Abstract:
Disclosed is an apparatus for disintegrating bales of agricultural material such as hay. The apparatus has a chassis, a processing tub with a discharge opening located in one of its side walls, a disintegrator mounted in the processing tub to disintegrate baled crop material positioned within the tub and discharge the processed bale material out the discharge opening and a manipulator mounted within the processing tub adapted to manipulate the baled crop material to expose different parts thereof to the disintegrator. The processing tub is adapted to be mounted on the chassis such that the discharge opening can be positioned on either the left or right side of the chassis. In an embodiment of the invention, the processing tub is sized to accommodated a large square bale lengthwise therein or two or more round bales. The apparatus is also provided with an adjustable fork lift to raise bales of different configurations into the processing tube and a hydraulic selector valve such that two sets of hydraulic systems on the processor can be operated by a single hydraulic line from a tractor or other power source.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
   The present application is a divisional application of application Ser. No. 10/090,213, filed Mar. 4, 2002 now U.S. Pat No. 6,708,911. 

   FIELD OF THE INVENTION 
   The invention relates to an improved apparatus for disintegrating bates of agricultural material such as hay. 
   BACKGROUND 
   Bale processors, including processors of the type having a tub with longitudinally disposed disintegration flail rollers and bale support rollers (as disclosed in Canadian Patent No. 2,086,569 owned by the applicant herein) are known. However, primarily due to the large size and weight of modern “square” bales (which have a rectangular configuration), problems may be encountered with operational flexibility and durability of some processors. Further, the majority of the processors known to the inventors are only adapted to process one type of common form of bale (i.e. “round” or “square”) and are only adapted to discharge out of one side of the processor. Moreover, some known processors are not adapted for easy use with older tractors due to hydraulic feed line requirements exceeding the typical number of hydraulic ports on such tractors. 
   SUMMARY OF INVENTION 
   It is an object of the present invention to provide a bale processor having operational flexibility and enhanced durability. According to a broad aspect of the invention, the invention provides an apparatus for processing baled crop material comprising: a chassis having a front and back end and a left and right side; a processing tub having two opposing end walls, two opposing side walls and a discharge opening located in one of the side walls; a disintegrator mounted in the processing tub adapted to disintegrate baled crop material positioned within the tub and discharge the processed bale material out the discharge opening; and a manipulator mounted within the processing tub adapted to manipulate the baled crop material to expose different parts thereof to the disintegrator; wherein the processing tub is adapted to be mounted on the chassis such that the discharge opening can be positioned on either the left or right side of the chassis. 
   According to another aspect of the invention, the invention provides an apparatus for processing baled crop material comprising: a chassis having a front and back end and a left and right side; a processing tub having two opposing end walls, two opposing side walls and a discharge opening located in one of the side walls; a disintegrator mounted in the processing tub adapted to disintegrate baled crop material positioned within the tub and discharge the processed bale material out the discharge opening; and a manipulator mounted within the processing tub adapted to manipulate the bald crop material to expose different parts thereof to the disintegrator; wherein the processing tub is sized to accommodate a large square bale or, at least two round bales longitudinally therein for processing. 
   According to yet another aspect of the invention, the invention provides an apparatus for processing baled crop material comprising: a chassis having a front and back end and a left and right side; a processing tub having two opposing end walls, two opposing side walls and a discharge opening located in one of the side walls; a disintegrator mounted in the processing tub adapted to disintegrate baled crop material positioned within the tub and discharge the processed bale material out the discharge opening; a manipulator mounted within the processing tub adapted to manipulate the baled crop material to expose different parts thereof to the disintegrator; and a fork lift mounted on the rear of the chassis to raise baled crop material from the ground into the processing tub wherein the fork lift is adjustable to receive baled crop material of different configurations. 
