Abstract:
A procedure and system for unloading a compacted cotton module from an on-board module builder of a cotton harvester, which in an automatic mode utilizes a controller to automatically monitor ground speed and operate unloading apparatus at a synchronized ratio to ground speed, for maintaining integrity and shape of the module, and which is quickly and easily switchable between the automatic mode and a manual mode that allows an operator to position and operate the unloading apparatus independent of ground speed for purposes such as placing the module at a precise location such as next to an already unloaded module or the like.

Description:
This application claims the benefit of U.S. Provisional Application No. 60/967,620, filed Sep. 6, 2007. 
    
    
     TECHNICAL FIELD 
     This invention relates generally to a procedure and system for unloading a compacted cotton module from an on-board module builder of a cotton harvester, and more particularly, to a system and procedure which in an automatic mode notifies the operator that the module is ready to unload, and utilizes a controller to automatically monitor ground speed and operate unloading apparatus at a synchronized ratio to ground speed, for maintaining integrity and shape of the module, and which is quickly and easily switchable between the automatic mode and a manual mode that allows an operator to position and operate the unloading apparatus independent of ground speed for purposes such as placing the module at a precise location such as next to an already unloaded module or the like. 
     BACKGROUND ART 
     U.S. Provisional Application No. 60/967,620, filed Sep. 6, 2007, is incorporated herein by reference in its entirety. 
     When loading a compacted mass of crop material, such as a cotton module, from the ground or another surface onto a ramp or other loading apparatus of a transport vehicle, or when unloading, it is typically desired for the speed of movement of the mass or module along or over the ramp, and the speed of the vehicle over the ground or other surface, to be synchronized. Particularly when unloading, if the speeds are not synchronized, e.g., the vehicle is moving significantly faster over the ground than the mass or module is moving along the ramp, the mass or module can be damaged, and even pulled apart, which is particularly not desired in the case of cotton modules, as it can make subsequent handling more difficult and affect the price paid for the cotton and subsequent ginning. 
     Various apparatus and systems for automatically synchronizing vehicle ground speed and unloader or crop drivers, such as chains belts or the like, on a ramp for moving a crop mass or module upwardly or downwardly therealong, are well known. Reference as examples, Pereira et al., U.S. Pat. No. 4,081,094, issued Mar. 28, 1978; Reed U.S. Pat. No. 4,419,042, issued Dec. 6, 1983; and Fewin, Jr. et al., U.S. Pat. No. 5,108,250, issued Apr. 28, 1992. 
     While any of the above-referenced apparatus and systems may provide satisfactory manners of synchronization for operation under a variety of circumstances, including on uneven terrain and the like, there are instances when unloading wherein it would be desirable to have additional or other capabilities than those disclosed. In particular, sometimes the human operator will be inexperienced and/or inattentive, and/or will drive the vehicle too fast or too slow for unloading the mass or module, so as to affect the shape of the module, e.g., cause it to lean, or damage the module, e.g., fracture or tear, even with a capability for synchronizing the unloader driver speed with the ground speed of the vehicle. In this instance, it has been found desirable to have the capability to inform the operator when a module moving down the ramp is close to contacting the surface onto which it is to be unloaded, and during unloading onto the surface, to warn or notify the operator of excessive ground speed, but without automatically taking steps such as limiting unloading speed, which could damage the module. 
     Also, sometimes when unloading a cotton module, it is desired to place the module in end-to-end relation or abutment with another module, for reasons including to make loading of the modules onto a transport vehicle in a continuous process easier, and to protect the abutting module ends from exposure to environmental elements, particularly moisture. This will entail one or more reverse or backing movements, or back and forward movements of the vehicle for positioning the end of the unloading ramp adjacent to and aligned with the bottom of the first or stationary module. This also requires a capability for unloading the second module down the ramp into abutment with, or close to, the stationary module, without dragging or pushing a portion of the second module over the ground, or exerting a force against the modules, which could damage one or both of the modules. The vehicle will then be moved forward as the second module is unloaded, which is facilitated by synchronization of the crop driver or drivers with ground speed to complete the unloading process, but not at a speed that is too fast, so as to result in an undesired gap between the modules or damage. 
     Accordingly, what is sought is an unloading system and method which provides one or more of the capabilities and overcomes one or more of the problems and shortcomings, set forth above. 
     SUMMARY OF THE INVENTION 
     What is disclosed is a system and method for unloading a mass or module of compacted crop material from a self-propelled machine, such as, but not limited to a cotton harvester with an onboard cotton module builder, which provides one or more of the capabilities and overcomes one or more of the problems and shortcomings, set forth above. 
