously
described. During movement in the direction of arrow 38, the strap guides 54
guide
the banding 44 on top of lower banding trough 60 and the banding is held there
by
each successively formed stack of three hay bales.
FIG. 18 shows a horizontal plunger 68 moving a first bundle of hay bales 80 in
the direction of arrow 70. Hay bale bundle 80 is bound by a pair of bindings,
one of
which is shown in dotted line form as element 82. Disposed above bundle 80 is
a pair
CA 02548635 1998-12-03
ll
of spaced upper compression members 58 and disposed below the bundle is a pair
of
lower spacxd compression members 60 which are attached to a lower frame member
78. Each of the four compression members 58, 60 forms a respective banding
trough
and compression zone for receiving one of the bandings 82. A pair of back
gates 72
(only one of which is shown in the figure for simplicity) on the aft portion
of the hay
bale stacking apparatus 40 are shown in the closed position in FIG. 18,
allowing the
hay bale bundle 80 to be horizontally compressed by the horizontal plunger 68
during
the banding operation. Following the securing of bandings 82 about the
periphery of
the hay bale bundle 80, the back gates 72 are moved outwardly then to the
right and
left of the hay bale stacking apparatus 40 and assume an extended position as
shown in
FIG. 19. Following formation of the first hay stack bundle 80, a second hay
stack
bundle 84 is formed in a similar manner and is also moved rearwardly in the
direction
of arrow 70 by the horizontal plunger 68 as shown in FIG. 20. Continued
rearward
displacement of the second hay stack bundle 84 by the horizontal plunger 68
causes a
IS corresponding rearward displacement of the first hay stack bundle 80. An
aft, lower
portion of the hay bale stacking apparatus 40 includes a hinged back floor 74
which
may be released as shown in FIG. 21 for the discharge of the first hay bale
bundle 80
as the second hay bale bundle 84 is moved by the horizontal plunger b8 in the
direction of arrow 70. The second hay stack bundle 84 will next be discharged
fmm
the hay bale stacking apparatus 40 in a similar manner following the formation
and
rearward displacement of a third hay stack bundle which is not shown in the
figure.
Referring to FIGS. 22-39, additional details of the structure and operation of
the hay bale stacking apparatus 100 of the present invention will now be
described.
Hay bale stacking apparatus 100 includes a hay bale receiving or inlet portion
l lb
adapted to receive a hay bale 120 shown in FIG. 22 in dotted line form. The
bale
receiving portion 116 of the hay bale stacking apparatus 100 sequentially
delivers flay
bales to a vertical lift or elevator 122 which lifts the bale while
reorienting the bale
90° from the orientation of bale 120 as shown in F1G. 22 and delivers
the bales to an
upper portion of a vertical plunger 128. The hay bales may be provided to the
hay
bale receiving portion 116 of the stacking apparatus either by hand or
automatically by
a hay baler (not shown for simplicity) which may be disposed in front of and
CA 02548635 1998-12-03
12
connected to the hay bale receiving portion. The hay bale stacking apparatus
100 is
intended for "on-the-go" operation as it traverses a field of hay. Vertical
plunger 128
forms a vertical stack of three hay bales, vertically compresses the stacked
bales
forming a pair of elongated, linear banding zones in the top and bottom bales,
and
delivers the three stacked bales to a horizontal plunger 132. Horizontal
plunger 132
moves the three stacked bales toward the rear of the hay bale stacking
apparatus 100,
or to the right as viewed in FTG. 22. In moving each stack of three hay bales
rearwardly, the vertical plunger 128 forms a bundle of stacked hay bales,
preferably
three bales high and seven bales in width as shown and described below. The
bundle
of hay bales is tightly wrapped by a pair of bands disposed about the bundle
by means
of a pair of strap guides and upper and lower compression members in
combination
with a banding apparatus 124 located on an upper portion of the hay bale
stacking
apparatus 100, Continued rearward displacement of the successively stacked
bales of
hay causes the banded large bundle of hay bales to be discharged from an aft
portion
of the hay bale stacking apparatus 100 afar a pair of back gates 134a and 134b
are
opened and a back floor 136 hingedly couplod to a floor 230 of the apparatus
is
lowered as described in detail below. The large bundle of banded hay bales is
thus
deposited in a field as the hay bale stacking apparatus 100 is transported
through the
field in an "on-the-go" operation.
Attached to a forward portion of the bale receiving portion 116 of the hay
bale
stacking apparatus 100 is a hitch 118 to facilitate pulling of the stacking
apparatus aft
of a baler by a traction vehicle (not shown in the figures for simplicity).
The bale
receiving portion 116 includes a bale support panel 144, a bale door 145,
three
forward support members 158, and a pair of aft support members 152a and 152b
for
ZS supporting the hay bales as they are displaced rearwardly toward vertical
Lift I22.
