Abstract:
A bale processing apparatus and method is provided to lift, hold, transport, and spread one or more round bales of hay or other material. The apparatus includes a belt, rollers, and a means for controlling tension on the belt to position the belt in first and second positions. In the first position the belt forms a cradle between the first and second rollers capable to hold a bale. In the second position the belt may eject the bale. The bale is lifted onto the belt, with the belt in the cradle position, is untied, and the belt is turned to unroll the bale. The apparatus may be connected to a vehicle that moves while the belt turns to feed the bale over an area. The bale is ejected from the belt by adjusting the tension on the belt to the eject position and moving the belt.

Description:
PRIORITY CLAIM 
   This application claims the benefit of U.S. patent application Ser. No. 60/558,679, filed Apr. 1, 2004, entitled “Bale Processing Apparatus,” which is incorporated by this reference as though fully set forth herein. 

   FIELD OF INVENTION 
   The present invention relates to farm machinery. More particularly, the present invention relates to an apparatus for feeding hay or other baled product to animals. 
   BACKGROUND 
   In the field of animal husbandry, hay is often used as a feed for livestock. Hay is often wound together in a square or cylindrical bale. To feed the bale to animals, the bale is normally taken apart by cutting twine or other material used to bind the bale. Preferably, the unwound bale then has its hay spread throughout a desired feeding area. 
   Unwinding round bales is particularly difficult and dangerous. A round hay bale can weigh several hundred pounds. It is difficult, therefore, to maneuver the bale. Because it is difficult to maneuver the bale, it is difficult to spread the hay throughout a desired area to feed multiple animals. Instead, the hay often sits in a single pile or must be manually moved in small portions. 
   SUMMARY OF THE INVENTION 
   There exists a need to provide an improved method and apparatus for processing bales which overcomes at least some of the above-referenced deficiencies. Accordingly, at least this and other needs have been addressed by exemplary embodiments of the bale processing apparatus according to the present invention. One such embodiment is directed to a bale processing apparatus. The apparatus includes a belt and first and second rollers positioned proximate the belt. The apparatus further includes means for controlling tension on the belt to position the belt in a first position in which the belt forms a cradle between the first and second rollers capable of holding a round bale and a second position in which the belt may eject the bale. 
   In another exemplary embodiment of the present invention, a method of processing a bale is provided. A bale is engaged, for example, by a bale lifting portion of an apparatus, such as a lifting portion including a bale spear. The bale is positioned on a belt, for example, by activating the lifting portion. Tension on the belt is controlled to selectively position the belt in either a cradle position in which the bale may be rotated in response to movement of the belt and or an eject position in which the bale may be ejected in response to movement of the belt. The belt is moved while the bale is positioned on the belt to eject at least a portion of the bale to be ejected from the belt. 
   In yet another exemplary embodiment of the present invention, a bale processing apparatus is provided. The apparatus includes means for engaging a bale, means for holding the bale, means for lifting the bale to the means for holding, and means for unwinding the bale while the bale is positioned in the means for holding. 

   
     BRIEF DESCRIPTION OF DRAWINGS 
     The detailed description will refer to the following drawings, wherein like numerals refer to like elements, and wherein: 
       FIG. 1  shows a perspective view of one exemplary embodiment of a bale processing apparatus attached to a vehicle; 
       FIG. 2  shows a more detailed perspective view of the bale processing apparatus shown in  FIG. 1 ; 
       FIG. 3  shows a more detailed perspective view of the actuator shown in  FIGS. 1 and 2 ; 
       FIG. 4  shows another perspective view of the apparatus shown in  FIGS. 1 and 2 ; 
       FIG. 5  shows a more detailed view of the motor assembly shown in  FIG. 4 ; 
       FIG. 6  shows a plan view of the apparatus with the lift portion in a lowered position at which the lift portion has begun to raise (without a bale); 
       FIG. 7  shows another plan view of the apparatus shown in  FIG. 6  with the lift portion in a partially raised position; 
       FIG. 8  shows another plan view of the apparatus shown in  FIGS. 6 and 7  with lift portion raised farther than in  FIGS. 6 and 7 ; 
       FIG. 9  shows an exemplary embodiment of the cradle portion of the apparatus, shown in  FIG. 1 ; 
       FIG. 10  shows an end view of the embodiment of the cradle portion shown in  FIG. 9 ; 
       FIG. 11  shows an end view of the cradle portion with a bale positioned thereon; 
       FIG. 12  shows an end view of the cradle portion shown in  FIG. 11 , in which the belts are moving to unroll the bale; 
       FIG. 13  shows an end view of the cradle portion of the apparatus with the belts in a tightened position; 
       FIG. 14  shows an end view of the cradle portion shown in  FIG. 13  in which the belts are moving; 
       FIG. 15A-E  show views of an exemplary embodiment of the bale processing apparatus of the present invention, in use with a bale; 
       FIG. 16  shows an alternative embodiment of a bale processing apparatus in which the apparatus includes a motor vehicle; 
       FIG. 17  shows another embodiment of a bale processing apparatus that includes two sets of wheels and is attached to a hitch of a tractor, truck, or other vehicle; 
       FIG. 18  shows a perspective view of the apparatus of  FIG. 1  in which two bales are positioned on the apparatus; 
       FIG. 19  shows a side view of another exemplary embodiment of the present invention; 
       FIG. 20  shows another side view of the embodiment shown in  FIG. 19 ; 
       FIG. 21  shows a perspective view of the embodiment shown in  FIGS. 19 and 20 , in which the apparatus includes two cylinders positioned underneath the belts; and 
       FIG. 22  shows a perspective view of another embodiment of a cradle portion having two rollers; and 
       FIG. 23  shows an end view of the cradle portion shown in  FIG. 22 . 
