HK1174781A - Round baler with variable speed baling mechanism - Google Patents

Description

Round baler with variable speed baling mechanism

Technical Field

The present invention relates to a round baler, and more particularly to a round baler having a rotary baling chamber.

Background

Conventional round balers receive crop material and form the crop material into compressed bales within a baling chamber. There are generally three main periods in the operation of a round baler: a bale forming cycle, a bale wrapping cycle, and a bale discharge cycle. The baling chamber is typically operated at a constant rotational speed during the bale forming and bale wrapping cycle. In a typical baler, the baling chamber rotates at a rotational speed of about 500 feet per minute, taking 20-25 seconds to perform bale wrapping and bale ejection at the time the tractor is stopped.

Drawings

Fig. 1 shows a schematic view of an exemplary embodiment of a variable speed round baler.

Fig. 2 shows a diagram of an exemplary embodiment of the variable speed round baler of fig. 1.

FIG. 3 shows a schematic view of an exemplary embodiment of an operator accessible console on a vehicle when towing the round baler of FIG. 2.

FIG. 4 shows a schematic view of an exemplary console accessible by an operator on a vehicle when towing a variable speed baler.

Fig. 5 shows a flow chart of an exemplary method of operating a round baler baling chamber.

FIG. 6 shows a flow chart of the operation of the variable speed baling chamber.

Fig. 7 shows a flow chart of the operation of a baler with a variable speed baling chamber.

Detailed Description

Overview

In an exemplary embodiment, the variable speed baler is configured to vary the speed of the baling mechanism according to a predetermined scheme. In one example embodiment, the baler varies the rotational speed of the baling chamber according to its operating cycle. For example, the baling chamber may be operated at a first speed during a bale-forming operation and at a second speed during a non-bale-forming operation, such as a bale-wrapping operation. The term "crop material" is meant to include grains and/or material other than grains (MOG), such as crop residue from a combine harvester. For example, the baler may be used to bale hay or biomass material, such as corn cobs or the like, or a mixture of both. Such an arrangement provides several advantages over prior art systems, including the ability to reduce the operating time required to make and pack the bale and to reduce the downtime of the baler.

In one exemplary embodiment, a variable speed baler includes a baling chamber adapted to form crop material into a bale and bale the bale; and a variable speed drive configured to operate the baling chamber speed according to a predetermined schedule. For example, the speed of the baling chamber may be manipulated according to the operational cycle of the baler, such as whether the baler is in a bale-forming cycle or a non-bale-forming cycle, such as a bale wrapping cycle. The variable speed baler may further include sensors to determine different periods of operation of the baling mechanism.

An exemplary method comprises: receiving crop material in a baling chamber of a round baler; and varying the speed of the baling chamber according to a predetermined scheme. In an example embodiment, the predetermined scheme includes varying the speed of the baling chamber according to an operating cycle of the baler. The method may further include determining an operating period of the baler.

Detailed Description

As required, exemplary embodiments of the present invention are disclosed herein. The different embodiments are intended to represent non-limiting examples of the various ways in which the invention may be practiced, and it is to be understood that the invention may be embodied in alternative forms. The present invention will be described more fully hereinafter with reference to the accompanying drawings, in which like numerals represent like elements, and in which exemplary embodiments are shown. The figures are not necessarily to scale, some features may be exaggerated or minimized to show details of particular elements, while related elements may have been eliminated to prevent obscuring novel aspects. Specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention.

It should be noted that although the exemplary embodiment is discussed in the context of a tractor-towed baler having a conveyor for delivering crop material to the baling chamber, the invention is not so limited and alternative arrangements may be used, for example arrangements in which a small truck is provided adjacent the baling chamber as is known in the art. For example, an alternative arrangement may be used in conjunction with a round baler, such as that disclosed in related patent application a 1047H.

Turning to the drawings, FIG. 1 shows a schematic view of a variable speed baler 10 that includes a baling chamber 12 configured to form a bale 20, and a variable speed drive 14 for varying the speed of the baling chamber 12. A vehicle, such as a tractor 22, may be used to power the baler 10 and to pull the baler through the field, as indicated by the large arrow in fig. 1.

