Abstract:
A large rectangular bale loading, hauling and stacking vehicle that mounts on a production truck chassis. Loading is accomplished with a bale manipulator that can selectively pick up and rotate bales, depositing them in tiers on a load rack, some in tie tiers. The manipulator works in conjunction with a transverse pivoting mast along the length of which the manipulator is selectively movable. A stack of bales is thus formed on the load rack and later deposited at a storage site.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     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.  
         [0002]     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 manual handling of bales 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 rectangular bales that have become increasingly popular over the last several years, and to which this invention is most concerned.  
         [0003]     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, greatly overload the front axle of the unit, and do not have adequate traction on rolling or wet terrain when loaded.  
         [0004]     Therefore, there is a need in the art for a convenient and automated system for loading a significant number of large rectangular bales onto a vehicle, using tie tiers, hauling them relatively long distances, and stacking the bales in a stable manner, and doing so with adequate traction in all types of terrain without overloading the front axle of the vehicle.  
       SUMMARY OF THE INVENTION  
       [0005]     Accordingly, it is an object of the present invention to provide a bale wagon that automatically loads, hauls and stacks large rectangular bales.  
         [0006]     Another object of the present invention is to provide an automatic bale wagon for large rectangular bales that is structured such that it provides adequate traction on rolling or wet terrain.  
         [0007]     Another object of the present invention is to provide an automatic bale wagon for large rectangular bales that does not overload the front axle of the unit.  
         [0008]     It is another object of the present invention to provide an automatic bale wagon for large rectangular bales that uses a truck chassis as the main support and source of motive power.  
         [0009]     Yet another object of the present invention is to provide a bale wagon based on an over-the-road truck chassis that loads, hauls and stacks large rectangular bales, some in tie tiers, with a robotic arm.  
         [0010]     It is yet another object of the present invention to provide a bale wagon that uses a robotic arm to load and stack large rectangular bales onto a load rack that tilts approximately 90 degrees for placing the formed stack onto the ground.  
         [0011]     It is yet another object of the present invention to provide a robotic arm for large rectangular bales that rotates the bale into the load&#39;s fore-and-aft orientation before the bale is moved over the load rack. The bale is then manipulated to the desired position and at the desired tier orientation and subsequently deposited on the load rack.  
         [0012]     These and other objects are attained by providing a large rectangular bale loading, hauling and stacking vehicle that mounts on a production truck chassis. Loading is accomplished with a bale manipulator that can selectively pick up and rotate bales, depositing them in tiers on a load rack, some in tie tiers. The manipulator works in conjunction with a transverse pivoting mast along the length of which the manipulator is selectively movable. A stack of bales is thus formed on the load rack and later deposited at a storage site. 
     
    
     DESCRIPTION OF THE DRAWINGS  
       [0013]     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:  
         [0014]      FIG. 1  is a rear plan view of the bale wagon of the present invention;  
         [0015]      FIG. 2  is a partial isometric view of the carrier and mast, showing how the bale grasping mechanism attaches and moves;  
         [0016]      FIG. 3  is a partial plan view of the carrier travel system;  
         [0017]      FIG. 4   a  is a partial plan view of the bale pivot system with the control cylinder extended;  
         [0018]      FIG. 4   b  is also a partial plan view of the bale pivot system with the control cylinder retracted;  
         [0019]      FIG. 5   a  is a partial front plan view of the bale rotation mechanism;  
         [0020]      FIG. 5   b  is a partial top plan view of the bale rotation mechanism of  FIG. 5   a,  taken generally along lines  5 - 5 ;  
         [0021]      FIG. 5   c  is a partial side plan view of the vehicle showing the components of the bale manipulation mechanism;  
         [0022]      FIG. 6   a  is a side plan view of the bale wagon of the present invention showing, inter alia, the backstop positioning a bale beside the bale wagon for grasping and pickup;  
         [0023]      FIG. 6   b  is a rear plan view of the bale wagon of  FIG. 6   a,  with the backstop removed and the bale clamped by the grasping mechanism;  
         [0024]      FIG. 7   a  is a rear plan view, similar to  FIG. 6   b,  with the bale pivoted vertically;  
         [0025]      FIG. 7   b  is a side plan view of the bale wagon as shown in  FIG. 7   a ;  
         [0026]      FIG. 8   a  is a rear plan view of the bale wagon, similar to  FIG. 7   a,  showing a bale pivoted onto the load rack in a transverse position;  
         [0027]      FIG. 8   b  is a rear plan view of the bale wagon, similar to  FIG. 8   a,  showing a second bale pivoted onto the first bale;  
         [0028]      FIG. 8   c  is a rear plan view of the bale wagon, similar to  FIG. 8   a,  showing a bale pivoted onto the load rack in a vertical position;  
         [0029]      FIG. 8   d  is a rear plan view of the bale wagon, similar to  FIG. 8   b,  showing a second bale pivoted onto the load rack in a vertical position;  
         [0030]      FIG. 9  is a side plan view of the bale wagon, showing alternate tiers of bales, horizontal-vertical-horizontal, being pushed rearwardly by the push bar;  
         [0031]      FIG. 10  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  
         [0032]      FIG. 11  is a schematic of a control system to manage the creation of bale stacks. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0033]     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.  
