Abstract:
A method of and apparatus for producing stacks of large square bales. Bales are received from the baler via a bale accumulator and formed into a stack, a plurality of bales high. The resulting bale stacks may be dropped in the field for pickup later.

Description:
RELATED APPLICATION 
     Priority is hereby claimed to U.S. Provisional Patent No. 62/043,243 to Kelderman, filed Aug. 28, 2014 to a six pack stacker and method of using same, which describes the present invention and is hereby incorporated by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     This invention relates generally to a device for delivering large square bales from an accumulator attached to a baler, moving the bales to a stacking machine to configure the bales into a stack at least two bales wide and at least two bales high. 
     BACKGROUND 
     U.S. Pat. No. 8,408,857 to a Bale Picking Truck by Kelderman shows a method and apparatus for quickly and efficiently picking up and removing biomass bales from a field in which the biomass was baled, compactly stacking the bales after picking the bales off the ground and efficiently depositing the bales on the ground at a staging area for later loading onto a semi trailer, straight truck, or train car, which application is incorporated herein by reference in its entirety. 
     Published U.S. Patent Application No. 2012/0045310 to a Bale De-Stacker by Kelderman relates to a method and apparatus for efficiently unstacking square bales from a stack and conveying the square bales in small sets or individually once they arrive from their aforementioned staging area to the place that they are to be used, such as in an ethanol production plant or a plant where the bales are to be burned for fuel. 
     Published U.S. Patent Application No. 2013/0315694 to Kelderman relates to a bale loading trailer and method of using it, specifically to loading and unloading stacks of six bales into or out of a trailer. U.S. patent application Ser. No. 14/326,149 to Kelderman shows a similar device to load or unload stacks of six bales into or out from a trailer that uses a center drive loader for a bale trailer. All the aforementioned patent documents are incorporated herein by reference in their entirety. 
     It is believed that a device for forming stacks of bales for use with the aforementioned equipment, a device to efficiently receive bales directly from a bale accumulator and form those bales into a stack of bales at least two bales wide and at least two bales high would be extremely useful but has heretofore never been contemplated or designed. 
     Accordingly, there is a need for a method and apparatus to efficiently load the bales directly from a baler accumulator to a bale stacker and form a stack at least two bales wide and at least two bales high. 
     SUMMARY OF THE INVENTION 
     Biomass is frequently formed into large bales of roughly rectangular parallelepiped shape. These are typically referred to by those having skill in this art as “large square bales,” or “big square bales,” and these terms will be used herein. Therefore, for the purposes of the instant document, including the claims, the synonymous terms, “large square bales,” and “big square bales,” are defined as bales of biomass, roughly shaped in rectangular parallelepiped shape. Typical large square bales run over 700 pounds and are bound with baling twine. The dimensions of these bales vary based on the needs of those involved in baling, storing, or feeding the bales. Although the present invention is not limited to a particular sized bale, ideal dimensions of the bale stacker of the present invention will be based on bale size. 
     Biomass is mowed in the fields in which it is grown, permitted to dry, windrowed, and baled. A bale accumulator associated with the baler may accept bales from the baler and organize them in a single layer, typically two or three bales wide. 
     The present invention is intended to trail behind the bale accumulator and accept bales from the bale accumulator. The bale stacker of the present invention creates a stack of a plurality of big square bales, convenient for loading onto another mode of conveyance. Multiple stacks may, for instance, be loaded onto the Bale Picking Truck of U.S. Pat. No. 8,408,857, or into the bale loading trailer of U.S. Published Patent Application No. 2013/0315694 or U.S. patent application Ser. No. 14/326,149. 
     An object of the present invention is to automatically create a stack of a plurality of large square bales. 