As shown in fig. 2, the baler 10 may be generally similar to those manufactured by AGCO corporation and U.S. patent No. 73376713; no. 6477824; no. 6675561; the banders disclosed in nos. 4850271 and 4524867 are similar; these are incorporated herein by reference in their entirety. The baling chamber 12 of the baler 10 may include a plurality of rollers and belts that cooperate to assume different shapes and sizes throughout the bale-forming cycle. In this regard, the exemplary round baler 10 may be referred to as a "variable cavity" belt machine, wherein the baling chamber 12 is initially smaller and then progressively larger as the diameter of the bale 20 within the baler 10 increases. However, it will be appreciated that the principles of the present invention are also applicable to "fixed chamber" machines (not shown) in which the size of the baling chamber is at least substantially constant throughout the baling cycle.

In view of the foregoing general explanation, in the exemplary embodiment shown in fig. 2, the bale forming chamber 12 includes a lower drive roller 24 and a starter roller 26. The upper drive roller 28 is above the lower drive wheel. A belt tensioning arm 30 is pivotally mounted within the baler, to which front and rear belt tensioning rollers 32, 34 are pivotally mounted. At the top of the front of the baling chamber, there are front upper idle rollers 36 and rear upper idle rollers 38. Following the interior of the baler wall in a clockwise direction, there are tailgate belt rollers 40, lower and rear tailgate rollers 44, and front and lower idler rollers 46. A bale density arm 48 is pivotally mounted within the baler and has a front bale density roller 50 and a rear bale density roller 52, both of which are pivotally mounted at a distal end of a pivotal mounting of the bale density arm 48. Near the top of the baling chamber, an upper baling chamber roller 54 is shown above the bale density roller. As shown in fig. 2, each of the rollers is provided with a plurality of bundle forming belts 56 (one shown in the figure). The bale forming belt is tensioned by front and rear belt tensioning rollers 32, 34 mounted on the belt tensioning arm 30 and rollers 50, 52 mounted on the bale density arm 48.

The baling chamber 12 is open at the bottom to provide a chamber inlet 42 generally defined between the starter roll 26 and the idler roll 46. The baling chamber 12 may be located above ground and off the ground, and is provided with means for picking up crop material and transferring the picked-up material into the baling chamber 12. In an exemplary embodiment, a conveyor 110 is used to provide crop material to the baling chamber. However, as shown in phantom in fig. 2, instead of a conveyor, a pick-up head 18 may be provided adjacent the baling chamber 12 as is known in the art. In an exemplary embodiment, a pickup head 18 having a standard resilient rotating rake tooth assembly for picking up crop off the ground may be used. If desired, the rake tooth assembly selected for use may be wider than the baling chamber 12 in a direction transverse to the path of travel of the machine, in which case the baler may be provided with a centrally centralised short auger (stub auger).

Rows of crop material 16 may be fed into the baler 10 by the pickup assembly 18 and moved to the chamber inlet 42, either directly into the bottom of the open throat baling chamber 12 when the pickup is in the vicinity of the baling chamber (shown in phantom in fig. 2), or through the use of a conveyor 110 of a pickup conveyor type device (shown in solid lines in fig. 1 and 2) in the case of the pickup 18 being moved from the baling chamber 12. When in the baling chamber 12, the crop material 16 contacts the surface of the upwardly moving belt tensioner 74. The forming belt 56 may be driven by the upper and lower drive rollers 28, 24 such that the forming belts 56, 74 carry the crop material 16 to the top of the baling chamber 12 and the movement of the forming belts 56, 72 rotates the crop material 10 downwardly against the starter roller 26 so that the core starts and begins to roll. The crop material 16 may be initially formed into small bales 20 within the baling chamber 12 and the process continued to form larger bales having a desired size. Although not illustrated in detail, it will be appreciated by those skilled in the art that the baling chamber 12 may initially assume a generally vertical triangular configuration when the baling chamber 12 is empty and becomes larger as the size of the bale 20 (shown in phantom in fig. 2) increases.

Once the bale 20 of crop material 16 reaches its full size, it may be desirable to bale the bale 20 prior to discharging the bale 20 from the baling chamber 12. Accordingly, the baler 10 may further generally include a baling device 76, the baling device 76 baling the formed bale 20 with a bale material 78 once the bale-forming cycle has been completed.

The bale press may be configured to press the bale 20 in a net or twine as is known in the art. In the exemplary embodiment shown in fig. 2, the baling device 76 may be a net bag (meshwrap), similar to that disclosed in U.S. patent application No.6050052 and U.S. patent application No.12/365077, entitled "net bag distribution mechanism for round baler", filed 2.3.2009, both assigned to the assignee of the present application, and both fully incorporated into the present invention and therefore not described in detail. It should be noted, however, that the bale 20 is rotated by the baling chamber 12 during a bale-wrapping cycle, and the variable speed drive 14 may be used to manipulate the speed of the baling chamber 12, and thus control the rotation of the bale 20 during the bale-wrapping cycle.

