Abstract:
An apparatus for loading a container with stacks of bales comprising biomass. Conveyors are driven from a mid-point between the ends of the container, thus reducing the strain on the conveyor material. Squeeze flaps help guide the stacks of bales into the container, and provide the ability to reduce the width of the bale stack by hydraulically actuating the squeeze flaps. A remote control device is used in the process of loading and a sensor senses when the container is full.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    This invention relates generally to a device for loading bales of biomass into a container for transporting to another location, and more particularly to a bale loading apparatus that simplifies and speeds up the loading process. 
         [0003]    2. Background Art 
         [0004]    U.S. Pat. No. 8,408,857to a Bale Picking Truck by Kelderman shows a method and apparatus for quickly and efficiently picking up and removing biomass bales from a field in which the biomass was baled, compactly stacking the bales after picking the bales off the ground, and efficiently depositing the bales on the ground or platform at a staging area for later loading onto a semi-trailer, straight truck, or train car. 
         [0005]    Published U.S. Patent Application No. 2012/0045310 to a Bale De-Stacker by Kelderman relates to a method and apparatus for efficiently unstacking square bales from a stack and conveying the square bales in small sets or individually once they arrive from their aforementioned staging area to the place they are to be used, such as in an ethanol production plant, a plant where the bales are to be burned for fuel, or a feedlot. 
         [0006]    U.S. Pat. No. 8,734,077 to a Bale Loading Trailer and Method of Using Same by Kelderman relates to the step of picking sets of bales off the ground, such as at the aforementioned staging area, and loading said bales into a trailer via a moving floor. The aforementioned patents and Published U.S. Patent Application are hereby incorporated herein by reference in their entirety. 
       SUMMARY OF THE INVENTION 
       [0007]    The present invention is an improvement over that disclosed in U.S. Pat. No. 8,734,077. The moving floor of the present invention comprises a hydraulic, electric, or other motor disposed approximately midway along the direction the bales are moved. The motor drives two sets of chains or belts, or any equivalent thereof. The first set of chains or belts is disposed rearmost in the container, while the second set is disposed front-most in the container. During loading from the rear of the container, the first set of chains can transfer sets of bales approximately up to the drive motor while the second set of chains can transfer sets of bales to the front of the container. In unloading, the second set of chains transfer sets of bales to the proximity of the drive motor, while the first set of chains deliver sets of bales to the rear of the container for unloading. 
         [0008]    An advantage of locating the motor such that conveyors are disposed on both sides thereof is a reduction in strain in the conveyors compared to the case where the motor is disposed at an extreme end of the container, and therefore, the conveyor. 
         [0009]    In other embodiments of the present invention, the bales are introduced into the container at the approximate center of the container. When the bales are introduced into the container near the drive motor location, the sets of conveyors must reverse direction in order to move the sets of bales to the extreme ends of the container. 
         [0010]    A novel aspect of the present invention is the open platform on which to load sets of bales from the side. In the case where the open platform is in the rear, rear loading is another option. Of course, a container may be made to load from the front, approximate middle, and rear. In any case, sets of bales may be loaded from either side of the container. 
