Abstract:
A foldable extension for an unloading door of a cotton receiving receptacle of cotton harvester which, when in a deployed position, increases the overall length of the door and directs cotton conveyed over the extension in a downward direction so as to facilitate more precise placement in a receiving receptacle. The extension does not have to be folded to its stored position each time the unloading door is closed, and when folded into its stored positions, does not increase the overall height of the harvester or interfere with telescopic operation of upper and lower portions of the basket.

Description:
TECHNICAL FIELD 
   This invention relates generally to a foldable extension for an unloading door of a cotton receiving receptacle of cotton harvester, and more particularly, to an extension which, when in a deployed position, increases the overall length of the door and directs cotton conveyed over the extension in a downward direction so as to facilitate more precise placement in a receiving receptacle. The extension does not have to be folded to its stored position each time the unloading door is closed, and when folded into its stored positions, does not increase the overall height of the harvester or interfere with telescopic operation of upper and lower portions of the basket. 
   BACKGROUND ART 
   Some baskets of cotton harvesters include an open side for unloading cotton from the basket interior to another location such as another basket, a wagon, or the like. The basket is typically raised to an unloading position and includes a door movable between an upwardly extending closed position enclosing the open side of the basket, and an open or unloading position extending outwardly from the open side of the basket as a continuation of a floor or other lower surface thereof and over which the cotton from the basket can be conveyed so as to be dumped or dropped into or on the other location or receiving receptacle. 
   Generally, it is desirable for such doors to have a capability for extending a distance from the cotton harvester basket up to about equal to the sideward extend of cotton harvester row units which extend in a line across the front of the harvester. This is to enable the harvester to be driven up to a position beside a cotton receptacle for unloading or dumping into the receptacle without significant maneuvering, particularly backing maneuvers. However, in many regions there are height limits imposed on cotton harvesters to allow movement under bridges and utility lines, both when self-propelled and when trailered, which limits are not to be exceeded by the basket or the basket door when closed. As a result, the sideward extend of the door must be correspondingly limited, or, if a longer sideward extent is desired or required, the door must be constructed so as to have a sideward length greater than its upward extend when in a transport mode. 
   As one alternative for a door having a longer sideward extent in the open position and a shorter height when closed, a foldable door could be used, that is, a door that folds at one or more locations along the length thereof. However, this may be an undesirable alternative if the thickness or sideward extent of the folded door is such that it significantly decreases the capacity of the basket. Many baskets include an upper portion which is telescopically received in a lower basket portion for transport, and any folding door should not interfere with this telescopic operation, nor extend outwardly so as to significantly increase the overall width of the harvester when shipped on trailers and rail cars with the harvesting units removed. Also, a folding door can require complex apparatus such as large fluid cylinders for automatic operation, and folding a door each time the basket is unloaded can be time consuming and result in more required maintenance and service. 
   Thus, what is sought is an unloader door or extension therefor, which when deployed provides an increased sideward extent, but which overcomes many of the shortcomings and problems set forth above. 
   SUMMARY OF THE INVENTION 
   What is disclosed is an extension for an unloader door of a cotton receiving basket of a cotton harvester, which provides one or more of the sought after features and overcomes many of the shortcomings and problems set forth above. According to a preferred aspect of the invention, the door has a proximal end connected adjacent to a floor of a cotton harvester basket for pivotal movement between a closed position in closing relation to an open side of the basket and an open position extending sidewardly from the floor in generally parallel relation thereto. The door has a distal end opposite the proximal end and a cotton conveying surface which faces the interior when the door is in the closed position and which faces upwardly when the door is in the open position and includes elements movable for conveying the compacted cotton from the interior of the basket sidewardly to the distal end. The extension according to the invention is supported adjacent to the distal end of the door for pivotal movement between a stored position in overlaying relation to the distal end of the door and a deployed position extending sidewardly therefrom, the extension including a free end which when the door is open and the extension is in the deployed position is preferably spaced sidewardly from and a predetermined distance below the distal end of the door. The extension includes an upper surface which extends from the distal end of the door to the free end and over which the cotton will be conveyed sidewardly and downwardly from the door. As a result, particularly if the cotton is compacted into a unitary body or mass, it will be directed in a predictable manner downwardly into a receptacle such as another basket located beneath the free end of the extension, so as to eliminate or substantially reduce the occurrence of problems such as cantilever extension of the cotton over the end of the door, unpredictable tipping and dropping, and missing the receiver so as to require cleanup and the like. 