First and second forward guide panels 140a and 140b in combination with third
and
fourth aft guide panels 142a and 142b ensure that the hay bales loaded onto
the bale
receiving portion 116 are moved to the vertical lift 122 without being
discharged or
falling from the apparatus. The bale receiving portion 116 includes an endless
transport chain 154 as shown in greater detail in the perspective view of FIG.
33. The
transport chain drive mechanism includes forward and aft sprockets where only
the
CA 02548635 1998-12-03
13
forward sprocket 156 is shown in FIG. 33 for simplicity. One of these
sprockets is
connected to drive means such as a hydraulic motor which also is not shown irt
the
figures. Disposed in a spaood manner along the transport chain 154 are a
plurality of
teeth 154a for engaging the hay bales and transporting them rearwardly toward
and
into the vertical lift 122. Element 108 generally designates.the support frame
of the
hay bale stacking apparatus 100 which supports the various components of the
stacking
apparatus which are described in detail below. As the hay bales are received
by the
bale receiving portion 116, they are displacxd in the direction of arrow 98 in
FIG. 33.
An optical sensor 90 such as a photoswitch detects the presence of a hay bale
and
activates the hydraulic motor which drives the transport chain 154.
Vertical lift 122 raises the hay bales to an upper portion of the hay bale
stacking apparatus 100 and positions the hay bales on a vertical plunger 128.
Vertical
lift 122 includes first and second side panels 160a and 160b as well as a
forward guide
panel I62 and an aft guide panel I'74 as more clearly shown in the partially
cut away
perspective view of FIG. 35. The aforementioned panels align each hay bale
with its
longitudinal axis generally vertical and confine the hay bale so that it is
properly
positioned at the upper end of the vertical lift 122 for deposit in the
vertical plunger
128. The lower portion of the forward guide panel 162 is curved so as to guide
the
hay bales to the proper position within the vertical lift 122. Forward guide
panel 162
~ is mounted to the support frame by means of a plurality of springs 148a and
148b to
permit the forward guide panel to urge the moving bales into the vertical lift
122 with
their lengthwise axis aligned generally vertical. An endless lift chain 164
disposed
within the vertical lift 122 engages and raises the hay bales to an upper
portion of the
vertical lift. Lift chain 164 is coupled to upper and lower sprockets, where
the lower
sprocket is shown as element 184 in FIG. 35. Sprocket 184 serves as the drive
sprocket for the lift chain 164 as it is coupled to and driven by a hydraulic
motor 180.
Disposed along the length of the chain 164 in a spaced manner are a plurality
of teeth
182 which engage and raise the hay bales within the vertical lift 122 in the
direction of
arrow 146 in FIG. 35. A second optical sensor (not shown for simplicity) in
the
vertical lift 122 detects the presence of a hay bale to hold the bale in the
vertical lift.
CA 02548635 1998-12-03
14
Disposed in an upper portion of the vertical lift 122 are a plurality of
curvilinear guide members 138 which engage and turn the hay bale 120 as shown
in
FIGS. 24 and 25 so as to change the orientation of the hay bale from vertical
to
horizontal; or~ flat. As also shown in the partially cut away view of FIG. 24,
as the
upper outer corner of hay bale 120 engages the curvilinear guide members 138,
continued upward displacement of the hay bale causes it to assume a generally
horizontal, or flat, orientation and to be displaced leftward in the direction
of arrow 92
in FIGS. 24 and 25. Once oriented horizontally, the hay bale 120 is positioned
upon
support panel 144. The hay bale is then displaced horizontally onto first and
second
strap guides 200a and 200b by means of a kicker arm 170. Kicker arm 170 is
initially
aligned with the curvilinear guide members 138 and has disposed on a lower end
thereof a kicker plate 170a. Kicker arm 170 is attached to and supported by a
pivot
shaft 178 at its upper end. Connected to pivot shaft 178 by means of a pivot
arm 176
is a hydraulic cylinder 1?2 having an extendible rod 1?2a. In the retracted
position, as
shown in FIGS. 23 and 24, kicker arm 170 is aligned with the curvilinear guide
members 138 and kicker plate 170a is disposed outside of the guide members.
Following the lifting and horizontal reorientation of a hay bale by the
vertical lift 122,
rod 172a is extended from the hydraulic cylinder 172 causing clockwise
rotation of the
pivot shaft 178 and kicker arm 170 attached thereto as viewed in FIG. 25.
