Abstract:
A large bale loading, hauling and stacking apparatus that mounts on a production truck chassis. Loading is accomplished with a centrally located bale clamping mechanism that picks up a bale, rotates it approximately 180 degrees and deposits it on a manipulator that can selectively reorient the bale for selective placement on a load rack. A stack of bales is thus formed on the load rack and later deposited in the field.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application is related to U.S. Application No. 11/106,310, entitled “Material Clamping Mechanism” in the name of the same inventor and filed on the same date as the instant application. 
   BACKGROUND OF THE INVENTION 
   The present invention relates generally to agricultural self-propelled bale handling machines, and more particularly to such a machine that loads, hauls and stacks big bales. 
   A large proportion of the resources and time of the agricultural industry is directed toward the production of feed for animals, and most specifically to the production of baled stem and leaf crops such as hay. The conventional process is to cut and condition the crop with a windrower, deposit it on the ground to dry, bale the crop when appropriately dry, and then position the bales in stacks for storage or transportation. High labor requirements and increasing costs of hand hauling have caused a growing number of commercial growers to abandon their small square bale operation for a large bale package, such as round bales, or large rectangular bales 3′×3′, 3′×4′, or 4′×4′ in cross-section. Commercial haulers prefer large square bales over small square bales because they can drive into a field and be loaded for a cross-country trip in less than an hour. Large rectangular bales are loaded onto flat-bed trucks or semi-trailers directly in the field at about 20 tons per man-hour. It is these large bales that have become increasingly popular over the last several years, and to which this invention is most concerned. 
   While a pull-type machine could be designed and built to accomplish the desired tasks of loading, hauling and stacking large rectangular bales, it is most practical to develop a self-propelled unit, using a generally available truck cab and chassis as the source of motive and hydraulic power. Some mechanical devices for loading, hauling and stacking these large rectangular bales have been developed, however, they are unable to stack high enough, do not have the capability to lay various tie tiers, may greatly overload the front axle of the unit, and may not have adequate traction on rolling or wet terrain while loading. 
   Therefore, there is a need in the art for a convenient and automated system for loading a significant number of large bales onto a vehicle, with the option of tie tiers, hauling them relatively long distances, and stacking the bales in a stable manner. 
   SUMMARY OF THE INVENTION 
   Accordingly, it is an object of the present invention to provide a bale wagon that automatically loads, hauls and stacks large rectangular and round bales. 
   Another object of the present invention is to provide an automatic bale wagon for large bales that does not overload the front axle of the unit. 
   It is another object of the present invention to provide a large bale loader, hauler and stacker that uses a truck chassis as the main support and source of motive power. 
   Yet another object of the present invention is to provide a large bale loader, hauler and stacker based on an over-the-road truck chassis that loads the bales, optionally with tie tiers, using a unique bale grasping mechanism. 
   It is yet another object of the present invention to provide a large rectangular bale wagon that uses a bale loader that engages the bale, centerline of the chassis to centerline of the bale. 
   It is yet another object of the present invention to provide a large bale handling machine that has a narrow front frame and loader arms for good forward visibility for the operator. 
   It is yet another object of the present invention to provide a large automatic bale wagon that clamps the bales for loading and manipulation rather than spearing or grasping them with hooks. 
   It is another object of the present invention to provide a large bale handling machine that clamps the bales on the side rather than on the twine covered surfaces. 
   It is another object of the present invention to provide a large bale handling machine that manipulates the bales while sitting on a table, not hanging on a spear or on grasping hooks. 
   It is another object of the present invention to provide a large bale handling machine that can selectively form tie tiers. 
   Another object of the present invention is to provide a large bale loading, hauling and stacking apparatus that can stack 3′×4′ bales six high with the twine down. 
   Another object of the present invention is to provide an automatic bale wagon that can make an ideal six high twine down stack with the second and fifth tiers cross tied, convenient to common clamp loading trucks. 