   According to another preferred aspect of the invention, the upper surface of the extension can be oriented at a downwardly extending angle from the distal end of the door to the free end. As an example, the downward angle can be between about a 5° and a 15° angle to the cotton conveying surface of the door. The upper surface of the extension can also include a plurality of elongate rollers rotatable in a direction for conveying cotton thereover downwardly toward the free end. As an alternative preferred aspect of the invention, all or a substantial portion of the upper surface of the extension can be located a predetermined distance offset below the cotton conveying surface of the door. As another alternative, the upper surface can include a belt which is preferably powered and movable toward the free end for conveying the cotton thereover. The belt can be movable at a variable speed, including a speed faster than a speed of elements on the cotton conveying surface of the door for conveying the cotton to the extension. 
   As a further aspect of the invention, the extension is mountable to the door and is configured so as to be capable of remaining in the deployed position when the door is both in its open position and its closed position, and can extend upwardly from the distal end of the door when in the closed position so as to cover a portion of the open side of the basket. 
   As another feature of the invention, the extension when in the stored position in overlaying relation to the distal end of the door, can be located sufficiently close to the cotton conveying surface such that an upper portion of the basket can be telescopically received in a lower portion of the basket. As a result, the overall height of the basket will not be increased when the basket is configured for transport, self-propelled transport over roads and the like, and when carried on a rail car or trailer. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a simplified schematic rear end representation of a cotton harvester with a cotton receiving basket thereof elevated to an unloading position, an unloader door of the basket in an open position and a door extension of the invention in a deployed position for unloading cotton into an adjacent cotton receiving basket; 
       FIG. 2  is an enlarged fragmentary schematic representation of the cotton harvester and receiving basket of  FIG. 1 ; 
       FIG. 3  is an enlarged fragmentary perspective representation of the cotton harvester basket with the unloader door in the open position and the door extension in the deployed position; 
       FIG. 4  is another enlarged fragmentary perspective view of the harvester basket of  FIG. 1  with the unloader door in the open position and the extension in a stored position; 
       FIG. 5  is another enlarged fragmentary schematic representation of the harvester of  FIG. 1 , showing the basket in the raised position, the unloader door in the open position, and another embodiment of a door extension shown in a deployed position for unloading cotton into an adjacent cotton receiving basket; 
       FIG. 6  is a simplified end view of the extension of  FIG. 5 ; 
       FIG. 7  is an enlarged fragmentary perspective view of the harvester basket of  FIG. 5  showing the unloader door in an open position and the door extension in the deployed position; 
       FIG. 8  is a fragmentary side view of the harvester basket of  FIG. 5  with the unloader door in the open position and the extension in the deployed position; 
       FIG. 9  is a simplified schematic rear view of the harvester of  FIG. 1 , showing the basket thereof in a lowered position, the unloader door in a closed position, and the extension in the deployed position; 
       FIG. 10  is a simplified schematic rear view of the harvester of  FIG. 1 , showing the basket thereof in a lowered position, the unloader door in a closed position, and the extension in the stored position; and 
       FIG. 11  is a simplified schematic rear view of the harvester of  FIG. 1 , showing the basket thereof in a lowered position, the unloader door in a closed position, and the extension in the stored position, with an upper portion of the basket telescopically received in a lower portion thereof. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Referring now to the drawings, in  FIG. 1 , a representative conventional self-propelled cotton harvester  10  is shown. Cotton harvester  10  includes a plurality of picker units  12  arrayed across a front end thereof, and a cotton receiving basket  14  adapted for receiving and holding cotton picked by picker units  12  in the well known conventional manner. Also in the well known conventional manner, basket  14  is of telescoping construction, including a generally rectangular, upwardly open lower basket portion  16 , which telescopically receives a correspondingly shaped, marginally smaller downwardly open upper basket portion  18 . Basket  14  is shown in  FIG. 1  with upper basket portion  18  telescopically extended from lower basket portion  16  and a cotton receiving and holding mode. Basket  14  is also shown raised to an elevated unloading position by a plurality of upstanding supports  20 , also in the well known manner. 
