HK1175360A - Continuous round baler - Google Patents

Description

Continuous round bundling machine

Technical Field

The invention relates to a round baler.

Background

Conventional round balers receive the crop and form it into a compact bale in a bale forming chamber. There are typically three main periods in the operation of a round baler: a bale forming cycle, a bale wrapping cycle, and a bale ejection cycle. The round baler is typically powered and towed by a tractor. Crop pickup picks up material located on the ground and supplies it to the bale-forming belts of the baler to form a bale.

Once the bale forming cycle is complete and the bale is fully formed, the towing vehicle may be stopped and the bale wrapping cycle may begin. For example, once the bale reaches the desired size and/or shape, the operator stops the forward movement and stops providing crop to the baler so that the baler can perform the baling operation. When the forward motion of the baler stops, an automatic mechanism associated with the baling chamber is used to wrap the net or rope around the bale.

Once baling is complete, a bale-ejection cycle may begin, wherein the baling chamber is opened, typically by lifting the tailgate, and the baled bale is dropped or pushed out of the baling chamber. After discharge, the bale forming cycle is restarted for a new bale, and the operator again provides crop to the baler and moves the baler through the field.

Drawings

Fig. 1 shows a schematic view of an example embodiment of a continuous baler.

Fig. 2 illustrates an example embodiment of a continuous baler including a round baler and an adjustable crop conveyor.

Fig. 3 illustrates an example embodiment of a continuous baler receiving crop from and being hauled by a combine.

Fig. 4 shows a schematic diagram of an example embodiment of an electronic control system of the continuous baler of fig. 2.

FIG. 5 shows a schematic view of an example embodiment of a console located on a vehicle that is accessible by an operator when towing the round baler of FIG. 2.

Figure 6 shows a flow chart of an example method of a continuous round baler.

Figure 7 shows a flow chart of an example method of a continuous round baler.

Fig. 8 shows a flow diagram of an example method for an adjustable conveyor used in combination with a continuous baler.

Figure 9 shows a flow chart of an example method of a continuous round baler.

Detailed Description

Overview

In an example embodiment, a continuous baler receives crop material from a crop source and bales the crop material into bales. The term "continuous" refers to the receipt of crop by a continuous baler as the baler forms a bale. For example, as crop material is collected and the baler advances through its cycle of operation, the baler may be pulled through the field without stopping. This eliminates the stopping of movement of the baler through the field and the stopping of the receipt of crop material that occurs in conventional methods when the baler performs various operations in which it does not receive crop material (e.g., during a bale discharge cycle). The term "crop material" is meant to include grain and materials other than grain (MOG), such as residue from a combine harvester. For example, a continuous baler may be used to bale hay or biomass material, such as corn cobs and the like. This arrangement provides several advantages over prior art systems, including the ability to continuously move the baler through the field and collect crop material during various operating cycles of the baler. The adjustable crop conveyor system can be used to collect crop material and provide the crop material to the baler according to various operating cycles of the baler.

In one example embodiment, an adjustable speed conveyor system comprises: an adjustable crop conveyor for receiving crop material from a crop source and providing the crop material to a baler; and a controller for controlling the speed of the adjustable crop conveyor. In one example embodiment, the crop source is a combine that provides crop material to the adjustable crop conveyor. A user interface may also be provided for receiving operating instructions from an operator of the continuous baler and for controlling certain functions of the baler and the adjustable crop conveyor in accordance with the operating instructions. For example, the controller may vary the speed of the conveyor according to a predetermined scheme provided by an operator via the user interface. In an example embodiment, the user interface may be used to direct the adjustable crop conveyor according to a scheme in which the speed of the conveyor varies according to different operating cycles of the baler. For example, the conveyor may be stopped, started, accelerated, decelerated, and/or reversed according to different operating cycles of the baler.

In an example embodiment, the adjustable crop conveyor may include one or more conveyor belts rotatably mounted on rollers (e.g., drive and idler rollers). The drive roller may be powered by a hydraulic motor which may be operated by a controller and various solenoids and flow control valves to vary the speed and direction of the drive roller and thereby the speed and direction of movement of the conveyor belt and thereby the supply of crop material provided to the conveyor from a crop source to the baler. The front or feed end of the conveyor may be positioned adjacent the crop source to receive crop material thereon. A rear or outlet end may be positioned adjacent the inlet of the baler such that crop material received from the crop source may be conveyed by the conveyor from the feed end into the baler for baling. In an example embodiment, the feed end is positioned to receive crop material from an outlet of a combine and the outlet end of the conveyor is positioned adjacent a feeder of the baler. Although example embodiments are discussed in the context of a belt conveyor, those skilled in the art will recognize that other conveyor arrangements may be used, such as an auger conveyor or a chain conveyor as known in the art, and the term "conveyor" is meant to include these alternative arrangements.

One example method of providing crop material to a baler includes: continuously receiving crop material at an adjustable speed crop conveyor configured to provide crop material to a baler; determining an operating cycle of the baler; and manipulating movement of the conveyor in accordance with operation of the baler to provide crop material to the baler. Another example method of providing crop material to a baler includes: continuously receiving crop material from a crop source on a crop conveyor; operating the crop conveyor to deliver crop material to a baler during a bale-forming cycle of the baler; stopping the conveyor during a baling cycle of the baler; and operating the crop conveyor after discharging the bale from the baler. In an example embodiment, the conveyor may be operated at a first speed during a bale forming cycle of the baler to deliver crop material to the baler until the bale reaches a first bale size; and operating the conveyor at a second speed during a bale forming cycle of the baler to deliver crop material received from the crop source to the baler until the bale reaches a second bale size.

