Patent Publication Number: US-2012045310-A1

Title: Bale Destacker

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to industrial equipment. More particularly the present invention relates to a method and apparatus for efficiently unstacking square bales from a stack and conveying said square bales in small sets or individually. 
     2. Background Art 
     Biomass as a fuel source is gaining interest and use in the United States and elsewhere. Some biomass products, such as switchgrass, can be baled in the same manner as livestock forage to increase its energy density, reduce its volume, and make storage and handling more efficient. 
     One consideration in the utilization of biomass as a source of energy is its net energy available. The raising, harvesting, and transport of biomass products all require energy input. It is counterproductive to expend more purchased energy (especially from fossil fuels) than can be extracted from the biomass. 
     Biomass bales typically arrive at a power plant site via flatbed semi trailer. The bales are unloaded from the trailer, but they must still be transported to the boiler where they are to be burned. 
     For transporting bales of forage material (used for animal feed) a relatively short distance, the bales are often speared with any one of a variety of bale spears available for use with agricultural tractors, pickup trucks and even draft animals. Bales of biomass, however, are preferably made so dense as to resist spearing. Additionally, spearing is likely to break the twine binding the bale together. 
     Another method used for transporting bales for animal feed in small lots for relatively short distances is the use of a frame, usually mounted on a loader on an agricultural tractor. Pivotally attached to the frame is a plurality of claws. The frame is set on a layer of bales, usually small square bales, and the claws rotated into the bales, hence capturing the layer of bales to the frame. The frame and bales may then be lifted and transported using the loader, and deposited in an orderly fashion at their destination. 
     Still another way used to transport forage bales is by agricultural elevator. Such elevators comprise a frame and at least one web chain with paddles or fins that provide sufficient friction to cause a bale to move with the web chain. Elevators are often used to elevate bales into a hay mow or to the top of a hay stack. A very similar apparatus is used to convey bales along a substantially horizontal path and dump the bales to a predetermined location for stacking and storage. 
     These latter two methods have traditionally been limited to small square bales. 
     Because the above transport methods have weaknesses for the transport of biomass bales (due to their large dimensions and greater density), there is a need for a method and apparatus for quickly and efficiently transporting biomass bales at the power plant site—as well as distribution sites. There is an especial need, not addressed in forage bale technology, for a method and apparatus for disassembling biomass bales from a stack of bales. 
     SUMMARY OF THE INVENTION 
     Bales of biomass are made using common agricultural balers just as livestock forages are baled. Preferably, the resulting bales are rectangular parallelepiped in shape, to be easily and stably stackable, and to be efficiently stored in conventional rectangular parallelepiped loads and buildings. Bale size is preferably that commonly referred to as a “large square bale.” These bales typically weigh over 700 pounds and are tied with baling twine. The dimensions of the bales vary to accommodate the wishes of those involved in baling, storing, or feeding the bales. The present invention is not limited to a particular bale size. 
     Bales may be collected in the field using a bale picking truck such as the one disclosed in U.S. patent application Ser. No. 12/824,540, to Kelderman, filed Jun. 28, 2010 which application is incorporated herein by reference in its entirety. 
     For the purposes of this document, including the claims, a bale is defined as a compacted mass of material, bound together with some kind of binding material in a roughly rectangular parallelepiped shape. A stack of bales is defined as a plurality of bales assembled with at least one bale supported entirely on top of at least one other bale. The term destacking is defined as a process, the result of which is a disassembled stack such that no bale is supported entirely by any other bale. 
     An object of this invention is to provide a method and apparatus for disassembling a stack of bales with no manual labor. 
