Patent Publication Number: US-7900557-B2

Title: System and method for automated application of inoculants onto forage materials

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part application of U.S. patent application Ser. No. 12/769,887, filed Apr. 29, 2010, which is a continuation application of U.S. patent application Ser. No. 12/421,392, filed Apr. 9, 2009, each of which are incorporated by reference in their entirety herein. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to a system and method for applying inoculants or conditioners to forage material used to feed livestock, and more particularly, to a system and method in which the amount of inoculants applied is automatically corrected to account for changes in the moisture content of the forage material, the relative humidity of the environment, and other factors. 
     BACKGROUND OF THE INVENTION 
     Inoculants or conditioning materials may be applied to treat various types of animal feed when the animal feed is harvested. Forage materials such as hay crops and corn may be treated upon harvesting in which inoculants are applied to the crops during baling or chopping of the crops. Both liquid and dry inoculants/conditioners may be applied in order to achieve a number of purposes to include conditioning the forage material for an increased storage life that prolongs the nutritional value of the forage material. 
     It is known in the art to apply inoculants to forage materials that have been chopped/baled in automated baling and chopping equipment. For example, it is known to selectively apply inoculants to the harvested crops wherein certain parameters are measured, and the amount of inoculants applied is adjusted to account for the measured parameters. Moisture content of the harvested crop is one measured parameter. However, one noteworthy shortcoming with respect to many prior art systems is that the moisture content of the harvested crop is not measured until that particular portion of the crop has been baled. Therefore, any adjustments made in terms of the type/amount of inoculants applied is conducted retrospectively, and not based upon the actual portion of the harvested crop that enters the baling/chopping machine. This retrospective analysis of the moisture content can result in very inaccurate and otherwise undesirable changes in application of the inoculants since it is well known that moisture content can widely vary in closely adjacent sections of the harvested crop. For example, a field which hosts a crop may have randomly scattered depressions or a slope resulting in a portion of the field lying in an area that naturally collects water and moisture in general. Shading of the field in various locations also results in very different moisture contents depending upon when the crop is harvested during the day. 
     It is difficult to accurately measure the moisture content of a windrow of forage material entering the intake of a baling machine. As the windrow enters the machine, it is laterally dispersed and must be funneled into a smaller area prior to entering the compaction chamber of the baling machine. Accordingly, this difficulty in measuring moisture content at the intake is why many prior art systems measure moisture content when the forage material is highly compressed in the bail since the compressed forage material is much easier to measure for moisture. This inherent difficulty in measuring moisture at the intake of the baling/chopping machine, coupled with the retrospective moisture analysis in the prior art devices, results in an inaccurate application of adjusted amounts of applied inoculants. 
     Therefore, there is a particular need for a system and method for applying inoculants to forage material in which the amount of inoculants applied may be adjusted in real time based upon a prospective analysis of measured parameters so that adjusted amounts of inoculants are applied to the actual portions of the forage material in which the parameters were measured. 
     There is also a need for capturing and recording data regarding measured parameters associated with the harvested crop and the inoculants applied to the harvested crop. This data can be used for production records, cost analysis, and other commercial needs. 
     There is also a need to provide a user friendly system and method in which an operator of the system can selectively apply inoculants to the forage material both in manual and automatic modes. 
     There is also a need for providing a system which can be easily incorporated into existing baling/chopping machines without significantly altering the operation of the existing machine. 
     Each of the above needs is met with the present invention as described below. 
     SUMMARY OF THE INVENTION 
     In accordance with the present invention, a system and method are provided for automated application of inoculants onto forage materials in which the amounts applied can be varied by a prospective analysis of the un-baled forage material. 
     In accordance with the system of the present invention, an applicator assembly or device is provided to dispense a dry inoculant product. A control system coupled to the applicator assembly monitors and controls the rate and amount of the inoculant applied to the forage material. A data collection means collects and stores data regarding measured parameters of the forage material and applied inoculants. The control system comprises various types of sensors to measure parameters such as the feed rate of the crop, the moisture content of the crop, and the relative humidity of the surrounding environment. Data measured by the sensors is input to a controller which in turn generates outputs to the dispensing device to adjust the rate and amount of inoculants applied to the forage material that has entered the baling machine, but has not yet been baled. Accordingly, the control system regulates applied inoculants in real time to take into account specific measured parameters. The control system further comprises a human machine interface (HMI) including various user interface screens generated by software or firmware associated with the controller allowing the operator to control dispensing of the inoculants. The HMI specifically includes four general categories of operator screens, namely, screens for automatic control, manual control, semi-automatic control, and screens that display the system status. 
     The applicator assembly further includes a bin or container for holding the inoculants to be dispensed and a means to controllably dispense the inoculants from the container. In a preferred embodiment, an auger is disposed in the bottom of the container and the auger is powered by a speed controlled motor. The auger has a discharge end or outlet that discharges the inoculants for delivery to the portion of the baling machine that takes up the forage material. Optionally, a blower communicates with the outlet of the auger to assist in conveying the inoculants to the designated area in the baling machine where the exposed forage material travels. The bin is mounted above the point where the inoculants are delivered so in some cases, gravity alone may be adequate for dispensing the inoculants to the desired location within the processing machine, namely, a baling/chopping machine. 
     The applicator device can be conveniently mounted to the side or top of the baling/chopping machine. The auger and blower can be disposed in an optimum manner with respect to the incoming stream of forage material so that the auger/blower evenly applies the inoculants to the incoming forage material. 
     In another aspect of the present invention according to one or more preferred embodiments, application of the inoculant materials are automatically applied by a control system that uses real-time measured system inputs to include the feed rate of the forage material (e.g., pounds per minute), percent moisture in the forage material, and the ambient humidity. The optimum amount of the inoculant material to be applied is continually adjusted based on an algorithm in which moisture percentage measurements are taken a number of times for incremental amounts of forage material that collectively form a bale of forage material. The system and method of the invention are responsive to adjust the amounts of inoculants applied within short time spans to account for variations in moisture percentages that may vary greatly between closely located amounts of forage material within the same bale. 