An example method of baling crop material includes: continuously providing crop material to a crop conveyor configured to provide crop material to a baler; determining an operating cycle of the baler; and controlling movement of the crop conveyor in response to an operational cycle of the baler. Another example method for baling crop material includes: continuously receiving crop material from a crop source on a crop conveyor; operating the crop conveyor to provide crop material to the baler; receiving crop material from the crop conveyor at a baler and forming a bale; stopping the conveyor; baling the bale; discharging the bale from the baler; and restarting the conveyor to provide crop material to the baler. It should be noted that crop material may be continuously provided to the conveyor during various periods of operation of the baler, with subsequent crop being provided to the baler by the conveyor, allowing the baler and the apparatus moving the baler to move continuously over the field and crop material to accumulate on the conveyor. In an example method, the crop conveyor may be operated at a first speed to provide crop material to the baler until the baler forms a bale of a first size in the baler; and running the conveyor at a second speed after the bundle reaches the first size.

Detailed Description

As required, example embodiments of the present invention are disclosed herein. The various embodiments are meant as non-limiting examples of various ways of implementing the invention, and it should be understood that the invention may be implemented in alternative ways. The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which like reference numerals refer to like elements throughout the several views, and in which example 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 be 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.

Turning to the drawings, fig. 1 shows a schematic of a continuous baler 10 including a baler 12 and an adjustable conveyor 14, wherein the adjustable conveyor 14 is for receiving crop material 16 from a crop source 18 and providing the crop material 16 (as indicated by the small arrows) to the baler 12 for formation into a bale 20. A vehicle 22, such as a tractor or combine, may be used to pull the baler 12 through the field, as indicated by the large arrow in fig. 1.

As shown in fig. 2, the adjustable conveyor 14 may be incorporated as part of a round baler 12 such as 5500 and 900 wire round balers manufactured by Agco, including Hesston 5545, 5556A and 5546 round balers; however, the present invention may be incorporated as part of other types of baling apparatus, such as fixed chamber balers and the like. Additional details of a round baler that may be used with the present invention are described in U.S. patent nos. 7,3376,713, 6,477,824, 6,675,561, 4,850,271 and 4,524,867, all of which are incorporated herein by reference in their entirety. As seen in the example embodiment shown in fig. 2, the round baler 12 may include a lower drive roller 24 and a starter roller 26. The upper drive roller 28 is located above the lower drive roller. A belt tensioning arm 30 is pivotally mounted within the baler, and front 32 and rear 34 belt tensioning rollers are pivotally mounted to the belt tensioning arm 30. A front upper idler roll 36 and a rear upper idler roll 38 are located at the top of the front of the baling chamber. Clockwise along the interior of the baler wall are tailgate belt rollers 40, rear lower tailgate rollers 44, and front 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, each pivotally mounted on a distal end of a pivotal mounting of the bale density arm 48. An upper baling chamber roller 54 is shown above the bale density roller near the top of the baling chamber. A plurality of bundle forming bands 56 (one shown in outline) are mounted around each of the above identified rolls as shown in fig. 2. 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 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 push rod 64 (shown in its home position) and two hydraulic cylinders (not shown). The bale thrower is used to prevent contact between the tailgate 58 and the bale when the tailgate is closed. 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 rearward, pushing the bale away from the tailgate. After the tailgate closes, the kicker returns to its home position.

The baler control system may include a controller 70 positioned on or near the round baler 12, and a user interface 500 (fig. 5) preferably positioned on the trailer 22 (e.g., tractor, combine) that pulls the baler 12. The controller 70 may receive data from a plurality of different sensors and responsively issue instructions to implement various operations of the baler and/or the adjustable conveyor 14. Although the controller 70 and user interface 500 are preferably separate components, their functions can also be combined in a single unit positioned on the baler 12 or the trailer 22 thereof. The baler controller 70 may be used to control the operation of the adjustable crop conveyor 14 and the baler 12, including various operational cycles of the baler, such as bale forming, bale wrapping, and bale discharge cycles. For example, a bale size sensor 68 (shown schematically) may determine a bale size of the bale 20 in the baling chamber and provide a corresponding signal to the controller 70 and the user interface 500. The controller 70 may then determine the desired operating period of the baler 12 and the desired operation of the adjustable conveyor 14.

A bale size sensor 68 may be provided on the density arm 48 that detects the angular position of the bale density arm during the bale forming cycle and sends a signal to the electronic control system indicating the bale size. In addition, the baler can comprise: a tailgate switch 80 (shown schematically), the tailgate switch 80 detecting whether the position of the tailgate is open or closed; a kicker switch 82 (shown schematically), the kicker switch 82 detecting whether the kicker's position is out or home; and a lockout switch 84 (shown schematically), the lockout switch 84 detecting whether the tailgate is locked out. The tailgate and kicker switch cause a signal to be sent to the controller 70 indicating the status of the elements to which they are connected.

In addition to the above elements, the baler 12 can include a hydraulic pump 88 and a clutch assembly and electronic control, none of which are shown in fig. 2, but which are necessary for operation of the baler as will be appreciated by those skilled in the art.

In the example embodiment shown in fig. 2, the adjustable conveyor 14 for use with the round baler 12 can include a conveyor 90 having a plurality of endless belts 92 that move in wrapping around rollers 94, 96. The top surface 98 of the conveyor belt 92 defines an active gathering and conveying surface for receiving crop material 16 provided to the conveyor from a crop source and conveying the crop material to the inlet 198 of the baler 12. The conveyor belt 92 may be arranged such that the conveyor belt 92 extends from a front or receiving end 112 positioned adjacent the crop source to a rear or exit end 114 adjacent an inlet 198 of the baler 12.

