HYDRAULIC CONTROL SYSTEMS FOR

REGULATING TRANSFER OF BALES

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Application No .61/665, 753, filed June 28 , 2012 , which is incorporated herein by reference in its entirety.

FIELD OF THE DISCLOSURE

[ 0002 ] The field of this disclosure relates to hydraulic control systems for regulating the transfer of bales in an apparatus for gathering bales and to methods for transferring bales that use such control systems .

BACKGROUND

[ 0003 ] Crop forages such as hay (e.g. , alfalfa and/or grass hay) are periodically cut in the field, dried and compacted into bales for transport and storage of the forage material . Recent evolutions in row crop production and in technology for processing these materials have led to changes in the scale and economics of harvest and to increasing potential for harvest of crop residues like corn stover . Corn stover is also baled inthe field and used as livestock feed, bedding or production of biofuels . In addition, harvest technology for cotton has been developed, that includes the step of baling the cotton in the field . Due to these relatively recent changes , the scale at which this type of harvest process is conducted in some instances is different than the traditional process . The density of the bales , in terms of the number of bales per acre , is higher in some instances , the labor availability is less in some instances and the criticality of timing is higher in some instances .

[0004] Materials may be baled into relatively large round (round in cross-section) bales whichmaybe tiedby twine, netting or plastic wrap depending on the type of material , the type of storage and the intended use of the material . The bales are typically left in the field, near the location where the bale was formed, to minimize labor and time required for the harvest process including the baling operation .

[ 0005 ] A continuing need exists for an apparatus for gathering and transporting round bales in the field after baling, one that allows the bales to be gathered relatively quickly and reliably and in a way to minimize demands on the operator, and that consistently positions the bales adj acent one another to minimize the area required for storage . A need also exists for methods for gathering bales that use such apparatus .

[0006] This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the disclosure, which are described and/or claimed below . This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure . Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art .

SUMMARY

[ 0007 ] One aspect of the present disclosure is directed to an apparatus for gathering bales . The apparatus includes a bed for holding a plurality of bales , a loading assembly forliftinga bale and

conveying it to the bed and a control system for

regulating transfer of bales from the loading assembly to the bed by controlofafirst conveyor belt and/or a second conveyor belt . The loading assembly has a first arm that includes the first conveyor belt and a second arm that includes the second conveyor belt . The control system includes a hydraulic motor for rotating the first conveyor belt and/or the second conveyer belt and a hydraulic relief valve configured to actuate in response toanincreasein hydraulic pressure to slow or stop movement of the first conveyor belt and/or the second conveyer belt .

[0008] Another aspect of the present disclosure is directed to an apparatus for gathering bales . The apparatus includes a bed for holding a plurality of bales . The bed includes a bed conveyor . The apparatus includes a control system for regulating the bed conveyor . The control system includes a hydraulic motor for rotating a bed conveyor and a hydraulic relief valve configured to actuate in response to an increase in hydraulic pressure to stop movement of the bed conveyor .

[0009] A further aspect of the present disclosure is directedto a method for gathering bales on an apparatus having a bed for holding a plurality of bales and a loading assembly for lifting a bale and conveying it to the bed . A first bale is loaded on the bed . A second bale is contacted using a first conveyor beltofafirst arm of the loading assembly and a second conveyor belt of a second arm of the loading assembly . The first and second conveyor belts are actuated to cause the second bale to move toward the first bale . Movement of the first conveyor belt and second conveyor belt is slowed or stoppedwhen the secondbale contacts the first bale .

[0010] Various refinements exist of the features noted in relation to the above-mentioned aspects of the present disclosure . Further features may also be incorporated in the above-mentioned aspects of the present disclosure as well . These refinements and additional features may exist individually or in any combination. For instance, various features discussed below in relation to any of the illustrated embodiments of the present disclosure maybe incorporated into any of the above-described aspects of the present disclosure, alone orin any combination . BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 is a perspective view of an apparatus for gathering bales ;

[ 0012 ] Figure 2 is a perspective view of a portion of the apparatus showing a hydraulic cylinder for tilting the chassis of the apparatus ;

[ 0013 ] Figure 3 is a perspective view of the apparatus prior to loading a round bale;