         [0034]      FIG. 6   a  provides a good general side depiction of a truck cab  20  and chassis  24  with the primary components of the bale wagon  10  mounted thereon. Chassis  24  includes several components well known in the art, including wheel pairs  26 ,  28  and  30  affixed to and supporting a main frame  32 . The wheel pairs are supported on axles (see, for example, drive axle  34  in  FIG. 1 ) and other well known drive components (not shown). In this particular embodiment, as can be partially seen in  FIG. 1 , the rear wheel pairs  26 ,  28  are duals, i.e., two wheels on each end of the tandem axles, for improved traction in field conditions and heavy load support and distribution. Of course, a 4-wheel drive system would also work in this environment. A bale manipulator mechanism  40 , to be described in further detail below, is mounted to the forward portion of chassis  24 , behind cab  20 . A load rack  100 , also to be described further below, is pivotably attached to chassis  24  at pivot axis  62 .  
         [0035]     The embodiment to be described herein employs an over-the-road truck chassis based machine that loads, hauls and stacks large rectangular bales. The loading and stack building is accomplished with a robotic arm onto a load rack that tilts rearwardly approximately 90 degrees to place the formed stack onto the ground. In this embodiment the machine stacks 3′×4′ bales six tiers high without overloading the front axles, and has good traction throughout the loading cycle. To reduce the overall length required, the robotic arm has the ability to rotate the bales into the load&#39;s fore-and-aft orientation before the bale is moved over the load rack. The bale is then manipulated to the desired position and with the desired tier orientation, and then deposited on the load rack.  
         [0036]     The figures and specification describe right side loading and 3′×4′ bales; however, loading could be left side as well and the loader/stacker could be adjusted for other sized large rectangular bales. The bale manipulator mechanism  40  includes a simple main mast  42  that pivots about pivot  43  only in a plane generally perpendicular to the direction of travel of the unit ( FIGS. 1, 6 ) under the power of mast hydraulic cylinders  44 ,  46 . The range of travel of mast  42  is shown in  FIG. 1  as arc  48 . The bale manipulator mechanism  40  to which a bale grasping mechanism  64  ( FIG. 5   c ) attaches, is mounted to a carrier  50  that engages and moves along the mast  42  on carrier tracks  52 ,  54  ( FIGS. 2 and 3 ). As will be understood shortly, the large rectangular surface of carrier  50  is affixed to the bale rotation mechanism which is, in turn, affixed to the bale grasping mechanism  64 . Opposing track roller pairs  56 ,  58 , (opposing pairs on both the top and bottom inside faces of carrier  50 , though only the bottom pairs shown) affixed to carrier  50  engage the insides of the carrier tracks to provide smooth and steady movement of the carrier in both directions under hydraulic control via cylinder  60  ( FIG. 3 ).  FIG. 3  shows the structure that moves carrier  50  back and forth along the length of mast  42  to include hydraulic cylinder  60  with movable cylinder rod  61  with two cylinder sprockets  35 ,  36  affixed thereto; one,  36 , adjacent the end of the cylinder rod and the other,  35 , spaced a short distance therefrom. A third sprocket,  37 , is affixed to mast  42  adjacent the base end of hydraulic cylinder  60 , and a fourth sprocket,  38 , is affixed to mast  42  adjacent the outward end of the mast. A first chain  39  is affixed to carrier  50  at point  45 , extends around sprockets  35  and  37  and is affixed at its second end to mast  42  at point  41 . A second chain  47  is affixed to mast  42  at point  63 , extends around sprockets  36  and  38  and is affixed at its second end to carrier  50  at point  65 . Therefore, as cylinder rod  61  is extended, carrier  50  moves to the left (in  FIG. 3 ), and as the cylinder rod is contracted, the carrier moves to the right. Thus, bale manipulator mechanism  40  (disregarding carrier movement along the mast) has two degrees of movement that make possible the bale positioning described above.  
         [0037]     The first manipulator mechanism movement is a 90 degree pivot, via pivot mechanism  55 , around an axis  66  ( FIGS. 4   a,    4   b ) parallel to mast  42 , under the control of hydraulic cylinder  68  acting at one end through bracket  69  affixed to carrier  50 , in order to move the bale grasping mechanism  64  from downward/outward facing to rear facing ( FIG. 4   b ). This manipulates the bale in the proper fore-and-aft orientation for insertion onto the load rack  100 . Mounting plate  70  in  FIGS. 4   a,    4   b  supports the bale grasping mechanism  64 , which includes a plurality of pivoting claws  72  that may selectively grasp and hold, or release, the bale under the control of hydraulics. Such claws are arranged in pairs so that they engage near the fore-and-aft ends of an 8′ long bale and, also for additional support of the long bale, intermediate pairs that engage the bale intermediate of the ends.  
