Abstract:
A wrapping system for plant material utilizes a first wrapping material dispenser disposed along a first upper periphery of a compacting chamber, and a second wrapping material dispenser opposite the first dispenser, for automatically dispensing sheets of wrapping material in overlapping relation over the chamber and plant material therein. The system includes apparatus for joining the overlapping sheets together. The system is automatically operable to dispense sheets of the material in overlapping relation over the chamber and join them for receiving a flow of the plant material thereon. Before or while the plant material is received, the sheets are further dispensed to move downwardly in the chamber to receive and wrap about the plant material. The system then dispenses opposite ends of the sheets in overlapping relation over the material and joins the ends to complete the wrapper.

Description:
[0001]    This application claims the benefit of U.S. Provisional Application No. 61/402,124, filed Aug. 24, 2010. 
     
    
     TECHNICAL FIELD 
       [0002]    This invention relates generally to a system and method for wrapping bales of agricultural plant material including, but not limited to, cotton bales, and biomass bales, in a plant material compactor or other bale forming apparatus, and more particularly, which forms a glued together wrapper in the compactor or apparatus, to be filled with the plant material, and then completes the wrapper prior to unloading of the bale. 
       BACKGROUND ART 
       [0003]    The disclosure of U.S. Provisional Application No. 61/402,124, filed Aug. 24, 2010, is hereby incorporated herein in its entirety by reference. 
         [0004]    Large unitary bales of agricultural material, e.g., cotton, biomass, hayage, silage, etc., also commonly referred to as modules, are a common manner of packaging for high productivity. Presently, large baling and compacting apparatus carried on or towed by harvesting machines, also referred to as module builders or on-board module builders (OBMB), are capable of forming bales and modules as large as 8 feet by 8 feet by 16 feet (approx. 250 by 250 by 500 cm). These bales and modules are typically unloaded to ground level without covers or other wrapping materials. This unloading can occur in the field, or at the periphery of the field, and the bales or modules are picked up later for processing, use, or storage. Tarps designed to cover the top and partially the sides of the bales or modules are often installed within a few hours after unloading. Such bales or modules would benefit, however, by being wrapped or packaged prior to being unloaded, that is, before the OBMB tilts to unload or otherwise unloads the bale or module onto a field or other location. An advantage would be that the integrity of the bale or module would be improved and ground losses of the agricultural material would be reduced. 
         [0005]    Therefore, what is sought is a system and method for wrapping large bales and modules of agricultural material including, but not limited to, cotton bales and biomass bales, before being unloaded onto the ground, so as to improve integrity and reduce ground losses. 
       SUMMARY OF THE INVENTION 
       [0006]    What is disclosed is a system and method for wrapping large bales and modules of agricultural material including, but not limited to, cotton bales and biomass bales, before being unloaded onto the ground, so as to improve integrity and reduce ground losses. The term “biomass” should be interpreted broadly to include that and other balable plant materials. 
         [0007]    According to a preferred aspect of the invention, the system and method are utilized on or in association with a mobile compacting apparatus. 
         [0008]    According to another preferred aspect of the invention, the system and method utilize a first wrapping material dispenser disposed along a first upper periphery of a compacting chamber, and a second wrapping material dispenser opposite the first dispenser, for automatically dispensing sheets of wrapping material in overlapping relation over the chamber and plant material therein. The system and method also utilize apparatus for joining the overlapping sheets together and for cutting the sheets. 
         [0009]    According to another preferred aspect of the invention, the system is automatically operable to dispense sheets of the material in overlapping relation over the chamber and join them for receiving a flow of the plant material thereon. Preferably, this is done with the sheets resting on an already wrapped bale in the chamber. After the existing bale is removed from the chamber, but before or while additional plant material is received, the sheets are further dispensed to allow the joined sheets to fall downwardly into the chamber. The system then dispenses opposite ends of the sheets in overlapping relation over the material and joins the ends to complete the wrapper. The initial steps can then be repeated to start a new wrapper before the wrapped bale is removed. 
