Abstract:
Systems methods and devices for packaging used grain bags as the grain bags are being unloaded. The system is located at the top of a grain unloader machine or a grain extractor machine. The invention uses a pair of plates with retractable winding cores placed at the center of each plate. At the start of the unloading process, the end of a grain bag is attached to both the retractable winding cores. As the grain bag is unloaded, the unloader moves down the length of the grain bag. The portion of the grain bag that is emptied is rolled up by the rotating winding cores. The winding cores are powered by one or two external motors controlled by a user. Once the empty grain bag has been completely rolled up, the retractable winding cores can be retracted.

Description:
RELATED APPLICATIONS 
       [0001]    This application is a non-provisional application of U.S. Provisional Patent Application No. 61/777,501 filed Mar. 12, 2013. 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention relates to grain bags. More specifically, the present invention relates to a roller mechanism for rolling up used grain bags as the grain is being unloaded from the grain bag. 
       BACKGROUND OF THE INVENTION 
       [0003]    The agriculture industry has significantly changed in the last few decades. Less and less farmers are feeding more and more people. To this end, labor saving devices are in higher demand so that less labor is required to perform the same functions. 
         [0004]    The use of grain bags for storing grain is now a standard industry practice, especially on North and South American farms. The grain bags are large plastic bags in which the grain is stored in the winter months. The grain is placed into the grain bags using grain bagger machines that push the grain into the bags. The bags are then sealed. To unload the bags, a grain unloader machine is used. These grain unloader machines use either augers or suction to pull the grain from the bag. The grain is then conveyed to a truck for transport to a processing facility. 
         [0005]    One problem with grain bags is their size—they range from anywhere from 9 to 12 feet in diameter and can be 200 to 500 feet in length. While they necessarily have to be such large sizes, once these bags are emptied of their contents, disposing of the grain bags themselves can be problematic. There are now initiatives for recycling these bags. However, given the size of these grain bags, gathering these up can be difficult and transporting the bags can similarly be difficult if these are not properly rolled up or otherwise neatly packaged. 
         [0006]    Currently, after the bags have been emptied, the bags are manually rolled up into rolls and hauled, by way of tractors or forklifts, onto trucks for transportation to a recycling center or for disposal. There are devices available that allow users to roll up the used grain bags after they are laid flat on the ground. Some unloader machines are equipped with rolling mechanisms that roll up the used bags once the bags have been emptied. Other unloader machines are even equipped with mechanisms that roll up the bags as they are being emptied. However, some of these mechanisms are not very convenient. Some mechanisms require that the rolled up grain bag be unrolled from the non-removable spindle attached to the unloader machine. Other mechanisms produce two rolls from a single grain bag, thereby doubling the amount of work required to dispose of the used grain bag. All of these mechanisms require that the rolled up used grain bags be manually loaded on to the transport before disposal. As can be imagined, the manual loading of large rolled up plastic grain bags is not an easy task. This labor dramatically increases when bags are not rolled up tightly. It should also be noted that bags which have not been tightly rolled up are much more vulnerable to rodent infestation. 
         [0007]    Based on the above, there is therefore a need for methods, devices, and systems which mitigate if not overcome the problems with the prior art. 
       SUMMARY OF INVENTION 
       [0008]    The present invention provides systems, methods, and devices for packaging used grain bags as the grain bags are being unloaded. The system is located at the top of a grain bag unloader machine or a grain extractor machine. The invention uses a pair of plates with retractable winding cores placed at the center of each plate. At the start of the unloading process, the end of a grain bag is attached to both the retractable winding cores. As the grain bag is unloaded, the unloader moves or delves deeper into the grain bag. The portion of the grain bag that is emptied is rolled up by the rotating winding cores. The winding cores are powered by one or two external motors controlled by a user. As the empty portion of the grain bag is rolled up, the rolled up grain bag is located between the two plates. Once the empty grain bag has been completely rolled up, the retractable winding cores can be retracted. By retracting the winding cores, the rolled up grain bag can be freely rolled on to the back of a truck or transport vehicle. 
         [0009]    Preferably, at least one of the retractable winding cores comprises a number of triangularly shaped elongated fingers, each finger protruding towards the other winding core. Each or at least one of the plates may rotate with the winding cores and may, depending on configuration, be configured to slide away from each other to thereby increase the gap between the plates. With the winding cores retracted, sliding the plates to result in this increased gap allows the rolled up grain bag to be released from between the plates. In one configuration, only one of the winding cores is powered—the other winding core is interlocked with the powered winding core and is driven by the powered winding core. In another configuration, the two winding cores are simultaneously driven by a single hydraulic circuit with each winding core having its own hydraulic gearbox. 