     Another object of this invention is to receive bales from bale accumulators accumulating bales either two or three bales wide. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
       The above mentioned need is at least partially solved through provision of the method and apparatus described in the following detailed description, particularly when studied in conjunction with the drawings, wherein: 
         FIG. 1  shows the bale stacker of the present invention in perspective; 
         FIGS. 2 a  and 2 b    illustrate how the bale stacker mechanism pivots on a horizontal axis of pivot relative to a tongue; 
         FIGS. 3 a -3 c    illustrate a tongue of the bale stacker, and show a pivoting of the tongue on a vertical axis of pivot relative to the bale stacking mechanism; 
         FIGS. 4 a  through 4 c    show the bale stacker in plan view, and illustrate how bales from a bale accumulator, accumulating bales three-wide, are accommodated by pivoting the stacking mechanism relative to the tongue on a vertical axis of pivot; 
         FIG. 5  shows a perspective view of an empty bale stacker prepared to receive bales from a bale accumulator containing one layer of three bales; 
         FIG. 6  shows a perspective view of the bale stacker, having received two of three bales from the bale accumulator; 
         FIGS. 7 and 8  show perspective views of the bale stacker raising two bales; 
         FIG. 9  shows a perspective view of the bale stacker prepared to receive two more bales from the bale accumulator, said two more bales to be disposed under two raised bales; 
         FIG. 10  shows a perspective view of the bale stacker having received two more bales from the bale accumulator, said two more bales to be disposed under two raised bales; 
         FIGS. 11 through 13  illustrate a process of raising four bales; 
         FIG. 14  shows a perspective view of the bale stacker with four bales at the top of their rise; 
         FIG. 15  shows a perspective view of the bale stacker with the four bales elevated and the roller bed being lowered to receive additional bales; 
         FIG. 16  shows a perspective view of the bale stacker, having received two additional bales on the roller bed; 
         FIG. 17  shows a perspective view of the bale stacker with its rear gates open, preparing to unload its stack of six bales; 
         FIG. 18  shows a perspective view of the bale stacker unloading a stack of six bales; 
         FIG. 19  is a top plan view of a cable lift mechanism, said mechanism having a roller floor at its lowest position; 
         FIG. 20  is a top plan view of the cable lift mechanism, said mechanism having the roller floor at its highest position; 
         FIG. 21  is a rear elevation view of the apparatus of the present invention, detailing a gripping mechanism for grasping bales, said gripping mechanism is in its open condition; 
         FIG. 22  is a rear elevation view of the apparatus of the present invention, showing the gripping mechanism in its closed condition, whereby bales are grasped; and 
         FIG. 23  is a side elevation view of the bale stacker showing an adjustable spindle. 
     
    
    
     Elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions and/or relative positioning of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments of the present invention. Certain actions and/or steps may be described or depicted in a particular order of occurrence while those skilled in the art will understand that such specificity with respect to sequence is not actually required. The terms and expressions used herein have the ordinary technical meaning as is accorded to such terms and expressions by persons skilled in the technical field as set forth above except where different specific meanings have otherwise been set forth herein. 
     DETAILED DESCRIPTION 
     Referring now to the drawings, wherein like reference numerals indicate identical or similar parts throughout the several views,  FIGS. 1-23  show a preferred embodiment of the present invention. 
     Referring now to  FIG. 1 , the large square bale stacker  100  is shown in perspective view. The tongue  110  is used to draw the bale stacker  100  behind a baler equipped with a bale accumulator, as well as behind any source of motive power. A plurality of ground engaging wheels  120  support the stacker  100  and its load. A roller bed  130 , having a plurality of rollers  135 , provides a surface onto which large square bales  400  (see, for instance,  FIG. 4 a   ) are slid in organized fashion. Transition rollers  115  are attached to the tongue  110  and aid in transferring bales  400  into the bale stacker  100  irrespective of the tongue&#39;s  110  position. A cable lift mechanism  140  is used to raise bales  400  to make room for more bales  400  below. Gates  150 , opened and closed by hydraulic cylinders  160 , hold the bales  400  in place until an unloading operation is initiated. 
     The following terms are hereby defined for the purposes of this document, including the claims. An arrow  170  indicates a forward direction. This is the direction of travel when the bale stacker  100  is in use. Front is forward-most when the bale stacker  100  is pulled in its forward direction. Back or rear is opposite that of the front and behind is defined as in back of or rear of something. Left is defined as the left side when viewed from the rear, that is, when an observer is facing in the forward direction. Right is defined as the right side when viewed from the rear, that is, when an observer is facing in the forward direction. Up or upward is a direction opposing gravity, while down or downward is opposite that of up. In particular, the verb, raise, implies movement in the upward direction while the verb, lower, implies movement in the downward direction. All these terms all have their usual and customary meanings. 