   

   DETAILED DESCRIPTION 
     FIG. 1  shows a perspective view of one exemplary embodiment of a bale processing apparatus  10  attached to a vehicle  100 . The apparatus  10  includes a cradle portion  12  and a lift portion  50 . The cradle portion  12  includes first and second rollers  22 ,  24 . Belts  32 ,  34 ,  36 ,  38  pass over the rollers  22 ,  24  and also pass around a third roller (not shown). The first and second rollers  22 ,  24  are connected at ends to first and second frame members  14 ,  15 . The first roller  22  is connected to the frame members  14 ,  15  at a fixed position. The second roller  24  is connected to the frame members  14 ,  15  at an adjustable position within a slot  16  defined in the frame members  14 ,  15 . An actuator  60  moves the second roller  24  relative to the frame members  14 ,  15  within the slot  16 , thereby tightening or loosening tension on the belts  32 ,  34 ,  36 ,  38  (a “tightened position” or a “loosened position”). In other embodiments, various other means may be used to change tension on the belts  32 ,  34 ,  36 ,  38  without moving the rollers  22 ,  24 , such as, for example, adding a separate roller for the exclusive purpose of changing tension, or adding any other sort of clutch-type device that engages the belts  32 ,  34 ,  36 ,  38 . 
   The lift portion  50  includes frame portions  52 ,  54  pivotally connected to each other at a hinge member  55 . Frame portion  54  moves relative to frame portion  52  about the hinge member  55  in response to movement by an actuator (not shown) to lift a hay bale (not shown) into the cradle portion  12 . A lift portion  50  further includes means for engaging a bale. In the embodiment of  FIG. 1 , the bale engaging means is a spear  40  that pierces the bale at or near a center portion of the bale. 
   In use, a bale is engaged by the spear  40 . The actuator (not shown) then causes the frame portion  54  to move relative to frame portion  52  at the hinge member  55 , thereby lifting the bale. The bale is raised by the lift portion  50  until the bale&#39;s weight causes it to disengage the spear  40  and fall into the cradle portion  12 . Once the bale is in the cradle portion  12 , the user removes any twine, cellophane, or other baling material to allow the bale to come apart. A motor (not shown) then causes the belts  32 ,  34 ,  36 ,  38  to move. With the rollers  22 ,  24  in the loosened position, the bale rotates within the cradle portion  12  in response to movement of the belts  32 ,  34 ,  36 ,  38  without falling out of the apparatus  10 . As the bale rotates, the hay unwinds from the bale and discharges from the side of the apparatus  10 . The user may cause the bale to unwind while driving the vehicle  100 , thereby spreading the hay across a desired area. If the user wants to discharge a full or partially-unwound bale, the user may cause the actuator  60  to move the rollers  22 ,  24  to the tightened position, thereby tightening the belts  32 ,  34 ,  36 ,  38 . With the rollers  22 ,  24  in the tightened position, the user may cause the belts  32 ,  34 ,  36 ,  38  to move, thereby discharging the bale. 
     FIG. 2  shows a more detailed perspective view of the bale processing apparatus  10  shown in  FIG. 1 . The embodiment of  FIGS. 1 and 2  is designed to removeably connect to a common flatbed or pickup truck. The apparatus  10  includes wheels  75  and jacks  72  to support the apparatus  10  when the apparatus is not connected to a vehicle (e.g.,  100  in  FIG. 1 ). Horizontal frame members  70  connect to the jacks  72  and to frame portion  52  of the lifting portion  50 . The roller  22  is connected to a motor  80  by a gear  82  and a drive belt  81 . The motor  80  causes the roller  22  to move, thereby moving the belts  32 ,  34 ,  36 ,  38 . 
