Abstract:
An apparatus and method for cotton module building utilizing one or more augers on a compactor frame movable for compacting cotton in a cotton compacting chamber of the module builder. The auger or augers are rotatable for moving accumulated cotton in opposite directions therein, and are tiltable by contact with cotton accumulated unevenly in the chamber. A position or positions of the auger or augers are sensed for detecting tilting of the auger or augers. A controller responsively controllably operates the auger or augers for moving cotton in contact therewith in an appropriate direction for reducing the tilting and more evenly distributing the cotton. The cotton can then be compacted into a cotton module having desired dimensions.

Description:
This application claims the benefit of U.S. Provisional Application No. 60/557,888, filed Mar. 30, 2004. 

   TECHNICAL FIELD 
   This invention relates generally to control of a process for compacting and building a cotton module, and more particularly, to control of a cotton module building process using a compactor position signal. 
   BACKGROUND ART 
   With an on-board cotton module builder or packager parameters such as, but not limited to, the distribution of cotton within the module building chamber, the number of packing positions, and the number of compacting strokes, are all critical factors in forming a good rectangular module of compacted cotton that can be unloaded onto the ground as a stand alone module of cotton, and subsequently handled for transportation to the gin for processing. As is known, the distribution of the cotton within the module chamber is typically accomplished using augers attached to a compactor frame of compactor apparatus movable upwardly and downwardly in the chamber. During the compacting cycle, the augers are operated in a forward and/or reverse direction for distributing the cotton under the compactor apparatus. The number of packing positions is used to index or move the location of the compactor apparatus up within the chamber as the module is built from the bottom up. This ensures that there is space under the compactor in which to distribute the cotton. The number of packing strokes is the number of times that the cotton is pressed downwardly and compacted and more packing strokes ensures a good tight, cohesive module of cotton. The length of time that the augers run in the different directions, the number of packing positions, and the number of compaction strokes before raising or indexing the compactor apparatus to the next position are typically dependent upon set values that have been written in the electronic compaction program and stored in the compactor controller. These values are based on time, pressure, or both and are dependent on the amount of cotton that is coming into the module chamber. Under what are considered to be high yield conditions, generally three or more bales per acre, the amount of time the augers run forward and the amount of time they run rearward is different than under what is considered to be low yield conditions, one bale per acre. The number of compactor positions and compacting strokes are different in high yield cotton versus low yield cotton. 
   Additionally, it would be desirable to have the capability of determining the level of the cotton in a module builder in the forward and rearward regions thereof, respectively, to enable better determining which rotational direction the augers should be operated in for more evenly distributing the cotton. Particularly under varying yield conditions, it may be desirable to determine the direction of auger rotation when operation of the augers is initiated. 
   Therefore, what is sought is a control for a cotton module building process which can vary various parameters thereof, including, but not limited to, the direction and duration of auger operation at a function of cotton levels in the module builder. 
   SUMMARY OF THE INVENTION 
   What is disclosed is apparatus and a control for cotton module building which involves sensing relative position of portions of a cotton compactor located within the module builder, for determining levels of the cotton in different regions of the module builder, for determining a direction of operation of augers for distributing cotton within the module builder. 
   According to a preferred aspect of the invention, the augers are supported on a frame of the compactor apparatus located within the module builder, the frame being movable upwardly and downwardly by drivers, such as fluid cylinders or the like. Additionally, the frame is connected to the drivers or otherwise supported so as to be tiltable in at least the forward and rearward directions, such that the augers supported thereby are also tilted. As a result, when the frame and augers are lowered into contact with the cotton in the bottom of the module builder, if the cotton is uneven in height forwardly and rearwardly, the frame and augers will be tilted. At least one, and preferably two, compactor position sensors will detect the tilt or orientation of the frame and augers, and output a signal to a compactor control which will responsively determine an appropriate direction of rotation for the augers, and responsively output a control signal thereto for rotating the augers in the appropriate direction. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a side view of a cotton harvester including an on-board cotton module builder; 
       FIG. 2  is a schematic diagram of a cotton module builder control operable using a compactor position sensing routine according to the invention; 
       FIG. 2A  is a continuation of the schematic diagram of  FIG. 2 ; 
       FIG. 3  is a high level flow diagram showing steps for operation of the control according to the invention; 
       FIG. 4  is a fragmentary side view of the cotton module builder, showing compactor apparatus thereof tilted; 
       FIG. 5  is another fragmentary side view of the module builder showing the compactor apparatus tilted at a lowered position; and 
       FIG. 6  is another high level flow diagram showing steps of a compactor position routine according to the invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Turning now to the drawings, in  FIG. 1 , a cotton harvester  10  is shown, including an on-board cotton module builder  12  for compacting cotton harvested by harvester  10  into a unitary cotton module (not shown) according to the invention. 