   According to yet another aspect of the invention, the invention provides an apparatus for processing baled crop material comprising: a chassis having a front and back end and a left and right side; a processing tub having two opposing end walls, two opposing side walls and a discharge opening located in one of the side walls; a disintegrator mounted in the processing tub adapted to disintegrate baled crop material positioned within the tub and discharge the processed bale material out the discharge opening; a manipulator mounted in the processing tub adapted to manipulate the baled crop material to expose different parts thereof to the disintegrator; at least one hydraulic motor for driving the manipulator; a discharge door pivotally mounted above the discharge opening to direct processed bale material discharged from the discharge opening; at least one hydraulic cylinder attached to the discharge door to raise and lower the discharge door; a selector valve having a first output connected to the at least one hydraulic motor and a second output connect to the at least one hydraulic cylinder, the selector valve being adapted to move between a first setting and second setting wherein hydraulic fluid flow from an input hydraulic line is directed to the first output or the second output respectively; and an actuator to move the selector valve between the first setting and the second setting. 
   According to yet another aspect of the invention, the invention provides an apparatus for processing baled crop material comprising: a chassis having a front and back end and a left and right side; a processing tub having two opposing end walls, two opposing side walls and a discharge opening located in one of the side walls; a disintegrator mounted in the processing tub adapted to disintegrate baled crop material positioned within the tub and discharge the processed material out the discharge opening; and a manipulator mounted in the processing tab adapted to manipulate the baled crop material to expose different parts thereof to the disintegrator; wherein the chassis has two ground engaging wheels rotatably mounted on an adjustable axle such that the distance between the two wheels can be adjusted. 
   The invention provides an improved bale processor that is easily convertible from a left-hand discharge arrangement to a right-hand discharge arrangement. Furthermore, the bale processor can process a large square bale or, alternatively, one or more round bales and includes an adjustable bale loading mechanism for loading bales of different configurations. Moreover, the bale processor includes a hydraulic selector assembly such that a single set of hydraulic lines can be used to operate two separate hydraulic systems on the bale processor. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Preferred embodiments of the invention will now be described by way of example with reference to the attached drawings in which: 
       FIG. 1  is an exploded perspective view of a bale processor according to an embodiment of the invention in the left-hand discharge arrangement; 
       FIG. 2  is a perspective view of the processing tub of a bale processor according to an embodiment of the invention; 
       FIG. 3  is an exploded perspective view of the processing tub of a bale processor according to an embodiment of the invention with a disintegrator mounted therein; 
       FIG. 4  is an exploded perspective view of the processing tub of a bale processor according to an embodiment of the invention with a feed roller mounted therein; 
       FIG. 5  is a partially exploded perspective view of a chassis of a bale processor with a fork lift mounted on the rear thereof according to an embodiment of the invention; 
       FIG. 6  is an exploded perspective view of a bale processor according to an embodiment of the invention in the right-hand discharge arrangement; 
       FIG. 7  is a perspective view of an end of the disintegrator adapted for connection to the PTO of a tractor according to an embodiment of the invention; 
       FIG. 8  is a perspective view of a rotation conversion device for a right-hand discharge arrangement of a bale processor according to an embodiment of the invention; 
       FIG. 9  is a perspective view of an end of the disintegrator adapted for connection to the rotation conversion device according to an embodiment of the invention; 
       FIG. 10  is a perspective view of a fork lift of a bale processor according to an embodiment of the invention; 
       FIG. 11  is an exploded perspective view of the processing tub of a bale processor according to an embodiment of the invention with a discharge door mounted thereto; 
       FIG. 12  is a side, cut away view of a bale processor according to an embodiment of the invention showing the hydraulic selector assembly; 
       FIG. 13  is an exploded perspective view of a hydraulic selector assembly according to an embodiment of the invention; 
       FIG. 14  is a perspective view of a bale processor according to an embodiment of the invention in the left-hand discharge arrangement; and 
       FIG. 15  is a perspective view of a bale processor according to an embodiment of the invention in the right-hand discharge arrangement. 
   

   DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
   As shown in  FIGS. 1 and 2 , the bale processor comprises a processing tub  1  mounted on a chassis  3 . The tub  1  has end walls  5  and  7  and side walls  9  and  11 . A discharge opening  13  is provided at the bottom of side wall  11 . In the embodiment shown in  FIGS. 1 and 14 , side wall  11  is located on the left-hand side of the bale processor. As discussed below, the processing tub  1  and the chassis  3  are designed such that the processing tub can be rotated  180  degrees to position side wall  11  on the right-hand side of the apparatus (see  FIGS. 6 and 15 ). 
