Abstract:
A bagging machine having a uniquely configured rotor that can be operated with a grill, enables removal or injection of fluid materials when filling a bag. In one mode, the rotor enables the removal or draining of an effluent created from the bagging process such as from silage. In another mode, the rotor enables the injection of a treatment agent such as an antifungal agent as material is bagged.

Description:
TECHNICAL FIELD 
       [0001]    The present invention relates to systems and bagging machinery as well as methods of bagging material, more particularly to bagging machinery and processes that include injection or removal of a fluid. 
       BACKGROUND 
       [0002]    Increasingly, expandable, storage bags are used as an alternative storage container for a variety of applications such as permanent feed storage structures as alternatives to barns and silos. In addition, processors store compost and waste materials using storage bags for short and long-term storage needs. 
         [0003]    A variety of bagging devices exist in the art including bagging machines for the aforementioned products and uses. In many of these applications, it would be desirable to capture or collect off gasses, effluent, or other fluids to improve packing efficiency and for protecting the environment. In many of these applications, it would be desirable to inject additives into the packing material. 
         [0004]    The bag for use with such bagging machines is typically manufactured and delivered in a pleated shape, i.e., folded into an accordion-bellows-type shape. Typically, a bag having a nominal ten-foot-diameter (approximately 3 meters diameter, or 9.6 meters circumference) and a 300-foot length (approximately 90 meters length) will be folded to a 10-foot-diameter (about 3 meters) ring about one foot (about 0.3 meter) long and 1 foot (about 0.3 meter) thick. To start the loading operation, this bag-ring is pre-loaded around the tunnel, and the pleats are unfolded one at a time as the bag is deployed and filled. Once any portion of the bag fills with fill material, such as feed, that portion becomes very heavy weighing down the bag on a surface so it does not move. Thus, the bagger machine itself is propelled along the ground in front of the bag being filled. 
         [0005]    There are numerous challenges to efficiently using conventional bagging machines. For example, in the processing of silage or wet materials, effluent fills the packing the space around a packing rotor. New incoming organic material floats on accumulated effluent and either cannot be packed by the rotor or is packed less efficiently. In such bagging processes, the process must be stopped to remove accumulated effluent. 
         [0006]    In addition, where it is desired to inject treatments, adjuvants, or other enhancements into the material being bagged, it is difficult to obtain an even distribution of the injected material within the bagged material. In many applications, the injected material is sprayed onto the material being processed, and much of the desired treatment additive escapes without mixing into the bagged material. 
         [0007]    There is a need, therefore, for modifying and improving bagging machinery where fluids can be added or removed during the bagging and packing process. 
       SUMMARY 
       [0008]    In one aspect, a bagging machine, is disclosed including a tunnel having an inlet and an outlet; a conveyor or a hopper operably connected to the tunnel; and a rotor positioned at the inlet of the tunnel, the rotor also comprising a cylindrical body having a circumference, an axial length, and a plurality of holes through which a fluid may pass through the cylindrical body. 
         [0009]    In another aspect, a system for removing effluent from a bagging process is disclosed, including a tunnel having an inlet and an outlet; a conveyor or a hopper operably connected to the inlet of the tunnel; and a rotor positioned at the inlet of the tunnel, the rotor also comprising a cylindrical body having a circumference, an axial length, and a plurality of holes through which a fluid may pass through the cylindrical body. 
         [0010]    In another aspect, a method of operating a bagging machine is disclosed. The method includes providing a rotor, the rotor having a cylindrical body with a circumference, an axial length, and a plurality of holes; passing a fluid through the plurality of holes and cylindrical body; and packing material into a bag. 
         [0011]    In some embodiments, the rotor also comprises packing tines arranged on the cylindrical body in between the plurality of holes. In some embodiments, the plurality of holes include one or more rows substantially spanning the axial length of the cylindrical body. In some embodiments, there are 2 to 8 rows. In some embodiments, there are 4 rows. In some embodiments, the packing tines are helically arranged about the cylindrical body. In some embodiments, the outlet has a plurality of stripping grill bars operably arranged over the rotor&#39;s plurality of holes. 
         [0012]    In some embodiments, the rotor also includes a shaft. In some embodiments, the rotor has a hose swivel adapter. In some embodiments, the hose swivel adapter is located on the shaft. In some embodiments, the bagging machine also includes a pump for conveying fluid through the rotor. In some embodiments, the pump conveys fluid through the plurality of holes and out of the rotor. In some embodiments, the pump conveys fluid into the rotor and out the plurality of holes. 
         [0013]    In some embodiments, the fluid is effluent from the material being bagged. In some embodiments, the fluid includes a treatment agent for preserving material bagged by the system. In some embodiments, the treatment agent is selected from the group consisting of: antifungal agents, antibacterial agents, and nutritional supplements. In some embodiments, the treatment agent is ammonia. 
