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Title:
APPARATUS AND METHODS FOR IN-LINE BALE WRAPPING AND FOR PERFORATING THE WRAP MATERIAL
Document Type and Number:
WIPO Patent Application WO/2019/118380
Kind Code:
A1
Abstract:
Methods and apparatus for wrapping bales and perforating the wrap in which the bales are enveloped are disclosed. The apparatus and methods may involve in-line processing of bales. The apparatus may include a wrapping device and a perforating device which perforates the wrap. The perforations may be provided in a longitudinal row or in a circumferential row that at least partially surrounds the bale. In some embodiments, the perforating device is configured to perforate the wrap in only an upper portion of the bales.

Inventors:
CORE MARK (US)
MUNK JESSE T (US)
Application Number:
PCT/US2018/064816
Publication Date:
June 20, 2019
Filing Date:
December 11, 2018
Export Citation:
Click for automatic bibliography generation   Help
Assignee:
VERMEER MFG CO (US)
International Classes:
A01F15/07; A01F15/14; A01F25/14; B65B11/00; B65B11/02; B65B27/12
Domestic Patent References:
WO2017200976A12017-11-23
Foreign References:
US5423161A1995-06-13
US5433058A1995-07-18
US5596864A1997-01-28
US20160029563A12016-02-04
US6070400A2000-06-06
US5661956A1997-09-02
Attorney, Agent or Firm:
VANDER MOLEN, Michael J. et al. (US)
Download PDF:
Claims:
WHAT IS CLAIMED IS:

1. An apparatus for wrapping bales of forage or crop material in a film comprising: a wrapping device for wrapping bales in tube wrap material; a conveying system for moving a bale and/or the wrapping device to envelop a bale in a film of the tube wrap material; and a perforating device for perforating the film.

2. The apparatus as set forth in claim 1 wherein the perforating device is configured to perforate the film in only a topmost 300° of round bales wrapped by the apparatus .

3. The apparatus as set forth in claim 1 wherein the apparatus is configured to wrap a plurality of bales in a single tube of material.

4. The apparatus as set forth in claim 3 wherein the conveying system is sized to support a first round bale while a second round bale is driven through the wrapping device .

5. The apparatus as set forth in claim 1 wherein the perforating device is configured to form perforations in at least one row in the film, the row being generally parallel to a longitudinal axis of the bale.

6. The apparatus as set forth in claim 1 wherein the perforating device is configured to form perforations in at least three rows in the film, the rows being generally parallel to a longitudinal axis of the bale.

7. The apparatus as set forth in claim 1 wherein the perforating device is configured to form perforations in a circumferential row that at least partially surrounds the bale.

8. The apparatus as set forth in claim 7 wherein the apparatus is configured to wrap a plurality of bales, each bale having two flat ends with a flat end of one bale being in contact with a flat end of another bale during wrapping, the perforating device being configured to form the circumferential row of

perforations where the flat end of one bale is in contact with a flat end of another bale.

9. The apparatus as set forth in claim 1 wherein the apparatus does not include a baling device for forming forage or crop material into bales.

10. The apparatus as set forth in claim 1 wherein the conveying system comprises a ram to contact bales to move the bales and/or the wrapping device .

11. The apparatus as set forth in claim 1 wherein the conveying system comprises a conveyor belt to move bales and/or the wrapping device.

12. The apparatus as set forth in claim 1 further comprising a roll of tube wrap material, the tube wrap material being non-permeable to water vapor before being perforated by the perforating device.

13. A method for wrapping bales of forage or crop material in a film on an apparatus comprising: wrapping a plurality of bales in a film on the apparatus ; perforating the film of the wrapped bales to form a plurality of perforations in the film; and discharging the wrapped bales from the apparatus and onto a surface.

14. The method as set forth in claim 13 wherein the bales are round bales each having a

longitudinal axis and comprising a cylindrical surface and two flat ends, the perforations being made in the film in only a topmost 300° of the cylindrical surface of each bale.

15. The method as set forth in claim 13 wherein the film is perforated in only an upper half of the bales .

16. The method as set forth in claim 13 further comprising loading the bales onto a wrapping apparatus, wherein the plurality of bales are wrapped in a film and the film is perforated when positioned on the wrapping apparatus.

17. The method as set forth in claim 13 wherein the film is non-permeable to water vapor before being perforated.

18. The method as set forth in claim 13 wherein the perforations are provided in a row, the row being generally parallel to a longitudinal axis of the bale .

19. The method as set forth in claim 13 wherein the perforations are provided in a

circumferential row, the circumferential row at least partially surrounding the bale.

20. A method for wrapping bales of forage or crop material in a film comprising: loading a bale on a wrapping apparatus, the wrapping apparatus comprising a wrapping device and a perforating device; driving the bale through the wrapping device to wrap the bale in a film; and operating the perforating device to form a plurality of perforations in the film.