   The processing tub  1  is sized such that a large square bale may be positioned lengthwise therein for processing. Typically, an inside width of approximately 7.5 feet (side wall  9  to side wall  11 ) and an inside length of at least 10 feet (from end wall  5  to end wall  7 ) is sufficient to accommodate most large bales. A tub of these dimensions can also accommodate two or more round bales lengthwise therein for processing at the same time. 
   As shown in  FIG. 3 , a disintegration member  15  is mounted within the processing tub  1 . In the embodiment illustrated, the disintegration member  15  comprises a flail roller  17  extending the length of the processing tub  1  and mounted in the bottom thereof. The flail roller  17  is rotatable about its longitudinal axis such that a series of flails  19  pivotally mounted thereon extend to engage and separate the baled material contained within the processing tub  1 . 
   The flail roller  17  is rotated by a power source (not shown). In the embodiment shown, the flail roller  17  is adapted to be detachably connected by a PTO drive of a tractor. The flail roller  17  is provided with axial rods  18  and  20  extending from opposing ends thereof. The flail roller  17  is secured in the processing tub  1  by axial rods  18  and  20  extending through a set of bearings  21  and  23  mounted on end walls  5  and  7  respectively, thereby permitting axial rotation of the flail roller. As discussed below, both axial rods  18  and  20  are adapted to be detachably connected to the PTO of a tractor. 
   As shown in  FIG. 4 , the processing tub  1  is provided with a bale manipulator. In the embodiment shown, the bale manipulator comprises a feed roller  27  positioned on each side of the flail roller  17 , each feed roller extending the length of the processing tub  1 . The feed rollers  27  are positioned such that the flails  19  engage the baled material between the feed rollers when the flail roller  17  is rotated. The side walls  9  and  11  of the tub  1  are shaped such that material is directed into the flail roller  17 . 
   Each feed roller  27  is rotatable in either direction about its longitudinal axis by a reversible hydraulic motor  33 . As shown in  FIG. 4 , each feed roller  27  is mounted to end walls  5  and  7  by a roller mount  29  secured on the end walls  5  and  7  by an adjustable hanger  36 . A set of bearings  31  is positioned within each roller mount  29  to support the feed roller  27  while permitting rotation thereof. The specifications for the bearings  31  are selected depending upon the typical load conditions of the feed roller  27  during operation. 
   Each hydraulic motor  33  is mounted on to a motor mount  35  which is secured at the upper end thereof to the adjustable hanger  36  and roller mount  29 . The hydraulic motor  33  is detachably connected to the end of feed roller  27 . In the embodiment shown, each end of each feed roller  27  has an axial rod  37  extending from it. The axial rods has a splined female connection (not shown) adapted to releasably receive a splined shaft  38  of the hydraulic motor  33 . Alternative arrangements for connecting the hydraulic motor to the feed roller would be known to those skilled in the art. 
   Each of the feed rollers  27  has teeth  39  and flanges  40  extending radially therefrom. The teeth  39  and flanges  40  engage the baled material as the feed roller  27  rotates thereby rotating the baled material and exposing different sections thereof to the flails  19  for disintegration. 
   As shown in  FIGS. 1 and 5 , the chassis  3  includes a hitch  41  mounted at the front thereof and an axle  43  positioned near the rear. As best seen in  FIG. 5 , axle  43  has a hollow center portion  45  extending transversely across and secured to chassis  3  and end portions  47  adapted to be inserted therein on each side of the chassis  3 . A ground engaging wheel (not shown) is attached to each end portion  47 . Each end portion  47  are adapted to slide axially within the center portion  45  to adjust the width of axle  43 . End portions  47  are lockable at the desired location by insertion of a locking pin  49  through holes provided in the center portion  45  and in the end portions  47 . Accordingly, the axle  43  can be widened to provide the apparatus with more stability over uneven terrain or narrowed to facilitate transport along a road or highway. 
   As shown in  FIG. 1 , axle  43  is also provided with jack mounts  51  to facilitate connection to a jack assembly (not shown). Each jack mount comprises a square bracket  53  with a hole  55  in the top and bottom thereof. The square bracket  53  is sized to accept the male connection of the jack assembly. A locking pin (not shown) is inserted through the holes  55  to maintain the jack assembly connected during operation. The jack assembly is used to raise a side of the bale processor such that the width of the axle  43  can be adjusted as set out above. 
