Patent Publication Number: US-9850016-B2

Title: Round cotton module opener

Description:
CLAIM OF PRIORITY 
     This application claims priority to U.S. Provisional Patent Application Ser. Nos. 61/915,748, filed Dec. 13, 2013, and 61/935,635, filed Feb. 4, 2014, the entire disclosures of which are hereby incorporated by reference herein. 
    
    
     TECHNICAL FIELD 
     The present invention relates generally to a device for removing a wrap from a bale of a fibrous substance. More particularly, the present invention relates to a device for removing a wrap from a cylindrically-shaped cotton module. 
     BACKGROUND 
     Some recently developed cotton pickers roll and wrap cotton into a cylindrically-shaped module, hereafter referred to as a “round module,” as shown in  FIGS. 1A and 1B . This is done inside the picking machine as the cotton is picked in the field. One such picking machine is the CP690 Cotton Picker manufactured by Deere &amp; Company, Moline, Ill., 61265. A typical round cotton module  10  can measure 7 to 8 feet in diameter, approximately 8 feet in length, and weigh approximately 7,000 pounds. A wrap  20  extends between the end faces  12  of the round module  10  and terminates at a tail  24 , covering the cylindrical side surface of the module so as to prevent contamination, wetting and soiling of the cotton when the round module is placed on the ground by the picking machine for retrieval by a truck or other module mover. Typically, the picking machine can store one wrapped round module  10  as it makes another. This enables the farmer to pick cotton for the second module without having to stop so that the previously wrapped round module can be dropped off at the edge of the field. The new cotton pickers eliminate up to three pieces of equipment when compared to previous methods of baling cotton, and the labor to operate them. For example, previous methods of baling cotton typically required a rectangular module builder, a bowl buggy and a tractor. However, even with the noted advantages, many cotton gins are not presently configured to process round modules. Specifically, wraps  20  on the round cotton modules are manually removed by workers, increasing labor costs. As well, it is not uncommon for portions of the wraps to be inadvertently left on the round modules, meaning that portions of the plastic wraps can enter the cotton gin, thereby contaminating the cotton. 
     Currently, feeders for cotton gins are supplied in three basic types: roller bed, moving chain and walking floor. Typical roller bed and moving chain type feeders have beds that are 60 to 80 feet in length. The beds are often divided into three sections so that modules can be loaded on one end and caught up to any previously loaded modules. Sections of the bed are simply turned on and off as needed to butt modules end to end before entering the dispersing head of the cotton gin, which is located at the opposite end of the feeder bed from where the bales are loaded. The walking floor type of feeder does not have the ability to catch-up modules, therefore trucks must unload modules by backing onto the moving floor. Trucks must butt modules together during the unloading for efficient ginning Preferably, wraps  20  would be recovered from the round modules  10  prior to the modules being placed on the feeder bed for the gin. 
     The present invention recognizes and addresses considerations of prior art constructions and methods. 
     SUMMARY OF THE INVENTION 
     An embodiment of the present invention provides a round module opener for use with a round module of cotton that is disposed within a wrap, the round module opener including a frame, an unload conveyor assembly that is rotatably supported by the frame so that rotation of the unload conveyor assembly moves the round module of cotton in a first direction from a first end to a second end of the round module opener, the first direction being parallel to a longitudinal center axis of the round module opener, a slitter assembly that is secured to the frame and positionable so that the slitter assembly slices through the wrap along its entire length as the round module of cotton moves from the first end to the second end of the round module opener, and a picker assembly including a plurality of projections, the picker assembly being adjacent the unload conveyor assembly and rotated relative to the frame so that the plurality of projections first pierce a first portion of the wrap and are subsequently withdrawn from the first portion of the wrap, thereby separating the first portion of the wrap from the round cotton module. 