     According to a preferred aspect of the invention, the system and method utilizes at least one driver on an unloading ramp, operable for controllably moving a mass of compacted crop material, which can include, but is not limited to, a cotton module, down the ramp and onto a surface therebelow, which can be, for instance, the ground or the like. The driver or drivers can include, but are not limited to, drag chains, belts or the like. The invention uses a controller connected in operative control of the at least one driver, and apparatus for providing information representative of a speed of movement of the vehicle over the surface to the controller. This can be a ground speed sensor, a wheel speed sensor, any device that accurately computes ground speed from engine or transmission speed data, or the like. The machine will include a propulsion control, e.g., including a conventional propulsion handle located in the operator cab, operable by the operator for controlling the speed of movement of the vehicle over the surface. The invention uses an input device connected to the controller and operable by an operator for inputting commands thereto, which is preferably disposed on or in connection with the propulsion control, for convenience and ease of use. This device is preferably a momentary contact switch, or the like. The invention also preferably includes a device connected to the controller for outputting information to a human operator, such as a signal alarm, or display device, located in the operator cab. 
     The invention also preferably utilizes an unloading routine programmed in the controller, which, upon initiation, will commence operation of the at least one driver for moving the mass, e.g., cotton module, down the ramp while monitoring the speed of movement of the vehicle (if any) over the surface, and the direction of movement. In a preferred automatic manner or mode of operation, if the speed of movement of the vehicle is equal to or greater than a predetermined value, which is preferably a number just above zero, then the controller will continue the automatic operation of the at least one driver to move the mass down the ramp and onto the surface. If the speed of movement of the vehicle is less than the predetermined value, e.g., is zero, or in the reverse direction, and absent an override command from the input device, the controller will automatically commence to pause the operation of the at least one driver to gradually stop the movement of the mass down the ramp before reaching the surface, and to output a message to the operator to commence movement of the vehicle. The pausing is preferably done gradually, to prevent damage, jerking and other objectionable occurrences. The controller will subsequently enable continued operation of the at least one driver to move the mass down the ramp onto the surface only if the vehicle commences movement in the unloading direction, or a predetermined command from the input device is received to place the system in the manual mode. For example, this command can be outputted by momentary operation of the input device. 
     When enabled, the further operation of the at least one driver is preferably selectable to be automatic, as a function of the speed of the vehicle, or operator or manually controlled. In the automatic mode, if the speed of movement of the vehicle is within a predetermined range, then the controller will automatically control the operation of the at least one driver for moving the mass down the ramp at a speed which is at a predetermined ratio to the speed of movement of the vehicle. The range can comprise, for example, a range from just greater than zero to a maximum safe speed for unloading without damaging the mass or module or the vehicle. The ratio will preferably be a value greater than 1:1, and more preferably about 1.1:1. Also preferably, if the speed of movement of the vehicle is greater than the predetermined range, the controller will automatically output information representative thereof to the operator. This information will preferably include a textual indication that the vehicle speed exceeds a maximum value, and/or it could be an audible/and or visual signal. 
     As an advantage of the system, an operator can initiate operation of the unloading system to automatically move the compacted mass or module down the ramp, before, after, and/or during maneuvering of the harvester into a desired position for unloading, and the system provides a safety measure which will gradually stop the downward movement of the module before it contacts the surface onto which it is to be unloaded, if the vehicle is not moving in the unloading direction. This is also advantageous as it gives the operator, particularly if inexperienced, a chance to verify positioning, etc., and to maneuver the harvester further, if required, before the module is actually unloaded. It also enables use of one unloader driver speed for initial movement of the module over the ramp while still completely on the ramp, and another speed when the module is only partially on the ramp so as to also be in contact with the surface onto which the module is being unloaded. If the vehicle is moving appropriately for unloading, the system will automatically synchronize the unloader driver speed at a predetermined ratio to the ground speed, to unload the mass or module. And, while being unloaded onto the surface, if the vehicle speed exceeds a maximum value, the system will output a signal or message to the operator, but will continue to operate the unloader driver or drivers at a speed sufficient for unloading while protecting the integrity of the mass or module. This can be the speed at the predetermined ratio, or another speed, as desired. 