   Basket  14  has an open side  22  communicating or connecting with an interior  24  ( FIG. 8 ) including a basket floor  26 . Basket  14  further includes cotton compacting apparatus (not shown) which can comprise, for instance, one or more augers in upper basket portion  18  which are movable downwardly against cotton in interior  24  for compressing or compacting and distributing it in a desired manner within interior  24 , also in the well known manner. 
   Referring also to  FIG. 2 , basket  14  of harvester  10  includes an unloader door  28  having a proximal end  30  mounted to lower basket portion  16  adjacent to floor  26  and open side  22 , for pivotal movement between an open position (shown extending sidewardly therefrom), and a closed position ( FIGS. 9 ,  10  and  11 ) at least partially enclosing open side  22 . As will be explained, the cotton in interior  24  is unloaded by movement sidewardly across floor  26  and open door  28  over a distal end  32  thereof so as to fall or drop to another location or another cotton receiver, such as representative cotton receiving basket  34 . Here, cotton being unloaded from basket  14  into basket  34  is depicted as being compacted into a cohesive or unitary body of cotton  36  having a generally rectangular shape, although it should be understood that the cotton can alternatively be compacted in a different shape mass or body, or can be less compacted or loose, as desired or required for a particular application. An important reason for compacting the cotton is to increase the capacity of basket  14 , thereby reducing the required frequency of unloading. 
   Referring also to  FIGS. 3 and 4 , door  28  has a cotton conveying surface  38  which faces upwardly when door  28  is in the open position shown. Cotton conveying surface  38  is generally flat and aligned with floor  26 , and both typically include elements for conveying the cotton thereover, which can include, for instance one or more belts, drag chains, or the like, as represented by slats  40  extending forwardly and rearwardly across surface  38 . Slats  40  are supported for sideward movement over surface  38  by a plurality of chains (not shown) which encircle sprockets  42  located adjacent to the proximal and distal ends  30  and  32  of door  28 . Driven ones of sprockets  42  are rotated by a suitable power source, such as a fluid or electric motor, in the conventional manner as will be explained. 
   A body of cotton, if sufficiently cohesive, may alternatively remain together so as to fall into the receiver as a unitary member, if not otherwise broken apart. It has also been found that in some instances it is desirable to include additional picker units  12  on harvester  10  so as to increase the overall sideward extent thereof, for instance, beyond that shown in  FIG. 1 , thereby increasing any problems in maneuvering harvester  10  into desired relation to a receiver, such as the position shown wherein distal end  32  of door  28  is located over basket  34 , if a longer or extended door is not used. 