     Another embodiment of the present invention provides a round module opener for use with a round module of cotton that is disposed within a wrap, the round module opener including a frame, an unload conveyor assembly that is rotatably supported by the frame so that rotation of the unload conveyor assembly moves the round module of cotton in a first direction from a first end to a second end of the round module opener, the first direction being parallel to a longitudinal center axis of the round module opener, a slitter assembly that is secured to the frame and positionable so that the slitter assembly slices through the wrap along its entire length as the round module of cotton moves from the first end to the second end of the round module opener, and a picker assembly that is adjacent the unload conveyor assembly on a downstream side of the slitter assembly so that the picker assembly engages a first portion of the wrap and separates the first portion of the wrap from the round cotton module. 
     The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more embodiments of the invention and, together with the description, serve to explain the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended drawings, in which: 
         FIGS. 1A and 1B  are perspective and end views of a round cotton module; 
         FIG. 2  is a side view of a round cotton module opener in accordance with an embodiment of the present disclosure; 
         FIG. 3  is a top view of the round cotton module opener as shown in  FIG. 2 ; 
         FIG. 4  is a side view of the round cotton module opener as shown in  FIG. 2  disposed between a round module mover and a feeder bed of a cotton gin; 
         FIG. 5  is a cross-sectional view of an alternate embodiment of a picker assembly of the round cotton module opener including a scraper assembly; 
         FIG. 6  is a front view of a color sensor assembly of the round cotton module opener as shown in  FIG. 2 ; 
         FIG. 7  is a side view of the color sensor assembly as shown in  FIG. 6 ; 
         FIG. 8  is an end view of a feeder bed of a cotton gin including a color sensor assembly; 
         FIG. 9  is a detailed side view of the color sensor assembly as shown in  FIG. 8 ; 
         FIG. 10  is a detailed side view of the take-up frame as shown in  FIG. 2 ; and 
         FIG. 11  is a side view of an alternate spike shape for use with the picker assembly shown in  FIGS. 2 and 3 . 
     
    
    
     Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention according to the disclosure. 
     DETAILED DESCRIPTION 
     Reference will now be made in detail to presently preferred embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation, not limitation, of the invention. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present invention without departing from the scope and spirit thereof. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents. 
     Referring now to  FIGS. 2 through 4 , a round module opener  100  in accordance with an embodiment of the present disclosure is shown. Preferably, round module opener  100  includes a sweeper assembly  116 , an unload conveyor assembly  120 , a picker assembly  150 , and a transfer assembly  170 , each of which extends between a pair of side frame members  114  of the module opener&#39;s frame assembly  110 . Sweeper assembly  116  is pivotably mounted to a first, or upstream, end  100   a  of frame assembly  110 . Unload conveyor assembly  120  is mounted between side frame members  114  downstream of sweeper assembly  116  and is configured to move a round cotton module  10  ( FIGS. 1A and 1B ) along round module opener  110  in a first direction that is parallel to a longitudinal center axis of round module opener  100 . Picker assembly  150  is rotatably mounted between side frame members  114  on the downstream end of unload conveyor assembly  120 . Picker assembly is configured to remove a bottom portion of a round cotton module&#39;s wrap  20  ( FIGS. 1A and 1B ) that has been previously cut along both sides of the round cotton module by a slitter assembly  130 , as discussed in greater detail below. Transfer assembly  170  is rotatably disposed between side frame members  114  at a second, or downstream, end  100   b  of round module opener  100 . Transfer assembly  170  is configured to move round cotton modules  100  off of round module opener  100  and onto a feeder bed  104  of a corresponding cotton gin. 
     Additionally, in the preferred embodiment shown, slitter assembly  130  includes a pair of elongated arms  134 , each elongated arm  134  being pivotably secured to a corresponding side frame member  114  such that they oppose each other over unload conveyor assembly  120 . Referring additionally to  FIGS. 6 and 7 , a color sensor assembly  190  extends between side frame members  114  at downstream end  100   b  of round module opener  100 . As best seen in  FIG. 4 , side frame members  114  are pivotably secured to a base  112  of frame assembly  110  so that the height of upstream end  100   a  of round module opener  100  above the floor of the cotton gin can be adjusted to accommodate unloading round cotton modules  10  from module movers, such as truck, having delivery decks of various heights. A ratcheting inclination assembly  115  is utilized to adjust the height of the module opener&#39;s upstream end  100   a.    