       FIGS. 2 a  and 2 b    depict the adjustable angle, θ, of the bale stacking mechanism  200 . The bale stacking mechanism  200  is pivotable about a pin  220  defining a substantially horizontal axis  340  (see  FIG. 3 a   ) by virtue of the hydraulic cylinders  210 . The adjustment of the angle, θ, of the bale stacking mechanism  200  allows the bale stacker  100  to be pulled behind baler accumulators (not shown) of varying heights. By adjusting the angle, θ, bales  400  may transition smoothly from the baler into the bale stacker  100 . 
     The frame  300  for the bale stacker  100  features an adjustable position tongue  110  as shown in  FIGS. 3 a -3 c   . The adjustable hitch makes it possible to pull the bale stacker  100  behind a baler utilizing either a two- or three-bale accumulator. This is because the bale stacker mechanism  200  may be laterally positioned directly behind any set—for instance, a pair—of bales  400  to be transferred from the bale accumulator to the bale stacker  100  as shown in  FIGS. 4 a   - 4   c.    
     Lateral positioning is effected by pivoting the tongue  110  about a substantially vertical axis  310  through the actuation of a pair of hydraulic cylinders  320 . Note that, here as well as elsewhere in this document, a hydraulic cylinder may be replaced by a pneumatic cylinder, linear electric actuator, screw actuator, etc. The present invention is not limited to hydraulic cylinders. 
     By actuating the cylinders  320 , the tongue  110  is offset, angularly, from a longitudinal axis  330 . The tongue  110  may be shifted left, as shown in  FIG. 3 b   , or right, as shown in  FIG. 3 c   , both from a perspective from the rear of the bale stacker  110 . 
     The right and left offsets of the tongue  110  are greater than a minimum required to align with the bales  400  as they are received from the bale accumulator. This is so an operator can adjust how the bale stacker  100  trails the baler and the bale accumulator on a side-hill and when turning. Position sensors may be placed on the tongue  110  and programmed to follow the motions of the baler to maintain optimal alignment with the bale accumulator. 
     In  FIG. 4 a   , the tongue  110  of the bale stacker  100  is disposed symmetrically on the bale stacker  100  to be pulled directly behind a hitch on the baler (not shown). This provides the narrowest configuration for transport on roads, through gates, etc. In this configuration, none of the bales  400  can enter the bale stacking mechanism  200 , directly. In  FIG. 4 b   , the bale stacker  100  is shown aligned with a right-offset—that is, the tongue  110  has been shifted left—to permit two of the bales  410 ,  420  to enter the bale stacking mechanism  200 . The bale stacker  100  can then be shifted, giving it a left-offset as shown in  FIG. 4 c   . In this position, the bale stacking mechanism  200  is aligned to allow two more bales  430 ,  440  to enter it. Details of the bale accumulator are well known to those skilled in this art. A disclosure of a bale accumulator is provided by Branson in U.S. Pat. No. 5,829,238, hereby incorporated in its entirety by reference. 
     The first step in the bale stacking process is depicted in  FIG. 5 . The adjustable position tongue  110  is shifted right, aligning the bale stacking mechanism  200  with the two leftmost bales  430 ,  440  on the accumulator. The roller bed  130  is in its lowest position, as evidenced by a retracted hydraulic cylinder  510  in the cable lift mechanism  140 . The bale stacking mechanism  200  has been angled back relative to the tongue  110 . No bales  400  are present in the bale stacker  100 . 
       FIG. 6  shows the bale stacker  100  receiving the two leftmost  430 ,  440  bales onto the roller bed  130  from the accumulator. The two bales  430 ,  440  are disposed in their lowest position in the bale stacker  100 . 
     The hydraulic cylinder  510  is now extended in  FIG. 7  indicating the cable lift mechanism  140  has raised the roller bed  130  and the two bales  430 ,  440  now residing on the roller bed  130 . The first two bales  430 ,  440  are raised to make room for two more bales  400  beneath the first two bales  430 ,  440 . 
       FIG. 8  depicts the bale grasping mechanism  810  gripping the now raised first bales  430 ,  440 . The first bales  430 ,  440  are gripped between two bars or grippers  820 . The adjustable position hitch  110  is shifted left aligning the bale stacker  100  with the two rightmost bales  410 ,  420  on the accumulator. 
     In  FIG. 9 , the cable lift mechanism  140  is shown returning the now empty roller bed  130  to its lowest position by retracting the hydraulic cylinder  510 . Another bale  400  has been received on the bale accumulator. 
