Patent Abstract:
A bale processor with a processing chamber includes a manipulator driven by a drive system that includes a hydraulic motor. The hydraulic motor of the drive system drives a drive shaft with an axis of rotation offset from a driven shaft of the manipulator. A rotation transmission mechanism allows a higher torque to be applied to the manipulator than may be applied by the hydraulic motor alone and, thereby, leads to improved performance for the bale processor. Additionally, the hydraulic motor may be sized such that the peak allowable pressure of the hydraulic motor is higher than the peak output pressure of the power source used to drive the hydraulic motor.

Full Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates to farm machinery for shredding bales and, more particularly, to a drive system for a bale processor bale manipulator and a bale processor using said drive system.  
         BACKGROUND  
         [0002]    In the livestock industry, large round and square bales are shredded to feed and bed livestock. One type of bale processor currently in the market includes a flail drum longitudinally mounted for rotation inside a processing chamber. The flail drum is rotated and flails on the drum engage a bale inside the processing chamber, shred the baled material and discharge the shredded material out of the processor. The processors include at least one manipulator for manipulating the bale within the processing chamber to expose different portions of the bale to the flails. The manipulator may be one or more “feed rollers”. The manipulator is typically driven by a hydraulic motor that allows the user to change the speed and direction of rotation of the manipulator. Typically some kind of flow restrictor is used to limit the speed of the manipulator for proper processing.  
           [0003]    High torque may be required to drive the manipulator when large bales are processed or when baled material becomes wound around the manipulator or wedged between the manipulator and the walls of the processor. High torque is often required when frozen bales are being manipulated.  
           [0004]    Low cost hydraulic motors typically have a peak or maximum intermittent hydraulic oil supply pressure allowance dependant on the design parameters of the motor. Torque capabilities of hydraulic motors vary directly with size (displacement) of the motor. However, as the size of the motor increases, low cost commercial motor design often does not provide for proportional increases in torque or pressure capabilities and the pressure allowance is accordingly decreased.  
           [0005]    If a hydraulic motor is used in an application where its maximum output torque is required and the power source (typically a tractor) can provide a peak pressure higher than the pressure allowance of the motor, then a pressure relief system must be used to protect the hydraulic motor from supply pressures exceeding the pressure allowance. Pressure relief systems are inconvenient, costly and limit the torque output of the motor.  
           [0006]    Problems have been encountered with hydraulic motor reliability or operability in some bale processors of the type described and/or a pressure relief system has been required.  
         SUMMARY  
         [0007]    A bale processor with a processing chamber includes a bale manipulator driven by a hydraulic motor. The hydraulic motor drives a shaft with an axis of rotation offset from the drive shaft of the manipulator. A drive transmission is used to increase the torque supplied to the manipulator from the hydraulic motor, which is rated to operate within the pressure range of the hydraulic feed from a power source.  
           [0008]    In accordance with an aspect of the present invention there is provided a bale processor bale manipulator drive system in a bale processor of the type having a disintegrator and a bale manipulator rotatably mounted in a processing chamber. The drive system includes a hydraulic motor mounted on the bale processor and adapted for receiving, and rated to operate within the pressure range of, the hydraulic feed from a power source and an offset drive transmission connected between the hydraulic motor and the bale manipulator, the drive transmission including torque multipliers having a ratio adapted to increase available torque to the manipulator.  
           [0009]    In accordance with another aspect of the present invention there is provided a bale processor. The bale processor includes a processing chamber, a disintegrator rotatably mounted in the processing chamber and adapted to disintegrate baled crop material, a bale manipulator rotatably mounted in the processing chamber and adapted to manipulate the baled crop material in the processing chamber to expose different parts thereof to the disintegrator and a bale manipulator drive system. The bale manipulator drive system includes a hydraulic motor mounted on the bale processor and adapted for receiving, and rated to operate within the pressure range of, the hydraulic feed from a power source and an offset drive transmission connected between the hydraulic motor and the bale manipulator, the drive transmission including torque multipliers having a predetermined ratio so as to increase available torque to the manipulator.  
           [0010]    In accordance with a further aspect of the present invention there is provided a bale processor bale manipulator drive system kit for use in a bale processor of the type having a disintegrator and a bale manipulator rotatably mounted in a processing chamber. The drive system kit including a mounting plate adapted for mounting on an end wall of the bale processor and for receiving a shaft connected to the bale manipulator, a hydraulic motor mounted on the mounting plate and adapted for receiving, and rated to operate within the pressure range of, the hydraulic feed from a power source and an offset drive transmission adapted for connecting between the hydraulic motor and the bale manipulator, the drive transmission including torque multipliers having a ratio adapted to increase available torque to the manipulator.  
