Abstract:
A method of electronically sensing the fill of material in a stuffer chute and tripping a stuffer of a baler.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This is a divisional of application Ser. No. 12/645,174 filed Dec. 22, 2009, now U.S. Pat. No. 8,291,818, which is hereby incorporated by reference in its entirety herein. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates generally to combine residue and collection for biomass fuel production. 
     BACKGROUND 
     The combine harvester, or simply combine, has a history of development directed toward combining several operations into one complete machine. The combine completes these operations in one pass over a particular part of the field. Early combines were pulled through the fields by teams of horses or mules. Today, combines utilize GPS and auto-steering, but baling is typically performed as an additional step after the harvesting. After the combining operations are completed, a separate baler towed by a tractor is required to gather cut crops such as plant stalks from the field to form the plant stalks into round or square bales. Biomass fuels such as straw, hay or cereals may be pressed into bales to increase their energy density. The bales are subsequently picked up and trucked to where they are needed. What is needed is an improved means of combining the baling operation along with the operations of the combine harvester so that the crop may be harvested and the residue baled in a single pass of a combine harvester. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1 . is a partial side view of a combine harvester and a side view of a baler towed by the combine harvester; 
         FIG. 2  is a top view of the combine and towed baler of  FIG. 1 ; 
         FIG. 3  is a bottom perspective view from the rear of the combine and towed baler of  FIG. 1 ; 
         FIG. 4  is a partial top perspective view from the front of the frame and tongue of the towed baler with a transfer pan and a pickup; 
         FIG. 5  is a is partial top perspective view from the front of the frame of the towed baler without the transfer pan and pickup; 
         FIG. 6  is a close-up side view of the transfer pan; 
         FIG. 7  is a top view of the towed baler of  FIG. 4  with the transfer pan and pickup; 
         FIG. 8  is a front view of the towed baler of  FIG. 4  with the transfer pan and pickup; 
         FIG. 9  is a top perspective view from the front of the towed baler with a transfer pan according to an alternative embodiment; 
         FIG. 10  is a close-up view of the pickup of the baler in combination with a cutter; 
         FIG. 11  is a front perspective view of a packer and stuffer chute of the baler; 
         FIG. 12  is a top view of the baler and towed baler of  FIG. 1  where the combine is turning; 
         FIG. 13  is a partial side view of the baler showing the packer and stuffer chute; 
         FIG. 14  illustrates a density control mechanism according to one embodiment of the present invention; 
         FIG. 15  illustrates a trigger assembly of the density control mechanism of  FIG. 14 ; 
         FIG. 16  illustrates the trigger assembly of  FIG. 15  when the trigger assembly has been tripped; and 
         FIG. 17  illustrates the stuffer arm of a stuffer of the baler rotated into the home position. 
     
    
    
     DESCRIPTION 
     The present invention will be described more fully hereinafter with reference to the accompanying drawings in which like numerals represent like elements throughout the several figures, and in which an exemplary embodiment of the invention is shown. This invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, the embodiments are provided to make this disclosure thorough and complete, and to fully convey the scope of the invention to those skilled in the art. The present invention is described more fully hereinbelow. 
       FIGS. 1-3  illustrate a combine  10  towing a baler  12  according to one embodiment of the present invention. The baler  12  is pivotally attached to the rear of the combine  10  via a tongue  16  which is coupled to the hitch point on the back of the combine  10 . The baler  12  is preferably powered by a hydrostatic motor affixed to the flywheel of the baler  12  drawing its power source from the engine of the combine  10  via a hydrostatic pump. 
     The tongue  16  is attached to the chassis or main frame of the baler  12 . The chassis is made of steel frame construction. As best shown in  FIGS. 4-9 , the tongue  16  is configured to be coupled to the combine  10  so that when the crop material from the combine  10  can be transferred from the combine  10  directly to the baler  12  without redirection through the air by the combine and without the use of a conveyor coupled to either the combine  10  or the baler  12 . The term “crop material” is intended to include grain and/or material other than grain (MOG), such as crop residue from the combine  10 . Moreover, the tongue  16  and the chassis of the baler  12  are configured to the flow of crop material therethrough as described below. The crop material from the combine  10  preferably is directly discharged from the combine  10  to the baler  12 . Also, the crop material from the combine  10  does not need to be oriented or moved upward from the back of the combine  10  in order to be transferred to the baler  12  or any other secondary vehicle according to an embodiment of the present invention. 