         [0011]    The term open, for the purposes of this document, including the claims, is hereby defined as without sides. The container of the present invention includes sides—solid, barred, meshed, etc.—to contain the bales of biomass during transport. The loading port, in contradistinction, has no such sides. Bracing along the top of the loading port may or may not be incorporated, but this type of loading port is still termed open. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    The above mentioned improvement is effected through provision of the method and apparatus described in the following detailed description, particularly when studied in conjunction with the drawings, wherein: 
           [0013]      FIG. 1  is a side elevational view of a bale loading container in conjunction with a semi-tractor trailer and constructed for loading sets of bales generally into the rear of the container; 
           [0014]      FIG. 2  is a side elevational view of a bale loading container in conjunction with a semi-tractor trailer and constructed for loading sets of bales generally into the approximate middle of the container; 
           [0015]      FIG. 3  is a side elevational view of a bale loading container in conjunction with a semi-tractor trailer and constructed for loading sets of bales optionally into the rear or approximate middle of the container; 
           [0016]      FIG. 4  is a side elevational view of a bale loading container in conjunction with a straight truck and constructed for loading sets of bales generally into the rear of the container; 
           [0017]      FIG. 5  is a top plan form view of a container moving floor comprising chain conveyors; 
           [0018]      FIG. 6  is a plan form view of a container moving floor comprising chain conveyors from the underside; 
           [0019]      FIG. 7  is a top plan form view of a container moving floor comprising belt conveyors; 
           [0020]      FIG. 8  is a plan form view of a container moving floor comprising belt conveyors from the underside; 
           [0021]      FIG. 9  is a side elevational view of a bale loading container in conjunction with a semi-tractor trailer wherein sets of bales are shown being loaded generally into the rear of the container; 
           [0022]      FIG. 10  is a flow diagram illustrating a procedure for loading the bale loading container; 
           [0023]      FIG. 11  illustrates a remote control device; 
           [0024]      FIG. 12  is a top plan form view of a container moving floor comprising chain conveyors illustrating a bale stack having been set on the moving floor; 
           [0025]      FIG. 13  is a top plan form view of a container moving floor comprising chain conveyors illustrating the bales stack having been advanced out of the loading port area; 
           [0026]      FIG. 14  is a top plan form view of a container moving floor comprising chain conveyors illustrating a full bale loading container; and 
           [0027]      FIG. 15  is a view like  FIG. 14  but with the bale loading container full of bales with the leading edge of the last bale stack between the squeeze flaps which have been actuated so they are in their narrowest position, clamping on the last bale stack, and with a single ratchet strap to secure the load in this configuration. 
       
    
    
       [0028]    Elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions and/or relative positioning of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments of the present invention. Certain actions and/or steps may be described or depicted in a particular order of occurrence while those skilled in the art will understand that such specificity with respect to sequence is not actually required. The terms and expressions used herein have the ordinary technical meaning as is accorded to such terms and expressions by persons skilled in the technical field as set forth above except where different specific meanings have otherwise been set forth herein. 
       DETAILED DESCRIPTION 
       [0029]    Referring now to the drawings, wherein like reference numerals indicate identical or similar parts throughout the several views,  FIGS. 1-15  show preferred embodiments of the present invention. 
         [0030]    Referring now to  FIG. 1  the bale loading container  10  of the present invention is shown in a configuration wherein it can be conveyed over public and/or private roads from place to place, either empty or loaded by a prime mover  100 , such as a semi-tractor, agricultural tractor, etc. The bale loading container  10  includes a loading port  110  disposed generally in the rear portion of the bale loading container  10  for loading and unloading. 
         [0031]    Squeeze flaps  120  are included on both sides in the general front of the loading area to: (1) guide the bale stack  910  ( FIG. 9 ) into the container  10 , and (b) to reduce the width, if necessary, of the bale stack  910  by hydraulically actuating the squeeze flaps  120  using actuators  510  ( FIG. 5 ). To effect these goals, the squeeze flaps  120  comprise a front post  130 , operatively, pivotally affixed to the bale loading container  10  and a rear post  140 , made to swing outward and inward as the front post  130  is rotated about its axis of rotation  150 . The squeeze flaps  120  are preferably hydraulically actuated, but may also be electrically or pneumatically actuated. 
         [0032]    Bale stacks  910  are transferred from and to the loading port  110  by virtue of conveyors, such as the chain conveyors  160  shown in  FIGS. 1-6  and  9 . The chain conveyors  160  are driven by a driver  170 , which may be hydraulic, pneumatic, electric, or power-take-off driven. 
         [0033]    In  FIG. 2 , the loading port  110  is near the middle of the bale loading container  10 . This location of the loading port  110  will be referred to as the center of the container, and is hereby defined as a location such that bale stacks  910  may be transferred both toward the front of the trailer and toward the back of the trailer during loading. Therefore, there is space to store bale stacks  910  fore and aft of the loading port  110 . Specifically, the term center as referring to the location of the loading port  110  is not limited to the exact geometric center (one half the length) of the bale loading container  10 , nor is it limited to the exact geometric center of the chain conveyors  160 . 
         [0034]    Squeeze flaps  120  are included on both sides in the general front of the loading area to: (1) guide the bale stack  910  into the container  10 , and (2) to reduce the width, if necessary, of the bale stack  910  by hydraulically actuating the squeeze flaps  120 . 
         [0035]    To effect these goals, the squeeze flaps  120  comprise a front post  130 , operatively, pivotally affixed to the bale loading container  10  and a rear post  140 , made to swing outward and inward as the front post  130  is rotated about its axis of rotation  150 . The squeeze flaps  120  are preferably hydraulically actuated. 