21. The method as set forth in claim 20 wherein the bale is a round bale having a longitudinal axis and comprising a cylindrical surface and two flat ends, the perforations being made in the film in only a topmost 300° of the cylindrical surface of each bale.

22. The method as set forth in claim 20 comprising loading a plurality of bales on the wrapping apparatus, the plurality of bales being driven through the wrapping device to wrap the bales in a single tube of film, the perforating device forming a plurality of perforations in the tube of film.

23. The method as set forth in claim 20 wherein the plurality of perforations are provided in a circumferential row that partially surrounds the bales.

24. The method as set forth in claim 20 wherein the film is non-permeable to water vapor before being perforated.

25. The method as set forth in claim 20 wherein the wrapping apparatus does not include a baling device for forming forage or crop material into bales.

26. A wrapped tube of crop or forage material comprising : a stack of at least two round bales, each round bale having first and second flat ends and a cylindrical surface that extends from the first flat end to the second flat end, the bales being stacked such that a flat end of one bale is in contact with a flat end of another bale, the stack having a longitudinal axis; and a film that envelopes the at least two round bales, the film having at least one row of perforations.

27. The wrapped tube of crop or forage material as set forth in claim 26 wherein the row is generally parallel to the longitudinal axis of the stack.

28. The wrapped tube of crop or forage material as set forth in claim 26 wherein the row is a circumferential row that at least partially surrounds the bale .

29. The wrapped tube of crop or forage material as set forth in claim 26 wherein the perforations have a nominal size of at least about 0.1 mm .

30. The wrapped tube of crop or forage material as set forth in claim 26 wherein the film has at least three rows of perforations that are parallel to the longitudinal axis of the stack.

Description:
APPARATUS AND METHODS FOR IN-LINE

BALE WRAPPING AND FOR PERFORATING THE WRAP MATERIAL

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 62/598,886, filed December 14, 2017, which is incorporated herein by reference in its entirety.

FIELD OF THE DISCLOSURE

[0002] The present disclosure relates to apparatus and methods for wrapping bales and for

perforating the wrap in which the bales are enveloped and, in particular, apparatus and methods that involve in-line processing of bales.

BACKGROUND

[0003] Crop and forage material may be wrapped in a film to isolate the bale from rain and moisture. In some instances (e.g., when the baled material is relatively high in moisture) the wrapped crop or forage material will spoil and the bale material cannot be used for animal feed. The wrap material may be relatively impermeable to water vapor which causes water vapor to remain in the bale and to cause it to spoil. [0004] Individual bales may be wrapped or a line or "module" of bales stacked end to end may be wrapped (e.g., two, three, four or even more bales wrapped together as a sealed unit) . Such modules allow a small number of bales to be stored and later opened for livestock feeding without exposing a large number of bales to the ambient .

[0005] A need exists for apparatus and methods for wrapping bales (e.g., a module of bales) that allow the film in which the bales are wrapped to be perforated and, as in some embodiments, to be selectively perforated in an upper portion of the bales to allow moisture to escape from the bales while inhibiting moisture from the ground from entering the bales.

[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 wrapping bales of forage or crop material in a film. The apparatus includes a wrapping device for wrapping bales in tube wrap material. The apparatus also includes a conveying system for moving a bale and/or the wrapping device to envelop a bale in a film of the tube wrap material. The apparatus includes a perforating device for perforating the film.

[0008] Another aspect of the present disclosure is directed to a method for wrapping bales of forage or crop material in a film on an apparatus. A plurality of bales are wrapped in a film on the

apparatus. The film of the wrapped bales is perforated to form a plurality of perforations in the film. The wrapped bales are discharged from the apparatus and onto a surface.

[0009] A further aspect of the present disclosure is directed to a method for wrapping bales of forage or crop material in a film. A bale is loaded on a wrapping apparatus. The wrapping apparatus includes a wrapping device and a perforating device. The bale is driven through the wrapping device to wrap the bale in a film. The perforating device is operated to form a plurality of perforations in the film.

[0010] Yet another aspect of the present disclosure is directed to a wrapped tube of crop or forage material. The wrapped tube includes a stack of at least two round bales. Each round bale has first and second flat ends and a cylindrical surface that extends from the first flat end to the second flat end. The bales are stacked such that a flat end of one bale is in contact with a flat end of another bale. The stack has a longitudinal axis. A film envelopes the at least two round bales. The film has at least one row of

perforations . [0011] 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 may be incorporated into any of the above-described aspects of the present disclosure, alone or in any combination.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 is a perspective view of an apparatus for wrapping bales and for perforating the film in which the bales are wrapped;

[0013] Figure 2 is another perspective view of the apparatus;

[0014] Figure 3 is a side view of the apparatus ;

[0015] Figure 4 is a side view of a round bale ;

[0016] Figure 5 is a perspective view of a perforating wheel of the apparatus;