   The present invention is directed at overcoming the problems set forth above by providing a door extension  44  that is mountable adjacent to distal end  32  of door  28  and has a deployed or open position for extending or increasing the sideward length of door  28 , and a stored or folded position in overlaying relation to distal end  32  so as not to increase the overall height of door  28  and harvester  10 . Extension  44  includes a free end  46  which when door  28  is open and extension  44  is in the deployed position is spaced sidewardly and a predetermined distance below distal end  32  of door  28 , as denoted by distance A in  FIG. 3 . Extension  44  includes an upper surface  48  which extends from adjacent to distal end  32  of door  28  to free end  46  and over which the cotton will be conveyed sidewardly and downwardly from door  28 , as illustrated by arrow B in  FIG. 2 . Here, surface  48  is generally parallel to and the distance A below cotton conveying surface  38  of door  28  such that it is possible that a compacted body of cotton such as body  36  conveyed over surface  48  will not be in contact with the entire sideward extent of surface  48 , but instead will contact it only adjacent to free end  46 . This is acceptable as it will provide guiding support for that portion of the body of cotton located thereover for controllably directing or orienting it sidewardly and downwardly so as to fall into a receiver therebelow such as the basket  34  in a predictable and controllable manner. The movement of the cotton downwardly onto the lower free end  46  can also result in some fragmenting of the cotton as illustrated at region C in  FIG. 2 , so as to break into and fall from extension  44  in predictable size fragments or pieces as opposed to as a unitary body or in varying size fragments. This feature is particularly advantageous with regard to the former possibility, as a unitary body of cotton could become lodged between a receiving basket such as basket  34  and the end of door  28 , so as to require substantial additional handling. A combination of sideward extent of extension  44  and distance A which results in a downward orientation of the cotton at from about a 5 to a 15 degree angle relative to cotton conveying surface  38  has been found to provide the desired effect. 
   In this embodiment, upper surface  48  consists of one or more forward and rearward extending endless belts  50  which encircles rollers (not shown) supported for rotation adjacent to the ends of extension  44  on shafts  52  and  54 . Shaft  52  can optionally be rotatably driven by a power source such as a fluid or electric motor. Here, sprockets  42  on distal end  32  of door  28  are driven by a fluid motor  56  on the forward end of door  28  via a chain drive  58 , as shown in  FIGS. 3 and 4 . Motor  56  or drive  58  can likewise be connected in driving relation to shaft  52  when extension  44  is in its deployed position via a suitable connecting drive  60  which can include for instance a pinch roller, or an electric or fluid clutch which automatic disconnects when rotation is stopped, to allow extension  44  to be moved to its stored position as shown in  FIG. 4 . Connecting drive  60  can optionally be operable for rotating belt or belts  50  at varying speeds, and/or at a speed greater than a speed of slats  40  over door  28 , such that the cotton is pulled over the extension as opposed to being pushed thereover. Belt or belts  50  can also include a surface which is relatively continuous and not perforated, such that cotton seeds and lint are not likely to become entangled or trapped therein. A load of cotton being unloaded over extension  44  can weigh several thousand pounds, and thus extension  44  can include suitable elements under belt or belts  50  for supporting the cotton thereon, such as additional rollers or a smooth surface over which belt  50  can ride. 
   Extension  44  preferably includes a suitable frame  62  of material such as sheet metal which supports and holds shafts  52  and  54  in spaced relation, along with the rollers and belt or belts  50 . Frame  62  includes a plurality of L shape members  64  at the forward and rear ends of extension  44 , which members  64  have ends which pivotally connect to distal end  32  of door  28  to allow pivotal movement of extension  44  between the deployed position ( FIG. 3 ) and the stored position ( FIG. 4 ). The L shape is advantageous as it positions extension  44  when in the deployed position at the desired location the distance A below cotton conveying surface  38 , and when in the stored position in overlaying relation thereto. Suitable supports such as stops and/or a prop rod or rods can also be provided on extension  44  and on door  28  for holding extension  44  in the deployed position, as denoted by stop  70  on L shape member  64  which abuts or bears against the bottom of distal end  32  of door  28 , as shown in  FIG. 2 . 
     FIGS. 5 ,  6 ,  7  and  8  show another door extension  66  constructed and operable according to the present invention for increasing the overall length of door  28  and facilitating unloading of cotton thereover in a predictable manner as explained above in reference to extension  44 , like parts of extension  66  and extension  44  being identified by like numbers. Extension  66  is mountable as shown to distal end  32  of door  28  of basket  14  of harvester  10  in the above described manner for pivotal movement between a deployed position extending sidewardly from door  28 , as illustrated in  FIGS. 5 ,  6 ,  7  and  8 , and a stored position in overlaying relation thereto, in the manner shown in  FIG. 4 . 
