Abstract:
A bale accumulator and method in which a plurality of hay bales can be accumulated and arranged into a cluster of ten bales (a “ten stack”). The accumulator first collects a bale in each of two angled bale receivers at the rear of the accumulator. These remain in position as four columns having two bales each are collected in a more forward collection. The result is two angled bales being dragged to the rear of a conventional “eight stack.” As the device releases all ten bales, gate mechanisms rotate the two rear bales 90 degrees so that they lie transverse to the eight bales comprising the “eight stack.” The two rear bales are pressed against the rear of the eight stack in order to form a ten stack.

Description:
MICROFICHE APPENDIX 
     Not Applicable 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to the field of agriculture. More specifically, the invention comprises a method and device for accumulating hay bales and arranging them into a compact cluster of ten bales. 
     2. Description of the Related Art 
     The inventor of the present invention has created prior bale accumulating devices. One such device is shown in  FIG. 1 . Bale accumulator  10  is designed to arrange eight hay bales into a compact cluster. The machine is designed to work with “square bales.” Square bales are actually rectangular.  FIG. 1B  shows a typical square bale. The hay is compressed by the baler and bound together using two loops of baling twine  7 . The orientation shown represents how the bale is deposited on the ground by the baler. “W” is the width (along short side  112 ), “H” is the height, and “L” is the length (along long side  110 ). While the actual dimensions vary, good approximate dimensions for a modern square bale are a height of 14 inches, a width of 18 inches, and a length of 36 inches. Those skilled in the art will know that the length of the bale is generally variable. However, for use in the present invention, it is helpful to set the length equal to twice the width. Thus, a bale having a length of 36 inches is preferable. 
     A square baler picks up cut hay and compresses it into bales which are then tied. The completed bales exit the rear of the machine and are deposited on the ground. The 18 inch side rests on the ground. The bales are randomly oriented, with the long axes typically being very roughly aligned with the baler&#39;s direction of travel. 
     The hay bales rest on a field of cut stubble. This is significant, because it means that the bales can be dragged along the field with relatively little friction and without destroying or significantly dirtying the bales. This dragging action is central to the present invention, as will now be explained. 
       FIG. 1  shows prior art bale accumulator  10 . Chassis  12  consists of a number of box-section steel members welded together. The chassis&#39; weight is supported by a pair of main wheels  18  near the rear and pair of castor wheels  16  at the front. The castor wheels are free to pivot. Tow bar  14  attaches to the front of the chassis. It connects the bale accumulator to a towing vehicle such as a tractor or large ATV. 
     Input chute  24  is located on the front of the accumulator. It receives square bales and directs them into the interior of chassis  12 . It is important for the reader to realize that the bottom of the bale accumulator is open (including the bottom of the input chute). The accumulator gathers the hay bales and drags them along the field as it arranges them into a cluster. However, at no point does the accumulator lift a hay bale clear of the ground. Thus, all the components (input chute, gates, etc.) are open on the bottom. 
     Once a bale passes through input chute  24 , a series of gates directs it into first chute  26 , second chute  28 , third chute  30 , or fourth chute  32 . The rear of each of the four chutes is open. However, stop gate  20  customarily closes the open end of the four chutes. Stop gate  20  pivots upward about pivot joint  22  to release the bales stored within the chassis at the appropriate time. 