   The processing tub  1  is detachably connected to the chassis  3  such that apparatus can be converted from a left-hand discharge arrangement as shown in  FIGS. 1 and 14  to a right-hand discharge apparatus as shown in  FIGS. 6 and 15  or vice-a-versa. The processing tub  1  has front to back symmetry to facilitate the conversion. 
   As shown in  FIG. 1 , in the left-hand discharge arrangement, three support legs  57  are bolted to the right-hand side of the chassis  3  by U-shaped bolts  59 . A step  61  extending the length of side wall  9  is positioned on the top of the support legs  57 . The processing tub  1  is connected to the support legs  57  by bolts  63 . End walls  5  and  7  of the processing tub  1  are provided with brackets  65  and  67  at the bottom thereof for connecting the processing tub  1  to the chassis  3  by U shaped bolts  69 . In the arrangement shown in  FIG. 1 , as a result of the configuration of the chassis  3 , bracket  65  on end wall  7  and bracket  67  on end wall  5  are use to connect the processing tub  1  to the left side of chassis  3 . 
   In the left-hand discharge arrangement, the flail roller  17  is rotated in a clockwise direction (viewed from the rear of the machine). Accordingly, the flail roller  17  can be connected directly to the PTO of most tractors. As shown in  FIG. 7 , the axial rod  18  is splined at the end thereof for insertion into the female splined connection on the standard PTO of a tractor. 
   As shown in  FIG. 6 , the bale processor is converted to the right-hand discharge arrangement by disconnecting the processing tub  1  from the chassis  3  and the support legs  57 . The support legs  57  are subsequently disconnected from the chassis  3  and moved to left side of the chassis  3  and secured thereto by U-shaped bolts  59 . The processing tub  1  is rotated by 180 degrees thereby positioning side wall  11  on the right-hand side of the apparatus. Step  61  in side wall  11  is positioned on top of support legs  57  and secured thereto by bolts  63 . The tub is attached to the right-hand side of chassis  3  by securing bracket  65  on end wall  5  and bracket  67  on end wall  7  to the right side of the chassis with U-shaped bolts  69 . 
   Prior to conversion of the apparatus from the left-hand discharge arrangement shown in  FIGS. 1 and 14  to the right-hand discharge arrangement shown in  FIGS. 6 and 15 , the hydraulic motors  33  and hydraulic motor mounts  35  must be disconnected and the flail drum  17  disconnected from the power source. Any other hydraulics or other systems would also be disconnected. Once the processing tub  1  is arranged in the right-hand discharge arrangement, the hydraulic motors  33  and motor mounts  35  are connected to end wall  7  of the processing tub  1  now located at the front of the chassis  3 . As bearings  31  are provided at each end of the feed rollers  27 , the feed rollers need not be removed to move the bearings from one end of the feed rollers to the other. 
   Any other hydraulics or other systems are also reconnected to the bale processor once the processing tub  1  is secured to the chassis. In particular, the power source is connected to axial rod  20 . However, in the right-hand discharge arrangement, the flail roller  17  must be rotated in a counter-clockwise direction (when viewed from the rear) during operation. Accordingly, if the power source rotates in a clockwise direction (i.e. a PTO of a typical tractor) a rotation conversion device must be positioned between the power source and the flail roller  17 . 
   In the embodiment shown in  FIG. 8 , the rotation conversion device comprises a gearbox  71  of the type commonly used in the industry. The gearbox  71  is positioned on a dampener  73  to reduce the load on bearings  23  and the power source due to the weight of the rotation conversion device. In addition, the dampener  73  also serves to absorb the vibrations and rotation of the gearbox  71  during acceleration or deceleration, especially during the start-up and shut down. 
   The damping mechanism  73  is mounted to the chassis  3  by brackets  75  which are secured to the chassis by U-shaped bolts  77 . An upper support  79  having a lip  81  is secured to each of the brackets  75 . A cross support  83  is secured to bottom of gearbox  71  and extends between brackets  75 . The cross support  83  is mounted to each of the upper supports  79  by bolts  85  which extend through the cross support and through lips  81 . Upper compression springs  87  are axially mounted on bolts  85  between the cross supports  83  and the lips  81  of upper supports  79 . Lower compression springs  89  are positioned on bolts  85  below lips  81  and maintained in position by a nut  91 . 