     Sweeper assembly  116  is shown in an extended position in which sweeper assembly  116  engages the bottom surface of each round cotton module&#39;s wrap  20  as it is unloaded from module mover  102 . Sweeper assembly  116  includes an elongated cylindrical brush  119  that is mounted to side frame members  114  of round module opener  100  by a pivotable frame  118 . An air cylinder (not shown) is used to pivot sweeper assembly  116  from the in-use position shown to a retracted position in which cylindrical brush  119  does not make contact with cotton modules as they are being unloaded. For instance, sweeper assembly  116  is placed in the retracted position when rectangular cotton modules are unloaded, as rectangular cotton modules do not include a wrap. However, where a wrap  20  ( FIGS. 1A and 1B ) is used, such as with round cotton modules  10 , it is desirable to remove any dirt, sticks, debris, mud, excess moisture, etc., that may be present on the bottom surface of the wrap. Sweeper assembly  116  is preferably rotated in a direction that is opposite the direction of travel of the round cotton modules. As best seen in  FIG. 2 , this would mean that cylindrical brush  119  is rotated in the counter-clockwise direction, such that rocks, dirt, and other debris that is removed from the bottom of each wrap  20  is moved away from unload conveyor assembly  120 , thereby reducing the chances that the debris will enter the cotton gin. 
     After the removal of debris from the bottom of wrap  20 , each round cotton module  10  is moved onto unload conveyor assembly  120 . Unload conveyor assembly  120  preferably includes approximately six feet of unload rollers  122 , each unload roller  122  extending between side frame members  114  transversely to the direction of travel of the round cotton modules. Preferably, each unload roller  122  is powered by one or more roller chains  181  that are driven by a motor  180 , and various numbers, and diameters, of unload rollers  122  may be used to construct unload conveyor assembly  120 . As shown, elongated grip bars  124  are provided on every other unload roller  122 . Grip bars  124  extend along the outer surface of the corresponding unload roller  122  in a direction that is parallel to a longitudinal center axis of the powered roller. In alternate embodiments, each unload roller  122  may include a plurality of grip bars  124  disposed on its outer surface. Grip bars  124  provide additional friction between unload rollers  122  and wrap  20  of the corresponding round cotton module  10 , thereby facilitating its movement in the first direction on round module opener  100 . Additionally, in alternate embodiments, grip bars  124  need not extend the entire length of the corresponding unload rollers. 
     In the preferred embodiment shown, each elongated arm  134  of slitter assembly  130  is pivotably mounted above a corresponding side frame member  114  by a vertical post  132 . Each elongated arm  134  is pivotable between an in-use position in which it extends outwardly over unload conveyor assembly  120 , as shown in  FIG. 3 , and a retracted position in which each elongated arm  134  is disposed above and parallel to its corresponding side frame member  114 . Each elongated arm is preferably rotated between the two positions by a corresponding air cylinder  136 . Note, however, in alternate embodiments hydraulic cylinders may be used rather than air cylinders. A knife holder  138  including a replaceable elongated knife blade  140  is pivotably mounted to the distal end of a corresponding elongated arm  134 . An air cylinder  142  is secured to each knife holder  138  and its corresponding elongated arm  134  so that the angle of inclination of each knife blade  140  relative to its corresponding elongated arm  134  may be adjusted. In so doing, air cylinders  142  also help determine the extent to which the knife blades  140  slice into the corresponding round cotton module  10  after slicing through wrap  20 . A gauge wheel  144  is mounted to each slitter arm at the point where each knife holder  138  is pivotably secured to the corresponding elongated arm  134 . Gauge wheels  144  make contact with the cylindrical side surfaces  14  of the corresponding round cotton module  10  as it passes between the elongated arms, thereby also limiting the overall extent to which each knife blade  140  is able to penetrate the corresponding round cotton module. Referring additionally to  FIGS. 1A and 1B , the angle of inclination of knife blades  140  relative to the corresponding elongated arms  134  is selected such that each knife blade is able to slice through the corresponding front lip  22  of wrap  20 , yet not slice deeper than is necessary to slit wrap  20  along its entire length as it passes along unload conveyor assembly  120 . 