     Accurate moisture measurement is a very important part of determining the optimum application of inoculants onto forage material. The moisture values for forage can be highly variable throughout a windrow of material that enters the baler. To improve the accuracy in inoculant application, two or more sensors for moisture measurement are placed in the area of the entrance to a loading duct in the baler that receives forage material from a feed manifold that lifts the forage material from the ground into the baler. Preferably, the sensors are spaced from one another across the entry area of the loading duct, such that sensor readings can be taken across most of the entry area of the duct. These readings are used in calculating a moving average of moisture measurements over time. In other words, moisture measurements are taken multiple times over a set period of time, and these readings are used as variables in an algorithm that calculates optimal inoculants to be applied. A single measurement taken for a bale of material will likely miss at least one high moisture area of the forage material in the bale and therefore, under application of the inoculants occurs resulting in spoilage or fire hazards for the producer. 
     In one calculation scheme or algorithm, it is observed that greater importance should be given to high moisture reading that may exceed a certain threshold level as compared to low readings within the same sample. In this case, calculating a simple moisture average among the moisture readings does not provide the needed protection to prevent loss of viable nutrients available in the forage material. Loss of nutrients means loss of value to a livestock feeder and loss of profitability for a livestock producer. Moisture values are exponentially weighted in a moving or time changing average to give the highest moisture readings greater influence in adjustments to the amounts to be dispensed. One example of a calculation supporting this weighted moving average is calculated by applying a percentage to the highest moisture reading above a maximum percentage of moisture that is acceptable for untreated forage. This maximum percentage of acceptable moisture is adjusted to account for bale sizes. Typical values for maximum acceptable moisture percentages may be about 16% for small square bales and 18% for large square and round bales. Another concept for using the weighted moving average in the algorithm is that the algorithm also provides greater emphasis on the most recent moisture data. The formula for the weighed moving average of the current moisture reading value can be expressed by (x)(2/n+1) where x is the amount of moisture content above the threshold moisture percentage level and n is the number of samples sets taken in the moving average. The result of this calculation is added to the previous exponential moving average calculations, and the sum of these calculations corresponds to predetermined amounts of inoculants to be applied. The sums are calculated over very short time spans, and an output is sent from a controller to modulate a dispense element, such as the auger in the inoculant bin, that meters inoculants into a delivery line that carries the inoculants to a dispense point onto the incoming forage material. One important aspect of the moisture sensing activity is that there are multiple measurements of the forage material taken prior to the forage material entering the baling chamber to form a bale, as well as a multiple sensors that take multiple measurements per point measurement. A point measurement can be defined as the moisture measurements taken at a particular instant in time of forage material passing through the loading duct. 
     Another calculation scheme or algorithm that could be used in order to provide information for determining proper inoculant amounts to be delivered is to select the highest moisture sensor reading per point measurement, and then adjusting the amount of inoculants based upon the sum of these highest values. With respect to spoilage lost, adjusting by this highest value may result in excess inoculant applied to the forage material at some points; however, a greater economical loss due to spoilage may be greater than the cost of increasing the increased amount of inoculant material applied. Therefore, the incremental increased amount of inoculants applied may still provide an economic benefit. 
     With respect to the number of measurements taken, it is contemplated that the average number of groups of forage material or flakes that are used to make a bale ranges between 28-32 flakes. The present invention contemplates the capability to provide at least one measurement for each flake and therefore, this high number of measurements provides very accurate moisture measurement and subsequently, application of inoculants can be optimized. 
     With the system and method of the present invention, a number of benefits are realized with respect to selectively applying desired inoculants. The present invention provides a convenient and economical retrofit solution for applying inoculants to forage materials to be chopped/baled. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic view of a prior art square baling machine; 
         FIG. 2  is a schematic view of a prior art round baling machine; 
         FIG. 3  is another schematic view showing the round baler of  FIG. 2  manipulating an amount of forage material to create a round bale; 
         FIG. 4  is a perspective view of the container or bin associated with the dispensing apparatus of the present invention; 
         FIG. 5  is a fragmentary front elevation view of the bin; 
         FIG. 6  is an enlarged fragmentary perspective view of the interior of the bin with an auger cover shown partially broken away to expose the auger; 
         FIG. 7  is a perspective view of an example baling machine with the dispensing apparatus of the present invention mounted adjacent the intake area of the baling machine; 
         FIG. 8  is a greatly enlarged fragmentary perspective view showing the intake area of the example baling machine illustrated in  FIG. 7  and showing the location where the inoculants are dispensed from a conveying line connected to the dispensing apparatus; 
         FIG. 9  is another greatly enlarged fragmentary perspective view showing the location where the inoculants are dispensed from a conveying line connected to the dispensing apparatus; 
         FIG. 10  is a schematic diagram illustrating the system of the present invention with respect to placement of system sensors in the intake area of a baling machine; 
         FIG. 10A  is an enlarged schematic diagram illustrating one example of contact-type sensors usable in the system of the present invention; 
         FIG. 10B  is an enlarged schematic diagram illustrating one example of non contact-type sensors usable in the system of the present invention; 
         FIG. 11  is a perspective view of a controller in accordance with a preferred embodiment of the present invention; 
         FIG. 11A  is a side view of an electrical junction box associated with the controller 
         FIG. 11B  is a bottom view of the junction box; 
         FIG. 12  is an example HMI in the form of a user interface screen that can be displayed on the controller for manual operation of the system; 
         FIG. 13  is another example HMI in the form of a user interface screen that can be displayed on the controller for automatic operation of the system; 
         FIG. 14  is another example HMI in the form of a user interface screen that can be displayed on the controller for semi-automatic operation of the system; 
         FIG. 15  is another example HMI in the form of a user interface screen that can be displayed on the controller for displaying a system status; 
         FIG. 16  is another example HMI in the form of a user interface screen that can be displayed on the controller for displaying additional information on the system status; 
         FIG. 17  is another example HMI in the form of a user interface screen that can be displayed on the controller for displaying a calibration function allowing an operator to calibrate the speed sensor installed on the baling/chopping machine; 
         FIG. 18  is another example HMI in the form of a user interface screen that can be displayed on the controller for displaying a calibration function allowing an operator to set the expected forage amounts based on the travel length of the baling/chopping machine; 
         FIG. 19  is another schematic diagram illustrating the system of the present invention with respect to an alternative embodiment in which moisture measurement is taken in the loading duct by a plurality of moisture sensors, and the data is used in an algorithm to finely adjust applied inoculants over short time spans; and 
         FIG. 20  is a cross sectional view of the duct in  FIG. 19  showing an array of sensors and load cells used for purposes of sensing moisture and amounts of forage material transferred to a baling chamber of the baler. 
     