     The crop material from the combine  10  is projected to a target defined by the baler  14 . As best shown in  FIGS. 4 ,  7 ,  8  and  10 , the target may be a baler collection device or feeding mechanism such as a pickup  20 , and/or a collector such as a transfer pan  22 . Pickup  20  may be a rotating drum-type mechanism with flexible tines or teeth for lifting and conveying material from the ground to the baler  12 . The pickup  20  may be mounted to the chassis of baler  12  for pivoting movement about an upwardly and rearwardly disposed transverse pivot axis. In one or more embodiments, at least a portion of crop material may be directly received from the combine  10  at the baler  12  without a pickup  20 . As best shown in  FIG. 11 , at least a portion of the crop material may be directly discharged to a transfer pan  292  in front of the packer  276  which prevents crop material that is thrown to the packer from falling to the ground. Packing forks  282  can grab at least a portion of the crop material collected on the transfer pan  292  and move the crop material back to the stuffer chute  90 . 
     Also, if desired, crop material may also be lifted or received from the ground with the pickup  20 . The pickup  20  may be either configured to receive material directly from the ground or directly from the combine  10 . However, it is preferable not to mix crop material received directly from the combine  10  with crop material received from the ground because of the dirt and other contamination that occurs when crop material is on the ground. Introducing dirt into the bale can cause significant issues in a fuel conversion process. The crop material on the ground may be from the combine  10  towing the baler  12  or some other vehicle. A portion of crop material received directly from the combine  10  may be discharged from the same location on the combine  10  as any other portion of crop material discharged onto the ground to be picked up by the pickup  20  of the baler  12 . However, in one or more embodiments, the combine  10  may have a chaff spreader as best shown in  FIG. 3  where at least a portion of the chaff may be directed into the trajectory of the crop material coming out from the combine  10  and the tailboard  66 . In another embodiment, the chaff can be directly discharged by the chaff spreader onto the baler  12 . For example, the chaff may be received and collected on the transfer pan  22  for the pickup  20  or on the transfer pan  292  for the packer  276 . 
     In one or more embodiments, air may be used to direct crop material collected on either of the transfer pans  22 ,  292  into the pickup  20  or just the packer  276  when the pickup  20  is not used. To much crop material on the transfer pans  22 ,  292  may become an obstruction and therefore could prevent additional crop material from being collected and baled as desired. The transfer pans  22 ,  292  may include one or more openings or apertures for passing pressurized air therethough at the collected crop material. Preferably, the pressurized air comes from the baler  12  itself by using a hydraulic motor that spins a fan such as the hydraulic driven fans known to be used on balers to keep knotters free of debris. The air may be passed through one or more passageways or tubes extending to the apertures in the surfaces of the transfer pans  22 ,  292 . At least a portion of the transfer pans may be hollow. Preferably the apertures are configured to pass air upward from the surface of the transfer pans  22 ,  292  and backward at an angle toward the pickup  20  and/or packer  276 . In another embodiment, the air could be directly blown at the crop material from the passageways or tubes. The direction of at least a portion of the air flow can be reoriented while the crop material is being collected. In another embodiment, at least a portion of the air flow can be used to clear the crop material from the transfer pans  22 ,  292  when the portion of crop material collected on the transfer pans is not to be picked up by the pickup  20  or to be packed by the packer  276 . More example, a portion of the crop material may be stuck and obstructing other crop material from being received on the transfer pans  22 ,  292 . 
     Preferably the transfer pan  22 ,  292  is coupled to the baler  10  in such a manner that the collected crop material is permitted to slide across the transfer pan  22 . Also, the transfer pan  22  may be permitted to bounce somewhat when impacted by the crop material or as a result of the baler  12  advancing along the ground behind the combine  10 . The bouncing allows at least a portion of the crop material to impact the transfer pan  22 ,  292  and then convey or funnel at least a portion of the crop material toward the pickup  20  or toward the packer  276 . Preferably, the transfer pan  22  directs the crop material onto the pickup  20 . The transfer pan  22 ,  292  may be coupled to the baler by springs or chains  26 , or a combination thereof. The shape and configuration of either of the transfer pans  22 ,  292  as well as the length of the chains  26  can be adjusted or the type of springs can be changed as needed to suit particular crops or conditions. 
     The transfer pans  22 ,  292  may also have an elongated portion  24 , as best shown in  FIG. 9 , extending over the draw bar portion of the tongue  16  to protect electrical and/or hydraulic lines extending forward of the cross member  50  along the length of the tongue  16  from the impact of the crop material from the combine  10  intended for the baler  12 . The electrical and hydraulic lines may run along the top of the tongue  16  or within the tongue  16  itself. In either case, the elongated portion  24  shields the electrical and hydraulic lines. Thus, the elongated portion  24  is a protective member and not intended for receiving material. The elongated portion  24  may be an integral part of the transfer pans  22 ,  292  or may be a separate part extending from the remainder of the transfer pans  22 ,  292  intended for receiving material from the combine  10 . The elongated portion may extend almost the entire length of the tongue  16  or only a portion thereof. 