     Referring to  FIGS. 2 and 3 , picker assembly  150  extends between side frame members  114  such that it is transverse to the direction of travel of the round cotton modules. As best seen in  FIG. 5 , picker assembly  150  includes an inner cylinder  152  that is disposed within an outer cylinder  160 , inner cylinder including a plurality of spikes  154  that extend radially outwardly therefrom. As shown, spikes  154  are mounted circumferentially on inner cylinder  152  on six (6) equally spaced positions and longitudinally on inner cylinder  152  at equally-spaced intervals. Note, however, that fewer or more rows of equally-spaced spikes can be used. For example, in an alternative embodiment shown in  FIG. 5 , five (5) equally-spaced rows of spikes  154  are used. Still referring to  FIG. 5 , outer cylinder  160  includes a plurality of slots  164 , each slot corresponding to a position of a spike  154  on inner cylinder  152 . The longitudinal center axis  156  of inner cylinder is offset from the longitudinal center axis  162  of outer cylinder  160  such that as inner cylinder  152  and outer cylinder  160  rotate simultaneously at the same speed, each spike  154  alternately extends outwardly from, and is retracted inwardly into, its corresponding slot  164 . As shown in  FIG. 5 , longitudinal center axis  156  of inner cylinder  152  is disposed above longitudinal center axis  162  of outer cylinder  160  such that each spike begins to protrude from its corresponding slot  164  at approximately the 8 o&#39;clock position. Continued rotation of inner cylinder  152  and outer cylinder  160  causes each spike  154  to fully protrude through its corresponding slot  164  in the 12 o&#39;clock position, and once again be fully retracted at the 4 o&#39;clock position. 
     Rotation of picker assembly  150  in the clockwise direction causes spikes  154  to pierce the bottom portion of wrap  20  which has been previously separated from the remainder of the corresponding wrap  20  by slitter assembly  130 . Once spikes  154 , such as those shown in the 12 o&#39;clock position, have pierced the bottom portion of the wrap, continued rotation of picker assembly  150  pulls the bottom portion of the wrap downward and away from the bottom of the corresponding round cotton module  10 . As picker assembly  150  continues to rotate in the clockwise direction, spikes  154  moving between the 12 o&#39;clock and 4 o&#39;clock positions begin to retract into outer cylinder  160  such that the bottom portion of the wrap is stripped away from the spikes  154 , thereby allowing the bottom portion of the wrap to fall to the floor of the cotton gin. 
     Preferably, each spike  154  includes a sharp distal point at an angle of approximately 20° to 30° to minimize the amount of force required to pierce each wrap  20 , which may include up to nine layers of plastic. Each spike  154  widens towards a cylindrical body portion  155  such that the wrap  20  is readily removed from the spikes  154  as they are retracted through their corresponding slots  164  into outer cylinder  160 . As best seen in  FIG. 2 , a take-up frame  158  is provided that support both inner cylinder  152  and outer cylinder  160  at their outermost ends and allows the distance between longitudinal center axis  156  of inner cylinder  152  and longitudinal center axis  162  of outer cylinder  160  to be adjusted radially. Specifically, referring additionally to  FIG. 10 , an air cylinder  159  is used to slide an inner frame member  161 , to which inner cylinder  152  is rotatably secured, both upwardly and downwardly within a vertical channel  163  that is defined by an outer frame member  165 , to which outer cylinder  160  is rotatably secured. As such, air cylinder  159  can move inner cylinder  152  both upwardly and downwardly relative to outer cylinder  160  as desired. Correspondingly, the points at which each spike  154  begins to extend from and retract into its corresponding slot  164  is adjusted. The distance between the longitudinal center axes determines the depth to which each spike  154  penetrates the corresponding wrap  20  when in the 12 o&#39;clock position. In the lowermost position of inner cylinder  152  relative to outer cylinder  160 , spikes  154  that are in the 12 o&#39;clock position are fully retracted within outer cylinder  160 . This allows “standard”, or square modules, which do not include wraps to be unloaded. As well, persons working on the round module opener  100  are now free to walk across the picker assembly  150  outer roller  160  as may be necessary during operations. 