[ 001 ] Figure 4 is a perspective view of the apparatus after the round bale has been loaded onto the bed;

[ 0015 ] Figure 5 is a schematic of hydraulic circuits for controlling the conveyor belts of the apparatus ;

[0016] Figure 6 is a perspective view of the apparatus after being loaded with bales;

[ 0017 ] Figure 7 is a perspective view of the apparatus during unloading of bales ;

[ 0018 ] Figure 8 is a side view of one arm of the loading assembly of the apparatus ;

[0019] Figure 9 is a cross-sectional view of the arm of Figure 8 taken through line 9-9;

[0020] Figure 10 is a cross-sectional view of the arm of Figure 8 taken through line 10-10 ; and [0021] Figure 11 is a cross-sectional view of the arm of Figure 8 taken through line 11-11.

[0022] Corresponding reference characters indicate corresponding parts throughout the drawings .

DETAILED DESCRIPTION

[ 0023 ] An embodiment of an apparatus for gathering round bales B is generally referredto as 5 in Figure 1. The apparatus 5 includes a bed 25 for holding one or more bales and a loading assembly 15 for lifting a bale off the ground and conveying it to the bed . The apparatus 5 includes a tongue 1 for pulling the apparatus by use of for example, a tractor or other pulling vehicle. In some embodiments (not shown) the apparatus 5 includes its ownpropulsionmechanismrather than being pulled by a pulling vehicle .

[0024] Generally, the apparatus 5 is suitable for picking up cylindrical bales commonly referred to as "round" bales . Roundbales are used for harvesting any material capable of being formed into a cylindrical bale such as traditional hay crops (e.g. , alfalfa or grass ) , corn stover or other crop residues , cotton, or woodyproducts like small diameter trees . The apparatus 5 shown in Figure 1 is configured for loading up to 5 bales . The apparatus 5 may be modified to carrymore or less bales without departing from the scope of the present disclosure . [0025] The apparatus 5 includes wheels 3 attached to a bed chassis 6. The bed 25 tilts between various positions, toa forward tilted position for loading the bales or unloading to the front, to amiddle position used after bales have been loaded for

transportation of the loadedbales (Fig. 6) and toa rearward tilted position for unloading and re-loading of bales to the rear ( Fig .7 ) . The apparatus 5 maybe tilted hydraulically throughmanual or automatic control by use of a hydraulic cylinder 17 (Fig.2) or by any other method available tothoseofskillin the art .

Tracks (not shown) maybe used as an alternative to the wheels 3.

[0026] The loading assembly 15 includes two arms 4, 24 that are the first portion of the apparatus 5 to contact the bale during loading . Each arm 4, 24 includes an endless conveyor belt 16, 18. Referring now to Figures 8-11 in which one arm 4 is shown in detail , the endless conveyor belt 16 moves along a path between a front idler roller 162i (Fig.9) that rotates freely and a driven rear roller 162 (Fig.11) connected to a rotary power device such as a hydraulic motor described below . The arm 4 includes support rollers 165 (Fig.10)

positioned between the front idler roller and the drive roller .

[0027] Eachbelt 16, 18 includes upper portions 16u, 18u (Fig.1) that are capable of carrying the weight of a bale . The effective length of these conveyors is approximately the length of this upper surface , or the distance between the front idler roller 162i (Fig. 9) and the rear drive roller 162 (Fig.11) . The movement of the belt , around the front idler roller 162i and backward along the upper portion of the belt path, has been found to be effective to lift a bale off the ground and for simultaneously causing the bale to move toward the bed 25. This lifting and transporting action occurs after the two conveyor belts contact the bale Bl (Fig.3) .

[0028] Referring again to Figure 1 , thebed 25 includes a number of bed conveyors 35 , each having an endless belt routed around a front idler roller and a rear powered roller that maybe rotated to cause the belt to move which results inmoving bales away from the loading assembly and toward the end 27 of the bed . Each conveyor 35 may have an effective length, the distance between the idler roller and the drive roller . This effective lengthmay be the length of about one bale . Typical bale lengths for forage products may be between about 40 and 60 inches andbales of cotton are in the range of 100 inches in length. It shouldbe noted that the apparatus 5 and the effective length of the conveyor belts 16, 18 are not limitedby bale size or to a particular length.