         [0010]    In a further configuration, the winding cores can be independently powered by separate motors. The separate motors can be separately operated by a user to take up whatever slack is present on the used grain bag. As the grain bag is emptied and as the unloader drives deeper into the grain bag, the user activates the motors as necessary to rotate the winding core and roll up whatever portion of the grain bag is emptied. In another embodiment, the each winding core has its own hydraulic motor. For ease of implementation, these two motors can be driven in parallel off of a single hydraulic circuit. 
         [0011]    To guide the rolled up grain bag as it rolls off the system, the system may be equipped with a pair of guide rails or arms pointed towards a transport vehicle for transporting the used grain bag. These guide rails or arms can be removable or can be pivotably movable such that they are only present when required. 
         [0012]    In one aspect, the present invention provides a system for packaging a grain bag as said grain bag is emptied by a grain extractor, the system comprising:
       a pair of plates placed opposite one another, a gap between said plates having a predefined width, each plate having a void at a middle of said plate;   at least one elongated winding core, the or each winding core having a deployed and a retracted position, the or each winding core being placed through at least one of said voids in a corresponding plate when in a deployed position, said at least one winding core being constructed and arranged to attach to said grain bag, said at least one winding core being rotatable about an axis perpendicular to said plates, said axis being parallel to a longitudinal axis of said at least one winding core;   at least one motor for rotating said at least one elongated winding core about said elongated winding core&#39;s longitudinal axis       
 
         [0016]    wherein
       said plates and said at least one winding core are located atop said grain extractor;   when the or each winding core is in a deployed position, the or each winding core is in said gap between said plates;   the or each winding core transitions from said deployed position to said retracted position by being retracted from said void, the or each winding core travelling along said axis when transitioning from said deployed position to said retracted position;   when said at least one winding core rotates about its longitudinal axis, said grain bag is rolled about said at least one winding core;   retracting said at least one winding core after said grain bag has been rolled about said at least one winding core allows said rolled grain bag to fall from between said plates.       
 
         [0022]    In another aspect, the present invention provides a grain extractor for extracting grain from a grain bag, the grain extractor comprising:
       a pair of plates placed opposite one another, each plate having a void at a middle of said plate, said pair of plates being separated by a gap;   at least one elongated winding core, the or each winding core being for deployment through at least one of said voids, the or each winding core being retractable through said void;       
 
         [0025]    wherein
       said at least one winding core being rotatable about its longitudinal axis to roll up said grain bag as said grain bag is emptied by said grain extractor;   said pair of plates and said at least one winding core being positioned atop said grain extractor.       
 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0028]    The embodiments of the present invention will now be described by reference to the following figures, in which identical reference numerals in different figures indicate identical elements and in which: 
           [0029]      FIG. 1  is an illustration of an extractor using a grain bag winder according to one aspect of the invention; 
           [0030]      FIG. 2  illustrates the extractor illustrated in  FIG. 1  with the grain elevator raised; 
           [0031]      FIG. 3  illustrates the extractor in use and showing the grain bag being rolled up; 
           [0032]      FIG. 4  illustrates another view of the extractor showing details of the grain bag winder in use; 
           [0033]      FIG. 4A  is a side oblique view of the grain bag winder with the winding cores in a retracted position; 
           [0034]      FIG. 4B  is a front close-up view of the grain bag winder with the winding cores in a retracted position; 
           [0035]      FIG. 5  is a front close-up view of the grain bag winder with the winding cores in a deployed position showing the interlocked winding cores; 
           [0036]      FIG. 6  is yet a further view of the grain bag winder in use; 
           [0037]      FIG. 7  is front view of the grain bag winder; 
           [0038]      FIG. 8  is a side view of the grain bag winder with the winder cores retracted; 
           [0039]      FIGS. 9-11  is a series of Figures illustrating the steps for removing the rolled grain bag from the grain bag winder; 
           [0040]      FIG. 12  is an illustration of a control panel according to another aspect of the invention; 
           [0041]      FIG. 13  is a block diagram of one configuration for a grain extractor with a wireless control panel; 
           [0042]      FIG. 13A  is a block diagram of a variant of the configuration in  FIG. 2  using a wired auxiliary control panel; and 
           [0043]      FIG. 14  is a detailed block diagram of a system according to another aspect of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0044]    Referring to  FIGS. 1 and 2 , a grain extractor with the invention attached is illustrated. The grain extractor  10  is equipped with a grain elevator  20 . An auger system (not shown) can be attached at the bottom of the elevator and the auger system is usually deployed inside a grain bag. The auger system moves grain from within the grain bag to the grain elevator and up the grain elevator to the hopper  30 . The grain is then moved up the hopper to a grain storage (usually a truck for transport) by way of a grain pipe  40 . 