The belt 92 may be driven by a drive roller 94, rotation of the drive roller 94 causing movement of the belt 92. The drive roller 94 may in turn be powered by a hydraulic motor 120. For example, fluid may be provided to the hydraulic motor 120 from the hydraulic pump 88 and manipulated through solenoids and/or flow control valves to vary the fluid flow to vary the speed of the motor 120. The drive roller 94 may be coupled to the motor 120 by a chain 130 or other means known in the art such that a change in the speed of the motor 120 changes the rotation of the drive roller 94 and the rotation of the conveyor belt 92 powered by the drive roller 94.

This arrangement enables the movement of the conveyor belt 92 to be controlled by the controller 70. In an example embodiment, the hydraulic pump 88 may be installed in the baler and powered by the output mechanism of the vehicle 22. The hydraulic line 140 may extend to a manifold 142 mounted in the baler 12 and be coupled to solenoids and/or flow control valves responsive to command signals sent from the controller 70 to manipulate hydraulic fluid provided to the motor 120. In an example embodiment, an "on" solenoid 150, an "off" solenoid 152, and a flow control valve 154 (all shown schematically in FIG. 4) may be communicatively coupled with the controller 70 and used to control the hydraulic motor 120, and thus the movement of the conveyor belt 92. The controller 70 may also operate other components of the baler 12 related to various operating cycles of the baler. It should be noted that although a single controller 70 is shown controlling the adjustable conveyor 14 of the conveyor system and the operating cycle of the baler, multiple controllers can be used to accomplish the same task.

As discussed in more detail below, the conveyor 90 may be operated by the controller 70 according to a predetermined scheme programmed by an operator. For example, the conveyor 90 may be driven at different speeds in conjunction with different operating cycles of the baler 12. For example, the conveyor belts 92 may be driven at a first speed during a bale-forming cycle of the baler 12 and driven or stopped at a second speed during a baling and/or discharge cycle of the baler 12 to allow crop material to accumulate on the conveyor belts 92. This allows for continuous movement of the baler 12 through the field because the crop material 16 may be continuously received from the combine 22 or other crop source and accumulated on the conveyor 90 during periods of baler operation when the conveyor 90 is not conveying crop material 16 into the baler 12. The gathered crop material 16 can then be fed into the baler 12 during a suitable operating cycle, such as a bale forming cycle.

The belt 92 may comprise a plurality of parallel spaced endless belts wound around rollers 94, 96. Other arrangements can be used, such as a single band of greater width. In an exemplary embodiment, the belts 92 may be staggered such that every other belt engages the lower idler roller 86. This arrangement creates a gap between the portions of the belt extending below the rollers 94, 96 to allow crop material 16 falling into the gap between the conveyor belts 92 to proceed to the ground.

To couple the adjustable conveyor 90 to the baler, a front mounting assembly 188 and a rear mounting assembly 190 (only one of each shown in fig. 2) may be provided. The mounting assembly may include mounting plates 192, 194 that couple the conveyor 90 to the tongue 200 and baler 12 and rotatably support the idler roller 96 and drive roller 94, respectively. Those skilled in the art will appreciate that other conveyor arrangements may be employed, such as auger conveyors or chain conveyors as are known in the art.

Various sensors in the baler 12 can be used by the controller 70 to control the operational cycle of the baler 12 and the movement of the conveyor belts 92 of the conveyor 90. For example, the controller 70 may direct the baler 12 to begin a bale-forming cycle, and if the bale size sensor 68 signals that the bale 20 is less than a minimum size, the controller 70 may cause the conveyor belt 92 to run at a first speed, e.g., a low speed. If the bale size sensor 68 indicates that the bale 20 is greater than the minimum size but less than the maximum size, the controller 70 may cause the conveyor to operate at a second speed, e.g., a high speed. If the bale size sensor 68 indicates that the bale 20 is greater than the maximum bale size, the controller 70 may stop the conveyor belts 92 and the baler belts 56 and direct the baler 12 to perform a baling and discharge cycle. When other sensors (e.g., the tailgate switch 80) indicate that the bale 20 has been ejected from the baler 12, the controller 70 may then begin a new bale forming cycle and restart the baler belts 56 and the conveyor belts 92.

Fig. 3 illustrates an exemplary embodiment of the continuous round baler 12 being hauled by the combine 22. The combine 22 is coupled to the baler 12 by a tongue plate 200 and discharges crop material 16 processed by the combine 22 to the conveyor belt 92. The conveyor 90 conveys the crop material 16 to the baler 12.

Figure 4 is a schematic diagram of an embodiment of an electronic control system 400 of the continuous round baler 12 of figure 2. The system 400 of fig. 4 includes a system box 402, the system box 402 housing the controller 70 and associated electronic components, the structure of which is understood by those skilled in the art, but the details of which are not important to the present invention. It will be apparent to those skilled in the art that the arrangement may comprise hardware, software, firmware or a combination thereof. 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 that may be programmed in the microcontroller.

Three harnesses are schematically depicted connecting the system box 402 and the controller 70 to the elements controlled by the controller distributed around the round baler 12 and the conveyor 90. A main harness 406, a mesh harness 410, and a kicker harness 414 are provided. Although shown as a single wire extending from the system box to the various elements, these wires are meant to represent a multi-wire connection that extends through the wiring harness and connects to the designated elements.