         [0010]    According to another preferred aspect of the invention, the wrapping material dispensers each including powered pinch rollers supported for movement from the sides of the upstanding structure to a location past a center of an upper region of the chamber, respectively. And, the pinch rollers are controllably operable in a first rotating mode for dispensing the sheets therefrom; in a second rotating mode for moving along the dispensed sheets; and in a non-rotating mode for extending the sheets. As a result, the dispensers are operated in the non-rotating mode to bring the sheets, and the ends of the sheets, into the overlapping relation to the chamber. The dispensers are operated in the first rotating mode to dispense the sheets to extend downwardly into the chamber. And, the dispensers are operated in the second rotating mode after the sheets and the ends of the sheets are extended over the chamber, respectively, but before being joined together, so as to be clear of the joining operation. 
         [0011]    According to another preferred aspect of the invention, the wrapping material dispensers are disposed on mechanisms configured and operable for moving the dispensers over the chamber and back to the sides. As non-limiting examples, the mechanisms can include pivoting arms, linear actuators, or the like. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  is a simplified side view of a plant material harvester having a plant material compactor including a wrapping system of the invention operable according to a method of the invention; 
           [0013]      FIG. 1A  is a top view of the harvester of  FIG. 1 , showing the wrapping system of the invention; 
           [0014]      FIG. 2  is a rear view of the harvester of  FIG. 1 , showing the wrapping system of the invention configured for performing a step of the method of the invention; 
           [0015]      FIG. 3  is another rear view of the harvester of  FIG. 1 , showing the wrapping system of the invention configured for performing another step of the method of the invention; 
           [0016]      FIG. 4  is another rear view of the harvester of  FIG. 1 , showing the wrapping system of the invention configured for performing another step of the method of the invention; 
           [0017]      FIG. 5  is another rear view of the harvester of  FIG. 1 , showing the wrapping system of the invention configured for performing another step of the method of the invention; 
           [0018]      FIG. 6  is another rear view of the harvester of  FIG. 1 , showing the wrapping system of the invention configured for performing another step of the method of the invention; 
           [0019]      FIG. 7  is another rear view of the harvester of  FIG. 1 , showing the wrapping system of the invention configured for performing another step of the method of the invention; 
           [0020]      FIG. 8  is another rear view of the harvester of  FIG. 1 , showing the wrapping system of the invention configured for performing another step of the method of the invention; 
           [0021]      FIG. 9  is another rear view of the harvester of  FIG. 1 , showing the wrapping system of the invention configured for performing another step of the method of the invention; 
           [0022]      FIG. 10  is another rear view of the harvester of  FIG. 1 , showing the wrapping system of the invention configured for performing another step of the method of the invention; 
           [0023]      FIG. 11  is another rear view of the harvester of  FIG. 1 , showing the wrapping system of the invention configured for performing another step of the method of the invention; 
           [0024]      FIG. 12  is another rear view of the harvester of  FIG. 1 , showing the wrapping system of the invention configured for performing another step of the method of the invention; 
           [0025]      FIG. 13  is another rear view of the harvester of  FIG. 1 , showing the wrapping system of the invention configured for performing another step of the method of the invention; 
           [0026]      FIG. 14  is a side view of the harvester of  FIG. 1 , showing the compacting structure tilted for unloading a bale wrapped using the wrapping system of the invention; 
           [0027]      FIG. 15  is another side view of the harvester of  FIG. 1 , shown towing an optional bale caddy carrying a bale wrapped by the wrapping system of the invention; 
           [0028]      FIG. 16  is another rear view of the harvester of  FIG. 1 , showing the wrapping system of the invention configured for performing another step of the method of the invention; 
           [0029]      FIG. 17  is still another rear view of the harvester of  FIG. 1 , showing the wrapping system of the invention configured for performing another step of the method of the invention; 
           [0030]      FIG. 18  is another rear view of the harvester of  FIG. 1 , showing the wrapping system of the invention configured for performing another step of the method of the invention; and 
           [0031]      FIG. 19  is a simplified fragmentary side view of the harvester, showing an embodiment of an unloading door for use therewith, in a folded closed configuration; 