    
    
     DETAILED DESCRIPTION 
     The system and method of the present invention provides the delivery of inoculants to forage material that is processed for baling/chopping. More specifically, the inoculants are provided to forage material that has been harvested, and is to be baled for storage and subsequent use. The system of the present invention is conveniently mountable to a conventional baling/chopping machine. Hereinafter, reference to a “baling machine” is also understood to be a reference made also to a chopping machine. 
     Accordingly, in one aspect of the present invention, a system is provided for delivering selected amounts and types of inoculants to forage material. 
     In another aspect of the present invention, a method is provided for delivery of the inoculant material. 
     In yet another aspect of the present invention, a combination is provided for an inoculant delivery system and a baling machine. 
     Referring to  FIG. 1 , a prior art square baling machine is illustrated. The particular baling machine illustrated in this figure corresponds to the invention disclosed in the U.S. Pat. No. 5,842,335, which is incorporated herein by reference for purposes of disclosing a known baling machine of the type which produces square bales. Typically, the baling machine or baler follows a mowing machine that cuts and crimps the forage, and discharges it into windrows. A raking device may be used to turn the hay over in order that the windrow can more completely dry. The baler collects the cut crop directly from the windrow and subsequently shapes and compresses the hay into a desired shaped bale for storage and subsequent use. The baler shown in  FIG. 1  may, for example, be pulled behind a tractor that cuts the hay in the field. 
       FIG. 1  shows the square baler  10  mounted on a wheeled chassis including a pair of laterally spaced wheels  14 . The chassis carries a horizontally extending baling chamber  18  that is centered between the wheels. A plunger  19  reciprocates in a fore and aft motion within the baling chamber  18  for compressing the forage material into cubical/square shaped bales. A windrow pickup assembly  20  is also supported on the chassis and is disposed in front of the wheels for picking up a windrow of crop material as the baler is advanced along a path of travel by the towing vehicle (not shown). A loading duct  22  is disposed between the pickup assembly  20  and the baling chamber  18 , and includes a stuffing mechanism  24  that transfers crop material from the pickup apparatus into the baling chamber, and pre-compresses the material prior to advancing it into the baling chamber  18 . A plurality of laterally spaced tines  34  of the pickup assembly  20  are driven upwardly and rearwardly to transfer the crop material from the ground to a laterally extending pan  36 . One or more augers  38  may be disposed on opposite sides of the pickup assembly  20  to convey crop material from the lateral edges of the pickup assembly to the center of the machine in alignment with the duct  22 . The converged flow of crop material is subsequently transferred to the duct  22  by the stuffer  24 . The plunger  19  is reciprocated within the baling chamber  18  so that each new charge of the crop material passing into the chamber is compacted rearwardly during a compaction stroke of the plunger  19 . As the crop material is compacted, it travels rearwardly into a squeeze mechanism  21  having moveable rails to apply inward pressure in order to shape the bale prior to reaching an outlet of the device. A suitable tying mechanism (not shown) is also provided for binding the bale prior to being ejected from the outlet. 
     Referring to  FIGS. 2 and 3 , an example round baling machine is illustrated. The particular baling machine illustrated in these figures corresponds to the round baling device disclosed in U.S. Pat. No. 5,136,831, the disclosure of which is hereby incorporated by reference for purposes of teaching a round baler. This round baler  10 ′ is also mounted on a frame including an axle  14 ′ supported by spaced ground wheels  16 ′. This particular machine has the capability of forming large round bales on a continuous basis. Specifically, the baler has mirror imaged front and rear sets  24  and  26  of endless flexible bale rolling members, preferably in the form of side-by-side endless flexible belts  27 . The baler also includes front and rear control mechanisms  28  and  30  with endless flexible chains  32  and  34  arranged in triangular patterns and mounted over rotatable sprockets  36 ,  38 ,  40  and sprockets  42 ,  44  and  46 , respectively. The front and rear control mechanisms  28  and  30  each include spaced positioning rollers which span the baler to interconnect the rear chains  34 . 
     Formation of a round bale of desired density is accomplished by applying a desired level of pressure on the crop material as it is rolled by the rolling members  24  and  26 . As the baler is towed across a field, the pickup assembly  98  continually lifts windrow materials off the ground into the baling chamber  88 . The materials are acted upon by the counter-moving belt stretches  84  and  86  to cause the material to tumble forwardly within the chamber  88 . 
     Referring to  FIG. 3 , a bale B is shown in full size as it has been formed within the machine. Once the bale reaches full size, it is lifted into a raised position as fresh material continues to enter the baler beneath the original bale. The full size bale in its raised position can be released from control of the forming belts by presenting the bale to a rearwardly inclined ramp so that the bale may be discharged from the baler by gravity down the ramp. 
     With respect to the system of the present invention, as described below, sensors may be conveniently mounted in the intake area directly adjacent the pickup assembly of the baler so that the necessary measurements/observations can be taken for the incoming crop material, and then immediately followed by an appropriate application of the inoculants as the forage material passes through the intake area. It shall be understood that the sensors of the present invention can appropriately mounted with varying types of baling machines in order that the sensors can take appropriate measurements just upstream of the flow of material prior to the forage material receiving an application of the inoculants. One of skill in the art will appreciate that sensors may be alternatively mounted near the inoculation application point wherein moisture, etc., are measured after the inoculant is applied. In this embodiment, the sensors are located downstream of the inoculant application such that the moisture measurement of yet to be bailed material is obtained. That measurement then may be used to selectively alter the amount of inoculant applied to the material associated with the next bail. For example, the sensors may be located prior to the plunger (for example, 0 to 6 ft. from the application point) where continuous measurements are obtained. Inoculant application adjustments could then be made as a function of the continuous measurements to ensure accurate application of inoculant to each bail. 