In the exemplary embodiment shown in fig. 2, a baling device 76 is disposed behind the baler 20 such that bale material 78 dispensed by the baling device 76 travels forward to a baling chamber entry opening (i.e., the chamber inlet 42 in the illustrated embodiment, although alternative openings may be used without departing from the teachings of the present invention) to be wrapped around the formed bale.

The bale press 76 may generally include a housing 92 containing the bale material 78 and a bale material dispensing mechanism 94 for paying out lengths of the bale material 78 during a bale press cycle. The bale material 78 may be paid out into the baling chamber 12 such that the bale material contacts the bale 20 as the bale 20 is rotated within the baling chamber by the forming belts. A cutting assembly (not shown) may also be provided to sever the bale material 78 so that the fully formed and baled bale 20 may be discharged from the baler 10 so that formation of a new bale may begin.

The example baler includes a tailgate 58 that opens and closes about a pivot point 60. A bale kicker assembly 62 (shown schematically) is associated with the tailgate. The bale kicker assembly includes a bale pusher bar 64 (shown in its home position) and two hydraulic cylinders (not shown). When the tailgate is closed, the bale kicker is used to prevent contact between the tailgate 58 and the bale. After the tailgate is raised, hydraulic pressure is applied to the base end of the kicker hydraulic cylinder. Before the tailgate closes, the bale push rod 64 is raised upward and pushes the bale rearward away from the tailgate. After the tailgate 58 is closed, the kicker returns to its home position.

The various baling cycles of the baler described above may be controlled by the controller 70. The controller may be located on the round baler 10 and an associated user interface 400 (fig. 4) that may be located on the trailer 22 towing the baler 10, or near the baler 10 and the user interface 400. The controller 70 may receive data from a variety of different sensors and issue commands in response to achieve various operations of the baler 10. Although the controller 70 and user interface 400 are preferably separate components, their functions can also be combined in a single unit positioned on the baler 10 or its trailer. The baler controller 70 may be used to control the operation of the baler 10, including its various operational cycles, such as bale forming, bale wrapping, and bale discharge cycles, as well as controlling the speed of the baling chamber 12. For example, a bale size sensor 68 (shown schematically) may determine a bale size of the bale 20 in the baling chamber 12 and provide a corresponding signal to the controller 70 and the user interface 400. For example, the bale size sensor 68 may send a signal to the electronic control system to indicate the bale size during the bale forming cycle. The controller 70 may then determine a desired operating speed of the baling chamber 12 and issue commands to achieve the desired operating speed. In addition, the baler may include a tailgate switch 80 (shown schematically) that detects whether the tailgate position is open or closed, a kicker switch 82 (shown schematically) that detects whether the kicker position is out or home, and a lockout switch 84 (shown schematically) that detects whether the tailgate is locked out. The tailgate switch and kicker switch cause signals indicative of the status of the elements to which they are connected to be sent to the controller 70. The controller can then use this information to move the baler 10 through various modes of operation and to vary the speed of the baling chamber 12 accordingly.

Power for operating the components of the baler 10 may be transmitted through a drive line (not shown) associated with the tongue plate 200. The forward end of the drive line may be adapted to be connected to a power take-off shaft (also not shown) of the trailer, while the rearward end of the drive line may be coupled to a gearbox 188 or other component mounted on the chassis 190. The gearbox 188 may be coupled with various drives and/or other components used to drive various baler components. In addition to the elements described above, the baler 10 may include a hydraulic pump 88 that may be used to power various components such as a hydraulic motor and a hydraulic cylinder. The baler may also include a clutch assembly and control electronics, neither of which are shown in fig. 2, but those skilled in the art will appreciate that they are necessary for operation of the baler. In an alternative embodiment, instead of the pickup 18, the conveyor 110 may provide crop material to the baler, as disclosed in US patent application serial no.