     Also, as shown in  FIG. 9 , one or more deflector panels  28  coupled to the baler  12  can be utilized to deflect the crop material from the combine  10  inward to the transfer pans  22 ,  292 . The deflector panels  28  may be fastened to either side of the forward frame members  44   a ,  44   b  but are preferably fastened to the inside of the forward frame members  44   a ,  44   b  and extend in a forward manner from the forward frame members  44   a ,  44   b . The deflector panels  28  may have a length generally corresponding with the length of the forward frame members  44   a ,  44   b  extending above the transfer pans  22 ,  292 . Each of the deflector panels  28  may have two portions angled relative to one another where outer portions of the deflector panels  28  extend outward from the forward members  44   a ,  44   b , and the inner portions are fastened to the side of the forward frame members  44   a ,  44   b.    
     As best shown in  FIGS. 3 and 10 , the baler  12  may include a cutter  30  positioned after the pickup  20  and before the packer  276  to reduce the distance the crop material must travel from the combine  10  before it is baled. As a result of using a cutter  30  in between the pickup  20  and the packer  36 , the pickup  20  is moved forward toward the tongue  16 , compared with when using just a pickup  20  on conventional balers, so that the distance between the back of the combine  10  and the target on the bailer  12  is reduced. By positioning the cutter  30  in between the pickup  20  and the packer  36 , the pickup  20  and transfer pan  22  may be moved forward approximately eighteen inches or more. Alternatively, the length of some tongues  16  may be adjusted mechanically to obtain the desired distance between the back of the combine  10  and the baler  12 .  FIG. 12  shows the combine  10  turning but the length and shape of the tongue  16  is sufficient to preclude the tongue  16  or baler  12  from impacting the combine  10 . 
     In another embodiment, the baler  12  may include a rotary feeding mechanism rather than the cutter  30 . A rotary feeder is distinguishable from the cutter  30  in that the blades are different and that on some occasions it is not desirable to cut the crop material any further than it already has been. On such occasions though it may be desirable to merely feed the crop material with the rotary feeder into the packer  276 . 
       FIGS. 4 and 5  best depict a cutaway of a portion of the baler  12 . Side frame portions  42   a ,  42   b  are similar to those used on conventional balers with conventional tongues adapted to be towed behind tractors. However, the main frame of baler  12  is modified from those of conventional balers because the baler  12  includes two forward frame members  44   a ,  44   b . Each of the forward frame members  44   a ,  44   b  is connected at its upper end to an end of one of the side frame portions  42   a ,  44   b  and extends downward from the main frame. The lower ends of the two forward frame members  44   a ,  44   b  are preferably oriented slightly forward of the pickup  20  and in front of the point to which they attach to the side frame portions  42   a ,  42   b . Moreover, the lower ends may be flared outwardly relative to one another, as best shown in  FIGS. 2 ,  7  and  8 , with a cross member  50  connected in between each lower end of the forward frame members  44   a , 44   b . The cross member  50  and the draw bar portion of the tongue  16  define generally a T-shaped tongue which is distinguishable from common U-shaped tongues in use today with conventional balers. The forward frame members  44   a ,  44   b  are oriented alongside one another to define an opening therebetween and above the cross member  50 . Because the lower ends of the forward frame members  44   a ,  44   bb  are flared outwardly, the opening is wider at its bottom adjacent the cross member  50  than the opening is at its top adjacent to where the forward frame members  44   a ,  44   b  join side frame portions  42   a ,  42   b . Moreover, the configuration of the tongue  16  allows for greater visibility into the pickup  20  of the baler  12 . The tongue  16  also permits flow of crop material directly from the ground as conventional balers do or directly from the combine  10  without either being obstructed by the tongue  16 . 
     The baler  12  may include a conventional density control mechanism broadly denoted by the numeral  302 . The stuffer chute  90  is sometimes referred to as a duct, passage, charge chamber or prechamber. As best shown in  FIG. 13 , the stuffer chute  90  defines an internal passage through which the crop material travels from pickup  20  to baling chamber  86  during operation of the baler  12 . The front end of the stuffer chute  90  is open to present an inlet. An outlet for the stuffer chute  90  is defined by an opening into the baling chamber  86 . Flake delivered to the baling chamber  86  is compressed by a reciprocating plunger. At least a portion of a top wall of the stuffer chute  90  is defined by a series of laterally spaced apart straps  92  shown in  FIG. 14  that extend downwardly and forwardly from baling chamber  86  and terminate in forwardmost upturned front ends generally above the inlet. The rear of pickup  20  has a centrally disposed discharge opening, in fore-and-aft alignment with the inlet to the stuffer chamber  90 . 
