Abstract:
A cotton receiving and densification apparatus for an upper region of a cotton module builder adapted for receiving a plurality of side-by-side flows of cotton and air and converging and densifying the cotton for distribution and conveyance downwardly into the module builder, including a cotton receiving chamber which tapers into a cotton densification chamber, both chambers being located above and downwardly opening into an upper region of a cotton compacting chamber of the module builder, the apparatus being capable of remaining intact when the module builder is collapsed for transport and storage.

Description:
TECHNICAL FIELD  
       [0001]     This invention relates generally to a cotton module builder or packager of a cotton harvesting machine, and more particularly, to cotton receiving and densification apparatus for a module builder adapted for receiving a plurality of side-by-side flows of cotton and air and converging and densifying the cotton for distribution and conveyance downwardly into the module builder or packager.  
       BACKGROUND ART  
       [0002]     Presently, when harvesting cotton, in many instances, it is desirable to harvest as many rows of cotton plants as possible during a pass of a harvesting machine through a field of cotton plants. It is now common for as many as 6 rows of plants to be simultaneously picked from both sides. Typically, a cotton harvesting machine includes a plurality of side-by-side ducts extending from the picker units of the harvesting apparatus to an inlet opening of a cotton receiver. Some cotton receivers are baskets and may, or may not, include apparatus for compacting cotton received therein to some extent. Typically, such baskets have an overall width which is about equal to the maximum allowed width of a vehicle for unescorted travel over public roads, which is about 12 feet in the USA. The ducts extending in side-by-side relation from the picker units are typically positioned to propel flows of cotton and air through an elongate inlet opening extending across all or much of the sideward extent of the upper front end of the basket. Thus, the overall sideward extent of the plurality of side-by-side ducts at their interface with the cotton receiving basket can be about equal to, or only marginally smaller than, the sideward extent of the upper region of the basket itself, for side-by-side flows of cotton into the basket. The flows of air from the ducts are typically strong enough to carry at least some of the cotton through the upper region of the basket into a rear region of the interior thereof. The basket can include cotton compacting and distributing apparatus therein, such as a frame carrying one or more augers rotatable in one or both rotational directions for distributing the cotton within a lower region of the basket, to the extent desired or required. Typically, when a cotton basket is filled to its capacity with cotton, the cotton is unloaded into another basket or other device for transport to a storage location or a gin. A common disadvantage of cotton baskets is that the cotton is not densely compacted, such that, when unloaded, it is not in a unitary, free standing state, and therefore, requires further handling which is not as efficient both costwise and timewise.  
         [0003]     More recently, cotton harvesting machines have been equipped with cotton receivers known as cotton module builders, and also cotton packagers, which receive the cotton from the plurality of side-by-side ducts, and include compacting and distributing apparatus operable for compacting the cotton in a cotton compacting chamber of the module builder or packager into a cohesive, unitary body or module of compacted cotton. Herein, the terms module builder and packager are to be interpreted interchangeably. The cotton distributing and compacting apparatus typically includes at least one auger rotatable for conveying cotton through the compactor and distributing the cotton in a desired manner or pattern within the module building chamber. Such a cotton module can be unloaded from the module builder onto the ground or another surface in a free standing, unitary state, for storage and eventual transport to a gin for processing. Typically, such cotton modules have dimensions including a length of about 16 feet, and a width at the bottom and height of between about 7 and 9 feet. A completed cotton module can have a weight of up to about 11,000 pounds. It has been found to be desirable for the upper region of a cotton compacting chamber to have a sideward extent which is substantially less than that of a completed module, such that the upper portion of a module compacted in the chamber will have a corresponding smaller sideward extent. Then, when the module is removed from the chamber, due to springiness of the compacted cotton, the upper region of the module typically expands sidewardly, such that the module will have a more rectangular shape.  