     The novel features which are believed to be characteristic of this invention, both as to its organization and method operation together with further objectives and advantages thereto, will be better understood from the following description considered in connection with accompanying drawings in which a presently preferred embodiment of the invention is illustrated by way of example. It is to be expressly understood however, that the drawings are for the purpose of illustration and description only and not intended as a definition of the limits of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a bale destacker of the present invention; 
         FIG. 2  is a top plan view of the bale destacker; 
         FIG. 3  is a side elevation view of the bale destacker; 
         FIG. 4  is an end elevation view of the bale destacker; 
         FIG. 5   a  is a first side elevation view of the bale destacker in operation; 
         FIG. 5   b  is a first perspective view of the bale destacker in operation; 
         FIG. 6   a  is a second side elevation view of the bale destacker in operation; 
         FIG. 6   b  is a second perspective view of the bale destacker in operation; 
         FIG. 7   a  is a third side elevation view of the bale destacker in operation; 
         FIG. 7   b  is a third perspective view of the bale destacker in operation; 
         FIG. 8   a  is a fourth side elevation view of the bale destacker in operation; 
         FIG. 8   b  is a fourth perspective view of the bale destacker in operation; 
         FIG. 9   a  is a fifth side elevation view of the bale destacker in operation; 
         FIG. 9   b  is a fifth perspective view of the bale destacker in operation; 
         FIG. 10   a  is a sixth side elevation view of the bale destacker in operation; 
         FIG. 10   b  is a sixth perspective view of the bale destacker in operation; 
         FIG. 11   a  is a seventh side elevation view of the bale destacker in operation; 
         FIG. 11   b  is a seventh perspective view of the bale destacker in operation; 
         FIG. 12   a  is a eighth side elevation view of the bale destacker in operation; 
         FIG. 12   b  is a eighth perspective view of the bale destacker in operation; 
         FIG. 13   a  is a ninth side elevation view of the bale destacker in operation; 
         FIG. 13   b  is a ninth perspective view of the bale destacker in operation; 
         FIG. 14   a  is a tenth side elevation view of the bale destacker in operation; 
         FIG. 14   b  is a tenth perspective view of the bale destacker in operation; 
         FIG. 15   a  is a eleventh side elevation view of the bale destacker in operation; 
         FIG. 15   b  is a eleventh perspective view of the bale destacker in operation; 
         FIG. 16   a  is a twelfth side elevation view of the bale destacker in operation; 
         FIG. 16   b  is a twelfth perspective view of the bale destacker in operation; 
         FIG. 17   a  is a thirteenth side elevation view of the bale destacker in operation; 
         FIG. 17   b  is a thirteenth perspective view of the bale destacker in operation; 
         FIG. 18  is a perspective view of a standard assembly for the destacker; 
         FIG. 19  is a perspective view of an inner sleeve of the standard assembly; 
         FIG. 20  is two side elevation views of the standard assembly; 
         FIG. 21  is a side elevation view showing squeeze arms of the destacker in a contracted mode; 
         FIG. 22  is a is a side elevation view showing squeeze arms of the destacker in an expanded mode; and 
         FIG. 23  shows both contracted and expanded modes of the squeeze arms. 
     
    
    
     BEST MODE FOR CARRYING OUT THE INVENTION 
     Referring now to the drawings wherein like reference numerals indicate identical or corresponding parts throughout the several views, the bale destacker  10  of the present invention in its preferred embodiment is illustrated in  FIGS. 1-17   b  and comprises squeeze arms  100  manipulated by a pair of squeeze arm actuators  110 , which may be stroked hydraulically, pneumatically, magnetically, electrically, etc. Each pair of squeeze arms  100  on one side of the destacker  10  is connected by a toothed cross member  120  to better grip bales  510  of biomass. The squeeze arms  100  are operatively, pivotally attached to a support beam  410 . 
     The upper assembly of the bale destacker  10  is supported by four standard assemblies  130 , details of which may be discerned in  FIGS. 18-20 . Each standard assembly  130  comprises an outer sleeve  1810 , an inner beam  1910 , and a standard actuator  1820  which may be stroked mechanically, hydraulically, pneumatically, magnetically, electrically, etc. The inner beam  1910  preferably comprises a plurality of hard plastic, or other polymer, bearings  1920  on which rides the outer sleeve  1810  as the standard actuator  1820  raises and lowers the outer sleeve  1810  relative to the inner beam  1910 , as depicted in  FIG. 20 . The inner beam is preferably rigidly attached to concrete, asphalt, or other ground surface material  1920 . 
     The bales  510  are moved within the vicinity of the bale destacker  10  by a destacker conveyor  140 , comprising a plurality of drag chains  150 , although belts, cables, or wheeled dollies may also serve the purpose. 
       FIGS. 5   a - 17   b  depict the process two stacks  500 ,  505  of individual bales  510  undergo as the stacks  500 ,  505  are destacked by the destacker  10 . In  FIGS. 5   a  and  5   b,  the stacks  500 ,  505  of bales  510  approach the destacker  10 , in these illustrations, from the left. The stacks  500  are conveyed by a conveyor system  520 ,  140 ,  530 , including a stack conveyor  520 , the destacker conveyor  140 , and a bale conveyor  530 . The extent and configuration of the conveyor system  520 ,  140 ,  530  is dependent on the nature of the destacking site—the topography, distance from the unloading dock to the boiler, etc. 
     Dimensions of the destacker  10  are such that each stack  500 ,  505  may pass between the standard assemblies  130  and under the support beam  410 . 
       FIGS. 6   a  and  6   b  illustrate a front bale stack  505  passing from the stack conveyor  520  to the destacker conveyor  140 . 
     In  FIGS. 7   a  and  7   b,  independent operation of the stack conveyor  520  and the destacker conveyor  140  is shown. Here the front bale stack  505  is separated from the rear bale stack  500  due to this independent operation. Because of the separation, the individual bales  510  between the two stacks  500 ,  505  do not contact one another, causing friction that can upset the rear stack  500  during destacking 
     Having separated the two stacks  500 ,  505 , the destacker can now begin destacking the front stack  505 . To effect this destacking, the squeeze arm actuators  110  are actuated, thus drawing the lower ends of the squeeze arms  100  inward and engaging the toothed cross members  120  to the pair of bales  510  immediately on top of the bottommost bales  710 . Then the standard actuators  1820  are actuated to raise all the bales  510  above the bottommost bales  710  as depicted in  FIGS. 8   a  and  8   b.    