     As best seen in  FIG. 5 , a scraper assembly  290  is preferably provided under picker assembly  150  along its entire length and is pivotably mounted to the frame at a pivot point  292 . A first end of scraper assembly  290  includes a plurality of scraper blades  293 , each scraper blade  294  being disposed between adjacent rows of spikes  154  of picker assembly  150 . Each scraper blade  293  includes a replaceable scraper tip  294  that is in contact with the outer surface of the picker assembly&#39;s outer cylinder  160 . Scraper tips  294  are preferably comprised of a phenolic material. A second end of scraper assembly  290  includes one or more tension springs  296  that bias the first end of the scraper assembly and, therefore, the plurality of scraper blades  294  into contact with the outer surface of the picker assembly&#39;s outer roller  160 . As such, scraper blades  294  help separate wraps  20  that are removed from the round modules  10  from picker assembly  150 . 
     Referring now to  FIG. 10 , in an alternate embodiment each spike  254  is designed with a sharp point  212  at an included angle of 20° to 30° to minimize the puncture force required to pierce nine (9) layers of plastic wrap at once. Point  212  is arrow head shaped to insure that the wrap remains on each spike  254  after it is punctured. A base  214  of each point  212  is angled opposite to point  212  thus lowering the stripping force to remove the wrap. A cylindrical shank  216  is of sufficient diameter to prevent the plastic from shrinking so far that it increases stripping forces. 
     As best seen in  FIG. 3 , transfer assembly  170  includes a plurality of driven roller portions  172  that are alternatingly spaced along the longitudinal center axis with a plurality of free roller portions  174  along the longitudinal center axis of the transfer assembly&#39;s elongated shaft  176 . Driven roller portions  172  are keyed to elongated shaft  176  such that they rotate in the same direction as the shaft. However, free roller portions  174  are not keyed to elongated shaft  176  and are therefore free to rotate in either the same direction as elongated shaft  176  or the opposite direction. Driven roller portions  172  are rotated by a 3-horsepower gear motor (not shown), Part No. QTN347352B33D634182TC, available from Emerson Power Transmission, in the direction of travel of the round cotton modules  10  to facilitate movement of each unwrapped module off of round module opener  100  and onto feeder bed  104  of the cotton gin. The speed of the gear motor is controlled by an adjustable frequency drive. Preferably, driven roller portions  172  are rotated independently of picker assembly  150 , which is rotated by a motor  180 , as best seen in  FIG. 2 . Operating driven roller portions  172  of transfer assembly  170  independently of picker assembly  150  facilitates the clearing of cotton buildup which may occur between transfer assembly  170  and picker assembly  150  by rotating transfer assembly  170  in a direction opposite to the normal direction of travel of the round cotton modules. This action also redirects plastic wrap  20  between picker assembly  150  and transfer assembly  170 , as shown in  FIG. 5 . To facilitate plastic wrap removal, a beam sensor (not shown) detects the front of each round module  10 , and rotates drive roller portions  172  in the reverse direction, at the same speed as picker assembly  150 , to redirect the lead edge of the wrap, as noted. After the wrap has been redirected, rotation of the driven roller portions  172  in the forward direction is then resumed. Specifically, upon resuming rotation in the forward direction, driven roller portions  172  are rotated at approximately twice the speed at which picker assembly  150  is rotated, for approximately 4 seconds. This period of higher speed rotation helps to pull any cotton that has been entrained downwardly with the front edge of the wrap back up from between picker assembly  150  and transfer assembly  170  onto the feeder bed. In alternate embodiments, transfer assembly  170  may also be driven by motor  180  rather than its individual motor. 