     The bale accumulator includes several bale sensor assemblies. Forward bale sensor assembly  34  senses the presence of a bale passing through the forward portion of the chassis. Rear bale sensor assembly  36  senses a bale passing through the central part of the chassis. The bale sensor assemblies control the operation of the gates, which direct the bales into the appropriate chute. The term “bale sensor assembly” encompasses many different possibilities. In the embodiment shown, each sensor assembly has one or more sensor arms  35  protruding downward into the path of the hay bales. A passing bale will push this sensor arm upward. The bale sensor assembly can be a group of purely mechanical components which move the gates in the appropriate fashion. On the other hand, the bale sensor assembly could be optical or electronic sensors which are used to control pneumatic, hydraulic, electrical, or other actuators to move the gates. Because the bale accumulator operates in a relatively hostile environment, the use of purely mechanical components is preferable. The motion of the gates is preferably produced by mechanical links and levers as well. 
       FIG. 2  shows a simplified plan view of the bale accumulator. It is shown with tow bar  14  connected to hitch  59  on towing vehicle  57 . The reader will appreciate how the offset nature of the tow bar allows the towing vehicle to pass by bale  56  while maneuvering to direct bale  56  into input chute  24 . Input chute  24  flares in the forward direction to ensure that each bale is collected. 
     Three gates control the destination of each bale taken into the accumulator. Primary gate  38  pivots between right position  52  (shown as solid in  FIG. 2 ) and left position  54 . Two more gates are located immediately behind the position of primary gate  38 . These are left gate  40  and right gate  42  (The terms “left” and “right” are based on the assumption that the observer is facing in the direction the bale accumulator is intended to travel). Left gate  40  pivots between closed position  48  (shown in the view) and open position  50 . Right gate  42  likewise pivots between closed position  44  (shown in the view) and open position  46 . 
     Several fixed guiding walls are also provided to appropriately arrange the bales. Left guide  58  runs from the middle region of the chassis up to one edge of input chute  24 . Right guide  60  lies in a similar position on the right side of the chassis. The rear portion of the chassis is divided by guiding walls into four chutes (first chute  26 , second chute  28 , third chute  30 , and fourth chute  32 ). Stop gate  20  selectively closes the rear extreme of the four chutes. 
     The operation of the gates and guiding walls will now be explained with respect to  FIG. 3 .  FIG. 3  depicts the accumulator as stationary and the bales moving. The reader should bear in mind that these views are taken from the perspective of the moving accumulator. In actuality, the bales remain in the same general area on the ground as they are being collected by the accumulator moving over them. The reader should also bear in mind that the sequencing of the gates depicted in  FIG. 3  is one option among many possibilities. Thus, it should be viewed as exemplary. 
     In  FIG. 3(A) , primary gate  38  is in right position  52 . As the bale passes through the input chute it is directed via left guide  58  and primary gate  38  toward the left side of the chassis. At this point the bale encounters left gate  40 , which is in open position  50 . The bale is thereby guided into second chute  28 . The bale travels to the rear of the chute where it is caught by stop gate  20 . The stop gate then drags the bale along the ground at the same speed as the rest of the accumulator. 
     Once the bale passes through primary gate  38 , the primary gate shifts to left position  54 , as shown in  FIG. 3(B)  (The primary gate preferably shifts position with the passage of each bale). The next bale is thereby guided to the right side of the chassis, where it encounters right gate  42  in open position  46 . The bale is thereby directed into third chute  30 , where it will travel rearward until being arrested by the stop gate. 
     The passage of the second bale loaded again shifts the position of primary gate  38 . The primary gate shifts to right position  52 , as shown in  FIG. 3(C) . The third bale next encountered passes through the primary gate and then to left gate  40 , which is again in open position. The third bale is thereby directed into second chute  28 , where it comes to rest against the first bale collected. 
     The passage of the third bale shifts primary gate  38  to left position  54  as shown in  FIG. 3(D) . The fourth bale encountered is thereby directed to the right side of the chassis. Right gate  46  then directs it into third chute  30 , where it comes to rest against the second bale collected. At this point, the second and third chutes have been filled. The bale sensor assemblies detect the presence of the first four bales (either by their presence in the chutes or their passage into the chutes). Thus, the accumulator should next load bales into the first and fourth chutes. In order to do this, the left and right gates must be activated. 