       FIG. 10 , the bale stacker  100  receives the two rightmost bales  410 ,  420  from the accumulator onto the roller bed  130 . The second two bales  410 ,  420  presently reside beneath the first two bales  430 ,  440 . A single bale  400  remains on the three-wide bale accumulator. 
     In  FIGS. 11 and 12 , the bale accumulator again fills, including the third two bales  1110 ,  1120 . 
       FIG. 13  shows the cable lift mechanism  140  raising the roller bed  130  and the second two bales  410 ,  420  now residing on the roller bed  130  until the second two bales  410 ,  420  touch the underside of the first two bales  430 ,  440 , being held by the bale grasping mechanism  810 . The bale grasping mechanism  810  releases the first two bales  430 ,  440  in its grasp. The first two bales  430 ,  440  are now supported by the second two bales  410 ,  420 , which continue to lift with the cable lift mechanism  140  and the extension of the hydraulic cylinder  510 . The bale stack residing on the roller bed  130  now contains four bales  400 , two wide by two high. 
     The bale grasping mechanism  810  now grips the second two bales  410 ,  420  in  FIG. 14  to maintain the entire stack of bales  410 ,  420 ,  430 ,  440  in an elevated position, making room for additional bales  400  under the second two bales  410 ,  420 . 
     The roller bed  130  has been returned to its lowest position in  FIG. 15 , preparing the bale stacker  100  to receive the third two bales  1110 ,  1120 . The third two bales  1110 ,  1120  have been received into the bale stacker  100  in  FIG. 16 . This completes the stack for the stacker configuration shown in the figures. 
     The next step in the process is to prepare to eject the completed bale stack  1710  from the back of the bale stacker  100 , as shown in  FIG. 17 . The hydraulic cylinders  160  for each of the two gates  150  are contracted to open the gates  150 , at which time, the completed bale stack  1710  will eject, as shown in  FIG. 18 , under the force of gravity due to the tilt of the bale stacking mechanism  200 . If the angle, θ, is insufficient at the time of the gate  150  opening, or if the bale stacker  100  is facing downhill, the angle, θ, may be increased by extending the hydraulic cylinders  210 . 
       FIG. 19  illustrates the cable lift mechanism  140  for the roller bed  130  in the down position. A slider  1900  is actuated by the hydraulic cylinder  510 , which is retracted in this lowest roller bed  130  position. The fixed length cables  1920  are attached at one end to the roller bed  130  and at the other end to a stationary frame member  1930 . Via a system of pulleys  1940 , the cables are disposed downward at the corners of the bale stacker  100 , as best seen in  FIGS. 21 and 22 . 
     In  FIG. 20 , the cable lift mechanism  140  for the roller bed  130  is in its uppermost position. The roller bed  130  is raised as the hydraulic cylinder  510  extends, and the slider  1900  is pushed to its extreme forward position. Extending the cylinder  510  increases the distance between stationary frame member  1930  and the slider  1900 . The fixed length cables  1920  move with the slider  1900  and raise the roller bed  130 . 
       FIG. 21  illustrates the bale grasping mechanism  810 . In this figure, the bale grasping mechanism  810  is in its open position, that is, it is not gripping any bales in this position. Hydraulic cylinders  2110  are used to actuate the bale grasping mechanism  810 . These hydraulic cylinders  2110  are, here, retracted so the bale grasping mechanism  810  is in its open position. 
     In  FIG. 22 , the bale grasping mechanism  810  is shown in rear elevation in its closed position. In the closed position, the hydraulic cylinders  2110  are extended and a set of bales  400  may be gripped. 
     The tongue weight may be adjusted by repositioning an adjustable spindle  2310 , shown in  FIG. 23 . The spindle is operatively affixed to a large plate with multiple adjustment holes, permitting the spindle to be disposed in more forward or more rearward positions to alter the balance of the bale stacker  100 . 
     All functions of the bale stacker  100  of the present invention may be automated using feedback from position sensors and a Controller Area Network (CAN) bus system. This will free up the baler operator to concentrate on controlling the baler functions. 
     Those skilled in the art will recognize that a wide variety of modifications, alterations, and combinations can be made with respect to the above described embodiments without departing from the spirit and scope of the invention, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept as expressed by the attached claims.