[0029] Alternatively and as shown in Figure 5 , the bed 25 may have one bed conveyor 35 on each side that extends from the firstend32 tothe second end 27 rather than a series of bed conveyors on each side . In some embodiments, the bed 25 has a single conveyor belt (not shown) that forms a floor of the bed upon which the bales rest for moving bales toward the second end 27. [0030] The conveyor belts 16, 18 of the first and second arms 4 , 24 of the loading assembly 15 and the conveyor belts 35 of the bed 25 maybe drivenby hydraulics, as discussed above, or alternately by any type of rotarypower device such as an electric motor . The position of the loading assembly 15 and bed 25 relative to the pull vehicle (i.e. , whether the apparatus is pulled directlybehind the pull vehicle or at an offset position such as when bales are being gathered from the field) maybe adjusted bymanipulating the angle between the tongue 1 and the bed chassis 6 ( Fig .1 ) by use of hydraulics or by any other suitable method .

[0031] The bed conveyors may be constructed from the same basic components used in the loading assembly conveyors , with an endless conveyor belt, an idler roller, a drive roller and supports . The

embodiments illustrated herein show an alternative construction for the bed conveyors 35 , each including an endless conveyor belt of a slightly different

construction than the belts 16 and 18 , routed around a drive pulley 62 and an idler pulley 62i . In some

embodiments the drive pulley 62 is positioned at the front or, in other embodiments , at the rear .

[0032] The surface characteristics of the conveyors 16, 18 may affect the frictional engagement between the conveyor belt and the bale . The conveyor belts 16, 18 may include a surface that will adequately engage the bale to enhance the capability for the loading assembly to reliably lift the bales while also minimizing potential for damage to the bale and anybale wrapping . [ 0033 ] It should be noted that any suitable type of conveyer belts or conveyor systems may be

included in the apparatus . For instance, a conveyor belt composed of a carcass of nylon or fiberglass fibers covered by a wide variety of materials including rubber, PVC, thermoplastic polymer or the equivalent may be used . Chain conveyor systems may also be used without departing from the scope of the present disclosure . In this

regard, "conveyor belt" as used herein includes any arrangement in which a belt , chain, track or the like is moved around a series of pulleys to cause movement of the belt, chain or track .

[0034] Inoperation, the apparatus 5 is pulled by the pull vehicle (not shown) toward a bale as shown in Figure 3. The vehicle may provide the power for running the various conveyors and positioning systems (e.g. , by use of hydraulics ) or the apparatus 5 may

include its own independent power system (e.g., hydraulic system) . The apparatus 5 may be described herein with reference to a hydraulic system . It should be noted that the present disclosure should not be limited to a

hydraulic system as the principles would apply to other power transfer technologies such as an electrical system.

[0035] As shown in Figure 3 , thebaleBl shouldbe oriented such that the ends 40 of the

cylindrical bale are perpendicular to the apparatus 5 as the apparatus 5 approaches the bale Bl . The chassis 6 and tongue 1 are caused to be at an angle λ relative to one another such that the loading assembly 15 andbed 25 travel outside of the path of the pull vehicle (not shown) to allow the pull vehicle to travel "outside of" or parallel to the bales B targeted for loading .

[0036] The first and second conveyor belts 16, 18 are driven or actuated to cause the belt to move while the apparatus 5 travels toward the first bale Bl . As the apparatus 5 approaches the bale Bl, the conveyor belts 16, 18 of the arms 4 , 2 contact the first bale causing the bale to be lifted and simultaneously moved toward the bed 25. The first bale Bl maybe loaded onto the loading assembly 15 without stopping the apparatus 5 such that the apparatus 5 and the vehicle that pulls the apparatus may continuallymove forward during bale pickup .

[ 0037 ] Once the bale Bl is loadedon the loading assembly 15 , belt conveyors 35 (e.g., the set of conveyors nearest the loading assembly for the embodiment illustrated in Figure 1, or the entire conveyor for the embodiment illustrated in Figure 5 ) move to transfer the bale Bl from the loading assembly 15 to the position on the bed 25 as illustrated in Figure 4. Once loaded onto the bed 25 , the bed conveyors 35 are slowed or stopped to position the first bale Bl adj acent the end of the loading assembly.