[0017] Figure 6 is a perspective view of another embodiment of an apparatus for wrapping bales and for perforating the film in which the perforating device includes spears; [0018] Figure 7 is a perspective view of a module of wrapped bales that include rows of perforations in the film in which the bales are wrapped;

[0019] Figures 8A-8G illustrate various perforation patterns;

[0020] Figure 9 is a perspective view of another embodiment of an apparatus for wrapping bales and for perforating the film in which the perforating device includes a perforating wheel to form a circumferential row of perforations;

[0021] Figure 10 is a perspective view of another embodiment of an apparatus for wrapping bales and for perforating the film in which the perforating device includes a knife to form a circumferential row of perforations ;

[0022] Figure 11 is a perspective view of another embodiment of an apparatus for wrapping bales and for perforating the film in which longitudinal and circumferential rows of perforations are formed by perforating wheels;

[0023] Figure 12 is a perspective view of another embodiment of an apparatus for wrapping bales and for perforating the film in which longitudinal and circumferential rows of perforations are formed with the circumferential perforations being formed by a knife;

[0024] Figure 13 is a side view of an embodiment of the apparatus showing several sensors; and [0025] Figure 14 is a schematic of a control system for controlling the perforating device.

[0026] Corresponding reference characters indicate corresponding parts throughout the drawings.

DETAILED DESCRIPTION

[0027] An apparatus 1 for wrapping bales of forage material or crop material is shown in Figure 1.

The apparatus 1 is an "in-line" wrapping apparatus in which one or more bales are processed and moved through the apparatus to sequentially wrap the bales. The apparatus 1 includes a wrapping device 7 that wraps one or more bales in wrap material 8 to envelope the bale in a film 15 of the wrap material 8.

[0028] In the embodiments illustrated in Figures 1-3 and 9-12, the wrapping device 7 is configured to rotate one or more strips of tube wrap material 8 around the bales with the strips overlapping to form a continuous film 15. In the embodiment illustrated in Figure 6, the wrapping device 107 is a stretching device that stretches a tube of the material to allow the bales to enter the tube. Generally any wrapping device which wraps bales in a film may be used unless stated

otherwise .

[0029] Generally, the bales that are wrapped in wrap material 8 by the apparatus 1 (Fig. 1) or apparatus 101 (Fig. 6) were previously baled by a baling apparatus. The bales may be tied by net -wrap, twine or other suitable wrapping material (e.g., wrapping material that is not weather resistant) before being wrapped by baling apparatus 1, 101.

[0030] The wrapping device 7 of the embodiments illustrated in Figures 1-3 and 9-12 include a pre-stretcher 21 which stretches the wrap material to allow it to tightly encase the bale. The pre-stretcher 21 holds a roll 10 of tube wrap material. The pre stretcher 21 is caused to rotate around a hoop assembly 27. The hoop assembly 27 includes a hoop 30 that rotates about a supporting frame 37. A hoop drive wheel within a wheel housing 65 is rotated by a motor (e.g., hydraulic motor) . The drive wheel contacts the hoop 30 causing the hoop 30 to rotate about the supporting frame 37 as the drive wheel rotates.

[0031] As the pre-stretcher 21 rotates around the hoop assembly 27, the wrap material unfurls from the roll 10 and wraps around the bale. The

illustrated apparatus includes three pre-stretchers which each unfurls a roll of wrapping material. In other embodiments, a single pre-stretcher, two pre-stretchers, or more than three pre-stretchers may be used.

[0032] The wrapping material may be a polymer material. The material may be adapted to be stretched and/or to shrink to the contour of the bale after stretching and placement of the film on the bale.

In some embodiments, the wrapping material (i.e., film) is non-permeable to water vapor (or semi -permeable ) and, generally, only passes moisture through the formed openings in the wrapping material. Generally, the wrapping material is not pre-perforated (i.e., perforated with slits or other openings) and is non-permeable prior to placement onto the bale. Generally the wrap material 8 is not part of the apparatus 1 unless stated otherwise.

[0033] The apparatus 1 has a loading end 29 and a discharge end 31 and a longitudinal axis A that extends through the loading end 29 and the discharge end 31. The apparatus 1 includes a chassis 34 that supports the wrapping device 7 and other components of the apparatus 1. The apparatus 1 includes a tongue 36 for pulling the apparatus 1 by, for example, a tractor, truck or other tow vehicle. In other embodiments, the

apparatus 1 includes its own propulsion mechanism rather than being pulled by a tow vehicle. The apparatus 1 includes wheels 38. Tracks (not shown) may be used as an alternative to the wheels 38.

[0034] The apparatus 1 includes a conveying system 33 toward the loading end 29 of the apparatus 1 for moving the bale and/or the wrapping device 7 to encase the bale in a film of the tube wrap material. Any conveyance mechanism (e.g., single belt, chain drive, powered or unpowered rollers, etc.) that facilitates movement of the bales toward the discharge end 31 of the apparatus 1 may be used unless stated otherwise.

