Patent Publication Number: US-2010124481-A1

Title: Apparatus and method for handling modules of material

Description:
RELATED APPLICATION  
     This application claims the benefit of priority under 35 U.S.C. §119(e) of U.S. Provisional Application No. 61/114,581, filed Nov. 14, 2008, the disclosure of which is incorporated herein by reference. 
    
    
     FIELD OF THE DISCLOSURE  
     The present disclosure relates to an apparatus and method for handling modules of material. In particular, the present disclosure relates to an apparatus and method for handling modules of material, such as wrapped modules of cotton, for being supplied to a machine for processing the material. 
     BACKGROUND  
     Modules of material may include, for example, material harvested from agricultural crops, such as, for example, straw, hay, and cotton. Such modules of material may take the general form of a cylinder, which are sometimes referred to as “round bales” or “round modules.” For example, harvesting machines may cut or harvest straw, hay, or cotton from crops of the corresponding plants and roll the harvested material into a generally cylindrical module form. The material may also be at least partially wrapped (e.g., on the side but not the ends of the cylinder) with a protective covering in order to hold the module together and/or protect the material constituting the module. 
     Some modules of material may be large enough to prevent manual handling, such that handling is facilitated with the assistance of one or more machines. Thus, such modules may be difficult to manipulate for transportation and/or further processing. For example, some modules may have a height or length dimension defined between circular ends of the module ranging from about 6 feet to about 10 feet (e.g., about 8 feet) and a side extending between the two ends and defined by a diameter dimension ranging from about 6.5 feet to about 8.5 feet (e.g., about 7.5 feet). Such modules of material may weigh from about 4,000 lbs. to about 6,000 lbs. (e.g., about 5,000 lbs.), depending on, for example, the density of the material constituting the module. 
     Further, some materials may receive further processing. For example, cotton may be harvested by machines sometimes referred to as “cotton pickers.” Such machines may remove the raw cotton from the cotton plants and form the raw cotton into modules. For example, some modules my generally take the form of large cylinders. Further, some cotton pickers wrap the module in a plastic or protective wrapping, and deposit the module on its side in the field in which the cotton is being harvested. As outlined above, such modules may be large and heavy, and thus, it may be desirable to use a machine, such as a material handler, to transport the modules to a location for processing. For example, modules of cotton may be processed by machines, such as cotton gins, that break up the modules and remove therefrom undesirable debris, such as, for example, sticks, leaves, seeds, seed pods, and/or other debris from the harvesting process. 
     Some module handlers are vehicles including a fork designed to pick up the cylindrical modules and load the modules onto a feeder bed associated with a processing machine or onto a larger vehicle for transporting the modules to a processing machine. Since some cotton pickers deposit the wrapped modules on their sides rather than on their ends, module handlers are designed to lift the module and carry them in the same orientation, in particular, on their sides rather than on their ends. Thus, when a module is loaded onto the feeder bed support structure of a processing machine, it is typically loaded onto the feeder onto its side rather than on its end. This may render it difficult to remove the wrapping from the module, which may be desirable before the module enters the material processing machine. 
     Thus, it may be desirable to provide devices and methods to facilitate the handling of modules of material (e.g., large cylindrical modules of cotton material). Further, it may be desirable to provide devices and methods to supply modules to material processing machinery. 
     SUMMARY 
     In the following description, certain aspects and embodiments will become evident. It should be understood that the aspects and embodiments, in their broadest sense, could be practiced without having one or more features of these aspects and embodiments. It should be understood that these aspects and embodiments are merely exemplary. 
     One aspect of the disclosure relates to an apparatus for handling a module of material, such as a round, wrapped module of cotton material, for being supplied to a machine for processing the material includes a support structure configured to support the module above a surface. The support structure includes a first segment, a second segment, and a hinging structure configured to operably couple the first segment and the second segment to one another, such that the first segment and the second segment can pivot with respect to one another. The apparatus also includes an actuator operably coupled to at least one of the first segment and the second segment. The actuator is configured to pivot one of the first segment and the second segment relative to another of the first segment and the second segment, and the apparatus is configured to re-orient the module. The apparatus may include a controller in communication with the actuator that causes re-orientation of the module to facilitate removal of a wrapper or protective covering of the module prior to processing of the module by one or more machines. 