Kicker
plate 170a engages and displaces hay bale 120 to the left as viewed in FIG. 25
so that
the hay bale rests upon and is su~orted by the first and second strap guides
200a,
200b. In this position, hay bale 120 is ready for stacking by the vertical
plunger 128
as described in the following paragraphs. The kicker arm 170 and its plate
170a also
compress bales that are too long approximately 3-4 inches. Following
displacement of
the hay bale 120 onto the first and second strap guides 200a, 200b, hydraulic
cylinder
172 retracts its extendible arm 172a resulting in kicker arm 170 again
assuming a
position in alignment with curvilinear guide members 138 in the upper portion
of the
vertical lift 122. A photo-electric sensor 94 detects the presence of a hay
bale at the
top of the vertical lift 122 for activating the kicker arm 170 for moving the
bale onto
the vertical plunger 128.
CA 02548635 1998-12-03
Vertical plunger 128 includes first and second pivoting arms 192a and 192b.
Pivoting arms 192x, 192b are coupled by cross members such as connecting arm
194
and move in unison. The pivoting arm assembly is pivotally coupled to the
vertical
plunger 128 by means of first and second pivot couplings 96a and 96b. The
first and
5 second pivoting arms 192x, 192b are moved between an upraised position as
shown in
FIGS. 23 and 24 and a lowered position as shown in FIG. 25. The pivoting arm
assembly in the vertical plunger 128 is moved between the upraised and lowered
position by means of a hydraulic cylinder 196 connected to a cross member of
the
assembly. Disposed below the first and second pivoting arms 192x, 192b when in
the
10 lowered position are the first and second strap guides 200x, 200b. Vertical
plunger
128 is mounted to and supported by first and second vertical rails 216a and
216b.
Attached to aft portions of the first and second vertical rails 216a and 216b
are
respective racks, while a pair of pinions are coupled to the vertical plunges
128 as
shown in FIG. 26. The first and second rack and pinion arrangements 206x, 206b
15 allow for vertical displacement of the vertical plunger 128 on the first
and sxond
vertical rails 216x, 216b. A pair of single flange rollers 186a and 186b allow
the
vertical plunger 128 to be displaced vertically on the first and socond
vertical rails
216a, 216b.
The first and second strap guides 200x, 200b are also respectfully attached to
and supported by the first and second vertical rails 216a and 216b. Strap
guides 200x,
200b support the hay bales as they are lowered and guide the banding into the
banding
apparatus 124 as well as to the lower banding compression zones. Upper and
lower
sprockets in combination with an endless drive chain are disposed on
respective
forward portions of each of the vertical rails. Thus, drive chain 210a is
disposed on
vertical rail 216x, while drive chain 210b is disposed on vertical rail 216b.
The
aforementioned sprockets are omitted from the drawings for simplicity. Drive
chain
210a is coupled to the first strap guide 200x, while drive chain 210b is
coupled to the
second strap guide 200b. Each of the first and second drive chains 210a, 210b
is
displaced by a respective drive sprocket for raising and lowering the first
and second
strap guides 200a and 200b on the first and second vertical rails 216a and
216b. First
CA 02548635 1998-12-03
16
and second double flange rollers 188a and 188b allow the first and second
strap guides
200x, 200b to be displaced vertically on the first and second vertical rails
216x; 216b.
As previously described, vertical plunger 128 in combination with the first
and
second strap guides 200a, 200b arranges three hay bales in a vertical stack
and
S compresses the stack of bales for forming a large bundle of hay bales. The
vertical
plunger 128 and strap guides 200x, 200b move downwardly the thickness of one
bale
as detected by a proximity switch (not shown) with the deposit of a hay bale
on the
vertical plunger 128. With three hay bales arranged in a vertical stack, the
first and
second pivoting arms 192x, 192b are lowered onto the upper hay bale and the
stack of
hay bales is compressed. Upper compression members .193a and 193b respectively
attached to the first and second pivoting arms 192x, 192b form a fir of upper
compression handing zones in the upper hay bale, while the first and second
strap
guides 200x, 200b form a pair of lower compression banding zones in the bottom
hay
bale as previously described.
Disposed in a forward portion of the hay bale stacking apparatus 100 is a
horizontal plunger 132. 1~Iorizontal plunger 132 includes first, second and
third
vertical panels 212a, 212b and 212c. A first vertical slot 214a is disposed
between
panels 212a and 212b, while a second vertical slot 214b is disposed between
panels
212b and 212c. The first strap guide 200a is disposed within slot 214a, while
the
second strap guide 212b is disposed within slot 214b. The elongated, vertical
slots
214x, 214b allow the first and second strap guides 200a, 200b to be displaced
vertically within the hay bale stacking apparatus, while permitting the three
panels
212a, 212b, and 212c to engage and displace a vertical stack of three hay
bales
rearvvardly within the apparatus in forming a bundle of stacked hay bales. The
three
panels 212x, 212b and 212c are connected by various structural members of the
horizontal plunger 132 to allow the three panels to be displaced in unison
forward and
aft by means of a hydraulic cylinder 218. Each of the strap guides 200a, 200b
has a
generally rectangular cross section and is in the form of a hollow tube
permitting a
strip of banding to extend through the strap guide from one end to the other.