         [0014]    In some embodiments, the method of operating a bagging machine also includes conveying fluid through the rotor. In some embodiments, the conveying conveys fluid through the plurality of holes and out of the rotor. In some embodiments, the fluid is effluent from the material being bagged. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0015]      FIG. 1  shows a top perspective view of bagging machine of the invention. 
           [0016]      FIG. 2  shows a partial cut away view of a rotor and in a bagging machine of the invention. 
           [0017]      FIG. 3  shows components of a rotor for use in the invention. 
           [0018]      FIG. 4  shows a frontal view of a rotor for use in the invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0019]    While the terminology used in this application is standard within the art, the following definitions of certain terms are provided to assure clarity. Units, prefixes, and symbols may be denoted in their SI accepted form. Numeric ranges recited herein are inclusive of the numbers defining the range and include and are supportive of each integer within the defined range. Unless otherwise noted, the terms “a” or “an” are to be construed as meaning “at least one of.” The section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described. All documents, or portions of documents, cited in this application, including but not limited to patents, patent applications, articles, books, and treatises, are hereby expressly incorporated by reference in their entirety for any purpose. 
         [0020]      FIGS. 1-4  illustrate a bagging machine  10  used to fill large, flexible bags (not shown). The bagging machine  10  includes a conveyor  16  and a tunnel  14  which has an inlet  15  and an outlet  17 . The conveyor  16  is used to load material from a material source, such as a truck, into the bagging machinery. The tunnel is used for manipulating the bag and transferring the packing material from the bagging machine into a bag. The bagging machine  10  also includes a bagging cavity  12  in which is located a packing rotor  20  and a grill  40  having a plurality of bars  42 . Packing material is fed by the conveyor  16  to the bagging cavity  12  where the packing rotor  20  packs the materials into the tunnel inlet  15 , through the tunnel and into a bag passing out the tunnel outlet  17 . 
         [0021]    In some embodiments, the conveyor  16  may be replaced with a hopper (not shown) in operable connection with the tunnel. The hopper receives and holds bagging material. As is known to one of skill in the art, hoppers are often used with bagging machines that are loaded with a front end loader or portable conveyor. 
         [0022]    The packing rotor  20  is a cylindrical body having a circumference and a central axis. The circumference of the rotor has a plurality of tines  30 . In some embodiments, the tines  30  are radially located about the circumference of the rotor  20 . The rotor  20  also has open, hollow ends  24  and  26  so that a cavity exists between the hollow ends through the rotor. At one or more of the hollow ends, a shaft  22  may be fitted into at least a portion of the rotor  20 , the shaft itself being hollow. 
         [0023]    The packing rotor  20  also has a plurality of through holes  28 . Each of the through holes  28  is located between the plurality of tines  30 . That is, a through hole is not radially located in the same plane (circumferential plane) as a tine about the central axis. As a result, when the packing rotor  20  is rotated about the central axis, the plurality of tines  30  pass between the plurality of bars  42  of the grill. In doing so, the grill bars  42  will catch material accumulating outside rotor  20  and above each of the through holes  28 . This action reduces or prevents occlusion of the through holes  28  so that any effluent in the packing material or accumulating in the bagging cavity  20  can be removed. It also enables a consistent injection of any desired fluid into the packing material. Without occlusion, the effluent can drain into the through holes and through the shaft to the open ends. Moreover, if operator wants to inject treatment material or some fluid containing treatment material, the spinning action of the packing rotor  20  and stripping facilitated by the grill bars  40  enable the injection to pass out the through holes into the packing material in a substantially uniform manner. 
         [0024]    Each tine  30  can be offset from adjacent tines forming a circumferential pattern whereby as the packing rotor  20  rotates about a central axis, the tines are in continuous engagement with fill material (not shown) and pressed or packed into a packing bag (not shown). The tines  30  are spaced apart from one another so that as the packing rotor  20  spins, the tines  30  pass through the grill  40 . 
         [0025]    The number and arrangement of tines  30  may be varied in several ways. For example, a plurality of tines may be circumferentially located about the packing rotor  20  and its central axis in a row represented by a common radial plane of rotation (circumferential plane). In one embodiment, the number of rows is from 1-20. The number of rows may be from 1-16. The number of rows may be from 1-15. The number of rows may be from 1-12. The number of rows may be from 1-10. The number of rows may be from 1-8. The number of rows may be from 1-6. The number of rows may be from 1-5. The number of rows may be from 1-4. The number of rows may be from 1-3. The number of rows may be from 1-2. The number of rows may be 1. In some embodiments, the number of rows is an integer selected from any one of 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, and 20. 
         [0026]    In one embodiment, the tines may be located along a common radius forming a straight row parallel to the packing rotor&#39;s central axis. In another embodiment, the tines may be located in a helical pattern about the packing rotor. Thus, there may be one or more helical rows of tines about the packing rotor. For example, there may be 1, 2, 3, 4, or more helical rows. 