       FIG. 3(E)  shows the accumulator as it encounters and stores the fifth bale. Primary gate  38  has cycled back to right position  52 . However, left gate  40  has now been pivoted to closed position  48 . This action propels the fifth bale down a corridor created by left gate  40  and left guide  58 . The fifth bale will be propelled into first chute  26 , where it will be arrested by stop gate  20 . 
       FIG. 3(F)  shows the passage of the sixth bale. Primary gate  38  is in left position  54 . Right gate  42  cycles to closed position  44 , which propels the sixth bale into fourth chute  40 .  FIG. 3(G)  shows the passage of the seventh bale. The primary gate is in right position  52  and left gate  40  pivots to closed position  48 . These actions drive the seventh bale into first chute  26 , where it comes to rest against the fifth bale collected. 
       FIG. 3(H)  shows the passage of the eighth bale. The primary gate is in left position  54 , while right gate  42  cycles to closed position  44 . These actions direct the eighth bale into fourth chute  40 , where it comes to rest against the sixth bale collected. 
     The prior art accumulator illustrated is designed to collect eight bales and deposit them in an ordered cluster. Thus, when the last bale arrives in the position shown in  FIG. 3(H) , the bale sensor assemblies detect that the accumulator is full and ready to dispense. Stop gate  20  is then released and allowed to pivot upward around pivot joints  22 . The eight bales thus collected slide out the back of the accumulator and are left in four columns having two bales apiece. This arrangement is referred to as an “eight stack.” The reader should bear in mind that the order of accumulating the bales (such as the first bale being directed into the second chute) is largely arbitrary. The machine could be configured to collect the bales in a different order, so long as four columns of two bales result. 
     An “eight stack” can be picked up by a hay grapple or similar device on the front end loader of a tractor. The eight stack can then be deposited as a unit into a trailer or barn. Thus, the use of the prior art accumulator allows the bales to be collected in clusters of eight rather than individually. This feature saves considerable time. 
     The prior art hay accumulator is useful and efficient. However, it is limited to the creation of “eight stack” clusters. These are not suitable for some applications. In certain applications, it is preferable to create a cluster of ten bales. This “ten stack” cluster makes more efficient use of certain storage geometries. The present inventive device and method is able to produce the desired “ten stack” cluster. 
     BRIEF SUMMARY OF THE PRESENT INVENTION 
     The present invention comprises a bale accumulator and method in which a plurality of hay bales can be accumulated and arranged into a cluster of ten bales (a “ten stack”). The accumulator first collects a bale in each of two angled bale receivers at the rear of the accumulator. These remain in position as four columns having two bales each are collected in a more forward collection. The result is two angled bales being dragged to the rear of a conventional “eight stack.” As the device releases all ten bales, gate mechanisms rotate the two rear bales 90 degrees so that they lie transverse to the eight bales comprising the “eight stack.” The two rear bales are pressed against the rear of the eight stack in order to form a ten stack. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is a perspective view, showing a prior art bale accumulator. 
         FIG. 1B  is a perspective view, showing a prior art hay bale. 
         FIG. 2  is a plan view, showing a prior art hay accumulator being towed by a vehicle. 
         FIG. 3  is a sequential plan view, showing the accumulation of eight bales in a prior art bale accumulator. 
         FIG. 4  is a perspective view, showing a bale accumulator made according to the present invention. 
         FIG. 5  is a detailed perspective view, showing the gate assemblies on the bale accumulator of  FIG. 4 . 
         FIG. 6  is a detailed elevation view, showing the gate assemblies on the bale accumulator of  FIG. 4 . 
         FIG. 7  is a sequential plan view, showing the accumulation of ten bales in a bale accumulator. 
         FIG. 8  is a sequential plan view, showing the release cycle of the bale accumulator. 
         FIG. 9  is a sequential plan view, showing the release cycle of the bale accumulator. 
         FIG. 10  is a plan view, showing more of the release cycle. 
       