Thus,
first and second strips of banding 202a and 202b are respectively let off of
the first and
second banding dispensers 112,114 and are routed through the first and second
strap
CA 02548635 1998-12-03
17
guides 200a and 200b. This arrangement allows the vertical plunger 128 and
pair of
strap guides 200x, 200b to arrange the hay bales in stacks of three, while
wrapping the
two sa-ips of banding about a bundle of stacked hay bales. Following the
stacking of
three hay bales, the horizontal plunges 132 is displaced rearwardly with the
extension
of the rod of hydraulic cylinder 218 causing pastels 212x, 212b and 2I2C to
ettgage aid
displace rearwardly a stack of three hay bales itn forming a bundle of hay
bales as
previously described. The first and second strips of banding 202a and 202b are
respectively dir~octed through first and second banding clamps 238a arid 238b
before
entering the first and second strap guides 200x, 200b. Banding clamps 238x,
238b
control the let out and take up of the strips of banding 202x, 202b from the
two
banding dispensers 112 and 114 and pukl the banding from the rear of a strap
guide to
the front of the strap guide. Rollers 254a and 254b are attached to respective
lateral
portions of horizontal plunger 132. Fixed structural members 252a and 252b
each
having a respective slot therein are oriented generally horizontal and are
aligned
parallel as shown in FiG. 27. The first and second rollers 254x, 2S4b are
disposed in
respective slots in tht first and second structural members 252a, 252b
allowing for a
forward displacement of the horizontal plunger 132 by means of hydraulic
cylinder
218. The horizontal plunger 132 is in the extended position upon the delivery
of a
first bale to the vertical plunger 128 to permit the bale door 145 to catch
the first bale-
. ,FIG. 28 is a front view of the inside of the hay bale stacking apparatus
where
the hay bales are stacked and arranged in a large bundle. The first and second
strap
guides 200x, 200b, arc shown extending through respective slots 214a and 214b
which
are respectively disposed between front panels 212x, 212b and 212c. Strips of
banding
202a and 202b. are let off of a respective banding dispenser and are secured
at one end
z5 to the banding apparatus which is not shown in the figure for simplicity. A
pair of
upper compression members 234x, 234b and a pair of lower compression members
232x, 232b arc disposed aft of and aligned with the first and second strap
guides 200a
and 2DOb. The upper and the lower compzessaan members maintain the compression
banding hones within the upper and lower stacked hay bales which are formed by
the
pivoting arms 192x. 192b of the vertical plunger 128 and by the aforementioned
first
and second strap guides. The lower compression members 232x, 232b are disposed
CA 02548635 1998-12-03
l8
upon and extend upwardly from a back floor 136 of the stacking apparatus,
while the
upper compression members 234a and 234b are attached to and extend downwardly
from an upper panel 150 of the stacking apparatus.
Referring to FIG. 29, there is shown a perspective view of a portion of the
second strap guide 200b showing a strap guide hinge 220b disposed on the aft
end
thereof. Strap guide hinge 220b is connected to the second strap guide 200b by
means
of a pivot pin 240 which allows the strap guide hinge to be displaced upwardly
as
shown in dotted line form in the figure. Banding 202b is disposed within and
extends
the length of strap guide 200b. Disposed on the distal end of strap guide
hinge 220b is
a miler 242 which facilitates displacement of banding 202b through the strap
guide.
hinge 220b. The pivoting strap guide hinge 220b allows for clearance of the
end of
the strap guide 200 from other components as the strap guide is vertically
displacxd
during let out of the banding 202b through the strap guide as the bundle of
hay bales is
banded.
Referring to FIGS. 30 and 31, there are shown back elevation views of the hay
bale stacking apparatus showing the back gates 134a and 134b in the open and
closed
positions, respectively. Additional details of the operation of back gates
134a, I34b
are described below, Each of the back gates is connected to the stacking
apparatus by
means of a plurality of hinges, as shown for the case of the second back gate
134b and
hinges 246 in the partial side elevation view of the stacking apparatus of
FIG. 32.
Three stacked hay bales 236x, 236b and 236c are shown in dotted line form in
FIG. 30
disposed in the hay bale stacking apparatus 100. A pair of upper banding zones
are
shown in the top hay bale 236a as formed by the first and second upper
compression
members 234a and 234b. A pair of lower banding zones are shown in the bottom
hay
bale 236c as formed by the first and second lower compression members 232x,
232b.