   Referring also to  FIGS. 2 and 2A , circuitry of a compactor control  14  operable according to the present invention is shown. Control  14  includes a compactor controller  16  operable for receiving signals outputted by a number of devices, including, but not limited to, a compactor pressure signal from a compactor pressure sensor  18 , compactor position signals outputted by two compactor position sensors  20 A and  20 B, auger pressure signal outputted by auger pressure sensor  22 , and a yield signal outputted by an operator controlled yield setting  24  or a cotton yield monitor  25 . Responsive to the signals from these devices, and/or other devices, controller  16  is operable for automatically responsively outputting signals to apparatus such as a compactor raise solenoid  26  and a compactor lower solenoid  28 , which control compactor drivers, such as fluid cylinders  30  of module builder  12  ( FIG. 1 ) operable for moving compactor apparatus  32  of module builder  12  upwardly and downwardly against cotton accumulated in a bottom region of a compactor chamber  34  of module builder  12 . The drivers can also be used for setting or indexing the compactor position. Compactor control  14  is also operable for outputting signals to augers  36  ( FIG. 1 ) of compactor apparatus  32 , for effecting forward or reverse rotation thereof via an auger on solenoid  38  and an auger reverse solenoid  40 . 
   Referring also to  FIG. 3 , a high level flow diagram  42  is shown, including preferred steps for operation of compactor control  14 . After start block  44 , control  14  will optionally determine the cotton yield based on signals from cotton yield monitor  25 , as denoted at block  46 . Control  14  will set parameters such as, but not limited to, the auger run time, direction of operation, and number of compaction strokes, and the positions of compactor apparatus  32  within compactor chamber  34 , as denoted at block  48 . As the module building process proceeds, compactor control  14  will either cycle through the steps of blocks  46 – 48  or end the routine if the module is complete, as denoted by block  50 . As noted above, as the module nears completion, for instance, when the module exceeds a predetermined weight, compactor control  14  can output a module complete signal, such as a light or an audio signal, to alert the operator. 
   Referring also to  FIGS. 4 and 5 , compactor apparatus  32  includes a compactor frame  52  which is oriented generally horizontally, or within a range of small acute angles relative to horizontal, and substantially entirely disposed within compactor chamber  34 , for movement downwardly against cotton contained therein for compacting the cotton against a floor  54  therein. Compactor frame  52  includes a front cross member  56  disposed in chamber  34  adjacent a front wall  58 , and having opposite ends which extends through sidewardly open slots  60  in module builder  12 . Similarly, a rear cross member  62  is disposed in chamber  34  and has opposite end portions which extend through sidewardly open slots  63  in the module builder. Augers  36  are supported in forward and rearward extending relation between cross members  56  and  62  within chamber  34 . Augers  36  can be rotated using any suitable commercially available drivers, such as a gear drive driven by a motor such as a fluid or electric motor, or directly by fluid or electric motors, as desired, and as controlled by auger solenoids  38  and  40 , for distributing the collected cotton in chamber  34  as will be explained. In this regard, it should be noted that it is desirable and a sought after feature to distribute the cotton evenly with respect to the plane of floor  54 , such that the resultant compacted cotton module will have a substantially uniform height along its length and width. 