The main harness 406 connects the system box 402 and the controller 70 to various sensors and switches including a cord arm sensor 420, a bale size sensor 68, a left cord run switch 424, a right cord run switch 428, an over-size limit switch 430, and a left tailgate latch switch 434. The bale size sensor 68 sends a signal to the controller 70 during the forming cycle to indicate the size of the bale. The cord arm sensor 420, if packaged with a cord, sends a signal to the controller 70 to indicate the position of the cord arm. Likewise, the left and right cord run switches 424, 428 indicate to the controller when the left and right cord rollers are rotating and thereby dispensing the cord. The over-size limit switch 430 indicates to the controller when the bale has exceeded a trigger point for a maximum bale size in the cavity. The left tailgate latch switch 434 indicates whether the left tailgate latch is open or closed. Line 440 is meant to schematically indicate that left tailgate latch switch 434 is actually connected in series with right tailgate latch switch 444 (described below).

The main harness 406 also connects the system box 402 and the controller 70 to the various solenoids and valves that initiate the flow of hydraulic fluid to the various systems of the baler 12 and conveyor 90. These solenoids and valves may include a rope feed solenoid 450, a rope home solenoid 454, a tailgate up solenoid 460, a tailgate down solenoid 464, a conveyor on solenoid 150, a conveyor off solenoid 152, a flow control valve 154, a kicker solenoid 470, and a clutch solenoid 472 and auxiliary solenoids (not shown). The cord feed solenoid 450 actuates the cord wrapping mechanism. The cord home solenoid 454 causes the cord arm to return to its home position. The tailgate up solenoid 460 actuates a hydraulic cylinder that lifts the tailgate 58. The tailgate down solenoid 464 causes the same hydraulic cylinder to close the tailgate 58. Kicker solenoid 470 actuates the hydraulic cylinder to reciprocate the kicker. The clutch solenoid 472 engages and disengages the main drive clutch to establish and discontinue a drive connection between the tractor's power take off shaft and various components of the baler 12, such as the baler's short auger, starter roll, and belt drive roll. The conveyor on solenoid 150 actuates movement of the conveyor belts 92 of the conveyor 90, the conveyor off solenoid 152 causes the conveyor belts 92 to stop, and the flow control valve 154 regulates the speed of the conveyor belts 92 by controlling the flow of hydraulic fluid to the motor 460. The auxiliary solenoid may be used to operate alternative devices.

The net harness 410 connects the system box 402 and controller 70 to the midnet switch 474, the net count switch 476, the net feed solenoid 478, the net cut switch 480, and the net home solenoid 482. The net wrapping mechanism is optional and thus may or may not be present on any given unit. The intermediate wire switch 474 provides position feedback to the controller 70 to stop the wire dispensing roller at the correct baling position. Net count switch 476 allows controller 70 to estimate the amount of net usage and indicate that a net is being applied. The web feed solenoid 478 causes the web to be fed into the baling chamber during the baling cycle. The net home solenoid 482 actuates a hydraulic cylinder which returns the net baling mechanism to its home position where a mechanical disconnect will cut the net and close the net cutting switch 480, signaling the controller 70 that the net baling process is complete.

Kicker harness 414 connects system box 402 and controller 70 to various switches including tailgate up switch 484, right tailgate latch switch 444, tailgate down switch 486, kicker out switch 488, and kicker home switch 490. When the tailgate 58 is in the up position, the tailgate up switch 484 signals the controller. When the tailgate 58 is latched, the right tailgate latch switch 444 wired in series with the left tailgate latch switch 434 signals the controller 70. Due to the series connection between the two switches, no signal is sent unless both switches are closed. When the tailgate 58 is in its down position, the tailgate down switch 486 signals the controller 70 and the kicker solenoid 470 should be de-energized. When the kicker is in its outward position, the kicker signals the controller at the outward switch 488. The kicker home switch 490 signals the controller 70 when the kicker is in its home position.

Fig. 5 is a top view of a user interface 500, the user interface 500 being in the form of a console 500 provided on an operator station located, for example, in the cab of a trailer, such as the combine 22 that pulls the baler 12 through the field and provides crop material 16 to the baler 12, wherein the user interface is accessible to an operator when operating the round baler 12. The console 500 may be configured with controls to provide the operator with different levels of control over the baler 12 and the adjustable conveyor 14. For example, the operator may be provided with a fully manual control mode, a semi-automatic control mode, or an automatic control mode of the round baler. In the fully manual mode, the operator initiates each major step in the baling process. In the semi-automatic mode, the operator will have less interaction and control less tasks. In the fully automatic control mode, the baler 12 and adjustable conveyor 14 may operate continuously without further input from the operator.

The exemplary embodiment of the console 500 of fig. 5 includes a power on/off button 502, a cord/net selection button 504, a drive control button 506, a cycle start button 508, a program set button 510, a value control button 512, a kicker on/off button 514, a field/total bale count button 516, a test button 518, and an auxiliary output on/off button 520. In addition, a variety of control buttons are provided, including net 522, cord 524, clutch 526, door 528, and kicker 540 and conveyor 542. A central display 540 is also provided which indicates to the operator the baler and conveyor status during various periods of operation of the baler as well as the conveyor mode of operation. In addition to the console 500, a remote control (not shown) may also be used to handle some of the control functions, including the cycle start function as described below.

The controller 70 can have a variety of operating modes: (1) neutral position; (2) testing; (3) programming; (4) driving; (5) semi-automatic; (6) manual operation; and (7) automatic/continuous. The system starts in neutral mode. Upon system startup, certain checks are performed by the system and the baler and conveyor status is displayed to the operator. From the neutral mode, the operator can press a test key, a set key, a drive key, or any mode key.