           [0032]      FIG. 20  is another simplified fragmentary side view of the harvester, showing the door of  FIG. 19  unfolded in a configuration for unloading onto the ground or another surface below the harvester; and 
           [0033]      FIG. 21  is another simplified fragmentary side view of the harvester, with the door of  FIG. 19  in rearward level orientation, for unloading onto the bed of a truck, a trailer, or other surface. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0034]    Referring now to the drawings,  FIGS. 1 and 1A  show a self-propelled agricultural plant material harvester  24  including an on-board plant material compactor  26 , for collecting and compacting the harvested plant material into compacted unitary bales. Harvester  24  additionally includes a wrapping system  28  constructed and operable according to the invention, for preparing a wrapper for the bales, and wrapping the bales, prior to unloading from compactor  26 . Harvester  24  and compactor  26  are configured and operable for unloading bales onto the ground or another surface, or another vehicle such as a self-propelled bale handler, trailer, wagon, truck, or the like, either as harvester  24  is stationary, or moves in a forward direction F over a field, or rearwardly. Harvester  24  here is configured to include apparatus on a forward end thereof, of conventional construction and operation for picking or picking up, and propelling an airborne stream of plant material upwardly and rearwardly through a duct or ducts  30  into a compacting chamber  32  of compactor  26 , as denoted by arrow S. Alternatively, or in conjunction with airborne flow, mechanical conveyance can also be used for moving the plant material. As representative examples, the plant material can include cotton, a variety of biomass products, such as typically used for silage and the like, hayage, sugar cane residue, and the like. It should also be noted that the invention can be used with a pull type harvester. 
         [0035]    Referring also to  FIGS. 2 and 3 , compacting chamber  32  is defined on the bottom by a floor  34 ; at the forward end by an upstanding forward wall  36 ; at the rear end by an upstanding unloading door  38  enclosing an unloading opening  40 ; and on the opposite sides by upstanding side walls  42 . Compactor  26  can include compacting apparatus  44  (illustrated schematically in  FIGS. 15 ,  16  and  17 ) of well-known construction, in an upper region of chamber  32 , operable to forcibly move downwardly therein for compacting the plant material against floor  34  for forming a unitary compacted module or bale  46  in chamber  32 , which will be unloaded through opening  40 , all in the well-known manner. Compactor  26  is supported on a frame  48  of harvester  24 , which also carries an operator cabin, an engine and a drivetrain (not shown) connected in driving relation to wheels  50  that support harvester  24  for movement over the ground and other surfaces, also all in the well-known manner. As representative, but non-limiting values, a bale  46  produced by compactor  26  will have a length of about 16 feet, a width of about 8 feet and a height of up to about 8 feet, or 500×250×250 cm. 
         [0036]    Wrapping system  28  of the invention includes a first wrapping material dispenser  52  disposed when in a standby position, along a first upper periphery  54  of compacting chamber  32 , which here is defined by an upper region of one of the side walls  42 . System  28  includes a second wrapping material dispenser  56  disposed when in its standby position, along a second upper periphery  58  of chamber  32 , which here is defined by an upper region of a second of side walls  42 , opposite first dispenser  52 . Dispensers  52  and  56  each extends substantially the front to rear length of chamber  32 , and each is configured for automatically dispensing a first sheet  60  and a second sheet  62 , respectively, of wrapping material over chamber  32  and the plant material therein, here, shown already compacted into a bale  46 . For this purpose, sheets  60  and  62  are of sufficient width (front to rear) for substantially covering chamber  32  from front to rear. Each dispenser  52  and  56  is controllably driven by a drive  66  ( FIG. 1 ) which can be electrical or fluid driven, e.g., including a fluid motor supplied by a pressurized fluid system  68  of harvester  24 , and a gear set, connected in driving relation with the rollers of pinch roll set  64  for counter-rotating the rollers in a commanded direction. Each dispenser  52  and  56  additionally includes a supply roll  70  of the sheet material, at a suitable location, such as along the respective bottom of side wall  42  of compactor  26 , such that sheets  60  and  62  extend generally vertically outwardly of side walls  42 , between supply roll  70  and pinch roll set  64  of the respective dispenser. Supply roll  70  of each dispenser  52  and  56  is also preferably driven by a drive  66 , which can again comprise, but is not limited to, a fluid or electric motor powered by a fluid system of harvester  24 . 