   Extension  66  has a free end  46  located the predetermined distance A below cotton conveying surface  38  of door  28 , to provide the sought after advantage of directing or orienting cotton conveyed over extension  66  in a desired downward direction, as set forth above. Extension  66  differs from extension  44  in several respects, including by having an upper surface  48  which is directed at a downward slant relative to surface  38  of from about 5 to about 15 degrees, as denoted by angle D in  FIG. 6 , for effecting the sought after downward direction or orientation of the cotton. Extension  66  also differs from extension  44  by the use of a plurality of forward and rearwardly extending rollers  68  for supporting and conveying the cotton thereover, instead of belt or belts  50 . The combination of slant and use of rollers is advantageous as it allows extension  66  to be unpowered, that is, rollers  68  can be free rolling as opposed to being rotatably driven. Rollers  68  can be of metal, or of plastics material so as to be lighter in weight and are preferably sufficiently close together such that a space of no more than about one inch exists between adjacent ones of rollers  68 , as denoted by space E in  FIG. 6 . 
   Extension  66  also includes a frame  62 , which can include a plurality of L shape members  64  having one end pivotally mounted to distal end  32  of door  28  for pivotal movement of extension  66  between its stored and deployed positions, and including supports such as stops and/or prop rods which bear against distal end  32  for positioning extension  66  at the indicated slant, as denoted by stop  70  in  FIG. 5 . 
   Also shown in  FIG. 5  is a representative body of compacted cotton  36  supported and being conveyed over extension  66  so as to be directed downwardly therefrom over free end  46 , as denoted by arrow B. Again, at location C, the upper region of that portion of body  36  supported on extension  66  is shown fragmenting in a predictable and desirable manner, so as to fall or drop predictably into or onto a receiver therebelow, such as cotton receiving basket  34 , in a predictable manner, and not as a unitary body or in larger fragments. 
     FIGS. 9 ,  10  and  11  show harvester  10  with a door extension representative of extensions  44  and  66  in the deployed position with upper basket portion  18  telescopically extended from lower basket portion  16 ; with door extension  44 ,  66  in the stored position and basket portion  18  extended; and with extension  44 ,  66  in the stored position and basket portion  18  telescopically received in lower basket portion  16 , respectively.  FIGS. 9 and 10  illustrate that extensions  44 ,  66  can optionally remain in the deployed position when door  28  is closed, or be pivoted to the stored position, as desired. In the stored position, the interior volume of the basket is not significantly reduced by the presence of extension  44 ,  66 .  FIG. 11  illustrates that with extension  44 ,  66  pivoted into overlaying relation to door  28 , there is sufficient clearance for the telescopic receipt of basket portion  18  in basket portion  16 , without requiring increasing the overall width of harvester  10  when prepared for transport on a trailer or rail car. Here, it should be noted that for such transport, picker units  12  are typically removed. Outer wheels  74  may also be removed. 
   Here also, one possible pivotal connection  72  for connecting extension  44 ,  66  to distal end  32  of door  28  is shown. Connection  72  can be include a suitable bearing and shaft arrangement allowing pivotal movement of extension  44 ,  66 , such as, but not limited to, a bearing on L shape member  64  which receives and is supported on a shaft on door  28 , which can be, for instance, a shaft which also supports sprocket  42 . As a result of at least free end  46  of extension  44 ,  66  being located below cotton conveying surface  38  when the extension is in the deployed position, as enabled by L shape members  64  pivotally connected to distal end  32  at pivotal connection  72 , the center of gravity of extension  44 ,  66  is located outside of door  28  as it is pivoted to its closed position, such that the extension will not be urged by its mass toward its stored position by the movement of the door. Extensions  44 ,  66  can optionally include apparatus such as a fluid cylinder or the like for pivotally moving it between the deployed and stored positions, or can be manually moved, as desired. 
   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.