   The upper compression springs  87  are compressed to exert a slight upper pressure on the gearbox  71  to remove stresses of the weight of the gearbox from bearings  23  and the power source. Furthermore, during operation, as the gearbox  71  rotates, opposing upper and lower compressions springs  87  and  89  co-operate to return the cross support  83 , and thus the gearbox  71 , to a level position. 
   Gearboxes known in the art are typically provided with a male splined connector for connecting to the input and output shafts (not shown). Accordingly, as shown in  FIG. 9 , axial rod  20  is provided with a female splined connector adapted to receive the male splined connector of gearbox  71 . As shown in  FIG. 8 , a connection arm  93  is attached to the top of the gearbox  71  at one end thereof and secured to a bracket  95  mounted on the processing tub  1 . The connection arm prevents the gearbox  71  from pulling away from the processing tub  1  thereby disconnecting from the axial rod  20 . 
   It would be understood by those skilled in the art that alternative rotation conversion devices, such as a belt or chain arrangement could be used without departing from the invention in its broadest aspect. 
   As shown in  FIG. 3 , a protective covering  25  is provided to cover the axial rod  18  or  20  extending from the back end wall of the machine. In the right-hand discharge arrangement shown in  FIG. 3 , the protective covering  25  is mounted on end wall  5  to cover the portion of axial rod  18  extending through bearings  21 . 
   As shown in  FIGS. 5 and 10 , an adjustable fork lift  97  is mounted on the rear of chassis  3  for raising baled material into the processing tub  1 . The adjustability of the fork lift  97  permits bales of different configurations to be lifted into the processing tub  1  (i.e. large “square” bales or one or more “round” bales). The fork lift  97  is mounted to each side of the chassis  3  by a mounting bracket  99  secured to the chassis by U-shaped bolts  101 . An L-shaped fork lift frame  103  is pivotally attached to each of the mounting brackets  99 . A hydraulic cylinder  105  is pivotally mounted between the fork lift frame  103  and mounting brackets  99  to raise and lower the fork lift frame. 
   Two forks  107  are mounted to a bottom cross bar  109  of the fork lift frame  103  by curved brackets  111 . The curved brackets  111  are adapted to slide axially along the cross bar  109  to adjust the separation between the two forks  107 . Each side of the cross bar  109  is provided with a series of adjustment holes  113  to receive a locking pin  115  which is inserted through a hole  117  provided in the front of curved brackets  111  to lock the forks  107  at the desired location. 
   As best shown in  FIG. 10 , the length of each fork  107  is also adjustable. Each fork  107  includes a rear section  119  and a front section  121  mounted on the rear section by square brackets  123 . The square brackets  123  slide axially along the rear section  119  to adjust the length of the fork  107 . Each square bracket  123  is provided with holes  125  on opposing sides thereof and the rear section is provided with a series of adjustment holes  127 . Accordingly, the fork  107  can be locked at a desired length by insertion of a locking pin or bolt through the holes  125  in the square brackets  123  and one of the adjustment holes  127  in the rear section  119 . 
   The front section  121  of each fork  107  has a bale carrier  129  extending inwardly towards the opposing fork. The bale carriers  129  are the main contact surface for the baled material and prevent the baled material from passing between the forks  107  as it is loaded into the processing tub  1 . A bale spear  131  is also mounted on the cross bar  109  between the two forks  107 . As the baled material is positioned on forks  107  and slides toward cross bar  109 , the bale spear  131  punctures the baled material to maintain the baled material in position as it is raised into the processing tub  1 . 
   As shown in  FIG. 11 , a discharge door  132  is pivotally attached to side wall  11  above the discharge opening  13 . The discharge door  132  is raised and lowered to direct the processed bale material as it is ejected from the discharge opening  13 . A hydraulic cylinder  133  is pivotally mounted between the processing tub  1  and the discharge door  132  to raise and lower the discharge door. When the bale processor is in the left-hand discharge arrangement as shown in  FIG. 14 , the hydraulic cylinder  133  is mounted to end wall  5 . When the bale processor is in the right-hand discharge arrangement as shown in  FIG. 15 , the hydraulic cylinder is mounted on end wall  7 . 