A back floor 136 is hingedly coupled to an aft portion of the stacking
apparatus
floor 230. A hydraulic cylinder (not shown in the figures for simplicity) on
the
underside of the stacking apparatus is coupled between the frame of the
apparatus and
the back floor 136 for lowering the back floor for the discharge of a large
bundles 258
of hay bales as shown in dotted line form in FIG. 32. First and second support
hooks
248a and 248b respectively attached to the first and second back gates 134a,
134b as
CA 02548635 1998-12-03
19
shown in FIGS. 30 and 31 are adapted for engaging respective lower sides of
the
hinged back floor 136 for maintaining the back floor in the upraised position
as shown
in FIG. 31. First and second latches 250a and 250b are also disposed on the
first and
second back gates 134a, 134b, respectively. When the back gates are closed,
the first
and second latches 250x, 250b respectively engage the first and second lower
compression members 232a, 232b for maintaining the back gates in the closed
position
as shown in FIG. 31. In lowering the back floor 136 to discharge a large
bundle of
hay bales as shown in FIG. 32, the two back gates 134x, 134b are moved
outwardly
by their respective hydraulic cylinders releasing the two support hooks 248a,
248b
from the back floor. This allows the back floor 136 to be lowered by means of
the
hydraulic cylinder on the bottom of the stacking apparatus. The back floor 136
is also
raised by the aforementioned bottom hydraulic cylinder, followed by the inward
displacement of the two back gates 134a, 134b permitting the two support hooks
248a,
248b to again engage and support the back floor. The two latches 250a, 250b
again
engage the first and second lower compression members 232x, 232b for
maintaining
the back gates 134a, I34b closed. A pair of hydraulic cylinders each mounted
to a
respective lateral portion of the stacking apparatus are coupled to the aft
panels of the
first and second back gates 134a, 134b as shown for the case of hydraulic
cylinder 256
in F1G. 32. These two hydraulic cylinders operate in conjunction with the
upper
hydraulic cylinders 244a and 244b for pivotally displacing the aft portions of
the back
gates outwardly when the back gates are opened, and for pivotally displacing
the back
portions of the back gates inwardly when the back gates are moved to the
closod
position.
A computer 258 is disposed within a closed housing 260 on a side portion of
the stacking apparatus as shown in FIG. 32. Computer 258 controls the
operation of
the stacking apparatus including the various components thereof as described
in detail
below. One of the components controlled by computer 258 is a hydraulic
manifold
262 which is shown in FIG. 34. The hydraulic manifold 262 is connected to the
various hydraulic cylinders discussed above by means of hoses also shown in
FIG. 34.
The hydraulic manifold 262 is further connected to the hydraulic system of the
traction
vehicle pulling the hay bale stacking apparatus, where a pair of hydraulic
lines 110
CA 02548635 1998-12-03
from the traction vehicle to the hay bale staclang apparatus 100 are shown in
FIG. 22.
Also shown in FIG. 34 is a portion of the first vertical rail 216a and the
first dive
chain 210a used in raising and lowering the strap guides. A hydraulic motor
264 is
coupled to' drive chain 210a by means of a slip clutch 266 which maintains the
pair of
5 strap guides at the same vertical level as they are displaced upward and
downward.
FIGS. 40-50 are a series of simplified side elevation views in schematic
diagram form which will be used in explaining the operation of the banding
apparatus
124 shown in the perspective views of FIGS. 36, 37, 38 and 39. FIGS. 40-50 are
directed to the left hand portion of the banding apparatus 124 as shown in
FIGS. 36-39
10 involving a first fetcher cylinder 282b and trough 288b and associated
components.
Like reference numerals are used in FIGS. 40-50 to identify the corresponding
structures in FIGS. 36-39. Banding apparatus 124 includes a housing 280 having
a
removable cover (which is not shown for simplicity). Banding apparatus 124
further
includes first and second feteher cylinders 282a and 282b respectively
connected to
15 first and second fetcher arms 290a and 290b and fetcher carriages 296a and
296b.
Each of the fetchers moves with the extension or retraction of the extendible
arm of its
associated fetcher cylinder. FIG. 36 shows the first and second fetcher
cylinders 282a,
282b in the retracted position with the first and second fetchers 290x, 290b
in position
toward a forward portion of the banding apparatus 124. The right hand or first
fetcher
20 cylinder 282a and associated components operate in a similar manner and
thus are not
described in detail herein.
As shown in FIG. 40, the banding apparatus 124 includes a first gripper foot
300, fetcher arm 290b, and a strap gripper 304 used in the gripping of
strapping 302a
(shown in dotted line form in FIG. 40) about a large bundle of hay bales as
described
hereinafter. With reference to FIGS. 18 and 22, as horizontal plunger 132
moves
stacks of three hay bales in the direction of arrow 70, strapping 302a is
pulled tightly
against first gripper foot 300 as shown in FIG. 42 is ready for engagement
with a
second gripper foot 308 shown in FIG. 43. The first step in the operation is
the
engagement of the second gripper foot 308 as shown in FIG. 43. This grips
strapping
302a between the first gripper foot 300 and second gripper foot 308 as shown
in FIG.