   Yet another object of the present invention is to provide an automatic bale wagon that can handle shorter bales like five or six feet long silage bales. 
   Yet another object of the present invention is to provide an automatic bale wagon that can handle 4′ long bales, positioning them side by side for an 8′ wide load. 
   Yet another of the present invention is to provide an automatic bale wagon that can handle 4′×4′ bales with loader pivot repositioning (repositioning is done either manually or hydraulically). 
   Another object of the present invention is to provide an automatic bale wagon that can handle round bales as well as large rectangular bales with the same loader and manipulator. 
   Another object of the present invention is to provide a large bale loader, hauler and stacker that is automated by the use of an integrated controller/sensor arrangement that allows the operator to select and manage the bale stack structure. 
   Another object of the present invention is to provide a bale loader, hauler and stacker that is adjustable to handle the popular sized big rectangular bales, 3′×3′, 3′×4′, and 4′×4′ as well as round bales. 
   These and other objects are attained by providing a large bale loading, hauling and stacking apparatus that mounts on a production truck chassis. Loading is accomplished with a centrally located bale clamping mechanism that picks up a bale, rotates it approximately 180 degrees and deposits it on a manipulator that can selectively reorient the bale for selective placement on a load rack. A stack of bales is thus formed on the load rack and later deposited in the field. 

   
     DESCRIPTION OF THE DRAWINGS 
     The advantages of this invention will be apparent upon consideration of the following detailed disclosure of the invention, especially when taken in conjunction with the accompanying drawings wherein: 
       FIG. 1  is a top plan view of the bale loading, hauling and stacking vehicle of the present invention; 
       FIG. 2  is a side plan view of the vehicle of  FIG. 1  showing a bale in the pickup position; 
       FIG. 3   a  is a side plan view, similar to that of  FIG. 2 , showing a bale on the manipulation mechanism above the cab; 
       FIG. 3   b  is a partial side plan view of the carrier mast, horizontal tracks and carrier rollers; 
       FIG. 3   c  is a partial front view of the loader boom cylinders and boom frame; 
       FIG. 3   d  is a partial side view of the loader frame, cylinders and pivot; 
       FIG. 4  is a partial side plan view of the bale manipulation mechanism, showing particularly the bale clamp; 
       FIG. 5  is a partial front plan view of the bale manipulation mechanism of  FIG. 4 , showing a bale in phantom; 
       FIG. 6   a  is a side plan of a vehicle with the bale manipulation components mounted thereon, showing a rotated bale being moved back and down the mast to position the bale on the load; 
       FIG. 6   b  is a top plan view of the vehicle of the present invention showing, inter alia, a bale on the bale manipulation mechanism partially rotated prior to deposit on the load rack; 
       FIG. 7   a  is a top plan view of the vehicle, similar to  FIG. 6   a , with a bale rear plan view, similar to  FIG. 6 , with a bale pushed to the right prior to deposit on the load rack; 
       FIG. 7   b  is a side plan view of the vehicle of  FIG. 7   a , showing a tier bale moving back and down the mast for positioning on the load rack; 
       FIG. 7   c  is a side plan view of the vehicle of  FIGS. 7   a  and  7   b , showing the deposited bale in position on the load rack; 
       FIG. 8  is a side plan view of the vehicle, similar to  FIGS. 6 and 7 , showing the bale manipulation mechanism depositing a bale on previously deposited bales on the load rack; 
       FIG. 9  is a side plan view of an alternative embodiment of the vehicle, showing alternative mounting locations in the frame for the boom pivot and cylinder trunion mounts to accommodate different length bales; 
       FIG. 10  is a side plan view of the vehicle, showing a stack of round bales being formed on the load rack, all bales on their sides; 
       FIG. 11  is a side plan view of an alternative embodiment of the vehicle handling round bales; 
       FIG. 12  is a side plan view of the bale wagon, showing alternate tiers of bales, horizontal-vertical-horizontal, being pushed rearwardly by the push bar; 
       FIG. 13  is a side plan view of the bale wagon, showing a stack of bales being pushed rearwardly off the load tines by the push-off bar onto the ground; and 
       FIG. 14  is a schematic of a control system to manage the creation of bale stacks. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENT 
   Many of the fastening, connection, processes and other means and components utilized in this invention are widely known and used in the field of the invention described, and their exact nature or type is not necessary for an understanding and use of the invention by a person skilled in the art, and they will not therefore be discussed in significant detail. Also, any reference herein to the terms “left” or “right” are used as a matter of mere convenience, and are determined by standing at the rear of the machine facing in its normal direction of travel. Furthermore, the various components shown or described herein for any specific application of this invention can be varied or altered as anticipated by this invention and the practice of a specific application of any element may already by widely known or used in the art by persons skilled in the art and each will likewise not therefore be discussed in significant detail. 