     The manual mode of operation of the invention is advantageous as it allows the operator to operate the unloader driver or drivers independent of vehicle speed and direction, and in a manner as desired or required for positioning a mass or module at a precise location, such as adjacent to or in abutment with an existing structure or item, such as another mass or module. This enables an operator to operate the unloader driver or drivers in the automatic mode to safely position the mass or module on the ramp in a desired position in relation to an existing module, e.g., so as to bring the tops of the modules into alignment and contact, and then switch to the manual mode, with the vehicle stationary, or moving in the unloading direction, or in reverse of the unloading direction, as required for bringing the bottoms of the modules together, and then, with the modules desirably positioned, to switch to operate in the automatic mode to finish unloading the module. Inputted operating commands in the manual mode can comprise, for instance, prolonged actuation of the input device. Commands for switching between the automatic and manual modes can comprise, for instance, momentary actuations of the input device. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a simplified side view of a self-propelled cotton harvester including an onboard cotton module builder, including aspects of a system and method of the invention for unloading a compacted module from the module builder; 
         FIG. 1   a  is a simplified schematic side view of the harvester of  FIG. 1 , shown in a tilted, unloading position with an unloading ramp deployed extending downwardly therefrom, and showing aspects of the system of the invention for unloading a compacted module from the module builder; 
         FIG. 2  is a high-level flow diagram illustrating steps of one embodiment of a method of the invention; 
         FIG. 3  is another side view of the harvester, illustrating an aspect of a method for unloading of a compacted module according to the invention; 
         FIG. 4  is a partial side view of the harvester, illustrating unloading of a module in the vicinity of another module; 
         FIG. 5  is another partial side view of the harvester, illustrating an initial step of aligning a module to be unloaded with another module; 
         FIG. 6  is still another partial side view of the harvester, illustrating unloading of a module in abutment with another module; and 
         FIG. 7  is still another partial side view of the harvester, illustrating the module unloaded in abutment with the other module. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to the drawings, in  FIGS. 1 and 1   a , a cotton harvesting machine  10  is shown, including a cotton packager or module builder  12 , and a pivoting unloading door  14 , shown in a folded or closed position ( FIG. 1 ), and in an unfolded or deployed position ( FIG. 1   a ). Module builder  12  includes an interior that defines a cotton compacting or module building chamber  16  for receiving cotton from harvesting units  18  of machine  10  and in which the harvested cotton is compacted into a unitary body or module of cotton (not shown) in the well known conventional manner. It should be noted that for the purposes herein, the terms ramp and door are considered to be interchangeable, and that the term cotton module builder is to encompass a cotton packager and also a basket, and is intended to be representative of a wide variety of apparatus from which a mass of crop material could be unloaded using the system and method of the present invention. 
     The bottom of chamber  16  is defined and enclosed by an upwardly facing floor surface  20 . A plurality of unloader drivers  22  extend forwardly and rearwardly in spaced relation one to the other over floor surface  20  and encircle drive sprockets at the rearward end of floor surface  20 , and suitable elements at the forward end thereof (not shown). Drivers  22  comprise elements of an unloader system of the present invention and preferably comprise drag chains of well-known construction, and are drivable in a predetermined unloading direction, denoted by arrow A, over floor surface  20 , for conveying a compacted body or module of cotton from the interior of the chamber. 
     Unloading door assembly  14  is also part of the system of the invention and includes a first door segment  24  pivotally connected at a pivot joint  26  to the rearward end of cotton module builder  12  of machine  10 , for pivotal movement of door segment  24  between a closed position in at least partial closing or covering relation to a rear unloading opening  38  as shown in  FIG. 1 , and an unloading or open position as shown in  FIG. 1   a . Door assembly  14  additionally includes a second door segment  28  pivotally connected by a pivot joint  30  ( FIG. 1 ) to first door segment  24  for relative pivotal movement of door segments  24  and  28  about a pivotal axis  32  extending through joint  30  transversely to predetermined direction A. Door assembly  14  is pivotable between a folded or closed position ( FIG. 1 ) with door segments  24  and  28  in generally overlaying relation and first and second conveying surfaces  34  and  36  thereof, respectively, facing in opposite directions, and an unfolded or open unloading position ( FIG. 1   a ) in end-to-end relation wherein floor surface  20  and first and second conveying surfaces  34  and  36  form a substantially continuous surface extending in direction A. Pivotal movement of first and second door segments  24  and  28  is effected, respectively, by fluid cylinders  40  and  42 , in the well known manner. Tilting of module builder  12  is also effected by a fluid cylinder or cylinders, in the well-known manner. 