           [0011]    Other aspects and features of the present invention will become apparent to those of ordinary skill in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]    In the figures which illustrate an embodiment exemplary of the invention:  
         [0013]    [0013]FIG. 1 is a front perspective view of a bale processor according to the invention;  
         [0014]    [0014]FIG. 2 is a front perspective view of a bale processor and drive system according to the invention;  
         [0015]    [0015]FIG. 3 is a detailed perspective view the drive system shown in FIG. 2;  
         [0016]    [0016]FIG. 4 is an exploded view of the front of a bale processor according to the invention;  
         [0017]    [0017]FIG. 5 is an exploded view of the rear of a bale processor according to the invention; and  
         [0018]    [0018]FIG. 6 is an exploded view of the drive system of FIG. 3. 
     
    
     DETAILED DESCRIPTION  
       [0019]    [0019]FIG. 1 illustrates an exemplary bale processor  10  showing one embodiment of the present invention.  
         [0020]    The bale processor  10  has a frame structure  12  that includes a hitch plate  14  and a pair of axle supports  16 . The hitch plate  14  is adapted for installation of a hitch (not shown) for connection of the bale processor  10  to a power source, typically a tractor (not shown). The axle supports  16  allow for support of the frame structure  12  on wheels (not shown). The processor  10  includes a processing chamber  18  having a front end wall  22 , a back end wall  24 , a left side wall  26  and a right side wall  28 . In the embodiment shown, the left side wall  26  includes a discharge opening  30  through which processed crop material is discharged.  
         [0021]    In the illustrated embodiment, a disintegrator comprising a flail drum extending the length of the processing chamber  18  is mounted in the bottom of the processing chamber  18  of the bale processor  10 . The flail drum is rotatable about its longitudinal axis such that, in operation, a series of flails pivotally mounted thereon extend to engage and separate the baled material and discharge it from the processing chamber  18 .  
         [0022]    Mounted between the front end wall  22  and the back end wall  24  of the processing chamber  18  is a manipulator, feed roller  38 , having a driven shaft  36  (see FIG. 4). In operation, rotation of the driven shaft  36  results in rotation of the manipulator, and manipulation of baled material (not shown) in the processing chamber  18 . During operation, a bale is supported above the disintegrator on the feed roller  38  and an opposing support means, which may be either passive or driven. In the illustrated embodiment, the manipulator of the bale processor  10  includes two driven feed rollers  38 ,  40  (see FIG. 2) and the bale is supported between said rollers. However, the roller  40  need not be driven, and may be a passive support roller as disclosed in applicants co-pending application PCT/CA02/00926. Generally, the manipulator functions to rotate a bale in the processing chamber  18  such that different portions of the bale are exposed to the disintegrator and the choice of the number of drives and required power will depend on the type of bale processor and the operating parameters thereof.  
         [0023]    As discussed, the illustrated embodiment includes two feed rollers. As the feed rollers and associated drive systems are identical, for simplicity, only one feed roller and drive system is described.  
         [0024]    In the embodiment shown, the feed roller  38  extends the length of the processing chamber  18 . The feed roller  38  is rotatable about its longitudinal axis and has manipulating members comprising teeth  42  and flanges  44  extending therefrom.  
         [0025]    The feed roller  38  is mounted to the front end wall  22  by attachment to a feed roller mounting plate  48 . Specifically, the driven shaft  36  extends through a set of bearings  52  that are attached to the feed roller mounting plate  48  and support the feed roller  38  while permitting rotation thereof. The bearings  52  are housed in a cylindrical flange  68  that extends into the processing chamber  18  from the feed roller mounting plate  48 . The specifications for the bearings  52  are selected depending upon the typical load conditions of the feed roller  38  during operation. As shown in FIG. 5, the feed roller  38  is mounted to the back end wall  24  through a further set of bearings housed in a rear feed roller mounting plate.  
         [0026]    The cylindrical flange  68  (see FIG. 3) extends through an aperture  74  in the front end wall  22  into the processing chamber  18 . The aperture  74  may be obround and sized to allow the feed roller mounting plate  48  including cylindrical flange  68  to slide during operation. Four retainer bars  72  on the front end wall  22  of the processing chamber  18  cooperate with four retainer clips  50  to support and maintain the orientation of the feed roller mounting plate  48  on the front end wall  22 . An adjustable stop plate  56  is rotatably secured to the front end wall  22  of the processing chamber  18 . The adjustable stop plate  56  cooperates with a protrusion  66  outstanding from the feed roller mounting plate  48  to limit the downward travel of the feed roller mounting plate  48  and, consequently, the first feed roller  38 .  
         [0027]    A driven sprocket  54  is detachably connected to the end of the driven shaft  36  of the feed roller  38 . Specifically, the driven shaft  36  of the feed roller  38  has a splined connection to the driven sprocket  54 . As will be apparent to a person skilled in the art, there exist many alternatives for this connection including keyed and cross-holed connections.  