[0035] In the embodiment illustrated in Figures 1-3, the conveying system 33 pushes the first several bales through the wrapping device 7 by moving a push gate or "ram" 39 toward the wrapping device 7 (i.e., the conveying system 33 moves the bales themselves) . Once several bales are wrapped and the tube of wrapped bales begins to contact the ground, the wrapped bales are generally stationary as further bales are wrapped. In this case after a bale loaded on the apparatus 1 has been moved forward by the conveying system 33 to contact the stack of previously wrapped bales, the conveying system 33 causes the apparatus 1 to move relative to the stationary bales (i.e., the conveying system 33 propels the apparatus forward by pushing against the tube of bales at least partially resting on the ground) .

[0036] To wrap one or more bales in the film, a bale is loaded on an alignment platform 35 of the conveying system 33 (e.g., by use of a skid steer or tractor) . The alignment platform 35 is curved to center the bale to allow the bale to be properly aligned as it enters the wrapping device 7.

[0037] The ram 39 is caused to move toward the wrapping device 7 to contact and push the bale toward the discharge end 31 of the apparatus 1. The ram 39 may be driven by cylinders (e.g., hydraulic cylinders) connected to each side of the ram 39. The ram 39 contacts the bale and causes the bale or the wrapping device to move (depending on whether one or more bales have been previously wrapped and are in contact with the ground) such that the bale approaches the wrapping device 7. The bale is at least partially pushed through the hoop assembly 27 of the wrapping device 7. The ram 39 may be retracted and a second bale may be set on the alignment platform 35. The ram 39 contacts the second bale which is caused to push against the first bale and move the first bale or move the apparatus 1 to cause the first bale to fully extend through the wrapping device 7 and be wrapped .

[0038] Additional bales may be placed on the apparatus 1 for additional wrapping cycles and to increase the length of the tube of wrapped bales (e.g.,

1, 2, 3, 5, 10, 20 or more bales may be wrapped in a single tube of film) . For example, Figures 1-3 show three bales Bl, B2 , B3 being wrapped. A discharge ramp 40 may be tilted downward (e.g., by actuation of one or more hydraulic cylinders) to allow bales to contact the ground as additional bales are wrapped and wrapped bales begin to be discharged from the apparatus 1.

[0039] Once the last bale to be wrapped is placed on the alignment platform 35, the ram 39 is actuated to push the bale toward the wrapping device 7.

In this position, the last bale may not fully extend through the wrapping device 7. After the ram 39 is retracted, a foldable arm (not shown) may be extended from the ram 39 toward the bale. The arm extends the reach of the ram 39 to cause the bale to be fully pushed through the wrapping device 7 upon further actuation of the ram 39. Once the last bale is wrapped, the wrap material may be cut and/or sealed to cause the bales to be enveloped in a single tube of wrap material. The apparatus 1 may be propelled forward (e.g., by a tow vehicle) to cause the portion of the tube of bales resting on the apparatus 1 to travel over the discharge rollers 41 and to move off the apparatus 1 to place the entire tube on the ground.

[0040] The apparatus 1 includes a perforating device 45 for perforating the wrapping material after it has been dispensed from the roll 10 on the wrapping device 7. In some embodiments, the

perforating device 45 is configured to perforate the film in an upper (i.e., topmost) portion of the wrapped bale(s) such that the portion of the film which contacts the ground after discharging the wrapped bales is not perforated. With reference to Figure 4, in some

embodiments, the film is perforated in only a topmost 300° arc of the bale (i.e., the wrap does not contain perforations in the bottom 60° of the bale) . In other embodiments, the perforating device 45 is configured to form perforations in only the upper half of the bale or the top third of the bale (i.e., topmost 120° arc for round bales) or even only the top quarter (i.e., topmost 90° arc) .

[0041] Referring now to Figure 5, the perforating device 45 includes one or more perforating wheels 55 having teeth 59. The perforating wheels 55 rotate about an axle 63. The axle 63 is connected to a leg 67 that is pivotally connected to a frame 69. The frame 69 extends around the bales and is connected to the chassis 34 (Fig. 3) . A biasing device or actuator 75 (e.g., hydraulic cylinder as shown or a spring or shock absorber) is connected to the frame 69 and to the leg 67. The actuator 75 (and the weight of the wheel) bias the perforating wheel 55 against the film in which the bales are wrapped. The wheel 55 applies a downward force against the film 15. This force overcomes a puncture resistance of the film 15 causing the teeth 59 to puncture the film and form perforations 77 in the film 15 as the bale moves. Movement of the bale causes the wheel 55 to rotate (indicated by the arrow in Figure 5) and to form a row 79 (Fig. 3) of perforations 77 along the cylindrical surfaces of the bales that are parallel to the longitudinal axis A (Fig. 1) of the apparatus 1 when viewed from above. The perforating wheel 55 rotates in a direction generally parallel to the longitudinal axis A of the apparatus 1 and the bales to form a longitudinal row 79 of perforations parallel to the longitudinal axis A (Fig. 1) as viewed from above. The term "row" as used herein should not imply a particular orientation of perforations as a circumferential row of perforations may also be formed as described further below.