         [0036]    Squeeze flaps  220  are included on both sides in the general rear of the loading area to: (1) guide the bale stack  910  into the container  10 , and (b) to reduce the width, if necessary, of the bale stack  910  by hydraulically actuating the squeeze flaps  220 . To effect these goals, the squeeze flaps  220  comprise a rear post  230 , operatively, pivotally affixed to the bale loading container  10  and a front post  240 , made to swing outward and inward as the rear post  230  is rotated about its axis of rotation  250 . The squeeze flaps  220  are preferably hydraulically actuated, but may be pneumatically or electrically actuated, instead. 
         [0037]    The bale loading container  10  shown in  FIG. 3  allows for loading and unloading to be accomplished at two loading ports  110 . One is center located while the other is located generally at the rear of the bale loading container  10 . 
         [0038]    Details of the chain conveyors  160  and the driver  170  are shown more completely in  FIGS. 3 ,  4 , and  9  where some of the floor of the bale loading container  10  has been made transparent. The driver  170  is located such that there are chains both fore and aft of the driver  170 . This location of the driver  170  will be referred to as the center of the container  10 , and is hereby defined as a location such that chain conveyors are driven thereby both fore and aft of the driver  170 . Specifically, the term center as referring to the location of the driver  170  is not limited to the exact geometric center (one half the length) of the bale loading container  10 , nor the exact geometric center of the chain conveyors  160 . 
         [0039]    Compared to driving the chain conveyors  160  from one extreme end of the bale loading container  10 , an advantage to driving the chain conveyors  160  in the center of the bale loading container  10  is the strain on the chains is reduced. 
         [0040]    Drive cogs  330  are employed at the driver  170  to engage the chain conveyors  160  and provide slipless drive. Outboard cogs  340  are engaged by the chain conveyors  160  at their respective extreme ends. 
         [0041]    The term forward is herein defined for the purposes of this document, including the claims, as the principle direction the bale loading container  10  is conveyed by the prime mover  100 . An arrow indicating the forward direction  350  is shown in  FIG. 3 . In particular, the forward chain conveyors  310  are located in the forward direction from the driver  170 . The term aft is defined as the opposite direction of forward. 
         [0042]    A sensor  330 ,  340  is included at each end of the bale loading container  10  toward which bale stacks  910  travel during loading. In a preferred embodiment, only one such sensor  330 ,  340  is included, and that at the forward end of the bale loading container  10 , as shown in  FIG. 9 . The sensor  330 ,  340  signals the driver  170  to stop conveying the bale stacks  910  when the forward-most bale stack  910  reaches an associated far end of the bale loading container  10 . It should be clear that the bale loading container  10  of  FIG. 1  needs only one sensor  330 , located at the forward end of the bale loading container  10  as this is the only end toward which bale stacks  910  travel upon loading. 
         [0043]    An alternative configuration is shown in  FIG. 4 , where the bale loading container  10  is transported on a straight truck. The bale loading container is not limited to any particular prime mover used to transfer the same from place to place. 
         [0044]    The chain conveyors  160  are shown from the top in  FIG. 5 . The chains appearing in this view contact the bale stacks  910  for the purpose of conveying the bale stacks  910  through the bale loading container  10  for loading and unloading. 
         [0045]    It is noted that the conveyors  160  are illustrated as roller chain conveyors, but web chains or belts  710 , such as those shown in  FIGS. 7 and 8 , may be used instead of the roller chain conveyor belts. Chain conveyor systems may be similar to the gathering chains  410  shown in  FIG. 5  of U.S. Pat. No. 8,734,077 to a Bale Picking Truck by Kelderman, incorporated herein in its entirety by reference. 
         [0046]    The underside of the chain conveyors  160  is shown in  FIG. 6 . Here, it can be seen how each driver  170  simultaneously drives forward chain conveyors  310  and aft chain conveyors  320  via shafts  610 . Cogs  330  are affixed to the shafts  610 , which engage the chain conveyors  160  to provide drive without slip. 
         [0047]    An alternate embodiment of the present invention is shown in  FIGS. 7 and 8 . Instead of chain conveyors  160 , conveyor belts  710  are used to move bale stacks  910  into and out of the bale loading container  10 . The belts engage belt pulleys  810 , the belt pulleys  810  being driven by the driver  170 . 