         [0028]    A hydraulic motor  46  is mounted on the feed roller mounting plate  48  such that the axis of rotation of a motor shaft  60  (see FIG. 6) is offset from the axis of rotation of the driven shaft  36 . As shown in FIG. 3, a motor mount  62  on the mounting plate  48  houses a drive sprocket  64  and supports the hydraulic motor  46 . The motor mount  62  supports and retains the hydraulic motor  46  stationary during operation, maintaining the motor shaft  60  engaged with the drive sprocket  64 . The feed roller mounting plate  48  includes a drive bearing set  70  to support the motor shaft  60  and to assist the internal motor bearing set (not shown) in absorbing forces on the motor shaft  60  including those forces transverse to the axis of rotation of the motor shaft  60 .  
         [0029]    The hydraulic motor  46  will typically be powered by the hydraulic feed from a tractor. Appropriate hydraulic hoses, fittings and valves (not shown) are used to connect the hydraulic motor  46  to the hydraulic feed. Where, as illustrated, two feed rollers are used to manipulate a bale in the processing chamber  18 , it should be apparent to a person skilled in the art that the two hydraulic motors driving the two feed rollers may be plumbed either in series or in parallel. Rotation of the motor shaft  60  by the hydraulic motor  46  results in rotation of the drive sprocket  64 . In the illustrated embodiment, a continuous chain (not shown) is used to transfer rotation of the drive sprocket  64  to the driven sprocket  54  and driven shaft  36  and, thus, to the feed roller  38 . Preferably, the hydraulic motor  46  is reversible such that the feed roller  38  can rotate in a clockwise or a counter-clockwise direction.  
         [0030]    As will be apparent to a person skilled in the art, transmission of rotational motion from the drive shaft of the hydraulic motor to the driven shaft of the feed roller is not limited to the exemplary sprocket and chain system. Many known mechanisms may be used to perform this task while acting as a torque multiplier. For instance, a pulley and belt system may use a drive pulley mounted to the drive shaft, a larger diameter driven pulley mounted to the driven shaft and a belt to transfer rotation of the drive pulley to rotation of the driven pulley. As a further alternative, a drive spur gear may be mounted to the drive shaft and a larger diameter driven spur gear mounted to the driven shaft. The driven spur gear meshes with the drive spur gear to transfer rotation of the drive spur gear to rotation of the driven spur gear.  
         [0031]    The gear, chain or belt drive system must be sized to have the proper ratios to increase the available torque to the manipulator to a level where bale processing may be efficiently carried out without excessive stalling under the range of typical operating conditions.  
         [0032]    In operation, as the flail drum is rotated, the flails extend radially to engage the baled crop material positioned between the feed roller  38  and the second feed roller  40 , separating some of the baled crop material from the rest of the baled material and discharging the separated material through the discharge opening  30 . As the feed roller  38  is rotated, the teeth  42  and the flanges  44  engage the bale in the processing chamber  18  to rotate the bale thereby exposing different sections of the bale to the flails for disintegration.  
         [0033]    The selection of an appropriate motor and gear ratio will depend on the application of the processor including the peak hydraulic pressure supplied by the power source and the required torque for efficient processing. For instance, economic, commercially available 22.8 cu. in. motors having a sufficiently high pressure allowance (3,250 psi) to reliably operate with power supplied from the hydraulic feed from most tractors are available. However, the torque available through such a motor is around 9,200 lb.-in. which is insufficient for efficient processing of large bales, particularly if they are frozen. A presently affordable motor that is able to deliver the required torque has a 32.7 cu. in. displacement. However, the pressure allowance on commercially viable motors of that size is generally around 2,500 psi, which is lower than the peak hydraulic pressure supplied by many modern tractors (around 3,000 psi). With a 2:1 ratio between the driven sprocket radius and the drive sprocket radius, the torque available from a given hydraulic motor may be doubled through the use of the disclosed drive system. Doubling the torque available through a 22.8 cu. in. motor provides sufficient torque for efficient processing of bales with the processors of the invention. Accordingly, a 22.8 cu. in. motor, is advantageously used as part of a drive system according to the invention having a 2:1 ratio between the drive sprocket and the driven sprocket.  
         [0034]    As will be apparent to a person skilled in the art, through the use of the drive system disclosed herein, a single hydraulic motor may be arranged to drive two feed rollers. In one example of such an arrangement, the motor shaft  60  supports two drive sprockets. Two chains may then be used to transfer rotation of each of the drive sprockets to rotation of driven sprockets attached to each of the feed rollers.  
         [0035]    Other modifications within the ambit of the following claims will be apparent to those skilled in the art and, the invention is accordingly defined by the claims.

Technology Classification (CPC): 8