     According to another aspect, a system for handling and processing a module of material includes an apparatus for handling the module of material and supplying a machine configured to process the material. The apparatus includes a support structure configured to support the module above a surface and facilitate movement of the module toward the machine. The support structure includes a first segment, a second segment, and a hinging structure configured to operably couple the first segment and the second segment to one another, such that the first segment and the second segment can pivot with respect to one another. The apparatus further includes an actuator operably coupled to at least one of the first segment and the second segment. The actuator is configured to pivot one of the first segment and the second segment relative to another of the first segment and the second segment. The apparatus is configured to re-orient the module. The system also includes a machine configured to process the material. 
     According to still a further aspect, a method for handling a module of material defining two ends and at least one side extending between the two ends, includes placing the module of material on a support structure such that the module of material is resting on the at least one side. The method further includes raising a first portion of the support structure such that the module of material is re-oriented such that the module of material is resting on one of the two ends on a second portion of the support structure. The method also includes moving the module of material toward a machine for processing the material. 
     Additional aspects and/or advantages of the disclosure will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the disclosed embodiments. 
     Aside from the structural and procedural arrangements set forth above, the embodiments could include a number of other arrangements, such as those explained hereinafter. It is to be understood that both the foregoing description and the following description are exemplary only. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings, which are incorporated in and constitute a part of this description, illustrate several exemplary embodiments and together with the description, serve to explain principles of the embodiments. In the drawings, 
         FIG. 1  is a schematic elevation view of an exemplary embodiment of an apparatus for handling material with an exemplary module in a first position and condition; 
         FIG. 2  is a schematic elevation view of the exemplary embodiment of apparatus shown in  FIG. 1  with the exemplary module in a second condition; 
         FIG. 3  is a schematic elevation view of the exemplary embodiment of apparatus shown in  FIG. 1  in a second configuration; 
         FIG. 4  is a schematic elevation view of the exemplary embodiment of apparatus shown in  FIG. 1  with the exemplary module in a second position; and 
         FIG. 5  is a schematic elevation view of the exemplary embodiment of apparatus shown in  FIG. 1  with the exemplary module entering an exemplary material processing machine. 
     
    
    
     DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     Reference will now be made in detail to exemplary embodiments. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts. 
     Referring to  FIG. 1 , a material, such as, for example, cotton, is formed into an exemplary module  10  defining a generally cylindrical shape defined by two opposing ends  12  and  14  having a generally circular shape, and a side  16  defined by a cylindrical surface extending between two ends  12  and  14 . Side  16  defines a length L extending between ends  12  and  14 , and ends  12  and  14  may have a diameter D defining the circular-shaped ends. For example, length L may range from about 6 feet to about 10 feet (e.g., about 8 feet), and diameter D may range from about 6.5 feet to about 8.5 feet (e.g., about 7.5 feet). Exemplary module  10  is at least partially covered with a wrapping  18 , which maintains the material constituting module  10  in a cylindrical form and/or serves to protect the material of module  10 . For example, exemplary wrapping  18  covers side  16  but does not completely cover ends  12  and  14  of exemplary module  10 . As shown in  FIG. 1 , wrapping  18  extends around an edge  19  between side  16  and ends  12  and  14 , but does not extend completely across ends  12  and  14 . Rather, wrapping  18  may extend, for example, only about several inches from edge  19  toward a center of sides  12  and  14 . Exemplar wrapping  18  may include plastic and/or other materials that serve to maintain module  10  in cylindrical form and/or protect the material constituting module  10 . 