         [0038]     The second movement of the manipulator mechanism is through rotation mechanism  121  ( FIGS. 5   a,    5   b  and  5   c ) which is sandwiched between mounting plate  70  of the pivot mechanism  55  and faceplate  122  of the grasping mechanism  64 . The rotation mechanism rotates the bale grasping mechanism  64  around a pivot that is perpendicular to and approximately in the center of the faceplate  122  of the bale grasping mechanism. Rotation about an axis  74  that extends through or near the center of mass of the bale minimizes the torque required to rotate the bale. This is accomplished, for example, by a modified production fork lift attachment that rotates the tines of the lift. A plate  120  is rotatably affixed to faceplate  122  about axis  74  as gear  124  rotates. A hydraulic motor and directional valve  126  rotates gearing  128  that, in turn, rotates gear  130  engaged with gear  124  (this rotation mechanism is shown best in  FIGS. 5   a - 5   c , and is not shown in other figures to reduce complexity and improve understanding). Rotation about axis  74  is used to place the bale in the crosswise or vertical orientation as it is placed on the load rack  100 . Angular positioning of the mast  42  and movement of the carrier  50  along the mast are also required for positioning the bale on the load rack in the forming of the desired tier pattern ( FIGS. 1, 2  and  3 ).  
         [0039]     A component important for the loading and stack building operation include a backstop  76  to position the bale beside the unit for grasping and pickup. Backstop  76  is attached to the main frame  32 , depends therefrom, and extends transversely to the direction of travel for a distance substantially equal to the width of a bale. The backstop also is adjustable in a fore-and-aft direction to center shorter bales for proper grasping by mechanism  64 .  
         [0040]     Another component useful in stack building is a push bar  78  to push each succeeding tier rearwardly on the load rack  100  until the load is complete ( FIG. 9 ). Push bar  78  extends transversely to the line of travel of the unit, and is moved through the extension and retraction of hydraulic cylinder  80 . 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  40  to be positioned rearwardly of the push bar without interference therebetween. In the alternative, push bar  78  may be easily made to pivot downwardly when moved in the forward direction (away from bales on the load rack  100 ).  
         [0041]     Finally, a plurality of tines  82  is affixed to the rear of load rack  100  to hold the load while tipping to place the completed stack on the ground and a push-off bar  84 . Load rack  100  is pivoted about pivot point  62  by hydraulic cylinder  83  between loading and unloading positions. Push-off bar  84  is powered by hydraulic cylinder  86  that pivots arm  88  about pivot point  90  to move bar  84  in an arc about point  90  to push the bale stack rearwardly, as the bale wagon  10  is driven forwardly, off of tines  82  onto the ground.  
         [0042]     Automation is accomplished by using a controller  140  integrated with position feedback sensors S 1  through Sn and electrically controlled hydraulic valves V 1  through Vm. The controller synchronizes movements and positions of the bale grasping mechanism, the rotation mechanism, the mast, the carrier 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  142 , 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 tier patterns. It would be desirable for the controller to have a “teach and repeat” capability for unforeseen stack building requirements.  
         [0043]     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 against the side guide  75  ( FIG. 7   b ) and against the backstop, and the operator or a switch on the backstop initiates the loading cycle ( FIGS. 6   a  and  6   b ). Backstop  76  may be pivotably mounted to the chassis and movable between operative and transport positions as shown in  FIG. 1 . Side guide  75  is fixed to the chassis and is an elongate strap or rod and positioned to guide the bale into proper contact with bale stop  76 . The grasping mechanism  64  is moved from the ready position inboard of the chassis outer limits, grasps the bale with claws  72 , lifts the bale clear of backstop  76 , and then pivots the bale rearwardly, through action of pivot mechanism  55 , and upwardly to the fore-and-aft orientation of the loaded bales ( FIGS. 7   a  and  7   b ). The bale is then moved to the desired tier location through movements of mast  42 , carrier  50 , and rotation mechanism  121  ( FIGS. 8   a,    8   b,    8   c  and  8   d ). Arrow  110  depicts the general paths of bale centroids as the bales are manipulated in various configurations on the load rack  100 . Arrow  112  depicts the rotation of the various bales relative to the mast  42  and carrier  50  to obtain the proper tier orientation. Grasping mechanism  64  is then released and the mast moves the grasping mechanism out from over load rack  100 , and the grasping mechanism is then pivoted to a ready position for the next bale. When a tier is complete, it is pushed rearwardly with push bar  78 . These steps are repeated until the load is complete ( FIG. 9 ).  
         [0044]     When the load is completed, the mast remains stored upright and the backstop is retracted for transport by, for instance, retraction of hydraulic cylinder  71 . The completed stack is placed at the storage location by tilting the load rack 90 degrees and then pushing the truck away with the push-off bar ( FIG. 10 ).  
         [0045]     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.