In the exemplary embodiment shown in fig. 1 and 2, the baling chamber may be powered by a variable speed drive 14 in the form of a hydrostatic system. For example, the bale-forming belt 56 may be driven by the lower and upper drive rollers 24, 28, the rotation of which results in movement of the bale-forming belt 56. The drive rollers 24, 28 may in turn be powered by hydraulic motors 100, 102. For example, fluid may be provided to the hydraulic motors 100, 102 from the hydraulic pump 88 and manipulated through solenoids and/or flow control valves to vary the fluid flow and thus the speed of the motors 100, 102. The drive rollers 24, 28 may be coupled with the motors 100, 102 by a chain 104 or other means known in the art such that changing the speed of the motors 100, 102 changes the rotational speed of the drive rollers 24, 28 and the bale forming belts 56 powered by the drive rollers 24, 28, and thus the rotational speed of the bale 20.

This arrangement allows the rotational speed of the bale 20 within the baling chamber to be controlled by the controller 70 by varying the speed of the forming belt 56. This speed may vary during different operating cycles of the baler 10. For example, the rotational speed may be a first value during a bale forming operation and a second value during a bale wrapping operation. In an exemplary embodiment, the hydraulic pump 88 may be mounted in the baler and powered by the vehicle's Power Take Off (PTO) mechanism. The hydraulic lines 140 may extend to a manifold 142 mounted in the baler 10 and couple with solenoids and/or flow control valves responsive to command signals sent from the controller 70 to manipulate hydraulic fluid provided to the motors 100, 102. In an exemplary embodiment, an open baling chamber solenoid 334, a close baling chamber solenoid 336, and a baling chamber flow control valve 332 (all schematically represented in fig. 4) are communicatively coupled to the controller 70 and are used to control the hydraulic motors 100, 102, and thus the movement of the bale-forming belt 56. The controller 70 may also operate other components of the baler 10 associated with various operational cycles of the baler. Although two hydraulic motors 100, 102 are employed in the exemplary embodiment, a single hydraulic motor may be used to power the drive rollers 24, 28. For example, the motor may be coupled to the drive roller by a chain or belt.

Baling chamber 12 may be operated by controller 70 according to a predetermined protocol programmed by an operator. In one exemplary version, the baling chamber 12 may be driven at different speeds in conjunction with different operating cycles of the baler 10. For example, the bale forming belts 56 may be driven at a first speed during a bale forming cycle of the baler 10 and at a second, faster speed during a bale wrapping cycle. This results in a reduction in baling time relative to conventional balers that use a single speed in both bale forming and bale baling operations.

The controller 70 may use various sensors of the baler 10 to control the operational cycle of the baler 10 and the movement of the bale forming belt 56. For example, the controller 70 may direct the baler 10 to begin a bale-forming cycle and operate the baling chamber 12 at a first speed if the bale size sensor 68 indicates that the bale 20 is less than a predetermined size and operate the baling chamber 12 at a second speed if the bale size sensor 68 indicates that the bale 20 is equal to or greater than the predetermined size. Similarly, the controller 70 may direct into a bale-wrapping cycle when the bale reaches a particular size, direct into a bale-ejection cycle when the wrapping cycle is complete, and stop the bale-forming band 56 during the bale-ejection cycle. Upon completion of the discharge cycle, the controller may restart the forming belt 56 to form a new bale. For example, when a sensor such as the tailgate switch 80 indicates that the bale 20 has been ejected from the baler 10, the controller 70 may begin a new bale forming cycle and restart the baler belt 56.

Fig. 3 is a schematic diagram of an embodiment of an electronic control system 300 of the variable speed baler 10 of fig. 2. The system 300 includes a system box 302 that houses the controller 70 and associated electronics, the structure of which is understood by those skilled in the art, and the details of which are not important to the present invention. The arrangement may include hardware, software, firmware, and combinations thereof, as will be apparent to those skilled in the art. For example, the controller 70 may be a microcontroller capable of receiving data and issuing instructions for controlling various systems and components according to a particular scheme programmed into the microcontroller.

A sensor box 310 to provide data to the controller, and a control box 320 to receive instructions from the controller 70 controlling the speed of the baling chamber 12 by manipulating various portions of the variable speed drive, are communicatively coupled to the system box 302 and the controller 70. The sensor box 310 may include one or more sensors for communicating information to the controller for use in generating various command signals. In the exemplary embodiment shown in fig. 3, the sensor box 310 includes a bale size sensor 68, a bale wrap sensor 314, and a bale discharge sensor 316 for providing operational information about the baler 10 to the controller 70. For example, the bale size sensor 68 may indicate the size of the bale 20 within the baling chamber 12 and indicate when the controller should direct the baling chamber 12 out of the bale-forming mode into the bale-wrapping mode. The bale sensor 314 may indicate when the bale wrapping operation is complete and when the controller should direct the baling chamber into the discharge mode. The bale discharge sensor 316 may indicate when the bale discharge operation is complete and when the controller should direct the baling chamber into a bale forming cycle. For example, the bale eject sensor 316 may be a tailgate latch switch 84 that indicates when the baler tailgate 58 is latched after a bale is ejected.