         [0045]    Atop the extractor  10  is a grain bag winder  50 . The grain bag winder has a motor  60  which powers one of two winder cores  70  (see  FIG. 2 ). The two winder cores  70  are both on tracks  80  such that the cores can travel longitudinally along the tracks and can be deployed and retracted as necessary. The winder cores have multiple fingers  90  with the fingers on one winder core locking or mating with the fingers of the other winder core to form a single winding core. 
         [0046]    The grain bag winder also has a pair of plates  100  which hold the wound up grain bag between them. The plates are rotatable with the grain bag being wound up. At the center of each plate is a hole or void  102  through which a winder core passes. When deployed, the winder cores  70  are preferably flush with the plates and the winder core fingers are intertwined or interlocked with each other in the space or gap between the two plates. When the winder cores are deployed, these winder cores hold the plates in place such that there is a fixed first distance between the two plates. When the winder cores are retracted, the plates are allowed to slide away from each other, thereby increasing the gap between the plates to a second distance. As can be imagined, the first distance is smaller than the second distance. The plates are supported by small wheels  85 . Each plate is supported by a pair of these small wheels  85  (one front wheel and one back wheel) and each plate can slide transversally along the small wheels  85 . 
         [0047]    The grain bag winder  50  is also equipped with arms  105 , one on each side of the rolled up grain bag. These arms are located below the rolled up grain bag. These arms also extend outwardly or away from the rolled up grain bag and extend towards a direction of travel of the extractor when the rolled up or wound up grain bag is being removed. A bridge  107  connects the two arms and is spaced from the two arms by risers  109 . When in use, the section of the empty grain bag being rolled up passes between the two arms and underneath the bridge  107 . Each of the arms  105  is equipped with a guide  95 . The guides  95  are hinged to be in a deployed position or in a loose position. In  FIGS. 1 and 2 , the guides  95  are illustrated in a loose position. When in a loose position, the guides act to guide the rolled up bag down the elevator  20 . In a deployed position, the guides  95  act to guide the empty grain bag as it is rolled up on the winding cores  90 . 
         [0048]    Referring to  FIG. 3 , an illustration of the extractor and the invention in use is provided. A grain bag  110  filled with grain is being emptied by the extractor  10 . The auger system (not shown) is inside the grain bag and, as the grain bag is emptied, the empty portions are wound up by the grain bag winder. Visible in  FIG. 3  are the plates  100  and the motor  60  of the grain bag winder. The distance or gap between the two plates  100  when the winding cores are deployed may be predetermined and set such that the rolled up grain bag has a set width. Once retracted, the winding cores allow the plates  100  to slide away from each other, thereby releasing the rolled up grain bag. 
         [0049]    Referring to  FIG. 4 , a side view of the grain bag winder in use is illustrated. As can be seen, the empty grain bag  110  is being rolled up using the intertwined or interlocked fingers  90 . It should be noted that the elevator is not visible as the elevator is inside the grain bag. 
         [0050]    Referring to  FIG. 4A , an oblique view of the grain bag winder with the winder cores  90  in a retracted position is shown. When in a retracted position, the winder cores are retracted through the holes  102  on the plates  100  and are placed outside the gap between the plates  100 . 
         [0051]    Referring to  FIG. 4B , a front view of the grain bag winder without a grain bag is illustrated with the winder cores in a retracted position. As can be seen, the small wheel  85  on the left side of the illustration is closer to the internal side (i.e. near the gap between the plates) than to the external side of the plate  100 . From this figure, it can also be seen that the guides  95  are in a deployed position. The edge of the guides  95  can be seen to be smooth to prevent an empty grain bag from catching or ripping as it is being rolled up. 
         [0052]    From  FIG. 4B , it should be clear that, once the empty grain bag has been rolled up, the winding cores can be retracted. Once the winding cores are retracted, the plates can slide away from each other. This causes the rolled up bag, previously captive between the two plates, to drop from between the plates. The elevator  20  can then be used to guide the rolled up grain bag on to the flat bed of a truck or on to the ground. 
         [0053]    Referring to  FIG. 5 , a front bottom view of the grain bag winder without a grain bag is illustrated. As can be seen, the interlocked or intertwined fingers of the winder cores are clearly illustrated. The end of a grain bag to be rolled up can be attached to the interlocked fingers. When the winder cores rotate due to the motor  60 , the empty grain bag wraps around the winder cores. While the discussion notes two winder cores, a single winder core, also retractable, may be used. As noted above, when in a deployed position, the winder cores push the plates  100  to a predetermined position so that there is a predetermined first distance between the plates  100 . 