The test mode is entered when the operator presses the test key 518. The test mode is used to check the condition of the electronic system components of the baler. This status will be displayed on the console screen 540.

The programming mode is entered by pressing the set key 510. The operator uses a programming mode to set various settings for controlling the functions of the baler and conveyor. The programming mode symbol will illuminate. The set name and value will appear on the display screen. To change values or set options, the operator can press the appropriate side of the value key 512. The set button can be pressed again to advance to the next set name. During the programming mode and the selected bale size conveyor scheme, the baler can be set to an automatic mode, also referred to as a continuous mode, among other values and settings.

Two semi-automatic modes are provided: automatic throwing and automatic packing. In the auto-throw mode, the baler 12 will form a bale and wait for a signal before baling the bale. Once the bale signal is issued, the bale is baled and immediately ejected without operator intervention. In the automatic bale mode, the bale is automatically baled after a predetermined bale size is reached, and the baler waits for an operator signal before discharging the baled bale. In the automatic or continuous mode, the bale forming, automatic throwing and automatic baling modes, and the movement of the conveyor may be performed without direct operator intervention. In the continuous mode, the baler 12 may be pulled through the field without stopping and crop material may be continuously provided to the conveyor.

The drive mode is entered by pressing drive key 506. When the drive mode is entered, the clutch is engaged and the forming belt 56 of the baler 12 begins to rotate, the conveyor motor 120 is powered and the conveyor belt 92 of the conveyor 90 begins to rotate. The operator may drive the combine 22 or other vehicle to pull the baler 12 forward behind it and provide the crop material 16 to the conveyor belt 92. The operation of the various modes of the baler 12 may be similar to that disclosed in U.S. patent No.6,675,561 entitled "semi-automatic sequential cycle of operation of a round baler and selective variable position of operator intervention," the contents of which are incorporated herein by reference, including bale forming, bale wrapping, and bale ejection modes, which may be operated in a semi-automatic manner with some or fully automatic manner without operator intervention. In either case, the operation of the conveyor 90 may be automatically operated in response to the various modes of the baler 12. For example, the conveyor may be programmed to move in response to different operating modes of the baler 12, whether the mode of the baler 12 is performed automatically, semi-automatically, or manually. The drive mode key 506 may be depressed to control the operational cycle of the baler, whether a manual mode, a semi-automatic mode, or an automatic (continuous) mode is to be employed. In the semi-automatic mode, when the baler 12 completes all cycles for forming and discharging the bale 20, the baler 12 will automatically return to the drive mode for a subsequent cycle, as described further below. In the automatic (continuous) mode, the baler 12 and conveyor 90 may be continuously switched between the continuous modes until further instructions and enable the baler 12 to be continuously towed through the field and continuously fed with crop material.

The semi-automatic baler mode may be entered during the programming mode by first selecting one of two modes (auto-toss or auto-bales) and then pressing the activation key 506 as previously described. The automatic or continuous mode may be entered by selecting the continuous mode during the programming mode and then pressing the actuation key 506 as previously described. The manual mode can be entered at any time by pressing one of the manual keys. Once in the manual mode, the operator controls the forming cycle by controlling the clutch with clutch button 526, the baling cycle by pressing web button 522 or rope button 524, the discharge cycle by controlling the tailgate with tailgate button 528 and the kicker with kicker button 530, and the conveyor by pressing conveyor button 532. In addition to the conveyor on/off button, a conveyor speed button 550 and a conveyor direction button 552 may be provided to manually control the speed and direction of the conveyor 90 when the system is operating in a manual and/or semi-automatic mode. These buttons 550, 552 will send signals to the controller 70 for operating the flow control valve 154 and the drive roller 94.

The baler 12 and conveyor 90 may operate as follows. A variable flow pump 88 within the baler receives energy from the power take off of the vehicle 22 and pressurizes the system. When the operator signals the start of a bale forming cycle by depressing the drive key 506, the electronic controller 70 sends a signal to the clutch solenoid 472 engaged with the clutch causing the starter roller 26 to rotate and the upper and lower drive rollers 24, 28 to rotate the forming belt 56 and feeder 196 and signals the conveyor on solenoid 150 and flow control valve 154 to power the conveyor motor 120 to drive the conveyor drive roller 94 and move the conveyor belt 92 at the desired speed. The feeder 196 may include: one or more augers provided with a screw, said augers rotating about the axis of the common shaft; and a finger located laterally inside the auger, the finger extending radially from the shaft. Alternatively, the short auger and fingers can be provided on separate rotating shafts. The feeder 196 can be driven by a starter roll drive as is known in the art such that the feeder 196 rotates as the baler belt 56 moves. The auger assists in moving the crop laterally inward toward the inlet 198 of the baler 12. For example, the conveyor 90 may have a width greater than the inlet 198 of the baler, such that the auger narrows the width of the mass of crop material 16 provided by the conveyor 90 to a suitable width for receipt into the inlet 198. The rotating fingers may assist in feeding the crop material 16 into the bale forming chamber 110 of the baler 12.