     Baler  12  further comprises a feeding mechanism for moving crop materials through stuffer chute  90 . The feeding mechanism may, for example, comprise a suitable rotor associated with a cutter mechanism, or it may comprise other apparatuses. In the illustrated embodiment, the feeding mechanism includes a packer broadly denoted by the numeral  276  and a stuffer broadly denoted by the numeral  280  as best shown in  FIG. 13 . As is conventional and well understood by those skilled in the art, packer  276  may include a plurality of packing forks  282  that are mounted along a crankshaft  284  and controlled by control links  286  for moving the tips of packing forks  282  in a generally kidney-shaped path of travel  288  as illustrated in  FIG. 13 . Packer  276  is thus used to receive materials from pickup  20  and pack the same into stuffer chute  90  for preparing a precompressed, preshaped charge of crop materials that conforms generally to the interior dimensions of stuffer chute  90  while the opening to the baling chamber  86  is closed by the reciprocating plunger  88 . 
     The stuffer  280 , as is conventional and well understood by those skilled in the art, functions to sweep through its own kidney shaped path of travel  290  as illustrated in  FIG. 13  to sweep the prepared charge up into baling chamber  86  between compression strokes of plunger  88  when the opening to the baling chamber  86  is uncovered. A conventional density control mechanism that includes a stuffer sensor door in the floor of the stuffer chute  90  functions in a manner well understood by those skilled in the art to check the density of each charge forming within the stuffer chute and to cause the stuffer  280  to pause in the event that a charge having predetermined characteristics has not accumulated within stuffer chute  90  by the next time stuffer  280  would normally sweep the charge up into the baling chamber  86 . The conventional density control mechanism in the floor of the baler  12  causes the stuffer  280  to dwell for one or more successive stuffing strokes in the event the charge accumulating within stuffer chute  90  has not reached the shape and density desired. The principles of operation of the stuffer  280  are well understood by those skilled in the art. 
     The baler  12  may include an improved density control mechanism  300  that also functions in a manner to check the density of each charge forming within the stuffer chute  90  and to cause the stuffer  280  to pause in the event that a charge having predetermined characteristics has not accumulated within stuffer chute  90 . The density control mechanism  300  includes a stuffer clutch assembly  310  and a sensor or trigger such as trigger assembly  320  positioned through one or both sidewalls of a stuffer chute  90 . A conventional stuffer sensor door in the floor of the stuffer chute  90  may be replaced with the trigger assembly  320  thereby eliminating any possible interruptions in the flow of crop material through the stuffer chute  90 . The stuffer sensor door creates interference or friction and now with the reduced interference and friction within the stuffer chute  90  the crop material such as MOG gets to the top of the stuffer chute  90  more easily to complete a fully filled flake. 
     The trigger assembly  320  may be positioned in various places along either side of the stuffer chute  90  depending on the type of crop material and depending on what conditions exist. Preferably, the trigger assembly  320  is positioned approximately halfway up the side of the stuffer chute  90  as best shown in  FIG. 14  to accommodate most crops materials and conditions. However, the trigger assembly  320  may be slidably attached in a slot positioned along a portion of the length of the side of the stuffer chute  90  so that the trigger lever assembly  320  may be repositioned at times according to the crop materials being baled or the conditions. Also, preferably trigger assemblies  320  are positioned on both sidewalls of the stuffer chute  90  so that either may be triggered. The trigger assembly  320  senses the flake in the stuffer chute  90  and trips when the stuffer chute  90  is full or when the desired amount of flake is present and the flake is ready to be moved to the baling chamber  86 .  FIG. 15  shows the orientation of a trigger lever  340  of one embodiment of the trigger assembly  320  when the trigger lever  340  extends though an opening of a bracket  342  and into the interior of the stuffer chute  90  through an opening in the sidewall of the stuffer chute  90 . Preferably, the trigger lever  340  extends approximately three to six inches into the interior of the stuffer chute  90  but the length of the trigger lever  340  may be adjusted to any suitable length to accommodate the crop and conditions. The trigger lever  340  is coupled to a spring  348  to bias the distal end of the trigger lever  340  pivoting about axis  344  into the opening in the sidewall of the stuffer chute  90 . The size of the spring  348  may determine the size of the charge. 