43. When strapping 302a is gripped by and between the first gripper foot 300
and the
CA 02548635 1998-12-03
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second grippes foot 308, fetches cylinder 282b extends outwardly releasing
strapping
302a from strap grippes 304 and fetches arm 290b. As fetches cylinder 282b
continues
to extend outwardly, fetches 290b and fetches carriage 296 guide strapping
302a into
trough 288b as shown in FIG. 44. Each of the troughs is aligned with a
respective
strap guide as well as with a respective banding zone in a hay bale as
previously
described. When fetches cylinders 282a, 282b are completely extended, fetches
arms
290~a, 290b are rotated out of the path of strap guide 306 as shown in FIG. 47
by the
extension of fetches swing cylinders 284a, 284b. When strap guides 306 are
raised to
the full up position in the banding apparatus 124, the fetches swing cylinders
284x,
284b retract and rotate fetches arms 290a, 290b into the path of the strapping
as shown
in FIG. 47 for the case of strapping 302x. Once fetches arm 290b is in the
path of
strapping 302x, the fetches cylinder 282b is retracted. The fetches carriage
296
maintains strapping 302a in trough 288b while the fetches arm positions one
section of
strapping 302a over another section of the same strapping. When fetches
cylinder
282b is fully retracted, strapping 302a is laid on top of itself and over the
second
grippes foot 308 and is ready to be spliced together as shown in FIG. 48. The
segment of strapping labeled 312 is gripped between fetches arm 290b and strap
grippes 304 and forms the starting end of strapping for the next bundle.
With the fetches 290b in the fully retracted position as shown in FIG. 49, a
die
' and cutter 314 is displaced outwardly by the second banding mechanism 292b
as shown
in F1G. 39. As shown in FIGS. 38 and 39, the first and second banding
mechanisms
292a and 292b are displaced outwardly following full retraction of the first
and second
fetches cylinders 282a and 282b. Die and cutter 314 attached to the first
banding
mechanism 292b then engages the two adjacent ends of strapping sections 302a
and
312 as shown in FIG. 49 for connecting the two ends together and severing the
second
end of the strapping disposed about the bundle of hay bales. After strapping
302a is
spliced and severed by the die and cutter 314, a first strapping section 310
is spliced
together and disposed about a first bundle of hay bales (not shown) as shown
in FIG.
50. A second section of strapping 312 is then engaged by the combination of
fetches
290b and strap grippes 304 as shown in FIG. 50 for wrapping around a second
bundle
of hay bales about to be formed. The new sections of strapping are shown in
FIG. 39
CA 02548635 1998-12-03
22
and are designated by numerals 294a and 294b. Strapping 294a is engaged by the
first
fetcher 290a, while strapping 294b is engaged by the second fetcher 290b.
Following
splicing and severing of the two straps or bands, the first and second banding
mechanisms 292a and 292b are displaced inwardly toward one another, as shown
in
FIG. 36 to initiate a new banding cycle. The second gripper foot 308 connected
to the
banding mechanism 292a also moves inwardly when the banding mechanisms are
drawn toward one another. This leaves the first gripper foot 300 as well as
the first
fetcher 290b and strap gripper 304 in position to engage strapping 312 for
positioning
about a second bundle of hay bales as shown in FIG. 50. The next cycle begins
with
strapping again pulled downwardly by the strap guide 306 as shown in
previously
discussed FIG. 40.
Referring to FIG. 51, there is shown a block diagram of the computer control
system used in controlling the hay bale stacking apparatus of the present
invention.
The computer control system includes a computer 320 having input and output
interfaces 322 and 324. The inputs to computer 320 include a first combination
of a
flow switch 336 and a pressure switch 334 and a second combination of a flow
switch
340 and a pressure switch 342. The two combinations of flow switches and
pressure
switches provide inputs to the computer 320 indicating a given operation or
procedure
is completed. For example, in detecting the completion of a cylinder stroke,
the flow
switch will indicate no hydraulic fluid flow and the pressure switch will
indicate a high
pressure signaling that the associated operation is completed and providing
the
appropriate input to computer 320. Upon being informed of the completion of a
given
operation or sequence of operations, computer 320 proceeds to the next step in
its
programmed operation. A manual reset input 326 allows the operator to
interrupt
stacking apparatus operation and begin the stacking operation over. The
operator may
want to re-initiate operation of the stacking apparatus upon detection of a
low strapping
condition and following replacement of the strapping supply. Photosensor 328
is
attached to the bale input stage as previously described, while photosensor
333 is
incorporated in the vertical elevator to detect the lifting of a hay bale.
Photosensor
332 detects the positioning of a hay bale on the vertical plunger. An input to
computer
320 from photosensor 332 initiates the sequence of operations by the computer.