An operator may move the baler 12 through the field by pulling the baler 12 behind the combine 22, with the combine 22 providing the crop material 16 to the conveyor belt 92. For example, the combine harvester 22 may be configured to discharge the crop material 16 from the outlet onto the upper surface 98 of the conveyor belt 92. The conveyor belt 92 moves the received crop material into the inlet 198 of the baler 12. The crop material 16 is then fed into the bottom of the open throat baling chamber 198 by the auger 196. Once in the baling chamber 198, the crop material contacts the roughened top surface of the upwardly moving forming belt 56. The forming belts carry 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 belt causes the crop material to rotate downwardly against the starter roll 26. The core is started and starts to roll. The hydraulic cylinder pulls the bale density arm 48 and the belt tensioning arm 30 downward. The bale density rollers 50, 52 are held down to reduce the size of the bale 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 rollers 50, 52 and the belt tension rollers 32, 34 are pushed upward. The bale density rollers 50, 52 apply an increasing downward force against the bale. The force maintains tension on the bale and compresses the crop material entering the bale chamber. The belt-tensioning roller moves upwardly to provide more forming belt for increasing the size of the bundle within the cavity.

As the bale size increases and the bale density arm 48 moves upward, the bale size sensor 68 continuously sends a signal to the controller 70 indicative of the bale size. The controller 70 will detect when the bale has reached or exceeded a desired bale size, which may have been initially programmed by the operator during the programming mode. The bundle size may also be indicated on the console screen 540. If the baler 12 is operating in the continuous mode, when the bale size has reached or exceeded the predetermined bale size, the baler 12 enters the baling cycle and the conveyor speed changes in response to the new baler mode. For example, as the baler 12 continues through the field and crop material is continuously provided to the conveyor 90 by the combine 22, the conveyor 90 may be slowed or stopped during the baling cycle so that crop material 16 accumulates on the conveyor 90.

During the baling cycle, the controller 70 may activate the net feed solenoid 478 or the rope feed solenoid 450 to bale the bale, depending on the baling method selected during the programming mode. As will be readily understood by those skilled in the art, the rope baling mechanism or net baling mechanism performs its function. Once the packaging cycle is complete, the clutch solenoid 472 is de-energized by the controller 70 to disengage the clutch and stop the movement of the forming belt 56. The controller proceeds to the discharge cycle. The conveyor 90 may be maintained in a slowed or stopped condition to continue gathering the crop material 16 as the baler 12 continues to move through the field during the discharge cycle.

During the discharge cycle, the controller 70 causes the tailgate 58 to lift by actuating the tailgate up solenoid 460. Once tailgate up switch 484 is closed, signaling the position of the tailgate to controller 70, controller 70 activates kicker solenoid 470 causing the kicker to push the bale away from the baler. The kicker advances outward until it is in its fully extended or out position, closing kicker out switch 488. The controller then activates the tailgate down solenoid 464 causing the tailgate 58 to move to the down position and close the tailgate down switch 486, which in turn indicates the down position to the controller 70. Controller 70 then causes kicker solenoid 470 to be de-energized. The tailgate latch switches 434, 444 close, causing the clutch solenoid 472 to energize and rotate the forming belt 56. De-energizing kicker solenoid 470 causes the kicker to return to home, thereby closing kicker home switch 490. The baler 12 then immediately begins a new forming cycle as described above, and the controller 70 restarts the conveyor 90 so that crop material accumulated on the conveyor 90 is provided to the baler 12.

If the operator selects the semi-automatic mode of automatic baling, the baler will form the bale as described above and, after a short delay, proceed directly to the baling cycle to bale the bale without operator intervention. The baler will then wait for operator intervention, including depressing the cycle start key 508 or a remote cycle start switch, before beginning the discharge cycle. Upon receiving the operator input, the baler 12 will lift the tailgate 58, unload the bale from the cavity, send the kicker out, lower the tailgate, and send the kicker back in place, all as previously described. When the tailgate latches 434, 444 are closed, the forward-driving arrow will illuminate on the display 540. The conveyor 90 is capable of automatically adjusting its speed in response to different modes of the baler 12. Similarly, in a fully automatic (continuous) mode, the baler 12 is able to move through various bale forming, baling and discharge cycles without operator intervention, and the movement of the conveyor is automatically changed according to the different operating cycles of the baler 12. If operating in a discontinuous mode, such as a manual or semi-automatic mode, the operator can control the movement of the conveyor 90 of the adjustable conveyor 14 by means of the conveyor on/off button 532, the conveyor speed button 550, and the conveyor direction button 552 on the console 500.

Fig. 6 shows an example flow diagram of a continuous baling operation, wherein the baler 12 is able to move continuously through the field through various baling operation cycles without stopping, and this allows crop material 16 to be collected continuously through various baler operation cycles. At block 602, crop material 16 may be continuously received on the conveyor 90. For example, crop material may be received on the conveyor through various operating cycles of the baler 12 as the baler 12 is pulled through a field. At block 604, the operational period of the baler 12 is determined. For example, the controller 70 may receive input from various sensors and switches to determine a desired period of operation of the baler 12 based on a variety of factors, such as, by way of example and not limitation, the size of the current bale. At block 606, the conveyor 90 is adjusted in response to the operational period determined at block 604. For example, the conveyor may be stopped, accelerated, decelerated, reversed, etc. depending on the particular operating cycle of the baler 12.

It should be noted that although three specific cycles of operation, bale forming, bale wrapping, and bale ejection, have been discussed, the term "cycle" is intended to be in connection with other existing or future operations that can be performed by the baler and is not limited to the three cycles mentioned above. Thus, many other cycles can be performed by the baler 12, and the conveyor 90 adjusted in response to the various cycles. In addition, for convenience, the term "mode" has been used to describe the movement and operation of the conveyor 90. It should be noted that the conveyor may be manipulated to change speed or direction during various modes, and while in some example embodiments the conveyor mode corresponds to a baler operating cycle, other operating modes can be employed independently of the baler cycle, and various modes of the conveyor may last longer or shorter periods of time than the baler operating mode.