     Referring to  FIGS. 4 and 5 , an applicator assembly  100  is illustrated which is used to dispense a dry inoculant product. As discussed further below with reference to  FIG. 7 , the applicator assembly can be directly mounted on the baling machine to dispense a controlled amount of inoculant onto the forage material prior to the material being baled. The applicator assembly includes a product bin or container  102  defined by plurality of sidewalls  104  including a converging lower portion  105  which funnels the inoculant product into the very lower most or bottom  107  of the container. The top opening  106  of the container may receive a cover (not shown) to prevent the inoculants from being blown out of the container during high wind conditions or from becoming wet from rain and therefore not easily transported. The container/applicator assembly is supported by vertical supports  108  located at each corner of the container. Lower horizontal supports  110  stabilize the lower ends of the vertical supports  108  and the supports  110  act as a bottom mount. A side mounting bracket  112  is provided for directly mounting the container  102  to the baling machine. In addition to the side mounting bracket  112 , other mounting brackets can be fashioned to enable the container to be mounted to the particular type of baling machine used. As also shown in  FIG. 4  by the broken lines, a dispensing auger  132  has one end which protrudes from the bottom  107  of the container for dispensing a metered amount of inoculant product. The rotational speed of the auger determines the rate at which inoculant material is dispensed. The auger dispenses the inoculant product into an outlet receiving container  116  that is mounted on plate  121 . The outlet receiving container  116  has a lower end that communicates with a blower motor  117  that extends below the plate  121 . An outlet cover  114  is provided to prevent inoculate material from being blown out of the receiving container  116  during high wind or rain conditions. 
     A conveying line  118  is provided for conveying the inoculate product from the receiving container  116  to the forage material. The conveying line  118  communicates with the bottom discharge end of the container  116  and the blower motor  117 . The blower motor provides the motive force for conveying the inoculant product through the conveying line  118 . The blower is optional as the conveying line can be positioned for gravity delivery of the inoculant product to the desired location within the intake area of the baling machine. 
     A sight glass  120  is provided on one of the sidewalls  104  in order for the operator to visualize the amount of inoculant product remaining in the container. The container may also incorporate level sensors (not shown) which alert the operator to a low level of inoculant product within the container. For example, the sensors can be mechanical switches or electronic sensing devices such as capacitive switches that warn the operator that the container is low on inoculant product. 
     Referring to  FIG. 6 , an overhead perspective view is provided of the interior of the container illustrating an auger cover  130  which covers the auger  132 . The auger cover can be in the form of an upside down v-shaped plate as shown that covers the full length of the auger. Inoculant product communicates with the auger  132  in the lateral gaps or spaces  134  located on both sides of the auger cover  130 . The auger cover helps to ensure the auger meters a consistent amount inoculant material that otherwise might be unduly compressed if the inoculant material was allowed to directly contact the auger overhead. More specifically, consistency of the dispensing rate of the auger can be affected by the inoculant product height in the container if in direct contact with an exposed auger. With an exposed auger, as product is dispensed, the pressure on the exposed auger decreases and the flow rate of the product will accordingly decrease. Accordingly, the auger cover  130  acts a flow regulating device and the cover  130  removes the variable downward pressure on the auger from the product. Thus, the side or lateral entry of the inoculant product into contact with the auger helps to ensure repeatability in terms of the rate at which inoculant product is dispensed by the auger. The auger is secured at each end of the container by bearings (not shown) mounted to the exterior sides of the opposing sidewalls. 
     During operation, the auger rotates at a selected speed by a speed controlled motor (not shown). The motor speed is controlled by a controller as discussed below. The control system of the present invention allows an operator to adjust the motor speed manually or automatically to dispense a desired amount of the inoculants. The v-shape of the container facilitates even and steady flow of the inoculant product into contact with the auger. 
     Referring to  FIG. 7 , an example baling machine  140  is illustrated with the applicator assembly  100  mounted to the towing tongue  141  of the baling machine  140 . The particular baling machine illustrated in  FIG. 7  is, for example, a Hesston® Baler, which is a large rectangular baling device that may be towed by a tractor. Although a particular type of baling machine is illustrated in  FIG. 7 , it shall be understood that the applicator assembly of the present invention is adaptable for mounting to any type of baling machine in which the conveying line  118  can be extended or shortened to enable the inoculant product to be applied to the incoming forage material located at the throat or intake opening of the baling machine. 
     With the example baling machine of  FIG. 7 , an uptake area generally represented by  142  is a location at which the forage material is received. The uptake assembly  142  is supported at each end by support wheels  144 . A pick-up reel  146  including a plurality of rotating pick-up teeth  148  transfer the windrow of forage material (not shown) into the machine. A cover  150  is disposed over the pick-up reel to channel the forage material into the machine. 
     Referring to  FIG. 8 , a greatly enlarged perspective view is provided of the intake opening or throat in which the forage material is received for subsequent passage to the baling chamber (not shown). Initially, the forage material is lifted from the ground by the upward motion of the rotating pick-up teeth  148 . After the forage material is received between the cover  150  and the pick-up reel  146 , the forage material continues in a downward motion by the force of the rotating pick-up teeth  148  and the opposing feed teeth  154  that also rotate in a downward fashion. The teeth  154  protrude through slots  157  of the feed manifold  156 . The feed teeth  154  continually traverse through the slots  157  in the downward motion to convey the forage material to a loading duct that rises upward to the entry of the baling chamber. The loading duct acts as a final conveying means for transport of the forage material into the baling chamber. 
     Also referring to  FIG. 9 , the throat or intake opening is shown by the bracket  152  and defines the confined area in which the forage material travels just prior to being conveyed to the baling chamber by the loading duct (not shown). A plurality of intake augers  158  are disposed on lateral sides of the intake area, and the side augers  158  are rotated to cause the forage material to converge within the intake area  152 . There may be one or more augers disposed on each lateral side of the intake opening  152 . The inoculant product is delivered by the conveying line  118  to the space defining the intake opening  152 . As shown, the conveying line  118  includes an outlet  119 , and the inoculant product (not shown) exits the outlet  119  for direct application onto the forage material. The outlet  119  may be configured in various ways to best disperse the inoculant product across the width of the intake opening  152 . For example, various shaped and sized nozzles (not shown) may be secured to the outlet  119  for even distribution of the inoculant product across the intake opening  152 . 