The various elements controlled by the controller 70 may be distributed around the round baler 10 and will not be described in detail. For example, the system box 302 and controller 70 may be coupled with solenoids and control valves to operate the hydraulic devices to control the various hydraulic cylinders to open and close the tailgate 58, operate the kicker assembly 62 to discharge the bale, and operate the baling assembly 76 to bale the bale 20.

As can be seen in fig. 3, the controller 70 may also be communicatively coupled with a control box 320. In the exemplary embodiment shown in fig. 3, the control box 330 includes a flow control valve 332, a solenoid 334 to open the baling chamber, and a solenoid 336 to close the baling chamber, which are controlled by the controller 70 and are used to manipulate the operation of the forming belt 56 in response to commands from the controller. For example, the controller 70 may issue commands to vary the flow of fluid to the hydraulic motors 100, 102, thereby varying the speed of the motors and the forming belt 56. Although not illustrated in detail, those skilled in the art will appreciate that the controller and pump 88 may be used to control other components of the baler 10, such as the starter roll 26.

Fig. 4 is a plan view of a user interface in the form of a console 400 provided in an operator station, such as the cab of a tractor pulling the baler 10 across a field. The console 400 may be configured with controls to provide the operator with varying levels of control over the baler 10. The console 400 may include various other controls for controlling various other portions of the baler 10, such as the pickup 18, the clutch (not shown), the tailgate 58, the kicker 62, the baling assembly 76, etc., which are omitted for clarity. The console 400 may also be configured to operate in different modes of operation, such as a manual mode or an automatic mode. For example, the operator may be provided with a manual control mode or an automatic control mode of the round baler. In the fully manual control mode, the operator may initiate various operating cycles of the baler 10, whereas in the automatic mode, the various cycles may be initiated automatically with little or no assistance from the operator.

In the exemplary embodiment 400 shown in FIG. 4, the console 400 includes a power on/off button 402, a cycle start button 408, a program set button 410, and a value control button 412. In addition, various other control buttons for operating other features of the baler, not described in detail, may also be provided. A central display 440 is also provided which indicates to the operator the baler status during various baler operating cycles. In addition to the console 400, a remote controller (not shown) may also be used to handle some control functions, including the cycle start function described below.

The controller 70 may have various modes of operation, including manual and automatic modes. The system starts in neutral mode. At system start-up, some checks may be performed through the system and baler and the status is displayed to the operator. Starting from the neutral mode, the operator may enter the program mode by pressing program set key 410.

The operator can thus set various settings for controlling the baler. For example, when the program setting key 410 is pressed, the program mode flag will illuminate and the set name and value will appear on the display screen 440. To change values or set options, the operator may press the appropriate side of the value key 412. The program set button 410 can be pressed again to proceed to the next set name. Between other values and settings, the baler may be set to an automatic mode during a program mode and a scheme of baling chambers is selected.

In the manual mode, the operator may use the baling chamber open/key 450 to open/close the baling chamber 12, and may use the baling chamber speed key 460 to change the speed of the baler by pressing the + or-portion of the key 460. For example, an operator may actuate the open baling chamber solenoid 334 and the close baling chamber solenoid 336 using the baler open/key to start and stop rotation of the baler forming strap 56, and manipulate the speed of the baler forming strap 56 using the baling chamber speed key 460. For example, when the baler 10 is first started, a user in the manual mode may select a button to open the baler to start the baler, and select the baling chamber speed key 460 to set the speed of the baling chamber 12 during a bale-forming operation of the baling chamber 12. When the baling chamber 12 is finished baling, the operator may use the baling chamber speed key 460 to increase the speed of the baling chamber 12 by increasing the speed of the forming belt 56. When the baling operation is complete, the user may use the baling chamber open/key 450 to stop the bale-forming strap during the discharge cycle, and once the bale is discharged, restart the bale-forming strap 56 using the baler open/key to initiate a bale-forming operation for a new bale.