         
           
                 
               
                 
                 
               
             
                 
                     
                 
                 
                   REFERENCE NUMERALS IN THE DRAWINGS 
                 
                 
                     
                 
               
               
                 
                     
                 
               
            
             
                 
                   5 
                   hay bale 
                 
                 
                   7 
                   baling twine 
                 
                 
                   10 
                   bale accumulator 
                 
                 
                   12 
                   chassis 
                 
                 
                   14 
                   tow bar 
                 
                 
                   16 
                   castor wheel 
                 
                 
                   18 
                   main wheel 
                 
                 
                   20 
                   stop gate 
                 
                 
                   22 
                   pivot joint 
                 
                 
                   24 
                   input chute 
                 
                 
                   26 
                   first chute 
                 
                 
                   28 
                   second chute 
                 
                 
                   30 
                   third chute 
                 
                 
                   32 
                   fourth chute 
                 
                 
                   34 
                   forward bale sensor assembly 
                 
                 
                   35 
                   sensor arm 
                 
                 
                   36 
                   rear bale sensor assembly 
                 
                 
                   38 
                   primary gate 
                 
                 
                   40 
                   left gate 
                 
                 
                   42 
                   right gate 
                 
                 
                   44 
                   closed position 
                 
                 
                   46 
                   open position 
                 
                 
                   48 
                   closed position 
                 
                 
                   50 
                   open position 
                 
                 
                   52 
                   right position 
                 
                 
                   54 
                   left position 
                 
                 
                   56 
                   bale 
                 
                 
                   57 
                   towing vehicle 
                 
                 
                   58 
                   left guide 
                 
                 
                   59 
                   hitch 
                 
                 
                   60 
                   right guide 
                 
                 
                   62 
                   swing gate 
                 
                 
                   64 
                   swing gate 
                 
                 
                   66 
                   pivot joint 
                 
                 
                   68 
                   pivot joint 
                 
                 
                   70 
                   latch 
                 
                 
                   72 
                   latch mounting frame 
                 
                 
                   74 
                   latch bolt 
                 
                 
                   76 
                   pivot joint 
                 
                 
                   78 
                   compressor plate 
                 
                 
                   80 
                   angled bale receiver 
                 
                 
                   82 
                   angled bale receiver 
                 
                 
                   84 
                   spring post 
                 
                 
                   86 
                   return spring 
                 
                 
                   88 
                   central divider 
                 
                 
                   90 
                   rear crossmember 
                 
                 
                   92 
                   slanted wall 
                 
                 
                   93 
                   inboard rear corner 
                 
                 
                   94 
                   rear wall 
                 
                 
                   96 
                   side wall 
                 
                 
                   98 
                   swing gate tip 
                 
                 
                   100 
                   rear bale 
                 
                 
                   102 
                   forward bale 
                 
                 
                   104 
                   middle bale 
                 
                 
                   106 
                   ten stack 
                 
                 
                   108 
                   gate assembly 
                 
                 
                   110 
                   long side 
                 
                 
                   112 
                   short side 
                 
                 
                   114 
                   trailing pivot joint 
                 
                 
                     
                 
               
            
           
         
       