   Broadly, the machine comprises a truck chassis fitted with two modules and a load rack. The first module is a loader that clamps and loads the bales endwise over the front center of the truck cab. Manipulation for positioning the bales into tiers is done by the second module, or manipulator, while the bale is sitting on a table. The manipulator then deposits the bales onto the load rack where the stack is formed. 
     FIGS. 1 and 2  provide a more specific depiction of the loader, hauler and stacker vehicle  10  of the instant invention. A truck chassis  20  with a cab  22  thereon provide the support and ruotwe power for vehicle  10 . Chassis  20  includes several components well known in the art, pairs  26 ,  28  and  30  affixed to and supporting a main frame  32  and the various elements making up a self-propelled vehicle combined with an aericuitural material-handling apparatus. The wheel pairs are supported on axles and other well known drive components (not shown). In this particular embodiment, the rear wheel pairs  26 ,  28  are duals, i.e., two wheels on each end of the axle, for heavy load support and distribution. A bale loader  40 , to be described in further detail below, is mounted to the forward portion of chassis  20 , in front of and over the hood and windshieid of cab  22 . A load rack  140 . also to be described further below, is pivotably attached to chassis  20  at pivot axis  136 . 
   The embodiment to be described immediately below employs an over-the-road truck chassis-based machine that loads, hauls and stacks large rectangular bales or, in other embodiments, round bales. The loading and stack building is accomplished with two modules, a bale loader  40  and a bale manipulator  80 . In this embodiment the machine forms a stack of twelve 3′×4′×8′ bales six tiers high with the twine down. This is accomplished without overloading the front axles, and providing good traction throughout the stack-building cycle. To reduce the overall length required, the manipulator has the ability to rotate the bales into the load&#39;s fore-and-aft orientation before the bale is moved to the load rack. 
   The bales are loaded, manipulated and positioned while clamped on the sides (surfaces without twine), thus minimizing bale damage and leaf losses when compared to handling with spearing and grasping hooks. The bales are loaded endways over the front of the truck ( FIG. 1 ). Bale loader  40  clamps the sides of the bales with opposing clamp arms  42 ,  44  that are each pivotably affixed to loader boom arm  46  and selectively movable relative thereto through the action of clamping cylinders  48 ,  50 . Boom arm  46  is rigidly affixed to loader boom  52 , and boom  52  is pivotably affixed at  54  to handler main frame  56 —which extends up and over cab  22 , and down the back side thereof where it is affixed to truck frame  32 . 
   As can be seen, handler main frame  56  is comprised of two primary frame members ( FIGS. 1 ,  3   c  and others). The boom  52  is pivotably connected at the generally horizontal axis extending through pivot points  54 - 54 . The loader pivots the bale upwardly and rearwardly from the ground, through 180 degrees to the manipulator table, with the bale lengthwise. The boom  52  is pivoted through the selective action of upper and lower respective hydraulic cylinders  61 ,  63  connected at pin  53 . These cylinders are mounted on trunions  55 - 55  to allow them to pivot as required during the raising and lowering of the boom  52  relative to main frame  56 . 