     In  FIGS. 9   a  and  9   b,  the independent operation of the destacker conveyor  140  relative to the stack conveyor  520  is again illustrated. This time, the bottommost pair of bales  710  is conveyed along the destacker conveyor  140  away from the destacker  10  while the remaining bales  510  remain engaged in the destacker  10 . The rear stack  500  remains stationary on the stack conveyor  520 . At this point, the bottommost pair of bales  710  has been destacked. 
     Note that, in  FIGS. 8   a - 9   b,  the standard actuators  1820  are extended sufficiently that they may be contracted more than a height of a bale  510  as shown in  FIGS. 10   a  and  10   b.  In these figures, the bales  510  that had been engaged in the destacker  10  are lowered to the destacker conveyor  140 . There is preferably a space between the bales  510  in the destacker and the pair of bales  710  already destacked. 
     At this point, as illustrated in  FIGS. 11   a  and  11   b,  the squeeze arm actuators  110  are contracted, thus drawing the lower ends of the squeeze arms  100  outward to disengage the bales  510  that, up to now, had been engaged in the squeeze arms  100 . The standard actuators  1820  are again actuated, this time they are expanded approximately the height of a bale  510 . Once the standard actuators  1820  are expanded, the squeeze arm actuators  110  are expanded, thus drawing the lower ends of the squeeze arms  100  inward and engaging the toothed cross members  120  to the pair of bales  510  immediately on top of the new bottommost bales  510 . 
     In  FIGS. 12   a  and  12   b,  the bales  510  engaged by the toothed cross member  120  are lifted by a further expansion of the standard actuators  1820  sufficiently to clear the bottommost bales  510 , which are conveyed away from the destacker  10  in  FIGS. 13   a  and  13   b.  The previously destacked bales  710  must be conveyed in the same direction at least as far—somewhat more than a length of a bale  510 . 
     The front most bales  710  in the system are now on the bale conveyor  530 , which preferably operates independently of the destacker conveyor  140 . 
     In  FIGS. 14   a  and  14   b,  the bales  510  that had been engaged in the destacker  10  are lowered to the destacker conveyor  140  by the contraction of the standard actuators  1820 . There is preferably a space between the bales  510  in the destacker and the pair of bales  510  already destacked. 
     At this point, as illustrated in  FIGS. 15   a  and  15   b,  the squeeze arm actuators  110  are contracted, thus drawing the lower ends of the squeeze arms  100  outward to disengage the bales  510  that, up to now, had been engaged in the squeeze arms  100 . 
     The standard actuators  1820  are again expanded approximately the height of a bale  510 . 
     At this time, the entire bale stack  505  has been destacked. No bale  510 , formerly a component of the stack  505 , is supported on any other bale  510 . The pairs of individual bales  510  may now be conveyed independently of additional destacking operations, or the conveying may be a function of these additional destacking operations. 
     In  FIGS. 16   a - 17   b,  a new stack  500  replaces the now destacked stack  505  in the destacker  10  and the process described above is repeated. 
     Details of the assembly that allows the gripping of the bales  510  are shown in  FIGS. 21-23 .  FIG. 21  shows the squeeze arms  100  in their inward or gripping position by virtue of the extended squeeze arm actuators  110  (only one shown in  FIGS. 21-23 ). In this position, bales  510  would be gripped for lifting and subsequent lowering. 
     In  FIG. 22 , the squeeze arms  100  are shown in their outward orientation. To effect this squeeze arm position, the squeeze arm actuators  110  are contracted. In this position, the toothed cross members  120  are clear of bales  510 , hence the destacker assembly may be raised or lowered to put the toothed cross members  120  in an appropriate position for disposal against the bale  510 , or the stacks  500 ,  505  or bales  510  may be moved into or out of position by the destacker conveyor  140 . 
     In  FIG. 23 , the squeeze arms  100  are shown in both the above positions for clarity and contrast. The squeeze arms  100  in their outward position are shown in phantom lines, and the other components of the assembly are also shown in phantom lines for this position. The components in solid lines correspond to the squeeze arms  100  in their inward position. 
     The bales  510  and the stacks  500 ,  505  may not be perfectly centered between the toothed cross members  120  at any point in the process outlined above. Equalizers  2110  (only one shown in  FIGS. 21-23 ) provide flexibility in the location of the bales  510  or stack  500 ,  505 . Because the equalizers  2110  are free to rotate about a center axis of pivot  2120 , irrespective of the position of the squeeze arm actuators  110 , the squeeze arms  100  may both be biased to one side or the other. Hence, bales  510  and the stacks  500 ,  505  that are not centered between the squeeze arms  100  may be accommodated without operator involvement. 
     The use of the bale destacker  10  described herein is not limited to use with bales  510  of biomass for fuel. Bales  510  to be used for livestock feed and bales  510  to be used for erosion control are examples of uses to which the bale destacker  10  may be applied. The present invention is not limited to bales  510  of a particular size or use. 
     It should be noted that many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.