[ 0038 ] In accordance with the present disclosure, each bale subsequent to the first bale Bl may be loaded until it contacts the previously loaded bale which causes the bale to stop . Once the first bale Bl is loaded, the apparatus 5 isdirectedtoa second bale B2. The conveyor belts 16, 18 of the arms 4 , 24 are inmotion and contact the second bale B2 to cause the bale to move toward the bed 25 and toward the first bale Bl . The loading assembly 15 grasps the secondbale B2 and carries the second bale B2 toward the bed 25 until it contacts the first bale Bl . Once the secondbale B2 contacts the first bale Bl, the conveyor belts 16, 18 of the loading assembly 15 are slowed or even stopped . One or more sets of bed conveyors 35 and conveyor belts 16, 18 of the loading assembly 15 are then actuated to move the first and second bales Bl , B2 partially down the bed 25 toward the second end 27. This process is repeated to load additional bales .

[0039] The sequencing of bales in accordance with embodiments of the present disclosure may be further described with reference to Figure 5 which shows a third bale B3 being loaded after loading of a first bale Bl and a second bale B2. It should be noted that the sequencing described with reference to Figure 5 applies to each bale loaded subsequent to the first bale Bl . After the second bale B2 is lifted andmovedback onto the bed 25 , the loading assembly 15 lifts andmoves the thirdbale B3 toward the bed 25. The thirdbale B3 is allowed to contact the secondbale B2. It shouldbe noted that Figure 5 is drawn, illustrating a small gap between the first bale Bl and the secondbale B2 and between the secondbale B2 and the thirdbale B3, in order to

identify the different bales . However, the bales may be positioned in an abutting condition, where this gap would be minimized or eliminated . [0040] Once the thirdbale B3 contacts the second bale B2 , one or more sets of bed conveyors 35 and first and second conveyors 16, 18 of the loading assembly 15 are then caused to move and bales Bl , B2, B3 travel partially down the bed 25 towards the second end 27 , as a unit . Once the bed conveyors 35 advance, the first and second conveyors 16, 18 of the loading assembly 15 may automatically advance to allow the third bale B3 to retain its position adj acent the previously loaded bale . Once the thirdbale B3 is moved off of the loading device, the bed conveyors may slow or stop so that the end of the third bale B3 is held adj acent the loading assembly 15 , ready to position the next bale B .

[0041] In accordance with embodiments of the present disclosure, the apparatus 5 may include a hydraulic control system for controlling the transfer of bales from the loading assembly to the bed . Among other things , the control system controls transfer by controlling the first conveyor belt 16 and/or the second conveyor belt 18. The control system 65 for the loading assembly 15 and other portions of the hydraulic circuit for operating the loading assembly are shown

schematically in Figure 5. This Figure illustrates one example of a hydraulic circuit, in a simplifiedmanner, using a type of hydraulic circuit known as an open center circuit . It should be noted that the principles of the open center circuit may also be implemented by those of skill in the art in other circuits such as a closed- center load-sensing circuit or closed-loop circuit without limitation. [ 0042 ] The hydraulic circuit includes a pump 72 that pumps hydraulic fluid from a source of hydraulic fluid 79 (whichmay also be referred tohereinas a

"reservoir" ) and that provides hydraulic pressure for operating hydraulic components (e.g., a hydraulic motor ) . The circuit also includes a spool valve 77. The spool valve 77 acts to direct hydraulic fluid back to the reservoir 79 or to one or more of the downstream

hydraulic components . Spool valves may also be referred to in the art as "directional control valves . "

[0043] The reservoir 79, pump 72 and spool valve 77 maybe integrated into the pulling vehicle rather than part of the control systemof the apparatus 5. In such embodiments , the spool valve 77 may include female hydraulic couplers for connecting male couplers (not shown) of the control system 65 of the apparatus 5. In other embodiments , the hydraulic pump 72, spool valve 77 and reservoir 79 are separate and independent from the pulling vehicle .