     The lateral plate  160  which abuts the manifold  156  provides a convenient location for mounting of the contact type sensors that are used to sense the moisture content of the forage material as it enters the intake opening  152 . The non contact type sensors can be mounted in the intake opening above the plate  160  and above a normal height of the forage material passing through the intake opening. 
     Now referring to  FIG. 10 , a schematic diagram is provided of the system of the present invention. As shown, the intake area  142  includes the pick-up reel  146  and plurality of pick-up teeth  148  that convey the forage material towards the feed teeth  154  protruding through the manifold  156 . In this small gap or space between the feed manifold  156  and the pick-up reel  146 , various types of sensors may be mounted for measuring the moisture content of the forage material as discussed below. The forage material is conveyed by loading duct  161  into the baling chamber  163 . The plunger  165  moves in a reciprocating fashion to compact the forge material in the baling chamber  165 . The inoculant container  102  holds a quantity of inoculants to be dispensed by the dispensing auger. Conveying line  118  conveys the inoculants to the specified location where the forage material is exposed so the inoculants can be evenly distributed. The inoculants are applied prior to the forage material being conveyed to the baling chamber. The amount of inoculants applied is determined by a controller  200 . The moisture content of the forage material is measured by one or more sensor assemblies  170  and  178 . The location(s) at which measurements are taken of moisture can be referred to as measurement point(s). A humidity sensor  210  also supplies inputs to the controller where the controller adjusts the amount of inoculants applied by speeding up or slowing down the motor that drives the auger. The controller is responsive to the inputs to provide an adjusted auger rotational speed within a very short time span. Thus, the inoculants are applied in varied amounts to account for forage material that may have significant moisture content differences over short windrow distances. 
     Also referring to  FIG. 10A , one type of sensor that can be used includes a contact type sensor assembly  170 . For the contact type sensor assembly  170 , the assembly may include a mounting surface  172 , supports  174 , and conducting sensors  176  mounted on the mounting surface  172 . The supports  174  in this figure may also represent load cells that can provide signals to a remote display or controller (not shown) for indicating the weight of the incoming forage material. The supports  174  may be mounted on the plate  160 . Contact type sensors may include conductive strips that provide a variable voltage signal back to a controller of the control system based upon the conductivity measured by the presence of moisture within the forage material. Other examples of contact sensors may include probes that protrude into the path of the forage material, and contact of the probes against the forage material can effectively measure moisture content. 
     In addition to or in lieu of the contact sensor assembly  170 , a non-contact type sensor assembly  178  may be used as shown in  FIG. 10B  to measure moisture. The non-contact type sensors may include ultrasound sensors that measure distance or infrared sensors  182  that measure moisture content. The volume of the forage material can be calculated as a function of the clear distance measured by the ultrasound sensor. With respect to the non-contact type sensors as shown in  FIG. 10B , sensing beams  184  have direct lines of sight with respect to the incoming forage material that passes below. 
     In accordance with the method and system of the present invention, manual or automatic control of the dispensing operation can be achieved. As previously mentioned, the application rate of the inoculant onto the forage material is determined by calculations including the forage feed rate into the baling machine (such as pounds per second), the moisture content of the forage material, and the relative humidity. When using an automated control system of the present invention, one or more of the values can be input into a controller and used to calculate the optimal dispensing rate for the inoculant product. 
     The feed rate of the forage material into the baling machine can be manually or automatically determined by the control system. Manual entry of feed rate values or automatic measure rates can be entered into the control system for calculation of the dispensing rate of the inoculant product. Automatic feed rate data can be measured by the control system using bale weight and cycle time. The bale weight can be input into the control system at the end of the baling cycle in which a single bale of hay has been produced. Each bale cycle can also be measured in terms of time to determine the cycle rate for each bale of hay. The feed rate would then be calculated in pounds per second. Another method for determining the desired dispense rate is to use the moisture content of the forage material and volumetric measurement of material passing through the intake area to calculate the intake in pounds per second. Volumetric measurement can be accomplished by the non-contact type sensors mounted at the intake opening over a reference plate in the bottom of the intake area, such as the plate  160  mentioned previously. As forage material passes through the intake, the actual volume of the forage material can be calculated in this manner. The moisture content of the forage material as measured at the intake opening is used to calculate pounds per second feed rate. 
     The inoculant application rate is adjusted for the moisture content of the forage material. The application rate is increased as the moisture content of the forage material increases. The moisture of the forage material is continuously measured at the intake opening of the baling machine prior to application of the inoculant and baling of the forage material. Moisture measurement of the forage material can be achieved using multiple means, to include the contact and non-contact sensors as described above. Examples of specific sensing methods include TDR technology (Time Domain Reflectometry) that measures a dielectric constant (the water content) of the material; NIR (Near Infrared) technology; and capacitive sensor technology. Further for example, the control system of the present invention may use moisture sensing devices with so various analog or digital outputs that best match the type of controller used. With NIR technology, the sensors are non-contact and would be positioned at the intake opening of the baling machine, as discussed above with respect to the non-contact sensor assembly  178 . Other devices, such as TDR and capacitive technologies, require contact of the material and the sensors are therefore can be mounted on the plate  160  in the same manner as the contact sensor assembly  170 . As noted above with respect to  FIG. 10A , the contact sensors may simply be mounted on a mounting plate  160  and placed in direct contact with the incoming forage material. 
     Relative humidity is one factor that should be taken into consideration for precise application of the inoculant products. The application of the inoculant product is increased as the relative humidity increases. Of course, the forage material moisture values typically increase with humidity as well. One example of industry standard moisture corrections for humidity levels is provided in the table below. 
     