CA 02548635 1998-12-03
23
Proximity sensor 338 is located in the vertical plunger to detect the lowering
of a hay
bale, or bales, by the vertical plunger so that the vertical plunger is
lowered the
correct distance according to the number of bales on the vertical plunger.
Proximity
sensors 344 and 346 are located in banding apparatus 124 as shown in FIG. 36
to
detect the position of banding mechanisms 292a and 292b, respectively.
Outputs from computer 320 include a back gate output 348, a back floor output
350, a vertical elevator output 352, and a vertical swing output 354. The
vertical
swing output 354 controls the position of the vertical plunger pivoting arms.
Additional outputs further include the vertical plunger output 364, the
horizontal
plunger output 366, the strap guide position control output 368, and a strap
clamp
output 370 for clamping the strap in the banding apparatus to allow the
strapping to
backfeed when the strap guide is lowered. Additional outputs include the
fetcher
retraction output 372, the fetcher extension output 374, the fetcher swing
output 376,
the lefthand banding apparatus output 378, and input 380 for retracting the
left and
right banding apparatus. The R-band output 356 provides for extension of the
righthand banding apparatus, while the sealcut up output 358 and sealcut down
output
360 control the aforementioned banding mechanisms for severing and joining the
ends
of strapping enclosing a large bundle of hay bales. The kicker output 362
controls the
operation of the kicker in positioning hay bales on the vertical plunger as
previously
described.
Referring to FIG. 52, there is shown a block diagram of the hydraulic circuits
in manifold 262 shown in FIG. 34. A valve 500 is used as a safety valve to
stop flow
to all manifolds. Circuit 450 controls hydraulics to the back floor. Circuit
452
controls hydraulics to the horizontal and vertical elevators. Circuit 462
controls
~ hydraulics to the kicker. Circuit 464 controls hydraulics to the vertical
plunger.
Circuit 454 controls hydraulics to the vertical swing plunger, while circuit
470 controls
hydraulics to the strap clamps. Circuit 468 controls the hydraulic motor for
the strap
guides 54. When strap guide 54 is to be raised from the lowered position shown
in
FIG. 13, valve 468a is energized and the hydraulic motor 264 shown in FIG. 34
raises the strap guides. When vertical plunger 48 is about to be lowered as
shown in
FIG. 8, valve 468b is energized causing the vertical plunger to mechanically
push the
CA 02548635 1998-12-03
24
strap guides down which in turn drives hydraulic motor 264 shown in FIG. 34
which
operates as a hydraulic pump, pumping hydraulic oil from the tank thmugh
hydraulic
pump 264 creating a restriction which produces a clamping action on the bales
as the
vertical plunger and strap guides are lowered. Circuit 466 controls hydraulics
to the
horizontal plunger as described in the following paragraph.
Referring to FIG. 53, there is shown a complex hydraulic circuit 466 for the
operation of the horizontal plunger. The purpose of hydraulic circuit 466 is
to reduce
the demand for a large capacity of hydraulic oil, as measured in gallons per
minute,
while maintaining the horizontal plunger's cycle time, speed and high
compression
needed to handle a large volume of hay bales, in forming a solid rigid, self
supporting
large package of hay bales formed into a bundle. The pressure supply line goes
through a pressure compensated flow control valve regulated at 20 gallons per
minute,
the two position four-way directional control valve in the de-energized mode
places the
horizontal plunger and cylinder 218b and 218a in the retracted position. When
the
directional control valve is energized, the pressure supply is directed to the
piston side
of cylinder 218a. Cylinder 218a is mechanically joined together with cylinder
218b so
that as cylinder 218a extends, it mechanically pulls or extends cylinder 218b
and
moves the horizontal plunger. As cylinder 218b extends mechanically, a pilot
check
valve allows flow from the tank to fill the piston side of cylinder 218b with
hydraulic
oil. Cylinder 218a produces ample force to displace the first six stacks of
three bales.
On the seventh and final stack of three bales when the bundle is highly
compressed for
banding, cylinder 218a extends approximately 1/2 stroke (10 inches). The
circuit
pressure exceeds the sequence valve setting, shifting the sequence valve so as
to allow
high pressure into the piston side of cylinder 218b which is then full of
hydraulic oil
from the tank and closes the pilot check valve. Cylinder 218a and cylinder
218b work
in tandem to produce high compression in displacing the horizontal plunger.
Cylinder 218b is used as a one way cylinder with hydraulic force on the piston
side of the cylinder. The rod side of cylinder 218b is used as a reservoir.
When the
directional control valve is de-energized, the pressure in the supply line is
directed to
the rod side of cylinder 218a and opens the pilot check valve allowing the oil
on the
piston side of cylinder 218a and cylinder 218b to return to the rod side of
cylinder
CA 02548635 1998-12-03
218b and to the tank. The return flow rate on the piston side of cylinder 218a
and
cylinder 218b is sixty-two (62) gallons per minute. The normal system return-
flow
rate is 20 gallons per minute. Forty-two (42) gallons per minute returns
through the
pilot check valve into the rod side of cylinder 218b and twenty (20) gallons
per minute
5 returns to the tank.