If the operator selects the automatic mode, the baler 12 may advance through various operating cycles under the control of the controller 70 without operator intervention. The operator may select a particular protocol for operation of the baling chamber 12. For example, the operator may be provided with options for various operating schemes to choose from. For example, one predetermined scheme may operate the baling chamber 12 according to an operating cycle of the baler, such as operating the baling chamber 12 at a first speed during a bale-forming cycle and operating the baling chamber 12 at a second speed during a bale-wrapping cycle. In one particular approach, the rotation rpm of the bale may be twice the final bale forming speed, thereby greatly reducing the baling time.

The bale forming operation may be initiated by depressing the drive key 470. When the drive mode is entered, the clutch is engaged and the hydraulic motors 100, 102 are powered to begin rotation of the forming belt 56. When the baling chamber 12 forms a bale 20, the operator can drive the tractor to pull the baler 10 behind it. The various modes of operation of the baler 10 may be similar to that disclosed in US patent No.6675561 entitled "round baler semi-automatic sequence operating cycle and selectable operator intervention variable point," which is hereby incorporated by reference, and may include bale forming, bale wrapping and bale ejection modes that may be manually operated by operator intervention or automatically operated with little or no operator intervention. Once in the manual mode, the operator may control various aspects of the baler, such as the clutch, baler assembly, tailgate, and discharge, using various buttons on the controller. When the system is operating in the manual mode, the bale chamber on/off button 450 and the bale chamber speed button 460 may be used to manually control the speed of the bale forming strap 56 and, thus, the speed of the bale chamber 12 and the rotation of the bale 20. For example, buttons 450, 460 may send signals to controller 70 to operate the open baling chamber solenoid 334, the close baling chamber solenoid 336, and the flow control valve 332, respectively.

The baling chamber 12 may operate as follows. A variable displacement pump 88 within the baler 10 receives energy from the power take-off of the trailer and pressurizes the system. When the operator signals the start of a bale forming cycle by pressing the drive key 470, the electronic controller 70 sends signals to the solenoid 334 and the baler flow control valve 332 which open the baling chamber so that the hydraulic motors 100, 102 operate and the starter roller 26 rotates and the upper and lower drive rollers 24, 28 rotate the forming belt 56.

Crop material 16 is picked up by the pickup head 18 and fed into the bottom of the open throat baling chamber 12 by the feeder 196. Once in the baling chamber 12, the crop material 16 contacts the roughened upper surface of the upwardly moving forming belts 56-74. The forming belt 56 carries the crop material 16 to the top of the starting chamber formed by the front and rear bale density rolls 50, 52. The movement of the forming belts 56-72 causes the crop material to rotate downwardly against the starter roll 26. The core starts and starts to roll. The hydraulic cylinder pulls the bale density arm 48 and the strap tensioning arm 30 downward. The bale density rolls 50, 52 are held down to reduce the size of the baling chamber to the starting size. The belt tensioning rollers 32, 34 are held down to provide tension to the forming belt. As the bale size increases, the bale density rolls 50, 52 and the belt tension rolls 32, 34 are forced upward. The bale density rollers 50, 52 apply an increasing amount of downward force to the bale. This force keeps the bale taut and compresses the crop material entering the baling chamber. The belt-tensioning roller moves upwardly to provide more forming belt for the increased size of the bale in the chamber.

As the bale size increases, the bale density arm 48 moves upward and the bale size sensor 68 continues to send a signal to the controller 70 indicating the bale size. The controller 70 will detect when the bale has reached or exceeded a desired bale size, which has been programmed into the controller by the operator during the program mode. Bundle size may also be indicated on the console screen 440. If the baler 10 is operating in the automatic mode, the baler 10 enters the baling cycle when the bale size reaches or exceeds the predetermined bale size, and the rotational speed of the baling chamber is changed in response to the new baler mode. For example, the controller 70 may send a signal to the baler flow control valve 332 to increase the speed of the forming belt 56 during the baling cycle, thereby increasing the rotational speed of the bale 20. The controller may also send a signal to the baling mechanism 76 to begin a bale baling cycle.

For example, the controller 70 may activate the baling mechanism 76 to feed the bale material 78 into the baling chamber 12, thereby baling the bale 20 as the bale 20 is rotated by the forming belts 56. The packaging mechanism 76 may perform its function in a manner readily understood by one of ordinary skill in the art, such as by the methods disclosed in [ reference packaging application ]. However, unlike conventional baler machines, the speed of the baling chamber 12 is different from the speed used during the bale-forming cycle. For example, the rotational speed of the baling chamber 12 may be increased to reduce baling time. The bale wrapping sensor 314 may indicate to the controller 70 when the bale wrapping cycle is complete. For example, the bale wrap sensor 314 may indicate when a predetermined length of wrapping material has been provided to the bale 20 for sufficient wrapping.