[0042] In embodiments in which the actuator 75 is a hydraulic cylinder, the cylinder may be part of a hydraulic system that includes an accumulator (not shown) in fluid communication with the cylinder to accommodate changes in the contour of the bales during perforation of the wrap 15. The hydraulic system may include one or more control devices that enable the wheel to be lifted when perforations are not desired and to be lowered to a perforating position to perforate the wrap.

[0043] In the illustrated embodiment, the perforating device 45 includes 6 perforating wheels 55 which form six longitudinal rows 79 of perforations. In other embodiments, the device 45 may form one, two, three, four, five or seven rows or more of perforations (e.g., 1 to 20 rows or 1 to 10 rows) . Alternatively, the perforating device 45 may form perforations that are not arranged in rows .

[0044] The perforating device 45 is an example perforating device and generally any device which is capable of perforating the film of wrapped bales may be used unless stated otherwise. The shape of the perforations 77 generally corresponds to the shape of the projections used to form the perforations (e.g., the profile of the teeth 59 of the perforating wheel 55 in the apparatus of Figures 1-3) .

[0045] Generally, the perforations 77 may have any shape such as, for example, ovals, circles, slits, cross-slits or the like. In some embodiments the perforations have a nominal size of at least about 0.1 mm, at least about 0.5 mm or at least about 1 mm (e.g., from about 0.1 mm to about 50 mm or from about 0.5 mm to about 25 mm) .

[0046] The perforations 77 may include a flap of film that remains after the film is punctured.

The flap may cover a portion of the perforation in a non sealing manner or may hang down leaving the perforations open. Such flaps may be produced by forming non- symmetrical slits (e.g., shaped slits) in the wrap. For example, the perforations may include U- or crescent - shaped slits (Fig. 8A) or V-shaped slits (Fig. 8B) which allow the flap to partially cover the perforation.

Alternatively, U-shaped slits (Fig. 8F) or V-shaped slits (Fig. 8D) that allow the flap to hang down to leave the perforation open may be used. Other shapes of slits include straight slits (Fig. 8C) , orthogonal cross-slits (Fig. 8F) , and non-orthogonal cross-slits (i.e., the x- shaped slits shown in Figure 8G) .

[0047] After the bales are perforated and as additional bales are wrapped, the perforated bales travel down the discharge ramp 40 (Fig. 3) and are discharged to the ground (typically the ramp 40 is tilted down from the position shown in Figure 3) . Because the perforating wheels 55 may be configured to perforate the film 15 in an upper portion of the bales and the wrapped bales are not rotated while being discharged, the bales may be positioned on the ground with the perforations being selectively disposed in the upper portion of the bales.

[0048] Another embodiment of an apparatus 101 for wrapping forage or crop material and for

perforating the film 15 is shown in Figure 6. The components shown in Figure 6 that are analogous to those of Figures 1-3 are designated by the corresponding reference number of Figures 1-3 plus "100" (e.g., part "36" becomes "136") . The wrapped bales processed by the apparatus 101 may be any suitable shape including round, large square bales, or small square bales.

[0049] In the illustrated embodiment, the apparatus 101 is configured to provide perforations in the film in a topmost 300° arc of the wrapped bales (e.g., top two-thirds, top half, top third or even top quarter) . The apparatus 101 is adapted for wrapping a line of bales (e.g., by sequentially operating the conveyor belts 132 to pick up bales in the field, by wrapping a pre-arranged line of bales, or by wrapping a series of bales introduced into the apparatus by a bale handler such as a tractor or skid steer) .

[0050] The apparatus 101 includes a wrapping device 107 for encasing the bales in a wrap. The wrapping device 107 stretches a tube of wrapping material while bales Bl, B2 are pushed through the tube. As the bales Bl, B2 are pushed through the tube of material, the wrap recedes to the contour of the bales and encases the bales in the wrap. After the bales (e.g., 2, 3, 4, 5, 6 or more bales) are pushed through the wrapper, the wrap material may be cut and sealed forming a tube of wrapped bales. The apparatus 101 includes a conveying system 133 for moving bales that includes a loading assembly 104, bed assembly 108, and discharge assembly 120 each having conveyors belts 132 for moving the bales. Other

arrangements for receiving and pushing bales through a wrapping device 107 may be used without limitation unless stated otherwise.