   Once the bale is positioned on the manipulator table  82  by the loader  40 , manipulator clamp  84  ( FIGS. 4 and 5 ) clamps the bale to maintain secure and precise positioning for manipulation. Then, the loader releases the bale and returns to its lowered position. Manipulator clamp  84  is comprised of two different clamping components, pivoting paddles on one side of the manipulator table and an elongate bar on the other. Bar clamp  86  pivots about point  88  via activation of hydraulic cylinder  90 . On the opposite side of manipulator table  82  are a pair  92 ,  94  of generally flat paddles pivotably attached, respectively, to table  82  at pivot points  96 ,  98 . Thus, the bale is clamped between paddles  92 ,  94  which pivot, through the operation of hydraulic cylinders  100  and  102 , in a plane generally perpendicular to table  82  and the side of the bale resting on table  82 , and bar clamp  86  that pivots into the opposing side of the bale. The pivoting paddles allow release of the clamped bale when positioned above or beside another bale; the paddles then being between the bales when the bale is positioned and then pivoted out from between the bales to release the positioned bale. Bar clamp  82  always pivots open into an unoccupied space. 
   Manipulator table  82  is pivotably affixed to manipulator carrier  113  via stub shaft  104 . A carrier mast  111  extends partially across the top of and down the back of cab  22  and is comprised of a pair of enclosed rails  106 ,  108  into which carrier rollers  110  (only the right side shown, but there are also rollers on the left side) fit for allowing the manipulator table with a clamped bale, to follow the tracks rearwardly and downwardly in a path specified by the rails. These enclosed rails, similar in purpose to those used in most garage doors, are used here for the stability and reliability they provide. When the manipulator table, with a clamped bale, is manipulated to its tier-building orientation, carrier  113  moves back and down the mast to the desired location for positioning the bale into the tier ( FIGS. 6   a ,  7   a  and  7   b ). The carrier  113  preferably moves with a gear (not shown) on the carrier engaged with a rack on the mast  111 . The gear is driven with an hydraulic motor through a worm gearbox (also not shown) for speed reduction and for holding position when stopped. In like manner, the mast with table is preferably positioned sideways by an hydraulically driven rack and pinion arrangement on horizontal tracks  112 ,  114  and  117  mounted to the frame  56 . The side shift tracks are in the form of a pair  112 ,  114  and extend outwardly from the portion of the loader main frame  56 , and, along with rollers  116  on carrier mast  111  control movements about a vertical axis and about a horizontal axis perpendicular to the direction of travel of the vehicle. Side shift track pair  117 , with rollers  116  carry the weight of the mast and carrier, control the moment about an axis in the direction of travel, and allow the carrier mast to be moved via hydraulic power in a plane perpendicular to the line of travel of the vehicle, and provides the flexibility to deposit the bale at varying locations side to side on the load rack  140 . Thus, after the bale is clamped on the manipulator table, the loader clamp releases and moves out of the way to allow manipulation of the bale. Manipulation of the bale is either 90 degrees counter-clockwise rotation (assuming the pivoting paddles  92 ,  94  are on the left) when viewed from above or sideways movement of the table right or left. Sideways movement is accomplished by moving the carrier mast  111  right or left ( FIGS. 6 ,  7  and  8 ). It is foreseen that both manipulations could be used for building tiers of 4′ long bales and round bales. Bale lengths may be anywhere from 4′ to 8′. For 4′×4′ bales, the loader boom pivot center and cylinder trunions need to be moved upward about seven inches. This could be accomplished by having alternative mounting locations in the frame or by having a movable sub-frame for the boom pivot and trunion mounts (see  FIG. 9 ). 