         [0004]     As a result, it has been found to be desirable for the cotton compacting chamber of a cotton module builder to have opposing side walls which taper convergingly from a floor in the chamber to an upper region of the chamber into which the cotton is received from the side-by-side plurality of ducts. The sideward extent or width of the cotton compacting chamber at the upper end can possibly be as small as from about 3 to about 6 feet for forming a module having a base width of about 7 to 9 feet. It is desirable to have as large as possible width available for the side-by-side array of ducts delivering cotton to the upper region of the cotton module builder, for instance, up to the maximum width of a machine for travel over public roads receiving basket, or about 12 feet, such that disassembly, folding or the like, of the ducts is not required for travel over public roads. As a result, a disparity can exist between the sideward extent of the incoming flows of air and cotton, which will be equal to the sideward extent of the array of ducts, and the possible sideward extent of the upper region of the cotton receiving chamber through which the cotton is to pass enroute to the chamber.  
         [0005]     Still further, it is desirable for cotton harvesters including module builders to have a height or upward extent in an operational mode which is significantly greater than that which is allowed for travel over public roads, but not so great so as to pose a danger of tipping. Therefore, a cotton module builder typically must be vertically collapsible from an operational height to a storage or travel height. Presently, known cotton module builders include an upper module builder structure which is telescopically movable upwardly and downwardly relative to a lower module builder structure, for configuring in an operational mode, and in a travel or storage mode. When placing the module builder in the travel or storage mode, it is desirable that any cotton receiving and densification structure not require time consuming assembly, disassembly, folding or unfolding.  
         [0006]     Thus, what is sought is cotton receiving and densification apparatus for a cotton module builder, which provides the advantages and overcomes one or more of the problems and shortcomings set forth above.  
       SUMMARY OF THE INVENTION  
       [0007]     What is disclosed is cotton receiving and densification apparatus for a cotton module builder of a cotton harvesting machine which provides at least one of the advantages and overcomes at least one or more of the problems and shortcomings set forth above.  
         [0008]     According to a preferred aspect of the present invention, a cotton module builder for a cotton harvesting machine includes a floor and opposing side walls extending upwardly from opposite peripheral edges of the floor defining an upwardly open compacting chamber. The compacting chamber includes an upper region having a predetermined first sideward extent. The module builder includes cotton distributing and compacting apparatus supported in the upper region of the compacting chamber for movement downwardly against cotton collected therein for compacting the collected cotton into a compacted cotton module. The cotton distributing and compacting apparatus is configured for supporting cotton thereon and includes at least one elongate auger rotatable for moving cotton supported thereon longitudinally therealong and downwardly therethrough for distribution of the cotton in the compacting chamber. The preferred cotton receiving and densification structure is disposed in covering relation to the upper region of the cotton compacting chamber and above the cotton distributing and compacting apparatus. The preferred cotton receiving and densification structure defines a cotton receiving chamber generally above and downwardly open to one end of the upper region of the cotton compacting chamber and possibly a middle region thereof. The structure preferably additionally includes a cotton densification chamber in connection with the cotton receiving chamber located generally above and downwardly open to an opposite end and a middle region of the cotton compacting chamber between the one end and the opposite end. The structure further preferably defines an inwardly facing inlet opening in connection with an inlet end of the cotton receiving chamber and disposed for receiving flows of airborne cotton from a side-by-side array of ducts in connection with harvesting apparatus of a harvesting machine, the inlet opening and the inlet end of the cotton receiving chamber having a predetermined second sideward extent which is at least about twice the first sideward extent of the upper region of the compacting chamber. The structure further preferably includes side wall portions defining sides of the cotton receiving chamber which taper convergingly from the inlet region to the densification chamber such that at least portions of flows of airborne cotton received through the inlet opening into the inlet region will be convergingly guided by the side wall portions into the densification chamber.  