[0051] The apparatus 101 includes a perforating device 145 for perforating the wrap material as the bales are wrapped. The perforating device 145 includes a plurality of spears 112 that are driven through the wrap by actuator 113 (shown as a hydraulic or pneumatic cylinder) to create rows 79 of perforations 77 in the wrap material.

[0052] In some embodiments the perforating device 145 is actuated periodically, such as by

performing a perforation cycle after the conveying system moves the line of wrapped bales a predetermined distance. In the example shown in Figure 6, the predetermined distance is illustrated to be approximately eight inches. The predetermined distance could be varied depending on crop and climate conditions.

[0053] In some embodiments, the

predetermined distance could be about the length of a bale. For example, the apparatus may be configured to form perforations where the flat ends of the bales (e.g., the plane where bales meet which is shown as a line between bales Bl, B2 in Figure 6) . Operation of the actuator 113 and the conveying system 133 may be

coordinated to form perforations at the desired location (e.g., where bales meet) . For example, the perforating device 145 of the embodiment of Figure 6 may be used with a push gate or ram 39 of the embodiment illustrated in Figure 1. The spears 112 may be located at the end of the stroke of the ram 39 (and in some embodiments adjusted to this position) to allow the spears to perforate at or near where two adjacent bales are in contact. In some embodiments and as further described below, a sensor (not shown) is used to determine the perforation location, such as the contact point between wrapped bales. The sensor could follow bale contour or monitor bale density to control operation of the

perforation device 145.

[0054] After wrapping the module of bales on the apparatus 1, 101, the wrap material may be cut and sealed .

[0055] Another embodiment of an apparatus 1 for wrapping bales is shown in Figure 9. The apparatus 1 includes a perforating device 45 that is configured to form perforations 77 in a circumferential row 79 that at least partially surrounds the bale. In the illustrated embodiment, the perforating device 45 includes a

perforating wheel 55 that rotates in a direction

perpendicular to the longitudinal axis A (Fig. 1) of the apparatus and of the bales (i.e., the wheel 55 has a rotational axis generally aligned with the longitudinal axis A of the apparatus and bales when viewed from above) .

[0056] The wheel 55 is connected to the hoop assembly 27 such that the wheel 55 rotates about the bale while perforating the film 15. In the illustrated embodiment, the wheel 55 is connected to the pre stretcher 21 which is caused to rotate about the hoop assembly 27.

[0057] The perforating device 45 may be configured such that the circumferential row 79 of perforations 77 only partially surrounds the bale. In some embodiments, the row 79 does not extend below the topmost 300° (Fig. 4) of the bale (i.e., the row is in only the topmost 300°) . In other embodiments, the row 79 in only in the upper half of the bale, topmost 120° or topmost 90°. The perforating device 45 may be configured to partially perforate the circumference of the bale by lifting the wheel 55 from the wrap 15 (e.g., by operation of an actuator or other mechanism to separate the wheel 55 from the bale film 15) .

[0058] The apparatus 1 may be configured such that the perforating device 45 forms perforations where two bales meet. In some embodiments, the

perforating device forms a circumferential row 79 of perforations 77 that fully surrounds the bale. Such a full circumferential row of perforations may be used to allow individual bales to be torn away from the stack of bales (i.e., the perforations act to form a weakened region in the wrap in which a bale may be picked up (e.g., by a tractor or skid steer) and pulled from the stack of bales to cause the wrap to tear at the site of perforations) .

[0059] Another embodiment of an apparatus 1 for wrapping bales and perforating bales is shown in Figure 10. The apparatus 1 functions similar to the apparatus 1 illustrated in Figure 9. The perforating device 45 of the apparatus 1 of Figure 10 includes a knife 60 to form perforations 77 (e.g., slits as shown) in a circumferential row 79 that at least partially surround the bale. The knife 60 rotates around the bale to form the row 79 of perforations 77. In the illustrated embodiment, the knife 60 is connected to the pre

stretcher 12 which is caused to rotate about the hoop assembly 27. In some embodiments, the circumferential row 79 does not extend beyond the topmost 300° (Fig. 4) of the bale (i.e., the row is in only in the topmost 300°), or as in other embodiments, the upper half, topmost 120° or topmost 90° of the bale. In other embodiments, the circumferential row 79 extends around the entire circumference of the bale (e.g., so as to form a weakened region in the film 15 in which individual bales may be torn from the stack of bales) .

[0060] In some embodiments and as shown in Figures 11 and 12, the apparatus 1 includes perforating devices which form both a circumferential row of

perforations (such as perforations in the film positioned at or near where the flat ends of bales meet) and longitudinal rows of perforations parallel to the longitudinal axis of the apparatus as viewed from above the apparatus 1. For example, the apparatus 1 includes a first perforating device 45A configured to form one or more longitudinal rows 79A of perforations 77A and a second perforating device 45B configured to form a circumferential row 79B of perforations 77B. The first perforating device 45A includes perforating wheels 55A that rotate parallel to the longitudinal axis A of the apparatus 1 when viewed from above. In the embodiment illustrated in Figure 11, the second perforating device 45B includes a perforating wheel 55B that rotates perpendicular to the longitudinal axis A of the apparatus 1. In the embodiment illustrated in Figure 12, the second perforating device 45B includes a knife 60.