         [0054]    Also referring to  FIG. 5 , the small wheels  85  are also visible. As mentioned above, the plates  100  rest on these small wheels  85 . It can be seen in  FIG. 5  that the small wheels  85  are thinner than the plates  100 . The plates  100  can slide along the axis of rotation of the small wheels  85 . When the winding cores are deployed (as show in  FIG. 5 ), the small wheels are adjacent to the external side of the plates. When the winding cores are retracted, the plates  100  can slide towards each other such that the small wheels  85  can then be adjacent the internal side of the plates. The effect of the slidability of the plates  100  is that, when the winding cores  90  are deployed, there is a fixed distance for the gap between the plates. When the winding cores are retracted, the plates  100  can slide away from each other to increase the distance of the gap between the plates. 
         [0055]    Another side view of the grain bag winder in use is illustrated in  FIG. 6 . As can be seen, the empty portion of the grain bag is rolled up as the grain bag is emptied. Also visible from this angle is an extra small wheel  85 A deployed closed to the top of the right plate  100 . A similar small wheel may also be deployed for the left plate  100 . The small wheel  85 A deployed at the top of each plate  100  may be placed there for added stability and support for the plate  100 . 
         [0056]    Referring to  FIG. 7  a front view of the grain bag winder is illustrated. As can be seen, the empty grain bag  110  being rolled up passes between the arms  105  and the risers  109  and passes beneath the bridge  107 . As the empty grain bag is rolled up around the interlocked or intertwined fingers, the rolled up portion is between the two plates  100 . The two plates  100  act to keep the used grain bag in a suitable roll as the grain bag is rolled up. If the plates  100  were not present, the grain bag may not roll into a roll with a predefined width. With the plates  100 , the used grain bag rolls into a roll with a predefined width. The predefined width is the distance between the plates  100  when the winding cores are deployed. 
         [0057]    It should be noted that  FIG. 7  also shows the guides  95  in a deployed position. As can be seen, the guides  95  guide the empty grain bag towards the rest of the rolled up grain bag to ensure a smooth and trouble free rolling up of the emptied grain bag. When in a deployed position (as seen in  FIG. 4B ), the guides  95  are pointed at each other. So that the emptied grain bag does not tear or catch, the outer edges of guides  95  (the edges which come into contact with the grain bag) are preferably rounded and relatively smooth. 
         [0058]    Referring to  FIG. 8 , a left front view of the grain bag winder is illustrated. The fingers  90  of the winder core can be clearly seen in the figure. It should be noted that  FIG. 8  shows the situation where the empty grain bag has been rolled up and is ready for removal. The winder cores have been retracted and the retraction of these winder cores causes the rolled up grain bag to drop to the grain elevator  20 . Since the grain elevator is raised, the rolled up grain bag does not roll off the elevator. Once the elevator  20  is lowered, the grain bag roll rolls off the elevator and, as the grain bag rolls off, it is guided by the arms  105  and the guides  95 . As can be seen, the guides  95  are in a loose position. 
         [0059]    It should be clear that the guides  95  are attached to and hinged to the arms  105 . When in a loose position, the guides  95  open up and their smooth edges point to the ground at an angle as shown in  FIG. 8 . When in a deployed position (as shown in  FIG. 4B ), the smooth edges of the guides  95  point to each other. 
         [0060]    Referring to  FIGS. 9-11 , the sequence for conveniently removing the rolled up grain bag is illustrated. In  FIG. 9 , the rolled up bag is removed from the grain bag winder by retracting the winder cores from the rolled up grain bag. This causes the rolled up grain bag to fall on to the raised elevator. In  FIG. 10 , the rolled up grain bag rolls down the elevator and is stopped by the bridge  105 . In  FIG. 11 , the elevator is lowered further and the rolled up grain bag can proceed to roll down the elevator and on to a transport vehicle for transporting the used grain bag. 
         [0061]    It should be clear that while the Figures illustrate an embodiment with a single motor  60  for driving the winding cores, another implementation uses one motor to drive each winding core. Preferably, the motors are hydraulic motors driven in parallel from a single hydraulic circuit. By driving both motors off a single hydraulic circuit, the motors self-synchronize and issues can be avoided. 
         [0062]    In another aspect of the invention, the grain extractor may be equipped with a remote control module for remotely controlling the various functions of the grain extractor. 