       FIG. 16 , on the other hand, shows the orientation of the trigger lever  340  when the trigger assembly  320  has been tripped. A predetermined force of the flake upon the distal end of the trigger lever  340  inside the stuffer chute  90  causes the trigger lever  340  to pivot such that a greater portion of the trigger lever  340  extends to the exterior of the stuffer chute  90  where the trigger lever  340  comes into contact with a position sensor or contact switch  330  of the trigger assembly  320 . When sensor/switch  330  is closed the circuit is completed to an electronic solenoid, hydraulic cylinder, actuator or motor  352  of the stuffer clutch assembly  310 . Preferably a continuously variable analog position sensor would allow intelligent timing so that the stuffer can be tripped at the closest position to the set point instead only after the set point had been passed. 
     Movement initiated by the trigger assembly  320  and the completing of the circuit, such as the rotation of the motor  352 , trips the linkage of the stuffer clutch assembly  310 . The linkage of the stuffer clutch assembly  310  includes a first arm  350  coupled at one end to the motor  352 . Coupled to the first arm  350  is a second arm  354 . The second arm  354  pivots at point  356 . The first and second arms  350 ,  354  are coupled together with a pin  360  in one of the first and second arms  350 ,  354  which is received in and slidably engages a slot  362  in the other of the arms  350 ,  354  so that a range of motion is provided to prevent the motor  352  from binding. A spring  366  in coupled between the distal end of first arm  350  and a point in between the pivot  356  and the position along the length of the second arm  354  where the pin  360  engages the slot  362 . In the home position of the stuffer clutch assembly  310 , a notch  370  on an end of a trip arm  372  receives and retains a roller  374  on the distal end of second arm  354 . When the trigger assembly  320  is tripped and the motor  352  is energized, the point at which the first arm  350  is coupled to the motor  352  begins to rotate and the roller  374  of second arm  354  is released from the notch  370  of trip arm  372 . Another roller  378  at the opposite end of trip arm  372  then engages the inner diameter of a rotating sprocket  380 . Preferably, one revolution of the motor  352  releases the roller  374  from the notch  370  so that the trip arm  372  engages the sprocket  380  which in turn rotates a clutch pawl  382  of the stuffer clutch assembly  310  to put a stuffer arm  384  in motion, and then returns the stuffer clutch assembly  310  to the home position with the roller  374  of arm  354  received in notch  370 . In an alternative embodiment, a hydraulic cylinder may be used instead of the motor  352 . The hydraulic cylinder can be extended in order to move the arms  350 ,  354  and release the roller  374  from the notch  370  of the trip arm  372 . 
     In one or more embodiments, in order for the motor  352  to rotate, two conditions preferably are met. First, the stuffer arm  384  of the stuffer  280  must be in the home position as shown in  FIG. 17 . A contact switch or position sensor may be used to detect when the stuffer arm  384  is in the home position. Second, the trigger lever  340  in the sidewall of the stuffer chute  90  senses a charge in the stuffer chute  90  closing the switch  330  of the trigger assembly  320 . When both of these conditions are net, the motor  352  turns allowing the roller  374  to drop off and fire the stuffer  280  one time. As soon as one of these two conditions is no longer met, the trip arm  372  goes back into a recessed position with its roller  374  retained in notch  370 . Once the stuffer  280  leaves its home position, the motor  352  resets the stuffer clutch assembly  310  to neutral and awaits the next occurrence when both conditions are met again. After the stuffer  280  moves the flake to the baling chamber  86 , the switch  330  of the trigger assembly  320  opens and is ready to sense the next flake formation. The electric tripping of the stuffer mechanism lends itself to finer control than the conventional mechanical linkages which is desirable when baling MOG or other material which easily may become an obstruction in the stuffer chute  90 . 
     As shown in  FIG. 1 , the combine  10  may include a chopper  410 . The chopper  410  preferably is a crop residue or MOG chopper for receiving straw and other residue from the combine  10 , and propelling or projecting it outward from the combine  10  as denoted by the trajectory path  420  by rotation of the chopper  410 . The chopper  410  is distinguishable from conventional choppers because chopper  410  includes dual knifes. 
     The foregoing has broadly outlined some of the more pertinent aspects and features of the present invention. These should be construed to be merely illustrative of some of the more prominent features and applications of the invention. Other beneficial results can be obtained by applying the disclosed information in a different manner or by modifying the disclosed embodiments. Accordingly, other aspects and a more comprehensive understanding of the invention may be obtained by referring to the detailed description of the exemplary embodiments taken in conjunction with the accompanying drawings, in addition to the scope of the invention defined by the claims.