       
         
           
               
               
               
             
               
                   
                   
               
               
                   
                 Relative Humidity 
                 Increase in Moisture Value 
               
               
                   
                   
               
             
            
               
                   
                 60% 
                 2.5% 
               
               
                   
                 70% 
                 3.3% 
               
               
                   
                 75% 
                 4.0% 
               
               
                   
                 80% 
                 5.0% 
               
               
                   
                 85% 
                 6.6% 
               
               
                   
                 90% 
                 10.0%  
               
               
                   
                   
               
            
           
         
       
     
     The control system of the present invention continuously measures humidity and moisture content, and calculates corrections for these parameters to determine the correct amount of inoculant product to be administered. The control system of the present invention is also capable of collecting data for production records and analysis. The particular data that can be collected with the present invention includes: 1) total tons of treated and baled forage material produced; 2) total bales produced; 3) tons per hour; 4) average moisture content of the forage material for each bale; 5) inoculant used per ton; 6) total inoculant used; 7) applicator run time; 8) total baling/chopping hours; 9) forage temperature; 10) ambient temperature; and 11) production session hours. The data collected can be saved to removable storage devices accessible on the control system hardware. Production records can than be transferred to other computer systems as desired. The data collection and transfer can be achieved using wired or wireless communication networks to include the incorporation of intranet networks between designated organizations or the use of the Internet. 
     As further described below, the control system of the present invention comprises a programmable control device such as a work station computer or a programmable logic controller (PLC) with a HMI, such as a touch screen, or a conventional user display with an input device such as a keyboard. The operator uses the HMI to operate the inoculant dispensing system. The HMI may comprise various user operator screens in order to control the dispensing system as also discussed below, to include the provision of various operational modes such as an automatic control mode, a manual control mode, a semi-automatic control mode, and status screens that show various system parameters in real time. These different operator screens can be accessed from push buttons on the front of the HMI panel or from traditional selection menus in software incorporated in the control system. The blower and auger can also be activated from various screen locations. The blower is optional for each process, as previously noted since gravity flow in some circumstances may be adequate for dispensing the inoculant material. 
     Activation of the auger commences the dispensing process. Data is collected throughout a production session and may be stored until the controller is reset, or the operator otherwise decides to transfer the data. Typically, the storage device is replaced or cleared between production sessions. A reset function can be provided to clear all production records in the controller. 
     The HMI also includes a setup screen for entering calibration information. Calibration factors for various parameters to include moisture, humidity, and the machine feed rate can be set in this screen. 
     In the event the control system in the present invention is used with a baling machine that is not equipped with any sensing devices, then the manual mode is best for operation in which the forage feed rate, moisture, and humidity can be entered from this mode. 
     Automatic operation results in control of the application of the inoculant using real time measured inputs of the feed rate (pounds per second), percent moisture in the forage material, and the ambient humidity. The application rate is continually calculated and adjusted to accurately apply inoculant to the forage material. Dispensing of inoculant only occurs when forage material enters the baler intake area. When the control system senses forage material entering the baler intake, than the inoculant dispensing will be activated. As discussed below, moisture content, application rate, and bales per hour is monitored and displayed on one or more of the user screens. 
     The semi-automatic operation mode monitors moisture content, application rate, and bales per hour. The application rate of the inoculant can also be manually set by the operator. As with the automatic control mode, moisture content, application rate, and bales per hour are monitored and displayed on one or more user screens. 
     In the manual operation mode, this requires operator input for the measured moisture content, application rate, and bales per hour. Dispensing of the inoculant in this manual mode only begins when the operator activates the machine auger. Dispensing continues until the operator deactivates the machines auger. The manually entered values for moisture content, application rate, and bales per hour are displayed on the screen. Additionally, depending upon the presence of particular sensors, one or more of the other parameters may be shown, such as the actual measured moisture content, the measured dispensing rate, and the measured ambient humidity. 
     One or more status screens can display information that summarizes a production session such as the number of bales produced, the amount/rate of inoculant product used, the time period in which the session took place, etc. 
     Data can be collected for baled forage material specific to each bale produced. For example, during the baling process, each individual bale can be tagged with a marker containing a bar code, and the bar code contains information corresponding to the amount/rate of the inoculant added to the particular bale, the measured moisture and humidity at the time the bale was produced, etc. The tag can be printed by a printing device that is mounted adjacent to the output of the baling device such that the tag can be automatically attached to the bale as it exits the baling machine. As necessary, a bar code reader can than be used to identify attributes of the bale as it was processed in the baling machine. Additional information can also be gathered using the bar code reference from the data collected by the control system. 
     Referring to  FIG. 11 , an exemplary controller  200  is illustrated in accordance with one preferred embodiment of the present invention. As previously mentioned, the control system of the present invention may be embodied in various forms to include a standalone work station computer, a programmable logic controller, or even a remote HMI interface that communicates with a central processing unit. The embodiment illustrated in  FIG. 200  can be considered any of these possibilities and is illustrated in  FIG. 11  in very general form. The controller  200  as shown includes a housing  202 , and a visual operator interface including a touch screen area  204 . Alternatively, the area  204  can represent a digital display in which the operator controls the system by manual operating controls incorporated on the housing. For example, one or more operating controls may be mounted on the housing, such as an auger and blower switch  206 , and an auger speed control  208 . For the auger and blower switch  206 , the operator may manually turn the auger on, or simultaneously turn the blower and auger on. The manual speed control  208  allows the operator to adjust the rotational speed of the auger which in turn, affects the dispensing rate of the inoculant product. 