         [0009]     In operation, as a result of the tapered walls and convergence of the airborne cotton flows within the cotton receiving and densification structure, portions of the airborne cotton flowing through the cotton receiving chamber will be deflected by the walls and forced by other flows of cotton, downwardly from the receiving chamber onto the cotton distributing and compacting apparatus therebeneath. Other portions of the airborne cotton flows will be convergingly directed into the cotton densification chamber wherein the cotton will fall onto the cotton distributing and compacting apparatus. The tapered transition from the receiving chamber to the densification chamber thus serves to more evenly distribute the incoming cotton. Additionally, at the same time, the at least one auger of the cotton distributing and compacting apparatus can be operated for moving cotton thereon and thereabove, longitudinally toward the cotton receiving chamber, or toward the densification chamber, as required or desired for achieving a desired distribution of the cotton into the compacting chamber therebelow. The cotton distributing and compacting apparatus will also be driven downwardly against cotton collected in the compacting chamber as desired or required for compacting the cotton into a unitary compacted body or module.  
         [0010]     According to another preferred aspect of the invention, the cotton receiving and densification chambers have sufficient vertical extent, such that cotton can collect on the cotton distributing and compacting apparatus and be distributed by operation of the auger in a desired manner, during continuous flow of cotton into and through the cotton receiving and densification chambers thereabove.  
         [0011]     Additionally, side portions of the cotton receiving and densification structure defining at least the cotton receiving chamber will extend sidewardly beyond the side walls of the module builder for accommodating the overall width of the side-by-side array of ducts, and the upper portion of the module builder is telescopically retractable vertically relative to the lower portion thereof with the sidewardly extending portions of the cotton receiving and densification structure fixed in position, such that no folding, unfolding, or over-disassembly of the cotton receiving and densification structure is required to prepare the module builder for transportation or storage in a vertically retracted or collapsed mode. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]      FIG. 1  is a side view of a cotton harvesting machine including a cotton module builder including cotton receiving and densification apparatus according to the invention;  
         [0013]      FIG. 2  is a simplified rear view of the cotton module builder of the machine of  FIG. 1  with an unloader door thereof removed to show interior features of the module builder;  
         [0014]      FIG. 3  is a simplified side view of the cotton module builder, showing a location of cotton distributing and compacting apparatus therein and illustrating flows of air and cotton into the receiving and densification apparatus;  
         [0015]      FIG. 4  is a simplified perspective view of the module builder and the receiving and densification apparatus;  
         [0016]      FIG. 5  is a simplified top view of the module builder and the receiving and densification apparatus, in association with an array of ducts conveying the air and cotton flows into the receiving and densification apparatus; and  
         [0017]      FIG. 6  is another fragmentary side view of the module builder, shown in a telescopically collapsed state, and showing the receiving and densification apparatus. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0018]     Referring now to the drawings, in  FIG. 1 a  cotton harvesting machine  10  is shown, including cotton receiving and densification apparatus  12  constructed and operable according to the teachings of the present invention on a cotton module builder  14  of the machine. Harvesting machine  10  includes a plurality of harvesting units  16  arranged in a side-by-side array across a forward end  18  of machine  10  for harvesting cotton from plants as machine  10  is moved in the forward direction along rows of the plants (not shown). The harvested cotton is conveyed by air flows individually through a side-by-side array of ducts  20  extending upwardly and rearwardly from units  16  into a forward end  22  of cotton receiving and densification apparatus  12 , as denoted by arrows A ( FIGS. 1, 3  and  5 ).  
         [0019]     Referring also to  FIGS. 2, 3  and  4 , cotton module builder  14  is shown. Module builder  14  is a structure of rectangular shape, including an interior cotton compacting chamber  24  defined by a floor  26 , forward and rearward end walls  28  and  30 , and opposing side walls  32 . End walls  28  and  30 , and the side walls  32 , extend upwardly from floor  26  to an upper region  33  of chamber  24  which defines a generally upwardly facing opening, which is covered by and enclosed by cotton receiving and densification apparatus  12  which extends upwardly therefrom. At least end walls  28  and  30 , and side walls  32 , are preferably constructed of an air permeable material, such as a mesh or perforated sheeting having holes or openings therein adequate for dissipation of air flow therethrough, but which will retain the cotton therein.  