   Compactor frame  52  of compactor apparatus  32  is supported in compacting chamber  34  on each side by an exterior side structure  64 , each structure  64  including a forwardly and rearwardly extending main beam  66  which extends between and connects front and rear cross members  56  and  62 . Each side structure  64  additionally includes a pair of braces  68  which extend downwardly and at converging angles from front and rear cross members  56  and  62 , and which are connected together by a gusset  70  located spacedly below about the middle of main beam  66 . Here, it should be noted that compactor frame  52  located within compacting chamber  34  and exterior side structures  64  on the exterior of module builder  12  are movable upwardly and downwardly together. 
   The upward and downward movement of exterior side structures  64  and compactor frame  52  is preferably achieved and controlled by fluid cylinders  30  extending, respectively, between gussets  70  of each exterior side structure  64  and a support frame  72  supported by and extending upwardly from a frame  74  of module builder  12 . Importantly, a rod  76  of each cylinder  30  is connected to gusset  70  at a pivot  78  which allows limited pivotal movement of side structure  64  and thus compactor frame  52  and augers  36  of compactor apparatus  32  about a side-to-side extending pivotal axis within a limited range of pivotal movement, as denoted by arrows A. 
   Support frame  72  on each side of module builder  12  includes a pair of diagonally extending braces  80  having lower ends connected to frame  74 , and upper ends which connect to and support vertical braces  82  which support a cross member  84  to which fluid cylinder  30  is attached. A more forward brace  80  of support frame  72  on that side of module builder  12  facing outwardly from the page, and the more rearwardly located brace  80  on the opposite side of the module builder, support the compactor position sensors  20 A and  20 B, respectively. Each compactor position sensor  20 A and  20 B includes an elongate actuator arm  86  which pivotally connects to gusset  70  on that side of the module builder. Each sensor  20 A and  20 B is a rotary type sensor, which will detect rotational movement of the respective actuator arm  86 , as denoted by arrows B, as compactor apparatus  32  is moved from the positions shown in  FIGS. 1 and 4 , for instance, to the lower position shown in  FIG. 5 . Because two compactor position sensors  20 A and  20 B are used, movements of compactor apparatus  32  at a tilt, such as denoted by arrow A, will result in different rotational displacements of actuator arms  86  of the respective sensors  20 A and  20 B, and thus the sensors will output different positional values. The difference between these positional values can be utilized for determining both the vertical position of compactor apparatus  34 , and also any tilt thereof, such as denoted by arrow A, and also the direction of the tilt. Compactor position sensors can include, for instance, potentiometers, which vary a voltage or current signal when an input thereof is rotated. Actuators  86  can be slidable relative to the input to prevent binding when rotated as denoted by arrows B, and also when rotated in the opposite direction. For instance, a vertical position of the compactor apparatus can be determined from an average of the values outputted by sensors  20 A and  20 B. 
   Referring also to  FIG. 6 , another high level flow diagram  88  showing steps of a routine for determining appropriate directions of rotation, and also possibly duration of rotation, of augers  36  is shown. After a start block  90 , compactor apparatus  32  is lowered to lower the augers  36 , as denoted at block  92 . At block  94 , the orientation, that is, any tilt of augers  36  is detected, using signals from sensors  20 A and  20 B, generally as described above. Controller  16  will then determine the appropriate direction, and possibly duration, of the auger rotation, and apply that rotation, as denoted at blocks  96  and  98 . Here, generally, if compactor apparatus  32  is tilted such that the rearward end is located higher than the forward end, the controller would likely determine that rotation in a forward direction would be appropriate, and the angle of the tilt can optionally be used in determining a projected or initial duration of the rotation. As one option, the augers can be operated for the determined time period, then automatically raised. As another option, at desired times during the rotation, or at the end of the designated duration, controller  16  can monitor signals from sensors  20 A and  20 B, to determine whether the augers are tilted, and by how much, as denoted at decision block  100 . If tilt is present, controller  16  can continue to apply the auger rotation, or detect the auger orientation and determine a new auger rotation and apply that rotation. As still another alternative, if auger tilt is determined, the controller can determine an auger rotation, as denoted at block  96  and apply the determined rotation, as denoted at block  98 . Once no auger tilt is detected, controller  16  can raise the augers, as denoted at block  102 , and proceed to the next operational step, which can be, for instance, a compaction step, as denoted generally by block  48  in  FIG. 3 . 
   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.