     As shown in  FIG. 1   a , at least second door segment  28  of unloading door  14  will include additional unloader drivers  22  of the system of the invention drivable in unloading direction A, for conveying a compacted body or module of cotton over the deployed door  14  assembly. Here, conveying surface  34  preferably comprises one or more low friction polymer sheets, for low friction movement of a compacted body of cotton thereover, so as to eliminate the need of unloader drivers on door segment  28 . Unloader drivers  22  are each driven using a suitable drive mechanism  44 , which can include a motor, such as, but not limited to, a fluid or electric motor, connected by a drive chain in driving relation to a sprocket encircled by the drag chain of the driver. The construction and operation of a typical module builder  10 , door assembly  14 , drivers  22  and drive mechanisms  44 , are explained in greater detail in Covington et al., U.S. Pat. No. 6,766,634, issued Jul. 27, 2004, and U.S. Pat. No. 7,322,460, issued Jan. 29, 2008, which are hereby incorporated herein by reference in their entireties. 
     Operation of unloader drivers  22  will be controlled according to a method of the present invention, using a processor based driver controller  46 , which can be, for instance, an electronic control unit (ECU) typically used for controlling unloading operations, also including tilting of module builder  12  and unfolding and folding of door assembly  14 , as disclosed in Covington et al., U.S. Pat. No. 6,766,634. Operation of drivers  22  can be commenced automatically when module builder  12  is appropriately tilted and door assembly  14  is unfolded, as commonly done using a contact switch in connection with a solenoid, or, can be initiated in any suitable manner, such as manually by a human operator in an operator cab  48 , using an input device  50  therein, which preferably comprises a momentary contact switch located on a propulsion control handle  52 . Device  50  can have one position, or more, so as to also be operable for effecting operation of drivers  22  in a reverse or loading direction, as desired. 
     The tilting and unfolding operations can be initiated also by input device  50 , or by a separate switch, as illustrated by switch  56  also located in cab  48 , as desired. Input device  50  and switch  56  are preferably connected to driver controller  46  via suitable conductive paths  54 , such as, wires of a wiring harness of machine  10 , a controller area network, wireless network, or the like. 
     A display device  58  is also preferably located in cab  48 , and connected to controller  46  via a suitable conductive path, and is operable for displaying information, including about the status of unloading operations, speeds, warnings, and the like. 
     A speed sensor  60  or other suitable apparatus is connected via a suitable conductive path  54  to controller  46 , and is operable for sensing rotation of a rear wheel  62  of machine  10 , representative of a speed of movement of machine  10  over a surface  64  on which it is located, which can be, but is not limited to, the ground. Alternatively, a ground sensor, e.g., sound or radar based, or transmission or engine rotation data, could be used for determining ground speed. A speed sensor is suitably located for sensing the speed of operation of at least unloader driver  22  located on second door segment  28 , and is also connected to controller  46  by a suitable conductive path  54 . All of the above elements are part of the unloader system of the invention. 
     Additional relevant aspects of machine  10  include an engine  68  operable for drivingly rotating at least front drive wheels  70  (and optionally rear wheels  62  if equipped with rear drive assist) via a suitable fluid and/or mechanical path; and an engine controller  72 , controllably operable for controlling propulsion of machine  10 , responsive to inputs received from propulsion control  52  in the well known manner. 
     Referring also to  FIGS. 2 ,  3 ,  4 ,  5 ,  6  and  7 , typically, when a cotton module is complete, or it is otherwise desired to remove the contents of module builder  12 , an unloading operation will be initiated ( FIG. 3 ). Sometimes, it will be desired to unload a module  78  in more of a general location , e.g., free standing alone in a general location on a surface  64  such as the ground ( FIG. 4 ). At other times, it will be desired to unload a module  78  ( FIGS. 5 and 6 ) so as to be precisely located, e.g., in abutting, or closely spaced, end to end relation with another module  78  already on surface  64  ( FIG. 7 ). In the first instance, essentially once module builder  12  is properly tilted and door assembly  14  unfolded, unloader drivers  22  can be actuated to moved the module over door assembly  14  and onto surface  64  synchronized with the speed of movement of machine  10 . In the second instance, however, particularly if a module  78  is to be unloaded in close abutment with an existing stationary module  78 , such as for any of the reasons set forth above, it may be desired or required to have a capability to maneuver door assembly  14 , by moving machine  10  while unloading for achieving such placement. 