         [0037]    Pinch roller sets  64  of dispensers  52  and  56  of wrapping system  28  are preferably carried on powered drive mechanisms  72  controllably operable for moving the roller sets sidewardly over the upper end of compacting chamber  32 . Here, drive mechanisms  72  are located at the front and rear ends of chamber  32  and include a suitable driver, such as, but not limited to, a linear or rotary actuator, controllable for pivoting support arms  74  and  76  carrying the respective pinch roller sets  64  between its standby position ( FIG. 2 ) adjacent the respective side wall  42 , and a range of operative positions over chamber  32  (illustrated by the position of support arm  74  in  FIG. 3 ), e.g., for pulling or extending the respective sheet  60  or  62  a desired extent over the chamber (illustrated in  FIG. 3  by the position of sheet  60 ), as will be explained. Further in this regard, rear drive mechanisms  72  is illustrated in unloading opening  40 , and will necessarily be configured so as to move out of the way of bales being unloaded, utilizing suitable additional support structure for that purpose, e.g., a folding arm, scissors mechanism, or the like (not shown). As a non-limiting alternative, mechanisms  72  can include linear drives such as screw drives, located over forward wall  36  and unloading opening  40  so as not to require movement out of opening  40 . Hereafter, in the subsequent illustrations, mechanisms  72  are deleted for simplicity. 
         [0038]    System  28  includes apparatus for joining sheets  60  and  62  together when overlapped, as will be explained, which here includes an adhesive spray apparatus  78 . Apparatus  78  extends forward and rearwardly above chamber  32 . Spray system  78  includes a linear array of spray nozzles  80  disposed for directing adhesive downwardly. Nozzles  80  are connected to a supply pump  82  via a supply line  84  for receiving adhesive from a reservoir  86  on harvester  24 . Nozzles  80  are contemplated to be positioned above compacting apparatus  44  and will necessarily be positioned so as to spray through suitable apertures or spaces therethrough. The adhesive dispensed by system  78  should be selected as a contact type adhesive which will become tacky immediately, so as to be sufficient for virtually immediately joining together and permanently bonding sheets of the wrapping material, e.g., sheets  60  and  62 , when brought together without substantial pressure exerted to press the sheets together. It is also desired that the adhesive be organic. It is contemplated that sheets  60  and  62  will comprise a suitable plastics material, such as, but not limited to, a commercially available polyethylene film, and the adhesive should be selected says to be compatible with the sheeting material used. 
         [0039]    Each of dispensers  52  and  56  includes cutting apparatus  88  operable along the length thereof ( FIGS. 4 and 6 ) for cutting sheets  60  and  62 , respectively. For example, apparatus  88  can include a traveling knife movable by a linear actuator, or a hot wire, that can be actuated at the proper time for cutting the sheet. 
         [0040]    Wrapping system  28  additionally includes a processor based controller  90  ( FIG. 1 ) connected in operative control of the various components of system  28 , including, but not limited to, drives  66  of dispensers  52  and  56 , drive mechanisms  72 , pump  82 , and cutting apparatus  88 , via suitable communication paths  90 , such as, but not limited to, wires of a wiring harness, or a wired or wireless controller network. 
         [0041]    Referring now to  FIGS. 2 through 18 , operation of wrapping system  28  for preparing a wrapper  94  for wrapping a bale  46  in compacting chamber  32  of compactor  26  on harvester  24 , according to a preferred method of the invention, will be explained. 