     FIG. 3  shows a more detailed perspective view of the actuator  60  shown in  FIGS. 1 and 2 . The actuator  60  is connected at one end to frame member  14  and at another end to the second roller  24 . The actuator  60  causes the roller  24  to move within the slot  16  between a tightened and loosened position. In the embodiment of  FIG. 3 , the roller  24  is in the loosened position. In one embodiment, a second actuator (not shown) is connected to the opposing end of the roller  24  and to the frame member  15 . 
     FIG. 4  shows another perspective view of the apparatus  10  shown in  FIGS. 1 and 2 . A second actuator  60  is connected to the end of the roller  24  and to frame member  15 .  FIG. 4  illustrates the third roller  26  positioned between the first and second rollers  22 ,  24  at a generally lower position in this embodiment. The belts  32 ,  34 ,  36 ,  38  pass around all three rollers  22 ,  24 ,  26 . 
     FIG. 5  shows a more detailed view of the motor assembly shown in  FIG. 4 . A gear  82  is connected to the first roller  22 . The gear  82  is driven by a drive belt  81  connected to the motor  80 . In one embodiment, the motor  80  can move the belts  32 ,  34 ,  36 ,  38  in either direction 
     FIGS. 6-8  show operation of the lift portion  50  of the apparatus  10 .  FIG. 6  shows a plan view of the apparatus  10  with the lift portion  50  in a lowered position at which the lift portion  50  has begun to raise (without a bale). In use, the lift portion  50  lifts a bale on the spear  40  to position the bale in the cradle portion  12  of the apparatus  10 . Actuator  57  connects between the frame portions  52 ,  54  to cause movement therebetween about the hinged member  55 . Actuator  57  may be controlled, for example, hydraulically or electrically. The spear  40  is connected to the frame portion  54  at a pivotal connection  58  that allows limited movement in a plane generally perpendicular to the cradle portion  12  of the apparatus  10 . In the embodiment of  FIG. 6 , that is the plane of the drawing sheet. Spring assembly  56  urges the spear  40  into the position shown in  FIGS. 6 and 7  in which the spear  40  is generally normal to the frame portion  54 . 
     FIG. 7  shows another plan view of the apparatus  10  shown in  FIG. 6  with the lift portion  50  in a partially raised position. Actuator  57  has extended, thereby causing frame portion  54  to rotate upward, about the hinge connection  55  relative to the frame portion  52 . Spear  40  remains generally normal to frame portion  54  in the position shown in  FIG. 7 . The angle of the lift portion  50  in  FIG. 7  is not yet great enough, in this embodiment, to cause the bale to release from the spear  40 . 
     FIG. 8  shows another plan view of the apparatus  10  shown in  FIGS. 6 and 7  with lift portion  50  raised farther than in  FIGS. 6 and 7 . In the embodiment of  FIG. 8 , the lift portion  50  has raised to a point at which a bale (not shown) has begun to disengage the spear  40 . The weight of the bale causes the bale to fall from the lift portion  50  into the cradle portion  12 , thereby causing the spear  40  to pivot about the pivotal connection  58  to release the bale from the spear  40 . Once the bale is released from the spear  40 , the spring assembly  56  will cause the spear  40  to return to its original position, shown in  FIGS. 6 and 7 . 
     FIG. 9  shows an exemplary embodiment of the cradle portion  12  of the apparatus  10 , shown in  FIG. 1 . Belts  32 ,  34 ,  36 ,  38  pass around rollers  22 ,  24 ,  26 . In the embodiment of  FIG. 9 , the belts  32 ,  34 ,  36 ,  38  are shown in the loosened position ready to receive and/or hold a bale. 
     FIG. 10  shows an end view of the embodiment of the cradle portion  12  shown in  FIG. 9 . In the embodiment of  10 , the belts  32 ,  34 ,  36 ,  38  are in the loosened position. As shown by belt  38 , the belts  32 ,  34 ,  36 ,  38  sag to receive a bale in the cradle portion  12 . 
     FIG. 11  shows an end view of the cradle portion  12  with a bale  1  positioned thereon. Because the belts  32 ,  34 ,  36 ,  38  are generally loosened, the bale  1  rests on the belts  32 ,  34 ,  36 ,  38  without falling off of the apparatus  10  as the apparatus  10  (or the vehicle (e.g.,  100  in  FIG. 1 ) to which it is attached) moves. 
     FIG. 12  shows an end view of the cradle portion  12  shown in  FIG. 11 , in which the belts  32 ,  34 ,  36 ,  38  are moving to unroll the bale  1 . As the belts  32 ,  34 ,  36 ,  38  turn, the bale  1  remains in the cradle portion  12  but hay from the bale  1  feeds out of the apparatus  10 . 