       FIG. 11A  illustrates a side view of an electrical junction box  201  in which various ports may be provided for interconnecting system inputs and outputs to the controller. For example, analog cable port  203  is provided for analog inputs such as the moisture sensor or other hardware that provides inputs to the controller  200 . Digital cable port  205  is provided for digital inputs from system hardware, which could also include moisture level sensors that generate a digital signal. Referring to  FIG. 11B , a bottom view of the housing  202  is provided in which various output ports are provided for sending signals to various output devices to include, for example, the blower motor and the auger motor. Other output ports  212  may be provided for controlling other outputs of the control system.  FIG. 11B  also illustrates a humidity sensor  210  which provides inputs to the controller to measure the relative humidity. As discussed, relative humidity is one of the parameters which is monitored to determine the optimal inoculant dispense rate. The humidity sensor  210  is conveniently mounted to the junction box; however, it shall be understood that the humidity sensor can also be located at other locations, such as on or adjacent to the container. Use of the junction box may provide a convenient solution for consolidating input/output lines however it shall be understood that the junction box is optional and other arrangement can be used for organizing input/output lines. 
       FIG. 12  illustrates a user interface screen, such as one which may be illustrated on the touch screen area  204 . It shall be understood that the touch screen area  204  can also be incorporated in a stand alone screen display in which all system controls are manipulated through the touch screen or through other input devices such as a keyboard and mouse. The particular user screen illustrated in  FIG. 12  illustrates the manual operation mode  214 . In this screen, the operator has the option of adjusting the dispense rate  216  of the auger, this rate being shown in pounds of inoculant per ton of forage material. The operator also has the option of adjusting the dispense rate of the auger by increasing or decreasing the voltage supplied to the auger motor which in turn changes the speed of the motor which drives the auger. For example, up button  218  if selected would increase the voltage to the DC drive motor by an increment of 0.1 volts, while selecting the down button  219  would reduce the voltage by 0.1 volts. Button  220  may provide a greater increment increase or decrease in voltage, such that selection of button  220  could, for example, increase the voltage to the DC drive motor by 1 volt, while the button  221  if selected would decrease the voltage by 1 volt. The motor speed controlled by voltage is calibrated to the auger dispense feed rate in pounds per ton. The dispense rate displayed can be in pounds per ton. This screen shown in  FIG. 12  may also include other attributes such as a manual blower on/off switch  222 , and a manual auger on/off switch  224 . Thus, the operator could also control the blower and auger independently through this user screen. The moisture content of the forage material is also displayed in this user screen at  226 . This moisture content can either be that which is manually entered by the user, or which has been independently measured by a separate device. Alarm icon  234  provides the operator an alarm condition, which may provide the operator with indication of a system problem based upon a number measured events, or conditions which exceed preprogrammed dispense rates based upon input moisture and/or humidity values. For example, in the manual operation mode, if the operator enters a particular moisture content, and then manipulates the rate of dispense such that either a clearly excess or clearly inadequate amount of inoculant product is to be applied, the alarm  234  can be triggered. This alarm condition can be a visual and audible alarm, and can also include a message that may be displayed (not shown) which explains the alarm condition to the user in a dialogue box appearing on the screen. Thus, the controller  200  may also communicate with the user&#39;s e-mail or other messaging capability in order to convey an alarm condition. For example, the controller may be linked to a user&#39;s email in a traditional wired/wireless communication network, or may be linked for transmission to the user&#39;s cellular phone. 
     The user interface in  FIG. 12  also shows a system button  232 , as well as various function buttons  230 . The function buttons, labeled as F 1 , F 2 , F 3 , and F 4 , may correspond to other user screens selected by the user, such as the other displays discussed below to include the automatic operation mode, the semi-automatic operation mode, and the status screens. The system button  232  if selected can provide another user screen (not shown) which lists various system parameters to include installed hardware in the control system, various data parameters, algorithms used to set dispense rates, etc. 
       FIG. 13  illustrates another user interface screen, and more specifically, an automatic operation mode  240 . In this automatic operation mode, the moisture content  226  displayed is the actual moisture content as calculated by the control system in conjunction with one or more of the sensors located at the intake opening  152  where the forage material passes. The application rate  216  is the real time application rate as measured by the current speed of the auger motor. The bales/hour display  242  is the actual number of bales produced per hour as the baling machine operates. The application rate is continually adjusted based upon the particular auger rate algorithms programmed used, that are based upon the moisture content, relative humidity, and intake rate of the forage material. In this automatic operation mode screen, the user still has the capability to turn on and off the blower and auger as shown. However, if the operator chooses to turn off the auger, this can result in a temporary delay of the information displayed since the controller will sense the stoppage of the auger and will therefore also cease dispensing of the inoculant product. 
       FIG. 14  illustrates the semi-automatic operation mode  250  in which the operator may adjust the dispense rate of the auger, or return to the automatic mode by selecting button  252 . In this semi-automatic operation mode  250 , the moisture content of the forage material is also displayed at  226 . The operator also has the option of turning on or off the blower and auger. 
       FIG. 15  illustrates an example status screen  260  in which various counters can be provided to the user. As shown in this figure, display  270  provides the total pounds of inoculant product used in the current dispensing operation in tons, display  272  provides the total baled forage material created during the job, and display  274  provides the total number of bales made during the baling session/job. This status screen  260  also provides other functionality to include an EOJ (End of Job) button  262  which allows the operator to signify the end of the job, in which the counters  270 ,  272 , and  274  are reset. The status screen  260  also provides a calibration button  264  which leads the operator to another screen for calibration of the system, as discussed further below with respect to  FIGS. 17 and 18 . The alarms button  266  if selected provides a listing of alarms available for monitoring the system, as well as capability for the user to add additional alarm conditions as desired. The user has the ability to select and edit various alarm conditions. Button  268  if selected allows the operator to view another status screen for other measured system parameters, as discussed with respect to  FIG. 16 . 
     Referring to  FIG. 16 , an additional status screen  276  provided in which other parameters are measured/counted. For example, display  277  provides an indication of the number of tons of forage material produced per hour, display  278  provides the present relative humidity conditions, and display  279  provides a display of the present temperature. Button  284  if selected allows the operator to return back to the pervious status screen. 
     The speed of the vehicle can be sensed by proximity sensors (not shown) mounted near one of the wheels of the vehicle. Referring to  FIG. 17 , a calibration screen  280  is provided which allows an operator to conduct a calibration of the speed sensor. As shown, instructions on the screen instruct the operator to drive the baling machine at a particular speed, and then to press the calibration button  282  which at that time measures the sensor input to the controller as related to the speed indicated on the calibration screen. This value will be used to calculate forage material pounds per foot as entered in user screen  290 . 