Fig. 7 shows a flow chart of an example embodiment of a method for continuous baling. Once the process is initiated at block 700, a determination is made at block 702 whether the system is operating in a continuous mode. If the system is not operating in the continuous mode, the system is operating in the manual mode or any other mode that has been selected. For example, the operator may have selected a manual or semi-automatic mode during the programming phase.

If the baler is in the continuous mode, the baler operates at an initial period at block 706. For example, the initial cycle may be a bundle forming cycle. The conveyor then operates in an initial mode at block 708. The initial mode of the conveyor 90 may be the mode that is desired to be used with the initial cycle of the baler 12. For example, the operational cycle of the baler 12 is a bale forming cycle, then the initial mode of operation of the conveyor 90 may be movement at a first speed to provide crop material to the baler 12.

At block 710, it is determined whether to change the cycle of the baler 12. For example, it may be determined whether the baler is ready for a baling cycle by receiving information that the size of the bale formed in the baler is greater than a predetermined size. If it is not the time to change the cycle of the baler, the baler may continue its current cycle at block 712 and continue to do so until it is deemed appropriate to change the cycle. If such a change is appropriate, the baler changes its operating cycle at block 714.

At block 716, a determination is made whether to change the mode of the conveyor. For example, in one approach that may be employed, the conveyor may be programmed to change modes as the operational cycle of the baler 12 changes. If it is determined that the baler mode should not be changed, the conveyor continues to operate in its current mode at block 718. If it is deemed that the conveyor should change its mode, the conveyor mode is changed at block 720. For example, the conveyor may be stopped, restarted, slowed, accelerated, reversed, and so forth.

At block 722, it is determined whether the system is still in continuous mode. If not, at block 704, the conveyor may switch to manual mode or some other mode. If it is determined at block 722 that the system is maintained in continuous mode, a new determination is made at block 710 to determine whether to change the baler operating cycle. As the baler moves continuously through the field and crop material is continuously provided to the conveyor 90, the process may be repeated continuously to allow the baler 12 to change between various operating cycles and the conveyor 90 to change between various modes.

Fig. 8 illustrates an example method of operating an adjustable conveyor and a continuous baler in which the conveyor is operated in various modes corresponding to specific operating cycles of the baler 12. At block 802, it is determined whether the baler is in continuous mode. If the baler is not in the continuous mode, the conveyor 90 is operated in the manual mode (or any other mode selected by the operator) at block 804 until the continuous mode is selected. At block 806, it is determined whether the baler is operating in a bale forming cycle. If so, the conveyor 806 is operated in a corresponding bale-forming mode (i.e., the mode that is desired when the baler is in a bale-forming cycle) at block 808. For example, the conveyor 90 may be run forward at a particular speed in a bale forming mode. If the baler is not in the bale forming cycle at block 806 (or upon the conveyor changing to the bale forming mode at block 808), a determination is made at block 810 as to whether the baler is in the bale wrapping mode.

If the baler is in the bale-wrap mode at block 810, the conveyor operates at bale-wrap mode speed at block 812. As mentioned above, the speed of the conveyor during the packing period may be zero, or in other words, the conveyor may be stopped. If the baler is not in the bale packing mode at block 810 (or once the conveyor has switched to the bale packing mode at block 812), a determination is made at block 814 as to whether the baler is in the discharge mode. If the baler is in the discharge mode, the conveyor is set to the discharge mode in block 816 at block 814. As previously mentioned, the conveyor may remain stopped in the discharge mode. The process then continues back to block 802.

In the example flow chart shown in fig. 8, the conveyor is set to different modes corresponding to different operating cycles of the baler 12. Fig. 9 shows an example embodiment of a flow chart in which the scheme for controlling the conveyor 90 includes additional factors. The baler is started at block 900 and the baler 12 enters a bale forming cycle at block 902. A determination is made at block 904 whether the size of the bundle 20 is greater than the minimum size. For example, the bale size sensor 68 may be used to determine the size of the bale and send it to the controller 70. If the bundle is not of sufficient size, the conveyor 90 is run at a first speed, e.g., a low speed, at block 906. This will allow more crop material 16 to accumulate and limit the amount of crop material 16 entering the bale chamber. The conveyor 90 will remain running at low speed until the bale is determined to be of sufficient size at block 904.

If the bundle 20 is of sufficient size at block 904, the conveyor 90 is operated at a second speed, e.g., high speed, at block 908. At block 910, it is determined whether the bundle 20 is a full bundle size. If not, the conveyor 90 remains running at the second speed. If the bale is of sufficient size at block 910, the conveyor is set to a third speed, e.g., stopped, at block 912. The packing and ejection cycle is performed at block 914 and a determination is made at block 916 as to whether the packing and ejection cycle is complete. If so, the process repeats at block 904 and the conveyor is operated at a first speed at block 906.

The foregoing has outlined 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 pertinent features and applications of the present invention. Other advantageous results can be obtained by applying the disclosed information in a different manner or by modifying the disclosed embodiments. Accordingly, other aspects and a more complete understanding of the present invention may be obtained by referring 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 (37)

1. A continuous baler comprising:

a baler configured to form crop material into a bale; and

an adjustable conveyor having a conveyor configured to receive crop material and to convey the crop material to the baler, wherein movement of the conveyor is adjustable according to a predetermined scheme.