     FIG. 13  shows an end view of the cradle portion  12  of the apparatus  10  with the belts  32 ,  34 ,  36 ,  38  in a tightened position. In comparison to  FIG. 11 , the upper portion of the belts  32 ,  34 ,  36 ,  38  (on which the bale  1  is positioned) is generally flatter than in the loosened position. The belts  32 ,  34 ,  36 ,  38  may be tightened for example, to move a bale  1  or a partial bale off of the apparatus  10 . 
     FIG. 14  shows an end view of the cradle portion  12  shown in  FIG. 13  in which the belts  32 ,  34 ,  36 ,  38  are moving. Because the belts  32 ,  34 ,  36 ,  38  are in a tightened position, the bale  1  is free to move laterally in response to movement of the belts  32 ,  34 ,  36 ,  38 , off of the apparatus  10 . 
     FIG. 15A-E  show views of an exemplary embodiment of the bale processing apparatus  10  of the present invention, in use with a bale  1 .  FIG. 15A  shows a perspective view of the apparatus  10  as it is positioned on a flatbed  101  of a vehicle  100 , such as a truck. The vehicle  100  backs up toward the apparatus  10  to engage the apparatus  10  and to connect the vehicle  100  to the apparatus  10 . As shown in  FIG. 15B , the jacks  72  are raised, and the apparatus  10  is attached to the vehicle  100 .  FIG. 15C  shows a perspective view of the apparatus  10  engaging a bale  1  with the spear  40  and lifting the bale  1  from the ground so that the bale  1  can be transported on the spear  40  or in the cradle portion  12 .  FIG. 15D  shows a perspective view of the apparatus once the bale  1  has been positioned in the cradle portion  12 .  FIG. 15E  shows a side view of the apparatus  10  with the bale  1  in the cradle portion  12 . 
     FIG. 16  shows an alternative embodiment of a bale processing apparatus  200  in which the apparatus  200  includes a motor vehicle. The cradle portion  12  may be permanently attached to the vehicle or may be removable. 
     FIG. 17  shows another embodiment of a bale processing apparatus  300  that includes two sets of wheels  75 ,  76  and is attached to a hitch of a tractor, truck, or other vehicle. 
     FIG. 18  shows a perspective view of the apparatus of  FIG. 1  in which two bales  1 ,  2  are positioned on the apparatus  10 . In the embodiment shown, the apparatus is designed to hold a first bale  1  in the cradle portion  12  and a second bale  2  on the spear  40 . In this manner, two bales  1 ,  2  may be unwound one after another, without picking up another bale. In the embodiment shown, the first bale  1  is being unwound, while the second bale  2  is positioned on the spear  40 . When the first bale  1  is completely unwound, the second bale  2  may be moved to the cradle portion  12 , and then the second bale  2  may be unwound. 
     FIG. 19  shows a side view of another exemplary embodiment of the present invention. The lift portion  50  is actuated by one or more cylinders  70 A mounted to the frame below the belts  32 ,  34 ,  36 ,  38 . The cylinder  70 A has an extended portion  70 B that pushes a cross-member  70 D (see also  FIG. 20 ) that is, in turn, connected to a bar  70 E that connects to the lift portion  50  at a pivot point  70 F. The cross-member  70 D engages a track  70 C running underneath the belts  32 ,  34 ,  36 ,  38 . The cylinder  70 A extends to raise the lift portion  50  and retracts to lower the lift portion  55 . The track  70 C guides cross-member  70 D as the cylinder  70 A extends and retracts. The track  70 C angles upward toward the end, to allow the lift portion  50  to be further raised. In the example of  FIG. 19 , the lift portion  50  is shown in a raised position. 
     FIG. 20  shows another side view of the embodiment shown in  FIG. 19 .  FIG. 20  shows a cut-away view of the track  70 C, with the lift portion  50  in a lowered position. In this example, the cross-member  70 D is located further toward the cylinder  70 A, within the track  70 C. 
     FIG. 21  shows a perspective view of the embodiment shown in  FIGS. 19 and 20 , in which the apparatus  10  includes two cylinders  70 A positioned underneath the belts  32 ,  34 ,  36 ,  38 . 
     FIG. 22  shows a perspective view of another embodiment of a cradle portion  12 A having two rollers  22 ,  24 , rather than the three shown in other embodiments. The two-roller configuration may be used, for example, in connection with the cylinders  70 A to actuate the lift portion  50 , as shown in  FIGS. 19-21 . 
     FIG. 23  shows an end view of the cradle portion  12 A shown in  FIG. 22 . 
   Although the present invention has been described with respect to particular embodiments thereof, variations are possible. The present invention may be embodied in specific forms without departing from the essential spirit or attributes thereof. It is desired that the embodiments described herein be considered in all respects illustrative and not restrictive and that reference be made to the appended claims and their equivalents for determining the scope of the invention.