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 4  shows a bale accumulator constructed according to the present invention. The rear of the accumulator is modified, with the balance of the accumulator preferably being the same as or similar to the prior art. The prior art input chutes, gates, and bale sensing assemblies can all be used. The novel features of the present invention reside primarily with a pair of pivoting gate assemblies which close the rear of the chutes. 
     Swing gate  62  pivots about pivot joint  66  on the left rear of chassis  12 . Likewise, swing gate  64  pivots about pivot joint  68  on the right rear of chassis  12 . Each swing gate is preferably urged toward its closed position (the position shown) by a return spring  68 . The return springs are connected to a spring post  84  located on each swing gate. The two swing gates are held in the closed position by the engagement of a pair of latches  70  with latch mounting frame  72 . 
     As discussed previously, the bottom of the accumulator is open. The hay bales it collects are not lifted off the ground but rather dragged along the ground by the accumulator (until released). The friction between the bales and the ground urges the bales rearward with respect to the accumulator. Thus, the bales will tend to bear against the two closed swing gates and will tend to force the swing gates open. 
       FIG. 5  shows the two swing gate assemblies pivoted into the open position. The outward motion of the gate assemblies is denoted by the arrows in the view. Rear cross member  90  spans the rear of the chassis. Latch mounting frame  72  is connected to the rear cross member. Central divider  88  descends from the latch mounting frame and serves to divide the second and third chutes. A pair of latches  70  are preferably mounted on the latch mounting frame. These are positioned to engage a pair of corresponding latch bolts  74  on the two gate assemblies  108 . 
     The reader will observe how the left gate assembly  108  pivots about a pivot joint  66  located on the left rear of the chassis. Likewise, the right gate assembly  108  pivots about a pivot joint  66  located on the right rear of the chassis. In the open position shown, the reader will observe how the two return springs  86  are stretched and thereby provide a restoring force. 
     The two gate assemblies are not rigid pieces. The trailing portion of each assembly includes a trailing pivot joint  114 . Each trailing pivot joint pivotally attaches a slanted wall  92 , so that the slanted wall can pivot with respect to rear wall  94 . 
       FIG. 5  also shows a pair of compressor plates  78 . The right compressor plate  78  pivots about pivot joint  76  on the right rear of the chassis. It includes a return spring which tends to bias the compressor plate inward to close the rear of the fourth chute (The return spring is internal and is not shown in the view). The left side of the chassis also includes a pivoting compressor plate  78 , which is positioned to close the exit of the first chute. 
       FIG. 6  shows a plan view of the two gate assemblies in the closed position. The two compressor plates  78  are likewise shown in the position they occupy when unloaded. They partially obstruct the open rear of the four chutes. The closed gate assemblies create a pair of angled bale receivers—designated as angled bale receiver  80  and angled bale receiver  82 . 
     The reader will observe that each gate assembly preferably includes three distinct wall portions. These are side wall  96 , rear wall  94 , and slanted wall  92 . Each slanted wall  92  ends in a swing gate tip  98  which preferably lies adjacent to central divider  88 . The two latches  70  are preferably located near the junction of a slanted wall and a rear wall. The reader will observe that each junction between a slanted wall and a rear wall creates an inside corner  71 . 
       FIG. 7  shows how angled bale receiver  80  and angled bale receiver  82  may be loaded with hay bales. In  FIG. 7(A) , the accumulator is moving along the ground and a first bale  56  has been taken into the input chute and directed by the gates (as in the prior art) into second chute  78 . As it exits the second chute it bears against the exposed end of compressor plate  78 , which urges the bale against central divider  88  and slanted wall  92  of the left gate assembly. In  FIG. 7(B)  the first bale has slipped past the left compressor plate and come to rest against slanted wall  92  and rear wall  94 . The reader will observe how inboard rear corner  93  of the bale rests within inside corner  71  formed by the intersection of slanted wall  92  and rear wall  94 . The compressor plate helps to ensure that the bale remains in this position. Those skilled in the art will recognize that the orientation of slanted wall  92  has reoriented the bale by rotating its long side in a clockwise direction. 
       FIG. 7(C)  shows the accumulation of a second bale. The prior art gate and chute mechanisms have directed this second bale into third chute  30 . As it exits the rear of the third chute, the right compressor plate  78  urges it against the slanted wall of the right gate assembly. The second bale comes to rest against the rear wall of the right gate assembly. The reader will observe how the slanted wall has rotated the long side of this second bale in an anticlockwise direction. 