[0061] In some embodiments, the apparatus includes a control unit 50 (Fig. 14) to control the locations of perforations in the wrapped bale(s) . The control unit 50 is communicatively coupled to an actuator 13 that may be operated to causes the perforating device 45 to begin/cease perforating the wrap. The actuator 13 may be electrically powered or may be hydraulic (e.g., hydraulic cylinder as shown in Figure 5) .

[0062] The perforating device 45 may be controlled to form perforations at select locations of the bale wrapper film (e.g., at or near where two bales meet when circumferential rows of perforations are formed) . In some embodiments, the circumferential position of perforations may be controlled by the control unit 50. For example, the control unit may cause the perforating device 45 to selectively form perforations in a lower portion of bale (e.g., 3:00 to 9:00 position to allow the upper portion to protect from precipitation) , an upper portion of the bale (e.g., 2:00 to 5:00 and 7:00 to 10:00 positions to allow the wrap to cover a portion of the bottom and provide a cover from precipitation) , or to form perforations that surround the bale.

[0063] User input may include, for example, perforation spacing (i.e., spacing between perforations within a row), perforation location (e.g., a row of perforations where bales meet or staggering of locations within a row) , perforation shape and/or known bale length . [0064] The apparatus 1 may include various sensors that sense the position of bales (e.g., the position of the end of a bale relative to the chassis 34), position of the perforating device 45, and the like. For example, the apparatus 1 may include a ram position sensor 89 (Fig. 13) that detects the position of the ram 39 (Fig. 1) relative to the chassis 34 (or the positon of a cylinder that acts to move the ram) . In the

illustrated embodiment, the ram position sensor 89 is an encoder having a base fastened to the chassis 34 and an encoder shaft that that records movement of the position of the ram 39.

[0065] The apparatus 1 may include a ram force sensor 85, shown a as a pressure transducer, that measures the force that resists movement of the ram 39 and/or a cylinder that moves the ram 39. Bale end position may be detected by monitoring both the ram position by the ram position sensor 89 and the ram force by ram force sensor 85. For example, the ram force sensor 85 may sense an increase in force when the ram 39 contacts the next bale loaded on the apparatus and may sense a further increase in force when this bale contacts a line of bales. The position of the ram 39 when these changes in force occur may be measured by the position sensor 89 to determine bale length. Alternatively, ram force sensor 85 may measure hydraulic pressure such as the pressure in valve block 86.

[0066] The apparatus 1 may include a wheel rotation sensor 84 (Fig. 14) that measures rotation of the wheels 38 and movement of the apparatus 1. The wheel rotation sensor 84 may sense movement of the apparatus 1 once the bales contact the ground and the apparatus 1 moves relative to the module of bales during wrapping.

The wheel rotation sensor 84 may indicate when the bale loaded on the apparatus 1 has contacted the module of bales. Once movement is sensed, ram position sensor 89 may sense the position of the ram to determine the length of the bale.

[0067] The apparatus 1 may include a wrapped bale movement sensor 83 to sense the position of the bales. The wrapped bale movement sensor 83 may sense movement of the wrapped bales relative the chassis 34 of the apparatus 1. The wrapped bale movement sensor 83 may be a pulse pickup sensor that senses movement of a roller over which the bale travels .

[0068] The apparatus 1 may include a wrap deflection sensor 81 that senses where adjacent bales meet. The wrap deflection sensor 81 may include a spring loaded arm with a rotary potentiometer attached to a pivot. A bearing on the end of the arm follows the outside of the bale with a depression indicating the ends of adjacent bales. The wrap bale sensor 83 and wrap deflection sensor 81 may be used in conjunction to determine the length of the bale and/or bale end

position .

[0069] In some embodiments, the

circumferential position of the perforating device 55 may be set by the control unit 50 to form perforations at select circumferential positions about the bale. The circumferential position of the perforating device 55 may be determined by a perforation device position sensor 87 which is shown as an encoder 87 that measures rotational movement and location of the perforating device 45 (e.g., by measuring the position of the pre-stretcher 21) .

Alternatively, the sensor 87 may be a pulse pickup device that includes a transducer capable of measuring the rotation of the sensor shaft with there being a known correlation between the rotation of the shaft and the rotational movement of the perforating device 55 around the hoop assembly 27.

[0070] The apparatus 1 may include any combination of these sensors to adjust the perforating device 45 and to form perforations at select locations in the wrap. As shown in Figure 14, the control unit 50 receives signals from one or more of the sensors and adjusts the perforating device 45 at least in part on the output of any one of sensors and/or by user input 80.