Referring to FIG. 54, there is shown a block diagram of the hydraulic circuits
in manifold B. Circuit 472 controls hydraulics to the fetcher cylinders.
Circuit 476
controls hydraulics to the fetcher swing cylinders. Circuit 456 controls
hydraulics to
the left banding mechanism, while circuit 478 controls hydraulics to the right
banding
10 mechanism. Circuit 458 controls the operation~of the dies and cutters.
Referring to FIG. 55, there is shown a complex hydraulic sequence circuit for
the operation of the back gate extension cylinders and the back gate swing
cylinders.
When directional valve 501 is de-energized, back extension cylinders extend
fully and
the sequence valve shifts. The back gate is then opened by swing cylinders.
When
15 directional valve is energized, pressure in the line is directed to the rod
side of the
back gate cylinders. Pressure in the circuit then exceeds the setting for the
sequence
valve 502. The sequence valve 502 then shifts and directs pressure to the rod
side of
the back gate extension cylinders 236a and 236b. When cylinders 236a and 236b
are
fully retracted, circuit pressure exceeds settings for sequence valve 503
which then
20 ~ shifts, directing pressure to the pilot of valve 504 which shifts and
connects the rod
side of the back gate extension cylinders to pressure relief valve 505.
Pressure relief
valve 505 is manually set to control the desired compression of the hay
bundles. As
the horizontal plunger compresses the hay against the back gates, the back
gates
mechanically pull out on the rod end of the back gate extension cylinders 236a
and
25 236b generating pressure at relief valve 505. When the pressure exceeds the
setting of
the relief valve 505, back gate extension cylinders 236a and 236b then extend
outwardly to produce a controlled setting for compressing a bundle of hay.
Referring to FIG. 56, there is shown the curved edge apparatus 404 used to
curve the edges of banding 44 as the banding is mechanically pulled from the
banding
dispenser 42 by retraction of the horizontal plunger 68. Guide roller 402 is
used to
keep the banding 44 in a horizontal plane to the curved edge apparatus 404,
while the
CA 02548635 1998-12-03
26
curved edge is being formed in banding 44. Thus, the banding is maintained
straight
while a pair of opposed curved edges are formed in the banding in accordance
with
one aspect of the present invention.
Referring to FIG. 57, horizontal plunger 68 is shown in the retracted position
408n after having mechanically pulled banding 446 off of banding dispenser 42
and
through curved edging apparatus 404, for forming the banding straight with
curved
edges. As the horizontal plunger moves to the retracted position 408, strap
clamp 46
clamps banding 44. An adjustable banding length bar 406 is used to determine
the
length of banding 44b pulled by the horizontal plunger 68 in the retracted
position 408.
Horizontal plunger pulley 400 is used to eliminate drag of banding 44b as the
horizontal plunger 68 pulls banding 44b.
FIG. 58 shows the horizontal plunger 68 in the extended position 410. Element
44c represents the slack in banding that was applied around the bundle of hay
bales as
the horizontal plunger 68 was being extended to position 410. This eliminates
the
cutting and shredding of hay and bale binding as the banding 44 is being
applied in a
slack condition around the bundle of hay bales.
Referring to FIG. 59 is a side view of the curved edge apparatus 404.
Referring to FIG. 60, there is shown is an end view of the curved edge
apparatus 404 showing the roller 416 and die 412 that forms the curved edge of
banding 414.
Referring to FIG. 61, there is shown an enlarged view of curved edge banding
414 showing the curved edge 422 in relation to a bale binding 420. As banding
is
pulled tight against bale binding 420, the curved edge 422 will not cut the
bale
binding.
Referring to FIG. 62, there is shown a partial upper perspective view of a
lower banding trough 60. Lower banding trough 60 includes a recess channel in
an
upper surface thereof. This allows banding to move freely within the
compression
zones within a hay bale as the horizontal plunger 68 moves forward and aft.
FIG. 58
shows the horizontal plunger 68 in an extended position for applying banding
44
without cutting or shredding hay and the bale binding.
CA 02548635 1998-12-03
27
While particular embodiments of the present invention have been shown and
described, it will be obvious to those stalled in the art that changes and
modifications
may be made without departing from the invention in its broader aspects.
lfierefore,
the aim in the appended claims is to cover all such changes and modifications
as fall
within the true spirit and scope of the invention. The matter set forth in the
foregoing
description and accompanying drawings is offered by way of illustration only
and not
as a limitation. The actual scope of the invention is intendod to be defined
in tho
following claims when viewod in their proper perspective based on the prior
art.