[0044] The control system 65 of the apparatus 5 includes hydraulic motors 74 for rotating the drive rollers for the conveyor belts 16, 18. When

movement of the conveyor belts 16, 18 is desired, the spool valve 77 is actuated to cause hydraulic fluid to travel to the motors 74. Hydraulic pressure causes the motors 74 to rotate which allows the conveyor belt to move. In this regard, any suitable arrangement of belts and pulleys maybe used to attach the motors 74 to the drive rollers of the conveyor belts 16, 18. [0045] Amotor supply conduit 62 provides fluid communication between the hydraulic motors 74 and the source of hydraulic fluid 79 when the spool valve 77 is open . After hydraulic fluid passes through the motor 74 , it is conveyed back through the spool valve 77 to the source of hydraulic fluid 79 throughmotor return conduit 61.

[0046] The control system 65 also includes a hydraulic relief valve 76. A relief valve supply conduit 64 is in fluid communication with the motor supply conduit 62 and the relief valve 76. The relief valve 76 is configured or programmed to open when the pressure in the control system reaches a pre-set relief pressure . Upon opening, hydraulic fluid passes from the relief valve supply conduit 64 , through the relief valve 76 and to the motor return conduit 61 , by-passing the motors 74. When fluid flows through the relief valve 76, fluid pressure equal to the pre-set relief pressure is maintained in the motor supply conduit 62 and applied to the motors 74. This allows the motors 74 to slow or stop moving while maintaining torque .

[0047] During loading of a bale the hydraulic motor 74 is powered by the hydraulic pressure which causes conveyor belts 16, 18 (Fig.4) to move to cause the bale to move toward the previously loaded bale(s) . The hydraulic pressure in the motor supply conduit 62 during this initial lifting and moving phase has been found to be less than the pre-set relief pressure so the oil flow is forced through the motors . Once the bale being loaded contacts the previously loaded bale ( s ) the pressure in the motor supply conduit 62 and relief valve supply conduit 64 increases . The relief

valve 76 opens once a minimum pressure is achieved which causes the conveyor belts 16, 18 to slow or even stop

rotating . The relief valve 76 prevents the conveyor

belts 16, 18 from continuing to move after the bale being loaded contacts the previously loadedbale . This

prevents the conveyor belts 16, 18 from slipping relative to the bale and therebyprevents damage to the bale .

[0048] If the relief valve 76 was not present in this circuit , the pressure may continue to increase thereby increasing the torque producedby the motor and the force that the conveyor belts apply to the bale until the static friction between the conveyor belt

and bale was exceeded . At that pressure (i.e., P slip) , the belt would begin to slip relative to the bale which would result in damage to the bale . The pre-set relief

pressure of the valve 76 can be set at a pressure that is less than P _s i _lp so that the motors 74 slow or stop and oil by-passes through the relief valve 76 to avoid damaging the bales .

[0049] The hydraulic circuit shown in Figure 5 may include other components or parts including oil

coolers, other relief valves and oil filters . In this

regard, it shouldbe understood that use of the term

"conduit" herein is not meant to imply direct transfer from one unit of the hydraulic circuit to another but

rather includes indirect transfer , e.g., the hydraulic fluidmaybe transferred fromone unit to another by any number of transfer parts and/or mechanisms . Each part including the intermediate parts themselves may be considered to form at leastaportionofthe "conduit" and the phrase "conduit" should not be construed in a limiting sense .

[ 0050 ] The hydraulic control system 65 may be used to control the first conveyor belt 16 and the second conveyor belt 18 as shown . In other embodiments , the second conveyor belt 18 may be controlled by a separate control system (not shown) . The second control systemmay be fluidly connected to the relief valve 76 or may include a separate relief valve . The second control systemmay also share other parts of the first control system (e.g. , one or more conduits ) .