   As shown in  FIGS. 12 and 13 , the bale processor has a hydraulic selector assembly  135  comprising a selector valve  137  mounted on the chassis  3  and the front end wall of the processing tub  1 , a rod  139  extending from the selector valve  137  to beyond the rear of the chassis  3  and an actuation assembly  141 . The selector valve  137  includes a selector valve head  143  mounted within a casing  145  by bolts  147  and nuts  149 . The selector valve  137  has inputs  151  positioned on the top thereof and a first and second outputs  153  and  155  positioned on opposing sides. A spool  157  is mounted within the selector valve head  137  and is axially slidable therein between a first position wherein the hydraulic fluid flow in the inputs  151  is directed to the first outputs  153  and a second position wherein the hydraulic fluid flow from the inputs  151  is directed to the second outputs  155 . 
   The actuation assembly  141  moves the spool  157  between the first position and the second position and includes two springs  159  and  161 , a spacer  163 , a washer  165  and a nut  167  each of which are axially mounted on a bolt  169  which is secured to spool  157 . Nut  167  secures the washer  165  and the spacer  163  to the spool  157 . Spring  161  has a diameter sufficiently large to be mounted over the spacer  163  and washer  165  has a diameter larger than spring  161  thereby maintaining the spring in position between the washer and the selector valve head  143 . The length of spring  161  and spacer  163  are selected such that, when assembled, the spring  161  is slightly compressed thereby exerting a rearward force on washer  165  to maintain the spool  157  in the first position when no forward force is exerted on washer  165 . 
   Spring  159  is positioned between a washer  171  mounted on the front end of rod  139  and washer  165 . A portion of rod  139  extends beyond washer  171  to maintain the spring  159  in position. The strength of spring  159  is greater than the strength of spring  161 . Accordingly, movement of rod  139  towards the selector valve  137  causes spring  159  to exert a force on washer  165  thereby compressing spring  161  and moving the spool  157  forward within selector valve head  143 . Sufficient movement of rod  139  towards the selector valve  137  moves the selector valve to the second position. The selector valve head  143  is designed such that the spool  157  cannot move forward in the selector valve head once it is in the second position. 
   A gap is provided between the rod  139  and the bolt  169 . Accordingly, if rod  139  is moved further towards selector valve  137  once the spool  157  has moved into the second position, spring  159  is compressed without altering the position of other elements of the connection assembly  141 . This arrangement allows facilitates adjustment of the system while preventing damage to the spool  157 , selector valve head  143  and/or rod  139 . 
   The rod  139  is forced towards the selector valve  137  by the lowering of fork lift  97 . As shown in  FIG. 12 , the rear end of rod  139  extends beyond chassis  3  and is threaded with a nut coupling  173  mounted thereon. The nut coupling  173  is rotated to provide slight adjustments in the length of rod  139 . 
   When fork lift  97  is lowered, the fork lift abuts rod  139  forcing it towards the selector valve  137 , thereby moving the spool  157  from the first position to the second position as described above. The front of spool  157  is provided with bolt  175  adapted to abut with a door  177  pivotally mounted to the casing  145  when the spool is moved to the second position, thereby raising the door as an indication that the selector valve  137  is activated. As the fork lift  97  is raised, spring  161  exerts a rearward force on washer  165  moving the spool  157  back to the first position and moving the rod  139  rearwardly. 
   The hydraulic selector assembly  135  provides the ability to operate the three hydraulic systems of the bale processor (the hydraulic motors  33 , the hydraulic cylinders  105  for the fork lift  97  and the hydraulic cylinder  133  for the discharge door  131 ) with only two hydraulic lines. The first set of hydraulic lines are attached to the hydraulic cylinders  105  to raise and lower the fork lift  97 . The second set of hydraulic lines are attached to inputs  151  of the selector valve  137 . The first and second outputs  153  and  155  of the selector valve  137  are each connected to one of the other hydraulic systems. Typically, the first outputs  153  are connected to the hydraulic system used most frequently (i.e. hydraulic motors  33 ). The fork lift  97  is raise and lowered to selectively direct the hydraulic fluid flow in the second set of hydraulic lines between the hydraulic motors  33  and the hydraulic cylinder  133 . 
   It will be understood by those skilled in the art that numerous alterations, modifications and variations to the above embodiments can be made without departing from the invention as claimed.