The controller 70 may then proceed to a bale discharge cycle in which the controller 70 causes the tailgate 58 to be raised, such as by actuating a tailgate-raising solenoid (not shown) and actuating the kicker assembly 62 to push the bale 20 away from the baler 10. The controller 70 may then activate the solenoid 336 that closes the baling chamber during the discharge cycle, thereby stopping the forming belt 56.

Once the bale 20 is discharged from the baler 12, the controller 70 may close the tailgate 58, for example, by actuating a tailgate-down solenoid (not shown). The bale discharge sensor 316 may signal when the discharge cycle is complete to the controller 70. For example, the bale ejection sensor 316 may include a tailgate latch switch 84, which switch 84 indicates when the tailgate closes after the bale 20 is ejected. The baler 10 then immediately begins a new forming cycle. For example, the controller 70 may activate the solenoid 334 and flow control valve 332 that open the baling chamber to operate the bale-forming belts 56 at a desired bale-forming speed.

Fig. 5 shows an example flow diagram of baling chamber operation 500, in which the baler 10 has a variable speed baling chamber 12. At block 502, the baling chamber operates at a first speed during a bale-forming cycle. For example, the bale forming chamber may operate at twice the final bale forming speed of revolutions per minute of rotation.

Fig. 6 shows an example flow chart 600 of the operation of the variable speed baler 10. At block 602, the baler is started. For example, as described above, the operator may start the baler 10. At block 604, it is determined whether the baler 10 is in a bale forming cycle of operation. For example, the controller 70 may initiate a bale forming cycle at start-up of the baler 10 or at the time of the previous bale discharge. If the baler 10 is in a bale forming cycle, the baling chamber 12 is operated at a first speed suitable for baling at block 606. The determination may be continued so that the baling chamber 12 operates at a first speed when the baler is in a bale-forming cycle of operation.

If at block 604 it is determined that the baler 10 is not in a bale forming cycle, then at block 608 it is determined whether the baler 10 is in a bale wrapping cycle of operation. For example, the controller 70 may receive information from sensors, such as the bale size sensor 68: the size of the bale 20 is sufficiently packed, then the controller 70 may issue a command to initiate a bale packing cycle. If the baler is in a bale wrapping cycle, the baling chamber 12 is operated at high speed at block 610. For example, as described above, controller 70 may issue a command to flow control valve 320 to increase the speed of the associated hydraulic motor 100. If the baler is not in a bale wrapping cycle, then at block 612 it is determined whether the baler 10 is in a bale discharge cycle. For example, the sensor 314 may indicate that bale wrapping is complete and the baler 10 should enter a bale discharge cycle, at which point the controller 70 may issue the necessary command to stop the baling chamber at block 614. For example, the controller 70 may activate the solenoid 336 that closes the baling chamber to stop rotation of the baling chamber 12.

At block 616, it may be determined whether a stop command has been issued, such as whether the operator has used the baling chamber on/off switch 450. If a stop command is issued, the baling chamber may remain stopped at block 618. If a stop command is not received, a new determination may be made at block 604. It should be noted, however, that at the example flow 600 in fig. 6, the speed of the baling chamber may be automatically changed by the controller 70, the operator may operate in a manual mode, and change the speed of the baling chamber 12 using the baling chamber control button 460. For example, input from an operator using the fast/slow control button 460 may be used to operate the flow control valve 332 according to the operator's preference.

Fig. 7 shows an exemplary flow chart 700 of the operation of the variable speed baler 10. At block 702, operations may be initiated, at block 704, the baler enters a bale forming cycle, and at block 706, the baling chamber operates at a first speed. As mentioned above, during the bundle forming process, the core forms small bundles 20 that will become progressively larger. At block 708, it is determined whether the bundle size is a desired size, such as the size of a standard bundle. For example, the bale size sensor 68 may be used to determine the bale size. If the bale is not the desired size at block 710, the baling chamber continues to operate at the first speed at block 710. If the bale is the desired size at block 708, the baler 10 enters a bale wrapping cycle at block 712.