2. The continuous baler of claim 1, wherein the predetermined scheme comprises varying the movement of the conveyor in accordance with operation of the baler.

3. The continuous baler of claim 1, wherein the predetermined scheme comprises varying the speed of the conveyor according to an operating cycle of the baler.

4. The continuous baler of claim 1, wherein the predetermined scheme comprises changing the direction of the conveyor according to an operating cycle of the baler.

5. The continuous baler of claim 1, wherein the conveyor is configured to receive the crop material from a combine.

6. The continuous baler of claim 1, wherein the crop material comprises material other than grain (MOG).

7. The continuous baler of claim 1, wherein the baler comprises a round baler.

8. The continuous baler of claim 1, wherein the conveyor comprises:

a mobile conveyor for receiving the crop material and providing the crop material to the baler; and

a controller configured to vary the movement of the conveyor according to the predetermined schedule.

9. The continuous baler of claim 8, wherein the movable conveyor comprises at least one conveyor belt configured for receiving crop thereon.

10. The continuous baler of claim 8, wherein the movable conveyor comprises at least one feed auger configured to convey crop material to the baler.

11. The continuous baler of claim 8, further comprising:

a user interface configured to allow an operator to select the predetermined protocol.

12. The continuous baler of claim 1, wherein the adjustable conveyor is movable in at least two directions.

13. The continuous baler of claim 11, wherein the adjustable conveyor is configured to vary the speed and direction of the conveyor according to the predetermined scheme.

14. An adjustable conveyor for a continuous baler, comprising:

a conveyor configured to receive crop material and provide the crop material to a baler; and

a controller configured to vary the movement of the conveyor according to a predetermined scheme.

15. The adjustable conveyor of claim 14, wherein the predetermined scheme includes varying the movement of the conveyor in accordance with the operation of the baler.

16. The adjustable conveyor of claim 15, wherein the predetermined scheme includes varying the speed of movement of the conveyor according to an operating cycle of the baler.

17. The adjustable conveyor of claim 14, wherein the predetermined scheme includes changing the direction of movement of the conveyor according to the operational cycle of the baler.

18. The variable conveyor of claim 14, wherein the conveyor comprises:

at least one conveyor belt;

a driving section for moving the conveyor belt; and

a controller for manipulating the drive to vary the movement of the at least one conveyor belt.

19. The variable conveyor of claim 14, further comprising:

a user interface configured to receive input from an operator to select the predetermined protocol.

20. The variable conveyor of claim 14, wherein the conveyor belt is movable in at least two directions.

21. A method, comprising:

receiving crop material at an adjustable conveyor configured to provide the crop material to a baler; and

varying the movement of the conveyor of the adjustable conveyor according to a predetermined scheme.

22. The method of claim 21, wherein said receiving crop material at an adjustable conveyor comprises:

continuously receiving the crop material on the conveyor during a plurality of operating cycles of the baler.

23. The method of claim 21, wherein said varying the movement of the conveyor of the adjustable conveyor according to a predetermined scheme comprises:

varying the movement of the conveyor according to the operational cycle of the baler.

24. The method of claim 23, wherein said varying the movement of the conveyor according to the operational cycle of the baler comprises:

varying the speed of the conveyor according to the operating cycle.

25. The method of claim 23, wherein said varying the movement of the conveyor according to the operational cycle of the baler comprises:

varying the speed of the conveyor according to the operational period, wherein the operational period includes a bale-forming period and a non-bale-forming period.

26. The method of claim 23, further comprising:

determining an operating cycle of the baler.

27. The method of claim 23, wherein said varying the movement of the conveyor according to the operational cycle of the baler comprises:

operating the conveyor at a first speed when the baler is in a first operational cycle; and

operating the conveyor at a second speed when the baler is in a second operational cycle.

28. The method of claim 23, wherein said varying the movement of the conveyor according to the operational cycle of the baler comprises:

running the conveyor in a first direction when the baler is in a first cycle of operation; and

operating the conveyor in a second direction when the baler is in a second cycle of operation.

29. The method of claim 23, wherein said varying the movement of the conveyor according to the operational cycle of the baler comprises:

operating the conveyor when the baler is in a first bale forming cycle;

stopping the conveyor when the baler is in a bale wrapping cycle; and

operating the conveyor when the baler is in a second bale forming cycle.

30. The method of claim 29, further comprising:

continuously receiving crop material at the conveyor during the bale wrapping cycle.

31. The method of claim 29, further comprising:

the conveyor is operated at zero speed during the bale discharge cycle.

32. The method of claim 21, wherein said varying the movement of the conveyor of the adjustable conveyor according to a predetermined scheme comprises:

operating the conveyor at a first speed until a bale in the baler reaches a first predetermined size;

stopping the conveyor when the second bundle size of the bundle reaches a second predetermined size; and

operating the conveyor after discharging the first bale.

33. The method of claim 32, further comprising:

determining a size of the bale in the baler.

34. The method of claim 32, further comprising:

determining when the bale is discharged from the baler.

35. A method for continuously baling crop material, comprising:

continuously receiving crop material on a conveyor of an adjustable conveyor;

providing the crop material on the conveyor to a baler for baling;

baling the crop material received by the baler from the conveyor; and

varying the movement of the conveyor according to the operational cycle of the baler.

36. The method of claim 35, wherein said baling the crop material received by the baler from the conveyor comprises:

forming the crop material into a bale;

baling the bale; and

discharging the bale from the baler.

37. The method of claim 36, further comprising:

stopping the conveyor prior to the step of baling the bundle; and

restarting the conveyor after the step of discharging the bundle.