The control unit 50 produces an output signal transmitted to the perforating device 45 (e.g., an actuator thereof) .

[0071] The control unit 50 includes a processor and a memory. The processor processes the signals received from various sensors, selectors and control devices of the system. The memory stores instructions that are executed by the processor.

[0072] Control unit 50 may be a computer system. Computer systems, as described herein, refer to any known computing device and computer system. As described herein, all such computer systems include a processor and a memory. However, any processor in a computer system referred to herein may also refer to one or more processors wherein the processor may be in one computing device or a plurality of computing devices acting in parallel. Additionally, any memory in a computer device referred to herein may also refer to one or more memories wherein the memories may be in one computing device or a plurality of computing devices acting in parallel.

[0073] The term processor, as used herein, refers to central processing units, microprocessors, microcontrollers, reduced instruction set circuits

(RISC) , application specific integrated circuits (ASIC) , logic circuits, and any other circuit or processor capable of executing the functions described herein. The above are examples only, and are thus not intended to limit in any way the definition and/or meaning of the term "processor."

[0074] In one embodiment, a computer program is provided to enable control unit 50, and this program is embodied on a computer readable medium. In an example embodiment, the computer system is executed on a single computer system, without requiring a connection to a server computer. In a further embodiment, the computer system is run in a Windows ® environment (Windows is a registered trademark of Microsoft Corporation, Redmond, Washington) . In yet another embodiment, the computer system is run on a mainframe environment and a UNIX ® server environment (UNIX is a registered trademark of X/Open Company Limited located in Reading, Berkshire, United Kingdom) . Alternatively, the computer system is run in any suitable operating system environment. The computer program is flexible and designed to run in various different environments without compromising any major functionality. In some embodiments, the computer system includes multiple components distributed among a plurality of computing devices. One or more components may be in the form of computer-executable instructions embodied in a computer-readable medium.

[0075] The computer systems and processes are not limited to the specific embodiments described herein. In addition, components of each computer system and each process can be practiced independent and separate from other components and processes described herein. Each component and process also can be used in combination with other assembly packages and processes.

[0076] Both the wrapping apparatus 1 of Figures 1-3 and 9-12 and the wrapping apparatus 101 of Figure 6 are generally configured to wrap bales into a stack and perforate the film in which the bales are enveloped. With reference now to Figure 7, in some embodiments the apparatus 1, 101 provides a stack or "module" 190 of at least two round bales (Bl, B2 , B3 . .

. ) with flat ends 193 of the bales being in contact with a flat ends 193 of an adjacent bale. The stack 190 is encased in a film 15. The film 15 includes at least one row 76 of perforations 77 (e.g., 1, 2, 3, 4, 5, 6 or more rows of perforations 77) that are generally parallel to the longitudinal axis A of the stack 190. The film 15 includes perforations in only the top 300° of the bales. In other embodiments, the film includes perforations in only the top half, top third, or top quarter of the bale. In some embodiments, each row 79 of perforations 77 has a length/width ratio over the bales that is at least about 10. The plurality of perforations 77 may be provided over at least half of the length of the stack 190 (and each individual bale) or even at least 75% or at least 90% of the length of the stack (and each individual bale) .

[0077] Generally, the wrapping apparatus 1 of Figures 1-3 and 6-9 and the wrapping apparatus 101 of Figure 6 do not include a baling device for forming the bale. The bales are previously formed in the field by a separate baling apparatus. The bales may be allowed to sit in the field for a period of time to allow the forage or crop material to dry to reduce spoilage of the forage or crop material.

[0078] Compared to conventional methods and apparatus for wrapping bales, the methods and apparatus of embodiments of the present disclosure have several advantages . The apparatus and methods may involve in line processing of bales to produce a wrapped stack of bales. The wrapped bales may include perforations in an upper portion (e.g., only an upper 300° of the bales or an upper half, upper third or upper quarter) which allows the bales to breath to reduce the moisture in the bales, isolating the bales from the ground to inhibit uptake of moisture from the ground while limiting exposure to the ambient and/or precipitation. By incorporating a perforating device on the wrapping apparatus, perforation of bales may be performed without separate processing steps (i.e., perforation is performed during bale wrapping) . In embodiments in which the apparatus is configured to form a circumferential row of perforations, the row may be positioned where adjacent bales meet. The row may form a weakened region in the wrap which allows individual bales to be torn-away from the wrap. [0079] As used herein, the terms "about," "substantially," "essentially" and "approximately" when used in conjunction with ranges of dimensions,

concentrations, temperatures or other physical or chemical properties or characteristics is meant to cover variations that may exist in the upper and/or lower limits of the ranges of the properties or

characteristics, including, for example, variations resulting from rounding, measurement methodology or other statistical variation.

[0080] 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.

[0081] As various changes could be made in the above constructions and methods 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.