     Such exemplary modules of material may, depending on the type of material constituting module  10 , weigh from about 4,000 lbs. to about 6,000 lbs. (e.g., about 5,000 lbs.), for example, if module  10  comprises (e.g., harvested cotton). Such a module  10  may be the supplied by, for example, a cotton picker (not shown) (or a cotton stripper equipped with a round baler (not shown)) designed to pick cotton from cotton plants, roll the picked cotton into a cylindrical form, and cover at least a portion of the cylindrical form of cotton (e.g., the cylindrical side but not the opposing ends) with a wrapping of plastic and/or other material, which maintains the cotton in a generally cylindrical form and/or protects the cotton. Although exemplary module  10  is a cylindrical-shaped module of cotton having the exemplary dimensions outlined above, modules of other shapes and sizes, modules not covered with wrapping, and/or modules containing other materials, are contemplated. 
     As shown in  FIG. 1 , exemplary module  10  may be loaded onto an exemplary apparatus  20  for handling modules of material and/or for facilitating the supply of modules  10  to a material processing machine, such as exemplary processing machine  100 . Apparatus  20  may be supported on a surface  22 , such as the floor of a material processing facility. Exemplary processing machine  100  may be, for example, a module feeder or cotton gin for breaking up modules  10  of cotton and/or for removing therefrom undesirable debris, such as, for example, sticks, leaves, seeds, seed pods, and/or other debris in the cotton resulting from the cotton harvesting process. For example, exemplary processing machine  100  may be a machine at least similar to machines disclosed in U.S. Pat. No. 6,038,741, U.S. Pat. No. 6,557,213, and U.S. Pat. No. 6,786,438, the disclosures of which are incorporated herein by reference. 
     As shown, exemplary apparatus  20  includes a support structure  24  for supporting module  10  and facilitating conveyance of module  10  from a first end  26  of apparatus  20  to a second end  28  of apparatus  20  adjacent material processing machine  100 . Support structure  24  may include two rows of a plurality of substantially upstanding supports  30  (e.g., vertical supports) extending between surface  22  and corresponding rows of one or more cross members  32 . ( FIGS. 1-5  show elevation views of exemplary apparatus  20 , and thus, only a single row of upstanding supports  30  and a corresponding single row of cross members  32  is shown in the figures.) Exemplary support structure  24  may include braces  34  extending obliquely between upstanding supports  30  and cross member(s)  32 , thereby providing additional support and/or rigidity to apparatus  20 . Support structure  24  may be formed of metal, such as, for example, one or more of steel and aluminum, and/or any other materials having sufficient strength and other characteristics for performing the exemplary functions described herein. 
     As shown in the figures, exemplary apparatus  20  includes a plurality of rollers  36  extending between the two rows of cross members  32 . Rollers  36  are configured to rotate, for example, as module  10  moves from first end  26  of apparatus  20  to second end  28  of apparatus  20 , to facilitate movement of module  10  into exemplary processing machine  100 . According to some embodiments, one or more of rollers  36  may be motorized to force module  10  to move along support structure  24 . It is contemplated that other structures known to those skilled in the art that serve the function of rollers  36  may be used, such as, for example, one or more belts (e.g., motorized belts). 
     According to the exemplary embodiment shown in the figures, support structure  24  includes three segments  38   a,    38   b,  and  38   c.  Segment  38   a  is hingedly coupled to segment  38   b  via a hinging structure  40 . Hinging structure  40  may be any known type of hinge that permits relative pivoting between segment  38   a  and segment  38   b  (see  FIG. 3 ). Although the exemplary embodiment shown in  FIGS. 1-5  includes segment  38   a  positioned behind and aligned with segment  38   b  and/or segment  38   c,  it is contemplated that segment  38   a  may be positioned next to segment  38   b  and/or segment  38   c,  for example, with hinging structure  40  extending along cross members  32  between segment  38   a  and segment  38   b  and/or segment  38   c,  such that segment  38   a  is configured to tilt-up about its cross member  32  via hinging structure  40 . 
     Exemplary apparatus  20  further includes at least one actuator  42  (e.g., two actuators, one associated with each row of cross member(s)  32 ) configured to pivot segment  38   a  relative to segment  38   b,  such that first end  26  raises up relative to hinging structure  40 . For example, actuator(s)  42  may include one or more air cylinders, hydraulic cylinders, and/or hoists (not shown). Other actuators(s) known to those skilled in the art for pivoting segment  38   a  are also contemplated. Further, it is contemplated that actuator(s)  42  may be located in different positions relative to segment  38   a  and/or hinging structure  40 , for example, to provide a mechanical advantage or packaging that takes into account space availability or other considerations. For example, one end of actuator  42  may be operably coupled to upstanding support  30  of segment  38   b  rather than surface  22 , and/or another end of actuator  42  may be operably coupled to one of braces  34  rather than cross member  32  of segment  38   a.    