         [0042]    In  FIG. 2 , as noted above, wrapping system  28  is at rest, with dispensers  52  and  56  in their standby positions above side walls  42 . A completed bale  46  resides in compacting chamber  32 . It can be observed and appreciated that sheet  60  extends upwardly from supply roll  70  along the outside of the adjacent side wall  42 , about the lower roller of pinch roller set  64  of dispenser  52 , and downwardly along the inside surface of side wall  42  and over midway across floor  34 . Similarly, sheet  62  extends upwardly from its supply roll  70  along the outside of the adjacent side wall  42 , about the lower roller of pinch roller set  64  of dispenser  56 , and downwardly along the inside of adjacent side wall  42 , and partially across floor  34 , and is permanently joined together with sheet  60  by the adhesive, forming the sides and bottom of a wrapper for bale  46 . 
         [0043]    In  FIG. 3 , drive mechanism  72  has been activated to pivot support arms  74  toward support arms  76  (front and rear), so as to move first wrapping material dispenser  52  over the upper region of chamber  32 . As this occurs, pinch roller set  64  is operated to counter-rotate and supply roll  70  is rotated, to extend first sheet  60  for covering a substantial portion of bale  46 . Here, it should be observed that two layers of sheet  60  extend over bale  46  as a result of the looping of sheet  60  over the lower roller of the pinch roller set  64 . Now, in  FIG. 4 , cutting apparatus  88  of dispenser  52  is operated to cut the lower layer of sheet  60 , so as to fall onto the top surface of bale  46 . 
         [0044]    Referring to  FIGS. 5 and 6 , drive mechanisms  72  is now operated to move support arm  74  to return dispenser  52  to its standby position. At the same time, the associated supply roll  70  will be operated to retract sheets  60  to maintain some amount of tension therein. Next, adhesive spray apparatus  78  is operated to discharge adhesive from nozzles  80 , along the forward to rearward length of sheet  60 , as illustrated in  FIG. 5 . Now drive mechanisms  72  will be operated to pivot support arm  76  to move second wrapping material dispenser  56  toward dispenser  52 , while pinch roller set  64  of dispenser  56  is operated to counter-rotate the rollers thereof, and the associated supply roll  70  is rotated, to extend sheet  62  over sheet  60  on top of bale  46 , as illustrated in  FIG. 6 . As with sheet  60 , sheet  62  loops about the lower roller of pinch roller set  64 , such that two layers of that sheet are present over the bale. Cutting apparatus  88  of dispenser  56  is now operated to cut sheet  62 , such that the lower layer will fall onto sheet  60  on top of the bale. Because the adhesive has been applied to the upper surface of sheet  60  and is immediately tacky, sheet  62  will be immediately adhered and permanently joined to sheet  60 , thereby completing a wrapper  94  about bale  46 . 
         [0045]    Before unloading the now wrapped bale  46 , the bottom of a second wrapper will be prepared on top of the wrapped bale. Referring to  FIGS. 8 and 9 , dispenser  52  will be operated to extend sheet  60  over bale  46  as shown. Here, it should be noted that because sheet  60  was previously cut, only one layer will be present. Thus, to perform this operation, pinch roller set  64  of dispenser  52  will not operate, but roller  70  will be operated to extend the sheet. As illustrated in  FIG. 9 , pinch roller set  64  of dispenser  52  will be counter rotated as indicated by the arrows, and the drive mechanism  72  operated to return dispenser  52  to its standby position, so as to leave a portion of sheet  60  over bale  46 . 
         [0046]    In  FIG. 10 , spray apparatus  78  is operated to dispense adhesive from nozzles  80  onto sheet  60  atop bale  46 . In  FIG. 11 , second wrapping material dispenser  56  is now moved to extend sheet  62  over bale  46 , and sheet  60  thereon. Similarly to sheet  60 , only one layer of sheet  62  extends over the bale. As a result, during this operation, the pinch roller set of dispenser  56  is not operated, but supply roll  70  is rotated to feed more material. Here, because of the presence of the adhesive on sheet  60 , it is important to maintain tension on sheet  62 , so as not to come into contact with sheet  60 . Now the pinch roller set of dispenser  56  will be operated to counter-rotate the rollers thereof, while dispenser  56  is moved back to its standby position, such that the free end of sheet  62  will fall onto and be adhesively joined to, sheet  60 , as illustrated in  FIG. 12 . 