     Aspects of a method of unloading a cotton module or mass of compacted crop material according to the present invention, are shown. In  FIG. 2 , a high-level flow diagram  74  illustrating steps of a preferred embodiment of the method of the invention, is shown. Referring to the diagram, upon initiation of an unloader routine of the invention, as denoted at block  76 , module builder  12  will be automatically tilted and door assembly  14  unfolded, and unloader drivers  22  operated to commence movement of a module  78  ( FIG. 3 ) downwardly along the floor of the module builder and onto door assembly  14 . Driver controller  46  will also monitor the speed of movement (if any) of machine  10 , as sensed by speed sensor  60 . Prior to module  78  reaching surface  64 , so as to be supported thereon in any substantial manner, as illustrated by the position X of the lower edge of module  78  in  FIG. 3 , controller  46  will determine if machine  10  is moving, e.g., any speed greater than zero, in an unloading direction (forward), as denoted by decision block  80 . If machine  10  is not moving in the prescribed direction and manner, controller  46  will determine if a predetermined input command from input device  50  is present, as denoted by decision block  82 . This can comprise a momentary operation of device  50 , operation of that input for a prescribed period, or other suitable signal. If the input is not present, controller  46  will automatically commence to pause the operation of drivers  22 , and thus the movement of module  78 , as denoted by block  84 , and loop back to decision block  80 . This provides a safeguard to prevent inadvertent unloading. Controller  46  can also optionally output a signal or message to the operator via device  58  or in another suitable manner, prompting or informing him or her to commence movement of the machine. 
     If movement of the machine is detected at block  80 , or is commenced by the operator, e.g., responsive to the outputted message, after initiating or completely pausing of drivers  22 , controller  46  will automatically continue or resume operation of drivers  22  for unloading the module  78 , as denoted at block  86 , in an automatic mode. In this mode, controller  46  will monitor the machine speed to determine if it is in a predetermined range, for example from just above zero to about 3.6 miles per hour, as denoted at decision block  88 . If yes, controller  46  will controllably operate drivers  22  at a predetermined ratio to the speed of movement of the machine, as denoted at block  90 , which controlled speed will preferably be marginally faster than the speed of the machine, or a ratio of about 1.1:1. That is, a speed about 10 percent faster. This ratio has been found to be advantageous as it is sufficient to prevent leaning, and tearing or fracturing of module  78  when partially on door assembly  14  and surface  64 , and other possible damage. 
     If, at decision block  88  the speed of machine  10  is not within the range, controller  46  will determine if it is greater than a maximum value, which can be, but is not limited to, the upper limit of the range, e.g., 3.6 miles per hour, or another suitable value, as denoted at decision block  92 . If yes, then a signal or information will be outputted to display device  58 , as denoted at block  94 , indicating this to the operator, who will hopefully decrease the machine speed using the propulsion control  52  to eliminate this message. Here though, controller  46  will preferably still automatically maintain the operation of drivers  22  at a speed sufficient to prevent damage to module  78  and/or module builder  12  and door assembly  14 . When module  78  has been unloaded, the unloading routine can be automatically or manually ended, to stop operation of drivers  22 , fold door assembly  14 , and lower module builder  12 . 
     While operating in the automatic mode, as denoted by decision block  96 , and also earlier as denoted by block  82 , and optionally at any other desired time during automatic operation, if a predetermined input command is received, e.g., momentary operation of input device  50 , or a pattern of contacts, the system can be switched to a manual mode of operation, to allow manual of drivers  22 , as denoted at block  98 . Likewise, while in the manual mode, if a predetermined input command is received, e.g., another momentary operation of device  50 , as denoted at decision block  100 , operation can be switched to the automatic mode. In the manual mode, the operator can move machine  10  in any desired direction, using propulsion control  52 , while using input device  50  to control operation of drivers  22 . 
     For example, referring more particularly to  FIGS. 5 ,  6  and  7 , machine  10  can be maneuvered to position door assembly  14  for locating an upper rear end  102  of a module  78  to be unloaded, in contact with or close to an upper front end  104  of an existing module  78  ( FIG. 5 ). This can be done with module  78  to be unloaded still in the module builder, moving down door assembly  14 , or already paused at the end of door assembly  14 . The manual mode allows operation of drivers  22  with or without accompanying movement of machine  10 . As an example, referring to  FIG. 6 , with module  78  to be unloaded on the end of door assembly  14  and in abutment with an existing module  78 , the manual mode allows operation of drivers  22  (arrow A) to push module  22  to be unloaded against the stationary module  78 , to achieve a desired closeness thereto. Then the propulsion control  52  can be operated as desired or required (typically slower than the speed of operation of drivers  22  at least initially) to move machine  10  in the unloading direction, as denoted by arrow B. Then, when the desired positioning has been achieved, manual operation can be continued, or automatic operation used, to synchronize unloader speed with machine speed, at the ratio set forth above, to complete the unloading operation as illustrated in  FIG. 7 . 
     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 invention. Accordingly, the following claims are intended to protect the invention broadly as well as in the specific form shown.