     Some embodiments may include a controller (not shown) in communication with actuator  42 . The controller may be configured to cause actuator  42  to re-orient module  10  to facilitate removal wrapping  18  from module  10 . For example, the controller may include an interface for manipulation by an operator. For example, the interface may include one or more of an operator panel associated with apparatus  20  and/or processing machine  100 , a hand-held remote control device, and a central control device or panel associated with a facility in which exemplary apparatus  20  and processing machine  100  are located. 
     Referring to  FIGS. 1-5 , during exemplary use of apparatus  20 , a module of material, such as exemplary module  10 , is placed on apparatus  20 . Such a module may be, for example, a cylindrical-shaped module of cotton formed via a cotton picker (not shown) and placed on apparatus  20  via a material handier (not shown), such that module  10  rests on its side  16  (see  FIG. 1 ) on first end  26  of apparatus  20 . Exemplary module  10  includes a wrapping  18 , and, as shown in  FIG. 2 , wrapping  18  may be sliced manually (e.g., via a knife) or via an automated cutter (not shown). For example, by virtue of module  10  being oriented on its side  16  rather than on one of ends  12  or  14 , wrapper  18  may be more easily sliced manually via a knife. 
     Referring to  FIG. 3 , exemplary actuator(s)  42  may be extended, such that segment  38   a  pivots relative to segment  38   b.  For example, actuator(s)  42  and/or segment  38   a  may be configured in response to inputs or signals from a controller to pivot through an angle a ranging from about 45 degrees to about 90 degrees (e.g., 70 degrees), or an amount sufficient to result in re-orienting module  10 , such that it rests on end  14  on, for example, segment  38   b,  rather than on its side  16  (see also  FIG. 4 ). 
     Referring to  FIG. 4 , after module  10  has been re-oriented to rest on end  14 , segment  38   a  may be lowered to the position shown in  FIGS. 1 and 2 . Module  10 , now resting on segment  38   b  and/or segment  38   c,  is in a position to facilitate removal of wrapping  18 . As outlined previously herein, exemplary wrapping  18 , although extending from side  16  and around the edges of ends  12  and  14 , does not completely cover ends  12  and/or  14 . Thus, exemplary wrapping  18 , already sliced, may be pulled off of module  10 , since module  10  is not resting on a significant portion of wrapping  18 . As shown in  FIG. 5 , module  10 , with its wrapping  18  removed, is ready to be moved to second end  28  of apparatus  20  and into exemplary material processing machine  100  when appropriate for processing. 
     According to some embodiments, one or more of the above-referenced exemplary processes may be at least partially automated. For example, apparatus  20  may be provided with a number of sensors to detect the presence of a module at various locations along the length of apparatus  20 . For example, a sensor may be provided to detect the presence of module  10  on segment  38   a.  Upon such detection, an automated cutter may be activated to slice wrapping  18 . Upon termination of automated cutter&#39;s activation, a solenoid may be activated, thereby extending actuator(s)  42 , such that segment  38   a  is pivoted relative to segment  38   b.  A sensor associated with segment  38   b  may be provided to detect the presence of module  10 , thereby activating a device for removing wrapping  18 . Upon termination of activation of the device, module  10  may be moved into position to enter material processing machine  100  via, for example, a motor-driven belt. 
     At least some portions of exemplary embodiments of the systems outlined above may used in association with portions of other exemplary embodiments. Moreover, at least some of the exemplary embodiments disclosed herein may be used independently from one another and/or in combination with one another and may have applications not disclosed herein. 
     It will be apparent to those skilled in the art that various modifications and variations can be made to the structures and methodologies described herein. Thus, it should be understood that the invention is not limited to the subject matter discussed in the description. Rather, the present invention is intended to cover modifications and variations.