         [0063]    More specifically, one aspect of the present invention relates to grain extractors which are provided with a wireless control panel for controlling the functions of the grain extractor remotely from the grain extractor. The wireless control panel communicates wirelessly with a control box on the grain extractor. The control box is wired, either directly or indirectly, to the various motors and controls on the grain extractor. The wireless control panel allows for various functions of the grain extractor to be controlled remotely. The remote control allows for various components of the grain extractor, such as the drive wheels, the auger lift cylinder, the elevator motor, and the winder motor, to be activated or deactivated remotely. 
         [0064]    It should be noted that the grain extractor illustrated in  FIG. 1  is only one example. Other grain extractors with similar components but with a different configuration are possible. The components for other grain extractors may be different from the components illustrated in  FIG. 1 . 
         [0065]    Referring to  FIG. 12 , an illustration of a sample control panel is provided. Depending on the configuration, the control panel may be a wireless control panel or an auxiliary wired control panel. As a variant of the invention, the control panel may be a hybrid control panel which is both wired to the system and communicates wirelessly with the wireless module. 
         [0066]    Referring to  FIG. 13 , a block diagram of a configuration of the grain extractor with a wireless control panel is provided. As can be seen, the wireless control panel  1300  communicates wirelessly with a wireless module  1310 . The wireless module  1310  is wired to a control box  1320  that determines which received command from the wireless control panel  1300  corresponds to which subsystem of the grain extractor. The control box  1320  is coupled to the central control panel  1330  on the grain extractor. 
         [0067]    The system operates with the user using the wireless control panel  1300  to operate one of the components of the grain extractor. The wireless control panel  1300  sends a wireless signal to the wireless module  1310 . The wireless module  1310  receives the wireless signal and transmits the command corresponding to the wireless signal to the control box  1320 . The control box  1320  then interprets the command to determine which of the various components are to be controlled and what/how the component is to be controlled. Once the interpretation has been performed, the relevant controls on the central control panel  1330  are then operated, thereby causing the relevant motors  1340 A,  1340 B,  1340 C to operate. 
         [0068]    Among the various functions/components which can be controlled by the wireless control panel are the following:
       1. Winder motor: winds up the bag onto the spool to create recyclable bale.   2. Drive wheel motors: walk extractor into the bag.   3. Auger lift cylinder: allows clearance for truck to drive into position and allows for adjustment of grain flow direction side to side on the truck   4. Spout sway: Allows adjustment of grain flow direction front to back on the truck   5. Elevator motor: Allows for adjustment of elevator paddle chain speed   6. Elevator lift cylinder: Allows lifting of elevator to form ramp for used grain bag dump onto transport vehicle for use in transporting the used grain bag       
 
         [0075]    It should be noted that the wireless characteristic of the wireless control panel  1300  is a preferred embodiment. In another embodiment, instead of a wireless control panel, a wired auxiliary control panel may be used in place of the wireless control panel. For this embodiment, a block diagram of which is illustrated in  FIG. 13A , the wireless module  1310  has been removed and the auxiliary control panel  1300 A is directly hard wired to the control box  1320 . 
         [0076]    It should further be noted that the central control panel  1330  may be equipped with a lock-out button or switch to lock out either the auxiliary control panel or the wireless control panel. The lock-out button or switch, when engaged, prevents the auxiliary control panel or the wireless control panel from operating any of the components of the grain extractor. A user who will be controlling the grain extractor from the central control panel  100  may engage the lock-out button to prevent others from accidentally operating the grain extractor. This can prevent conflicting commands or it can be used for safety purposes. Alternatively, to address potentially conflicting commands for the same component, commands from the central control panel can be set to override commands received from either the wireless control panel or the auxiliary control panel. 
         [0077]    Referring to  FIG. 14 , a more detailed block diagram of a wireless control system according to another aspect of the invention. The system  1400  has a remote control  1410  which communicates wirelessly with a control box  1420 . The control box  1410  sends signals based on the received commands from the remote control  1410  to either solenoids  1430  on a valve bank or to a relay box  1440 . If solenoids  1430  are activated, these in turn operate specific hydraulic valves in a hydraulic valve bank  1450 . The valves in the valve bank  1450  in turn control the flow of hydraulic fluid through hydraulic lines  1460  to various assorted hydraulic components  1470 . These components  1470  are then activated/deactivated/controlled by the hydraulic fluid flow. If, on the other hand, the relay box  1440  is activated by the control box, the relay box operates one or more electronic actuator(s)  1480  to activate/deactivate/control electronically actuated components. 
         [0078]    Returning to  FIG. 12 , a sample remote control panel implementing the various functions enumerated above is illustrated. 
         [0079]    A person understanding this invention may now conceive of alternative structures and embodiments or variations of the above all of which are intended to fall within the scope of the invention as defined in the claims that follow.