         [0027]    The tines themselves may be made from any durable material including various metals, metal alloys such as steel, and carbides and affixed to the packing rotor  20  by welding. In some embodiments, the tines may be removable such as those described in U.S. Pat. No. 6,009,692, which is expressly incorporated herein by reference. In some embodiments, the tines may be formed with a concave face such as those described in U.S. Pat. No. 6,820,735, which is expressly incorporated herein by reference. The tines may also have a leading edge or wear strip  32  that can be replaced as the tine wears. 
         [0028]    The number and arrangement of the through holes may be varied in several ways. For example, the through holes may be circumferentially located about the packing rotor and its central axis. In one embodiment, the number of through holes located in a single plane of rotation (circumferential plane) about the packing rotor is one or more. In some embodiments, the number of through holes located in a single plane of rotation about the packing rotor is from 1 to 8. In some embodiments, the number of through holes is an integer selected from any one of 1, 2, 3, 4, 5, 6, 7, and 8. 
         [0029]    In one embodiment, the through holes may located along a common radius forming a straight row parallel to the packing rotor&#39;s central axis. In another embodiment, the through holes may be located in a helical pattern about the packing rotor. Thus, there may be one or more helical rows of through holes about the packing rotor. For example, there may be 1, 2, 3, 4, or more helical rows. 
         [0030]    In some embodiments, a row of through holes substantially spans the axial length of the packing rotor and its cylindrical body. In some embodiments, a row of through holes spans only a portion, i.e. less than the full length, of the packing rotor and its cylindrical body. In such embodiments, the holes may span 80% or less than the length of the packing rotor and its cylindrical body. In some embodiments, the holes may span 50% or less than the length of the packing rotor and its cylindrical body. 
         [0031]    In some embodiments, the through holes are located in a circumferential plane adjacent to another circumferential plane in which a tine is located. 
         [0032]    In one embodiment, such as the one depicted in  FIG. 3 , the packing rotor has two parallel rows of through holes located about 180 degrees from one another and parallel to the central axis. In that embodiment, two helical rows of tines are also located circumferentially about the central axis where each of the tines in a common plane perpendicular to the central axis is about 180 degrees apart. 
         [0033]    The grill bar widths are generally of a width approximate to the width between tines. The grill bar widths are generally of a width approximate to or greater than the diameter of a through hole. 
         [0034]    The hollow ends  24  and  26  can also be fitted with a shaft  22  that passes through at least a portion of the rotor  20 , a bearing  52  and a swivel adapter  50 . The bearing  52  supports rotor  20  and shaft  22  and is fastened to a side wall  58  of the tunnel  14 . The swivel adapter enables fluid transfer from a stationary source into a rotating piece of machinery, in this case the packing rotor  20 . In some embodiments, the swivel adapter  50  is connected to collection tank (not shown) for collecting the effluent. In some embodiments, the collection tank is located on the bagging machine  10 . In some embodiments, the effluent can be drained from the packing rotor and allow to fluid flow onto the packing bag surface such as the ground or pavement. In some embodiments, a vacuum is applied to help draw out the effluent. In some embodiments, a pump is operably connected to the packing rotor to pump material out of the rotor. In some embodiments, a pump is operably connected to the packing material to pump material into the rotor and out the through holes. 
         [0035]    In other embodiments, the swivel adapter is connected to a treatment tank holding a treatment material. The treatment material can be pressurized or the added to a pressurized stream which is injected into the rotor and out the through holes. 
         [0036]    The swivel hose adapter  50  may include a flange  54  having a hole  60  through which a locking shaft  56  may extend. The locking shaft  56  may be mounted to a tunnel side wall  58  to anchor and prevent the hose swivel adapter  50  from rotating with the shaft  22  (if present) and rotor  20 . 
         [0037]    A number of treatment materials can be included depending on the desired application. For example, feed supplements such as nutritional supplements can be injected into silage and other feed materials. Examples of such feed supplements include: urea, molasses, and others commonly employed in animal feed materials. Other treatment materials can include preservatives and other additives such as antifungal agents and antibacterial agents. The treatment material can be ammonia or aqueous ammonia solution. 
         [0038]    The hollow ends  24  and  26  of the rotor can be fitted with a bearing  52  that enables the packing rotor to rotate to a fixed frame of the bagging machine. The packing rotor  20  can be rotated in a counterclockwise fashion when packing material is packed into a bag. A transmission (not shown) on the bagging machine  10  can be operated to select a desired speed at which the packing rotor  20  is operated. 
         [0039]    The claimed invention may be embodied in other specific forms without departing from its structures, methods, or other essential characteristics as broadly described herein and claimed hereafter. The described embodiments are to be considered in all respects only as illustrative, and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their full scope.