   Round bale diameters up to 5′ can be stacked on their sides (see  FIG. 10 ). With stanchions  120  ( FIG. 11 ), bales of any diameter could be load. The manipulator table would need be adjustable, either hydraulically or manually, for 32″ (referred to as “3-foot bales” or 48″ wide bales (referred to as “4-foot bales”), each side would move in or out from center ( FIG. 5 ). With round bales, 60″ wide table adjustment could be considered as well as 48″. Also, with round bales the loader would stop less than 180 degrees rotation ( FIGS. 10 and 11 ), depending on the diameter to set the bale properly on the manipulator table. 
   The main frame assembly  58  and load rack assembly  140  can be two preassembled modules for quick installation onto a truck chassis. The truck would only have to be set up to supply hydraulic and electrical power for the bale handling system. The main frame assembly would include hydraulic reservoir, valves, and associated plumbing, and electronic controller and associated wiring. 
   Another component required for stack building is a push bar  122  to push each succeeding tier rearwardly on the load rack  140  until the load is complete ( FIG. 12 ). Push bar  122  extends transversely to the line of travel of the unit, and is moved through the extension and retraction of hydraulic cylinder  124 . The push bar need not extend much beyond the level of the load rack and, in fact, is low enough in its forward position to allow bales maneuvered by the bale manipulator mechanism  80  to be positioned rearwardly of the push bar without interference therebetween. In the alternative, push bar  122  may be easily made to pivot downwardly when moved in the forward direction (away from bales on the load rack  140 ). 
   A plurality of tines  126  is affixed to the rear of load rack  140  to hold the load while tipping to place the completed stack on the ground and a push-off bar  128 . Load rack  140  is pivoted about pivot point  136  by hydraulic cylinder  138  between loading and unloading positions. Push-off bar  128  is powered by hydraulic cylinder  130  that pivots arm  132  about pivot point  134  to push the bale stack rearwardly, as the unit is driven forwardly, off of tines  126  onto the ground. 
   Automation is accomplished by using a controller  142  ( FIG. 14 ) integrated with position feedback sensors S 1  through Sn and electrically controlled hydraulic valves V 1  through Vn. The controller synchronizes movements and positions of the bale loading mechanism  40 , the bale manipulator mechanism  80 , the mast  111  and other components throughout the loading and stack building process. The sensors are preferably electric, but can be any type that can meet reliability and endurance requirements. A visual display  144 , with or without a touch screen, makes the setup and operation reasonably simple for the operator. The controller also has preset programs for the different sized bales and for different tie ter patterns. It would be desirable for the controller to have a “teach and repeat” capability for unforeseen stack building requirements. 
   In operation, the truck, with the bale handling components described above, approaches the bale to be loaded in the same direction as the baler traveled through the field (approaching the bale along its lengthwise axis). The truck is driven so that the bale is located centrally of the cab, in line with the bale loader, and the operator or a switch on the loader initiates the loading cycle. The bale loader  40  grasps the bale with clamp arms  42 ,  44  pivots upwardly and rearwardly, lifting the bale through approximately 180 degrees and deposits it on manipulation table  82  where it is clamped by bar clamp  86  and paddles  92 ,  94 . The loader clamp then releases and returns to a clear position. Next, the bale is moved to the desired tier location through movements of manipulation table  82  along mast  111 . When a tier is complete, it is pushed rearwardly with push bar  122 . These steps are repeated until the load is complete. The completed stack is placed at the storage location by tilting the load rack approximately 90 degrees and then separating the stack from the load rack with push-off bar  128  ( FIG. 13 ). 
   The main frame assembly and load rack assembly can be two preassembled modules for quick installation onto a truck chassis. The truck would only have to be set up to supply hydraulic and electrical power for the bale handling system. The main frame assembly would include hydraulic reservoir, valves, and associated plumbing; and electronic controller and associated wiring. This modular approach offers the opportunity for the manufacturer, a dealer or an end-use customer to provide the truck for the bale handler. 
   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 inventions. Accordingly, the following claims are intended to protect the invention broadly as well as in the specific form shown.