         [0020]     Cotton distributing and compacting apparatus  34  is shown in upper region  33  of interior compacting chamber  24 . Apparatus  34  includes side-to-side extending cross bars  36  adjacent to end walls  28  and  30  which extend through vertical slots  38  through the side walls  32 , and are supported by a support structure  40 , including a pair of fluid cylinders  42  located beside the side walls, for moving apparatus  34  reciprocally upwardly and downwardly within chamber  24 , as denoted by arrows B in  FIGS. 2 and 3 . Essentially, in operation, as cotton, denoted by arrows D in  FIG. 2 , is conveyed into compacting chamber  24  by rotation of at least one augers  48 , at times, apparatus  34  will be operated to move reciprocally in the downward direction denoted by arrow B, against the collected cotton to compact the cotton against floor  26  to gradually build a compacted body or module as represented by module  44  in  FIG. 3 . Apparatus  34  includes forwardly and rearwardly extending compacting members  46  extending between and supported by cross bars  36  in compacting chamber  24 . Additionally, apparatus  34  includes at least one, and preferably a plurality of the elongate helical augers  48  extending forwardly and rearwardly between and supported by cross bars  36  at spaced locations between compacting members  46 . Each auger  48  is connected in rotatably driven relation to a suitable drive (not shown) operable in the well known conventional manner for rotating the auger  48  in a desired direction, as denoted by arrows C, about a longitudinal rotational axis  50  extending therethrough. Compacting members  46  and augers  48  are preferably constructed and are sidewardly sufficiently close together, and apparatus  34  extends sidewardly across substantially the sideward extent of upper region  33  of compacting chamber  24 , so as to retain or hold at least some of any cotton conveyed into apparatus  12  therein and above compacting chamber  24 , when apparatus  34  is in the position shown and augers  48  are not rotated. When augers  48  are rotated, depending on the direction of rotation, they will convey cotton disposed thereon and thereabove either forwardly or rearwardly therealong, and simultaneously downwardly into compacting chamber  24 , as denoted by arrows D in  FIGS. 2 and 3 . Here, it should be noted that it is usually desirable for a cotton module, such as module  44 , to be compacted so as to have a substantially uniform height in the forward and rearward directions, and, as result, it is desirable to operate augers  48  in a manner for achieving a relatively uniform distribution of cotton within compacting chamber  24  in the forward and rearward directions. It should also be noted that upper region  33  of a compacting chamber such as chamber  24  will typically have a sideward extend, here denoted as extent X in  FIG. 2 , which will preferably be within a range from about 3 to about 6 feet, which will be smaller than the sideward extent of chamber  24  adjacent to floor  26 , such that side walls  32  taper convergingly upwardly toward upper region  33 , for imparting initial tapered shapes to the sides of a module such as module  44 . As noted above, the tapered shape of the sides of a module will eventually be lost after the module is removed from chamber  24 .  
         [0021]     Cotton receiving and densification apparatus  12  preferably includes structure  52  disposed above and in covering relation to upper region  33  of cotton compacting chamber  24 , above cotton distributing and compacting apparatus  34 . Referring to  FIGS. 4 and 5 , that portion of structure  52  that comprises forward end  22  of apparatus  12  defines an interior cotton receiving chamber  54  located generally above and downwardly open to a forward end of upper region  33  of cotton compacting chamber  24 , and can optionally extend over a more middle region thereof. Structure  52  preferably additionally includes a cotton densification chamber  56  in connection with cotton receiving chamber  54 , located rearwardly thereof and generally above and downwardly open to an opposite end and a middle portion of upper region  33  of cotton compacting chamber  24 . Structure  52  further preferably defines an inwardly facing inlet opening  58  in connection with an inlet region  60  of cotton receiving chamber  54 , disposed for receiving flows A of airborne cotton from side-by-side array of ducts  20  in connection with harvesting units  16 . Inlet opening  58  and inlet region  60  of cotton receiving chamber  54  have a predetermined second sideward extent Y, as shown in  FIG. 5 , which is equal to at least about twice the sideward extent X of upper region  33  of compacting chamber  24 . Here, sideward extent Y is illustrated to be from about 11 to 12 feet, which is the maximum permissible width of a vehicle for unescorted travel over public roads in the USA, and sideward extent X is about 4 to 5 feet, although other values for X and Y can be used as desired or required for a particular application. Structure  52  further preferably includes opposing side wall portions  62  defining sides of cotton receiving chamber  54 , and which include tapered portions  64  which taper convergingly from inlet region  60  to densification chamber  56 , defining a transition region  66  of receiving chamber  54 , wherein at least portions of flows of airborne cotton received through inlet opening  58  will be convergingly guided by tapered portions  64  into densification chamber  56 , as best shown by arrows A in  FIG. 5 . Tapered wall portions  64  can be straight, or convex or concave or otherwise curved, as desired or required for a particular application.  