[0051] In embodiments wherein the second control system includes a second relief valve (not shown) for control of the second conveyor belt 18 , each conveyor belt 16, 18 is able to slow or stop independent of the other conveyor belt when loading bales . This allows a bale that is loaded onto the arms 4 , 24 at an angle

(i.e. , when the flat ends 40 (Fig.3) of the bale are not perpendicular to the apparatus 5 ) to be made square with the bales that are previously loaded on the bed 25. In such embodiments, one side of the skewedbale being loaded contacts a previously loadedbale causing the conveyor belt to slow or stop on that side of the

apparatus . The conveyor belt on the opposing side may continue to move until the skewed bale fully contacts the previously loadedbale causing the flat ends 40 to become perpendicular to the apparatus 5. [0052] In this regard, while the control system 65 described above maybe used in connection with an apparatus configured for loading round bales , in other embodiments the apparatus may be configured to gather small square or large square bales , or any packages where it is desirable to position the packages in an abutting condition, while automatically minimizing potential damage that canbe causedby slippage between the package and a conveyor, without limitation.

[0053] As shown in Figure 5 , the apparatus may include one or more separate hydraulic circuits for rotating the bed conveyors . Each bed conveyor hydraulic circuitmay include a source of hydraulic fluid 89, pump 82, spool valve 87 and hydraulic motors 86 for rotating the bed conveyors 35. In this regard, it should be noted that the pump 82 and spool valve 87 may be part of the pulling vehicle and not the gathering apparatus . The bed conveyor hydraulic circuit may also include a hydraulic relief valve similar to relief valve 76 that is

configured to actuate in response to an increase in hydraulic pressure to slow or stop movement of the bed conveyor. In this regard, a control system similar to control system 65 (e.g., a system in including a relief valve 76) maybe used to control bed conveyors 35 through hydraulic motors 86. Such a control systemmay be useful during unloading of bales ( from the front or back) as bales may be pushed off the bed conveyors 35 without the conveyors 35 slipping beneath partially unloaded bales .

[ 0054 ] The bed conveyors 35 may operate once the bale being loaded contacts the previously loaded bale to cause the bales to move in the direction of the second end 27 of the bed.

[ 0055 ] Bales may continue to be loaded onto the apparatus 5 until the apparatus becomes fully loaded. Once fully loaded, the apparatus 5 maybe adjusted to promote ease of travel to the unloading site . As shown in Figure 6, the bed chassis 6 of the apparatus 5 maybe leveled by use of hydraulic cylinder 17 (Fig.2) and the tongue 1 and the relative position between tongue 1 and the bed 15 may be adjusted (e.g., the tongue may be adjusted to be more parallel to the bed) .

[0056] As shown in Figure 7 , once the apparatus 5 is pulled to the desired unloading site for the bales , the bed chassis 6 is tilted by use of the hydraulic cylinder 17 (Fig.2) . The bed conveyors 35 are operated and the apparatus 5 is caused to move forward while the bales are unloaded . Alternatively, the apparatus 5 maybe caused to move backwards such that bales are unloaded from the loading assembly 15. In embodiments in which bales are unloaded in this manner, the bales maybe unloaded such that each successive bale touches the previously unloaded bale (i.e., the conveyors 16, 18 may travel faster than ground speed) without slipping the conveyor belts 16, 18 and damaging the bales by use of a relief valve .

[ 0057 ] Compared to conventional apparatus for gathering bales , the apparatus 5 described above has several advantages . By using one or more relief valves 76 (Fig.5) the first and conveyor belts 16, 18 may slow or stop rotating upon contact between the bale being loaded and previously loadedbales . This prevents the conveyor belts from slipping relative to the bale being loaded and thereby inhibits or prevents damage to the bale . In embodiments wherein the hydraulics for each conveyor belt 16, 18 include separate relief valves 76, the orientation of a bale that has started to be loaded in a skewed orientation (relative to the apparatus and other bales ) maybe corrected so that the orientation is aligned with the apparatus and the other bales .

[ 0058 ] When introducing elements of the present disclosure or the embodiment (s ) thereof, the articles "a", "an", "the " and "said" are intended to mean that there are one or more of the elements . The terms "comprising, " "including, " "containing" and "having" are intended to be inclusive and mean that there may be additional elements other than the listed elements . The use of terms indicating a particular orientation (e.g. , "top", "bottom", "side", etc.) is for convenience of description and does not require any particular

orientation of the item described .

[0059] As various changes couldbemade in the above constructions andmethods without departing from the scope of the disclosure , it is intended that all matter contained in the above description and shown in the accompanying drawing [ s ] shall be interpreted as illustrative and not in a limiting sense .