     The first and second bales are then dragged along inn the position shown in  FIG. 7(C)  as additional bales are accumulated. The order in which the additional bales are accumulated is not significant to the present invention. If a total of ten bales are desired before discharging the cluster, then two bales should be accumulated in each of the four chutes. This arrangement is shown in  FIG. 7(D) . A first set of four middle bales  104  are accumulated in the rearward position of the chutes while a second set of forward bales  102  are accumulated in the forward position. The two bales in the angled bale receivers are denoted as rear bales  100 . 
     The sequence of events in discharging the “ten-stack” cluster will now be described with reference being made to  FIGS. 8-10 .  FIG. 8(A)  shows a detailed plan view of the two rear bales  100  just prior to the initiation of the discharge cycle. The reader will observe how the two bales are engaged within the respective angled bale receivers. The two compressor plates  78  hold the bales in position. Those skilled in the art will realize that the dragging action of the bales along the ground would tend to hold the two rear bales in the position shown even without the compressor plates. However, the use of the compressor plates is preferable since they tend to positively locate the rear bales as the chassis goes through a turn, passes over undulations, etc. 
     The prior art bale sensor assemblies are used to detect the presence of all the desired bales prior to the initiation of the discharge cycle. As for the prior art, the detection can be accomplished via any desirable sensing means, with the preferred approach being the use of purely mechanical linkages. 
     The discharge cycle commences when the two latches  70  are unlatched. The rearward force exerted by the bales being dragged along the ground then acts to open the two rear gate assemblies.  FIG. 8(B)  shows the two rear gate assemblies as they just begin to swing open. The reader will observe how the two inboard rear corners  93  of each of the two rear bales remain engaged with the pivoting gate assemblies. The pivoting of the left gate assembly tends to rotate the left bale in a clockwise direction while the pivoting of the right gate assembly tends to rotate the right bale in an anticlockwise direction. 
     Each inboard rear corner  93  is formed by the intersection of a rear wall  94  and a slanted wall  92 . The connection between the two walls is actually made by a trailing pivot joint  114 . An actuator is provided to regulate the angle between each rear wall and slanted wall and to increase the angle as the gate assembly opens. This actuator can assume many forms, but is preferably a mechanical linkage. The reader will observe in comparing the transition from  FIG. 8(A)  to  FIG. 8(B)  how the slanted wall on the right gate assembly has rotated counterclockwise with respect to the rear wall. The results is that as the entire gate assembly opens outward the rear walls open outward a bit faster than the gate assembly as a whole. The angle found at inboard rear corner  93  in  FIG. 8(B)  is larger than the same angle in  FIG. 8(A) , which is a result of this action. 
     As the two rear bales move toward the rear, the set of middle bales  104  also slides toward the rear. Compressor plates  78  act to retain all the bales in the orientation shown and provide a smooth exit from the chassis.  FIG. 9(A)  shows the process as the two gate assemblies swing further open. The two rear bales  100  are further rotated so that their long sides lie almost perpendicular to the long sides of the bales exiting the chutes. Each slanted wall  92  has rotated further with respect to the rear wall to which it is pivotally connected. The rear bales exiting the first and fourth chutes have now rotated the two compressor plate  78  outward to the position shown. All eight bales within the chutes then slide to the rear in unison. 
     In  FIG. 9(B) , the two rear bales are seen as they exit the gate assemblies. The two swing gate tips  98  swing free of the of the two rear bales. The two compressor plates urge the exiting bales inward to form a tighter cluster. The two slanted walls  92  have rotated even further outward so that they clear the bales exiting the rear of the accumulator. 
     In  FIG. 10  all ten bales have exited the rear of the gate assemblies. As soon as the swing gate tips  98  clear the most forward bales, the pair of return springs  86  urges the two gate assemblies back toward the closed position. As the gate assemblies swing closed the two latches reengage and the accumulator is ready for the next accumulation cycle. The entire process shown from  FIGS. 8 through 10  is preferably performed rapidly, with the discharge cycle taking between 3 and 5 seconds. 
     Although the preceding description contains significant detail, it should not be construed as limiting the scope of the invention but rather as providing illustrations of the preferred embodiments of the invention. As an example, although the invention has been illustrated with respect to the accumulation of a “ten-stack” of hay bales, it could perform just as well in the creation of a cluster of six bales (where only a single bale would be accumulated in each of the four chutes). The invention could also be made to function with a chassis accumulating more than ten bales. Likewise, the order of the operations presented should not be deemed particularly significant except where specified to be significant. Thus, the scope of the invention should be fixed by the following claims rather than any specific examples provided.