         [0048]    Stacks of bales  910  are shown being loaded into the open loading port  110  in  FIG. 9 . A stack of bales may comprise, for instance, six bales—two wide and three high. The bales are set on the platform of the loading port  110  using a fork lift, bale spear, bale squeeze, or any other device capable of lifting at least one bale to the platform. 
         [0049]    The procedure for loading the bale loading container  10  is illustrated in  FIG. 10 . In step  1010 , a bale stack  910  is set on the platform of the bale loading container  10 . The operator, or other person involved in the loading process, uses a remote  1100  such as that shown in  FIG. 11 , or a lever  920 , pushbutton (not shown), or other control action to actuate the drive  170 , causing the chain conveyors  160  to move the bale stack  910  adequately to clear the platform of the open loading port  110  to make room for another bale stack  910 , as shown in step  1020 . If the bale loading container  10  is full  1030 , as indicated by the sensor  330 ,  340 , or by counting the bale stacks  910  already loaded, a final bale stack  910  is loaded onto the platform of the bale loading container  10 , as indicated in step  1040 . If possible, this last bale stack  910  is advanced sufficiently to enter the squeeze flaps  120 , and the squeeze flaps  120  narrowed at the end opposite the pivot axis  150  to hold the last bale stack securely for transport. 
         [0050]    If the bale loading container  10  is not full at comparison block  1030 , the process is repeated, starting with step  1010  where a bale stack  910  is set on the platform of the bale loading container  10 . 
         [0051]    The example remote control unit  1100  shown in  FIG. 11 , includes a display  1110  for warnings and other feedback, forward (F) and reverse (R) chain conveyor controls  1120 , chain conveyor speed control  1130 , and squeeze flap control  1140 . It is to be understood, this is only an example. The remote control device  1100  is not limited to these functions, nor are all these functions necessarily part of the present invention. The remote control device  1100  may be wired or wireless. 
         [0052]    The display  1110  of the remote control unit  1100  may be used to indicate the bale loading container  10  is full. However, that information may also be provided by a sound, emanating from a sound generator  1150 , or vibration, generated by a vibrator  1160 , both detectable by the operator. 
         [0053]    Unloading the bale loading container  10  may be accomplished by reversing the loading process. The driver  170  is necessarily reversible. Typically, the bale stacks  910  are unloaded from the rear of the bale loading container  10 , even if they are loaded into the center. 
         [0054]    The action of the squeeze flaps  120  is illustrated in  FIGS. 12-15 . The bale stacks  910  in these figures are shown in a semi-transparent state so the conveyor system  160 ,  170  and squeeze flaps  120  may be seen. In  FIG. 12 , a bale stack  910  has been set on the platform of the bale loading container  10 , ready for loading. Note that the bales are not well aligned with the sides of the bale loading container  10 . 
         [0055]    The bale stack  910  is then advanced in the direction of the arrow, as shown in  FIG. 13 . Due to the need for alignment, the squeeze flaps  120  are pivoted inward on the pivot axis  150  (not shown in  FIGS. 12-15 ), thus forcing the bales inward. The result is better alignment and a narrower footprint of the bale stack  910 . When individual bales have broadened due to being stacked on or other influences, the squeeze flaps  120  are brought to bear to reduce the breadth of the overall bale stack  910 , and hence, the individual bales. 
         [0056]    In  FIG. 14 , the bale stack has been aligned and cleared out of the loading port  110 . The squeeze flaps  120  have been returned to their broadened position where they can act as a funnel to direct bale stacks not needing much alignment or narrowing. 
         [0057]    The bale loading container  10  has been filled in  FIG. 15 . The sensor  330  has sensed the proximity of a bale stack and signaled the operator. In response to this signal, the operator has loaded a last bale stack  1510  and advanced it so the leading edge of the last bale stack  1510  resides between the squeeze flaps  120 . The squeeze flaps  120  have been actuated so they are in their narrowest position, clamping on the last bale stack  1510 . A single ratchet strap  1520  is typically all that is required to secure the load in this configuration. 
         [0058]    In the event the last bale stack  1510  cannot be advanced sufficiently to bring its leading edge between the squeeze flaps  120 , a second ratchet strap  1520  is typically applied to the last bale stack  1510  in order to secure the same. 
         [0059]    Those skilled in the art will recognize that a wide variety of modifications, alterations, and combinations can be made with respect to the above described embodiments without departing from the spirit and scope of the invention, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept as expressed by the attached claims.