         [0022]     Structure  52  includes opposing side walls  68  which define cotton densification chamber  56  and extend from tapered portions  64  to an end wall  70  of structure  52  which encloses and defines the end of cotton densification chamber  56 . A roof  72  covers transition region  66  of chamber  54 , and all of cotton densification chamber  56 . Side wall portions  62  and  64 , side walls  68 , end wall  70 , and roof  72  can be of solid sheet metal or plastic, or have holes or perforations therethrough, as required or desired for a particular application. Inlet region  60  of cotton receiving chamber  54  is preferably covered by a screen  74 . That portion of cotton receiving chamber  54  disclosed directly above upper region  33  of cotton compacting chamber  24 , and substantially all of cotton densification chamber  56 , are downwardly open in connection with region  33 , essentially over the entire forward to rearward length thereof. Referring more particularly to  FIGS. 4 and 5 , it is evident that cotton receiving chamber  54  extends sidewardly beyond side walls  32  of module builder  14 , for accommodating the width of array of ducts  20 , and the bottoms of those portions of chamber  54  which extend beyond side walls  32  are enclosed by floor panels  76 . As a result, it is evident that structure  52  defines an upwardly closed and downwardly open continuous cavity which is significantly wider at inlet opening  58  and inlet region  60 , and which tapers down through a transition region to a much narrower densification region of chamber  56  having a sideward extent about equal to sideward extent X of upper region  33  of chamber  24 . As a result, flows of cotton A from ducts  20  through inlet opening  58  will pass through inlet region  60  and into transition region  66 , wherein portions of the flows will fall onto apparatus  34 , and portions will be converged and consolidated so as to pass in a denser state into densification chamber  56 . Some of the cotton will fall from cotton receiving chamber  54  into the more forward portion of upper region  33  of compacting chamber  24  and onto cotton distributing and compacting apparatus  34 , while some of the cotton will fall from densification chamber  56  into more mid and rear regions of upper region  33  so as to fall on corresponding portions of compacting apparatus  34 . During the inflow of cotton, augers  48  can be operated as required for distributing the cotton into compacting chamber  24 , and compacting apparatus  34  can be driven downwardly against cotton collected in chamber  24  for compacting it into a compacted module, such as module  44 .  
         [0023]     Cotton receiving and densification apparatus  12  can include an inlet hood  78  extending forwardly from inlet opening  58  for facilitating smooth transition of flows of cotton A from ducts  20  into inlet opening  58 . Hood  78  is removed in  FIGS. 4 and 5  for clarity.  
         [0024]     In  FIG. 6 , module builder  14  is shown in a vertically retracted or collapsed state, wherein an upper portion thereof on which apparatus  12  is mounted, is telescopically received in a lower portion of the module builder. Here, it can be observed that a lower periphery  80  of structure  52  remains above the lower portion of module builder  14 , such that no folding, unfolding, disassembly or other steps in regard to apparatus  12  is required when placing module builder  14  in the retracted state. Such state shown is suitable for travel on public roads, under bridges and the like.  
         [0025]     It will be understood that changes in the details, materials, steps, and arrangements of parts which have been described and illustrated to explain the nature of the invention will occur to and may be made by those skilled in the art upon a reading of this disclosure within the principles and scope of the invention. The foregoing description illustrates the preferred embodiment of the invention; however, concepts, as based upon the description, may be employed in other embodiments without departing from the scope of the invention. Accordingly, the following claims are intended to protect the invention broadly as well as in the specific form shown.