     As shown, the diameter of each driven roller portion  172  is greater than the diameter of each free roller portion  174 , with the circumferential rows of spikes  154  on picker assembly  150  being aligned with a corresponding row of the free roller portions  174 . Because free roller portions  174  are free to rotate in either the clockwise or counter-clockwise directions about elongated shaft  176 , should portions of the wrap or excess cotton begin to build up between picker assembly  150  and transfer assembly  170 , rotation of the free roller portions  174  in the counter-clockwise direction facilitates clearing of the built-up matter. Motor  180  is preferably a standard right angle gear box with a 7.5-horsepower drive motor. An example motor  180  is Part No. QTN347352P3340T24213T7.5 available from Emerson Power Transmission. The speed of motor  180  is controlled by an adjustable frequency drive and, therefore, it can be matched with the speed at which round cotton modules  10  are delivered by the module mover  102 , as well as the speed of the feeder bed  104  of the gin. Motor  180  is reversible to facilitate clearing any buildup of cotton or portions of wrap  20  that may become clogged between various components of round module opener  100 . 
     Referring additionally to  FIGS. 6 and 7 , color sensor assembly  190  is mounted between side frame members  114  on the downstream side of transfer assembly  170 . As shown, color sensor assembly  190  includes a transverse frame member  194 , a plurality of color sensors  192  mounted thereto beneath an elongated hood portion  191  that extends the length of transverse frame member  194 . The color sensors  192  used in the preferred embodiment are available from Keyence Corp., Part No. CZ-VZ21AP, Smart RGB Digital Sensor. A plurality or apertures  193  is defined in hood  191 , each aperture  193  being disposed above a corresponding color sensor  192 . Hood  191  is angled downwardly such that any cotton that may fall on color sensor assembly  190  tends to fall to the floor of the gin rather than building up on top of color sensor assembly  190 . However, to further prevent the buildup of cotton on color sensor assembly  190 , an air jet  195  is provided for each color sensor  192  and is activated at intervals to blow any loose cotton off of the corresponding color sensor  192 . 
     In operation, a sensor beam  196  passes upwardly through the corresponding aperture  193  on hood  191  and onto the bottom of a corresponding round cotton module  10  as it exists round module opener  100  and passes on to feeder bed  104  of the gin. Color sensors  192  are programmed to detect the presence of various colors that are typically used for the wraps  20  that are disposed around the round cotton modules. For example, typical colors used for the wraps are yellow, pink, white, blue, and tan. The detection of any of these colors on the bottom of a corresponding round cotton module  10  indicates that a portion of the wrap  20  that was thought to have been previously removed may still be present on the bottom of the round cotton module. Preferably, detection of these colors by color sensor assembly  190  activates an alarm that allows the corresponding round cotton module  10  to be stopped so that the remaining wrap  20  may be removed prior to the round cotton module  10  being fed into the gin. As such, color sensor assembly  190  aids in preventing the contamination of the cotton that is being processed in the gin with plastic. 
     Referring now to  FIGS. 8 and 9 , an alternate embodiment of a color sensor assembly  200  is shown. Preferably, color sensor assembly  200  includes a color sensor  202  that is disposed on a cable  208  that extends between two pulleys  210 . A piston  212  is also disposed on cable  208  and facilitates movement of cable  208  about pulleys  210  such that color sensor  202  may be moved upwardly and downwardly within its corresponding housing  201 . The piston drive system is available from Tol-O-Matic, Part No. CC05. This allows a single sensor  202  to be positioned on a corresponding side wall  105  of the gin&#39;s feeder bed  104  and be alternatingly moved upwardly and downwardly as each round cotton module  10  passes by. As such, a single color sensor may scan a large portion of each cotton module. As shown, a color sensor assembly  200  is disposed on each side wall  105  of feeder bed  104  for the detection of any wrap  20  that may be present. Preferably, housing  201  includes a clear window  206  disposed over color sensor  202  to prevent cotton from building up within the color sensor assembly, thereby reducing its effectiveness. In alternate embodiments, various drive systems may be used to move color sensor  202  vertically up and down, such as, but not limited to, rack and pinion drives, magnetic linear slides, etc. As well, in alternate embodiments, multiple stationary color sensors  202  may be used rather than the single movable sensor that is shown. 
     While one or more preferred embodiments of the invention are described above, it should be appreciated by those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope and spirit thereof.