To quickly bale the bale 20, the baling chamber is operated at a second speed, such as a high speed, at block 714 during the bale-wrapping cycle. At block 716, it is determined whether bundle wrapping is complete. For example, the bale wrapping sensor 314 may be used to indicate when bale wrapping is complete. If the bale wrapping is not complete, the bale wrapping cycle continues and the baling chamber 12 continues to operate at high speed. If bale wrapping is complete, the speed of the baling chamber is stopped at block 718 and a bale discharge cycle is started at block 720. At block 722 it is determined whether the bale discharge cycle is complete and if so, a new bale forming cycle is started at block 704 and the baling chamber is operated at the first speed at block 706.

It should be noted, however, that three specific cycles of operation: the bale forming, bale wrapping, and bale ejection cycles have all been discussed, and the term "cycle" is intended to be inclusive of other existing or future occurring operations that may be performed by the baler, and is not limited to a particular cycle described above. Thus, many other cycles may be performed by the baler 10, with the speed of the baling chamber 12 adjusted accordingly.

The foregoing has outlined rather broadly some of the more pertinent aspects and features of the present invention. These should be construed as merely illustrative of some of the more prominent features and applications of the invention. Other advantageous results can be obtained by implementing the disclosed information in a different manner or by modifying the disclosed embodiments. Furthermore, other aspects and a more complete understanding of the present invention may be obtained by reference to the detailed description of the exemplary embodiments taken in conjunction with the accompanying drawings, in addition to the scope of the invention defined by the claims.

Claims (21)

1. A variable speed baler comprising:

a bundling mechanism; and

a variable speed mechanism for manipulating the speed of the baling mechanism.

2. The variable speed baler of claim 1, further comprising:

a controller configured to control the variable speed mechanism to operate the baling mechanism according to a predetermined schedule.

3. The variable speed baler of claim 1, wherein the predetermined scheme comprises:

the speed of the baling mechanism is manipulated according to the operating cycle of the variable speed baler.

4. The variable speed baler of claim 1, wherein the predetermined scheme comprises:

operating a baling mechanism at a first speed during a bale-forming cycle of operation of the baler; and

the baling mechanism is operated at a second speed during a non-bale-forming cycle of operation of the baler.

5. The variable speed baler of claim 1, wherein the predetermined scheme comprises:

operating a baling mechanism at a first speed during a bale-forming cycle of operation of the baler; and

the baling mechanism is operated at a second speed during a bale wrapping operation cycle of the baler.

6. The variable speed baler of claim 5, wherein the second speed is faster than the first speed.

7. The variable speed baler of claim 1, wherein the variable speed drive comprises a hydraulic drive.

8. The variable speed baler of claim 7, wherein the hydraulic drive comprises:

a variable speed pump; and

a hydraulic motor in fluid communication with the variable-speed pump and rotatably coupled with the forming belt of the baling mechanism.

9. The variable speed baler of claim 1, wherein the baling mechanism includes a baling chamber.

10. The variable speed baler of claim 1, wherein the baling chamber comprises at least one forming belt.

11. The variable speed baler of claim 1, further comprising:

a user interface configured to receive input from a user to control a speed of the baling mechanism.

12. A method, comprising:

the speed of the baling mechanism of the round baler is varied according to a predetermined scheme.

13. The method of claim 12, wherein the varying the speed of a baling mechanism according to a predetermined scheme comprises:

the speed of the baling mechanism is varied according to the cycle of operation of the round baler.

14. The method of claim 12, wherein varying the speed of the baling mechanism according to a predetermined scheme comprises:

the rotational speed of the baling chamber of the round baler is varied according to a predetermined scheme.

15. The method of claim 12, further comprising determining an operating cycle of the baler.

16. The method of claim 12, wherein the varying the speed of a baling mechanism according to a predetermined scheme comprises:

operating a baling mechanism at a first speed during a bale-forming cycle; and

the baling mechanism is operated at a second speed during the non-bale-forming cycle.

17. The method of claim 16, wherein the varying the speed of a baling mechanism according to a predetermined scheme comprises:

operating a baling mechanism at a first speed during a bale-forming cycle; and

the baling mechanism is operated at a second speed during a bale wrapping cycle.

18. The method of claim 16, wherein the second speed is faster than the first speed.

19. The method of claim 16, wherein the second speed is at least twice the first speed.

20. The method of claim 16, further comprising:

the baling mechanism is operated at a third speed during the non-bale-forming cycle.

21. The method of claim 13, further comprising:

the operational cycle of the baler is determined.