       FIG. 18  shows another calibration related user screen  290  in which the user can set the amount of forage entering the baler/chopping machine in pounds per foot of travel distance in the display  292 . From this entered value in display  292 , the system uses this value to calculate the dispensing rate of the inoculant as related to the speed traveled. 
     Referring to  FIG. 19 , another schematic diagram is provided illustrating the system of the present invention with respect to an alternate method in which to sense moisture and to deliver optimal amounts of inoculants. In  FIG. 19 , instead of measuring the moisture content just forward or upstream of the feed manifold  156 , the moisture is sensed within the most upstream or forward portion of the loading duct  161 . Referring also to  FIG. 20 , the moisture is measured by a plurality of sensors  300  that may be dispersed or spaced across the duct  161  in order to sense or measure moisture across a greater surface area of the forage material passing through the duct. As shown, there are two sets of moisture sensors  300 , one set located on the lower area of the duct, and another set located on the upper area of the duct. Conveniently, the sensors  300  may be mounted upon a mounting plate or base  302  that is secured to the duct walls. As the forage material passes through the duct on its way to the baling chamber  163 , multiple measurements are taken. Preferably, moisture measurements are taken by the sensors at least once per flake of forage material making up a bale. As previously mentioned, there may be approximately 28 to 32 flakes per bale. Therefore, there would at least 28-32 moisture measurements taken for each bale. 
     Optionally, the base plate  302  may be mounted on load cells  304 , and as the forage material passes through the duct  161 , pressure will be applied against the plate and transferred to the load cells. From the data captured by the load cells, an approximate moving mass average may be calculated to determine the mass and density of forage material making up each bale. In the event the forage material appreciably, varies in density across flakes making up a bale, this variation in density can be accounted for by the load cells in order to increase or decrease the amounts of inoculants applied. Therefore; in addition to adjusting inoculants applied by the moisture sensors  300 , real time inputs can be provided to the controller with respect to mass/density of the forage material passing through the duct. More particularly, for less dense/lighter forage material, it may be appropriate to apply a lesser amount of inoculants, while more dense/heavier forage material, it may be appropriate to apply greater amounts of inoculants. 
     Once the data is received by the controller  200 , an algorithm is applied to the data inputs in order to generate an output signal to control the metering or dispense element such as the dispense auger that meters the inoculants onto the moving mass of forage material. As shown in  FIG. 19 , the schematic shows a simple gravity feed of the inoculants through the conveying line  118 . However, it is also contemplated that a blower (not shown) can be used to more quickly evacuate the conveying line to ensure the forage material is timely applied to the flake of forage material previously measured. In general, it is desirable to have the capability to quickly and accurately modulate the dispense element and to quickly deliver the inoculant material onto the forage material since the forage material is moving. A delay in applying the inoculants results in inaccurate amounts of inoculate applied. Minimizing the length of the conveying line and placing the outlet of the conveying line as close to the measurement location as possible are also methods that may increase accuracy of applied inoculants. In the schematic of  FIG. 19 , the outlet of the conveying line  118  is shown in the gap between the upstream side of the manifold  156  and the entrance to the duct  161 . This location is close to the sensors  300  and therefore helps to ensure accurate delivery of the inoculants. 
     As mentioned, one algorithm or formula for calculating the weighted moving average of the moisture reading value can be expressed by (x)(2/n+1), where x is the amount of moisture content above a predetermined maximum threshold percentage and n is the number of sample sets taken in the moving average. For example, consider a group of ten moisture reading values measured over a period of time. The most recent moisture reading value has the greatest effect on the sum of the moisture values. The sum of the ten averages at a specific time is compared to a table/database that correlates the applicable average to an optimal amount of inoculants to be applied. Depending upon the value of the sum of the previous calculations, the controller may generate an output to adjust the dispense element/auger. For example, if the new sum is greater than the previous sum, then this change would result in the controller generating a signal to increase the rate of rotation of the auger an incremental amount to dispense a greater amount of inoculants. Similarly, if the new sum is less than the prior calculated sum, then the control signal would slow the speed of rotation of the auger to reduce the amount of inoculants dispensed. Each group of calculations can be analyzed over a set frequency in order to provide output control signals from the controller for adjusting the dispense element. According to this weighted moving average analysis, fine control can be achieved with respect to metering of inoculants applied to the forage material. 
     As also set forth above, another calculation or algorithm could simply include analysis of the highest moisture sensor reading per point measurement, and then evaluating these moisture readings over a period of time in order to adjust application of inoculants. 
     In the weighted moving average algorithm, each of the sensors provides data to the controller, and each of these sensors can be accounted for in the algorithm. For example, the value x may comprise the average of the sum of each moisture reading from each sensor. Thus, x may equal the average of x 1 +x 2 +x 3 +x 4 +x 5 +x 6 +x 7 +x 8 , in which each of these numbered values corresponds to a particular sensor reading. As set forth in the previous embodiment, a humidity sensor  210  is also used in determining amounts of inoculants to be applied. In the algorithm, the relative humidity can also be a variable. The amount of forage material passing through the duct at the time the moisture measurements are taken can also be assigned as a variable. Therefore, in an expanded algorithm taking into account the relative humidity and the mass of the forage material, the algorithm could be expressed by (z)(y)(x)(2/n+1), where z is the mass of the forage material, y is the relative humidity, x is the amount of moisture content above the threshold level, and n is the number of sample sets taken in the moving average. 
     A system and method are provided for accurately dispensing a desired quantity of inoculant product based upon real time data that regulates the amount of inoculants dispensed. The real time measurement of forage material moisture content enables the system to control the dispense rate in fine increments to account of varying moisture contents in the forage material that may occur over short distances as the baling machine travels. The control system of the present invention provides a number of user options for manual, automatic, and semi-automatic control based upon the type of baling machine to which the system is mounted. The automatic mode requires less operator effort, and assuming the baling machine is equipped with the proper sensors, the dispense rate of the inoculant product is automatically controlled without the necessity of operator intervention. However, the system controller of the present invention is flexible enough to allow manual intervention in the event the operator decides to override preset parameters for dispensing. The contact and non-contact type sensors retrofitted to the intake opening of the baling machine provide effective capabilities in measuring moisture content. The inoculant container may be easily mounted to the baling machine, and the robust construction of the dispense auger insures that a consistent dispense takes place.