         [0047]    Referring now jointly to  FIGS. 13 ,  14  and  15 , wrapped bale  46  can be unloaded from chamber  32  of compactor  26  in a desired manner.  FIG. 14  illustrates one manner of unloading, wherein compactor  26  is tilted and unloading door  38  unfolded, such that the wrapped bale can be conveyed over floor  34  and door  38  onto the ground or another surface.  FIG. 15  illustrates another manner of unloading, wherein compactor  26  is not tipped, but unloading door  38  is configured as a conveyor lowerable in parallel relation to floor  34 , for unloading onto a bed of a truck  98 , a trailer, or a caddy. In  FIG. 13 , it can be observed that after unloading, joined together sheets  60  and  62  will be suspended from dispensers  52  and  56  above or in an upper region of, chamber  32 . At this time, pinch roller sets  64  and supply rolls  70  of dispensers  52  and  56  will be operated to extend sheets  60  and  62  such that the joined together ends thereof will be lowered within chamber  32  to form the bottom of a new wrapper against floor  34 . At this time also, the unloading door can be closed, and operation of harvester  24  resumed to direct the flow of plant material into chamber  32  for forming another bale. 
         [0048]    As can be seen in  FIG. 16 , plant material  96  entering chamber  32  above joined together sheets  60  and  62  will land on those sheets so as to exert weight thereagainst. Referring also to  FIGS. 17 and 18 , periodically during the forming of a bale, compacting apparatus  44  of compactor  26  will be lowered into chamber  34  against the material  96  to compact it against floor  34 . This and the weight of the material will serve to conform joined together sheets  60  and  62  to floor  34  and also the side walls and ends of chamber  32 , to impart a rectangular shape to the material and sheets. At this time, it can be observed that sheets  60  and  62  again loop about the bottom rollers of the respective pinch roller sets to  64 . Now, when the material  96  is compacted to the desired extent, e.g., forms a bale as described above, the wrapper can be completed in the above described manner, and the bale unloaded. 
         [0049]    Referring also to  FIGS. 19 ,  20  and  21 , harvester  24  is shown including an unloading door  100  configurable in a folded manner next to the rear of compactor  26  ( FIG. 19 ); extended downwardly to the ground to for unloading a bale  46  thereon ( FIG. 20 ); and in a rearwardly extending orientation ( FIG. 21 ) for unloading to a truck  98 , trailer, caddy, or the like. The door  100  can also be used in the configuration of  FIG. 21  for receiving a bale  46 , and then tilted as shown in  FIG. 20 , for unloading the bale onto the ground or other surface therebelow. In this regard, drivers  102  such as fluid cylinders or the like, can be used for manipulating door  100  between the positions shown, and door  100  can include drivers  106  for extending a moving belt  104  thereof for reaching the ground or other surface onto which the bale is to be unloaded. Other door configurations can also be used, as desired or required for a particular application. 
         [0050]    It can be observed that wrapper  94  will provide greater adhesion and integrity to a bale  46 , and will reduce ground losses of the plant material. 
         [0051]    In light of all the foregoing, it should thus be apparent to those skilled in the art that there has been shown and described a novel bale wrapping system and method. However, it should also be apparent that, within the principles and scope of the invention, many changes are possible and contemplated, including in the details, materials, and arrangements of parts which have been described and illustrated to explain the nature of the invention. Thus, while the foregoing description and discussion addresses certain preferred embodiments or elements of the invention, it should further be understood that concepts of the invention, as based upon the foregoing description and discussion, may be readily incorporated into or employed in other embodiments and constructions without departing from the scope of the invention. Accordingly, the following claims are intended to protect the invention broadly as well as in the specific form shown, and all changes, modifications, variations, and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention, which is limited only by the claims which follow.