Patent Description:
Forages, such as but not limited to, grasses, legumes, maize, crop residues, etc., are commonly harvested and fed to ruminant animals. One common practice for storing these forage materials is to harvest the forage and place the forage in an oxygen limiting structure, such as a bunker silo, a tightly wrapped bale, or a tower silo. The forage material ferments within the oxygen limiting structure, thereby preserving the forage material. The forage may then be removed and fed to the animals on an as-needed basis. This forage preservation process is often referred to as ensilage, and the forage material is often referred to as silage.

Research has shown that digestibility of forage materials may be improved by extremely processing the forage material prior to feeding the forage material to the animals. This extreme processing is referred to as maceration. Increased digestibility of the forage materials due to maceration increases the amount of nutrients absorbed by the animal for a given volume of forage. The increase in nutrient absorption results in increased production for the given volume of forage, e.g., increased milt production in dairy cattle. However, maceration at the time of harvesting the crop material is not practical because the energy required to macerate the forage material at a volume and speed sufficient to keep up with typical harvesting operations is too great for standard agricultural equipment to supply.

The forage materials are often combined with other feed materials to define a feed ration for an animal. Feed rations may be formulated based on measured nutritive constituents of the forage material. For example. the nutritive constituents of the forage material may include, but are not limited to, Neutral Detergent Fiber (NDF), Acid Detergent Fiber (ADF), Crude Protein (CP), Ash (minerals), etc. It is generally understood by those skilled in the art how much of each nutritive constituent is required, for example, for a cow to produce a given amount of milk. This process is used because nutritive values, e.g., fiber digestibility, changes as the crop material matures. Normally, fiber digestibility decreases as the crop material matures. <NPL> and <CIT> and <CIT> and <CIT> disclose devices and methods for the treatment of forage material and other agricultural plants by crushing and impact maceration. <CIT> discloses a waste management apparatus comprising means for receiving and storing organic waste and processing means configured to process the organic waste into feedstock. <CIT> discloses a system for screening a crop plant for the plant's starch digestion, fiber digestion and/or nutritional composition characteristics.

According to the invention, A mechanical macerator for macerating silage material, the mechanical macerator comprising: a macerating mechanism operable to macerate the silage material a nutrition sensor positioned relative to the macerating mechanism and operable to sense nutritive levels of the silage material; a ration controller coupled to the nutrition sensor, and including a processor and a memory having a ration algorithm stored thereon, wherein the processor is operable to execute the ration algorithm to: receive data from the nutrition sensor indicating the nutritive levels of the silage material; determine a desired amount of maceration of the silage material based on the nutritive levels of the silage material; control the macerating mechanism to achieve the desired amount of maceration of the silage material, wherein macerating the silage material includes high intensity crop processing of the silage material resulting in cell wall rupture and the release of intracellular solubles of the silage material. The mechanical macerator further comprising a macerator sensor coupled to the ration controller, wherein the macerator sensor is operable to sense an actual amount of maceration achieved by the macerating mechanism, and the processor is operable to execute the ration algorithm to receive data from the macerator sensor indicating an actual amount of maceration achieved by the macerating mechanism. Macerating the silage material includes high intensity crop processing of the silage material resulting in cell wall rupture and the release of intracellular solubles of the silage material.

In an embodiment, the mechanical macerator includes a first processor roll and a second processor roll arranged in parallel with each other to define a roll gap therebetween. Each of the first processor roll and the second processor roll is operable to rotate at a respective rotational speed to define a differential roll speed therebetween. The first processor roll and the second processor roll are operable to receive silage material through an inlet of the roll gap, macerate the silage material as the silage passes through the roll gap with the first processor roll and the second processor roll rotating at their respective rotational speed, and discharge the silage material through an outlet of the roll gap. A nutrition sensor is positioned adjacent the inlet of the roll gap. The nutrition sensor is operable to sense nutritive levels of the silage material. A ration controller is coupled to the nutrition sensor. The ration controller includes a processor and a memory having a ration algorithm stored thereon. The processor is operable to execute the ration algorithm to receive data from the nutrition sensor indicating the nutritive levels of the silage material. The ration controller may then determine a desired amount of maceration of the silage material based on the nutritive levels of the silage material, and control the roll gap and the respective rotational speed of the first processor roll and the second processor roll to achieve the desired amount of maceration of the silage material.

The macerator sensor is coupled to the ration controller. The macerator is positioned adjacent the outlet of the roll gap. The macerator sensor is operable to sense an actual amount of maceration achieved by the first processor roll and the second processor roll.

The processor is operable to execute the ration algorithm to receive data from the macerator sensor indicating an actual amount of maceration achieved by the first processor roll and the second processor roll. When the actual amount of maceration of the silage material is not within a defined range of the desired amount of maceration of the silage material, the ration controller may then adjust the roll gap and/or the respective rotational speed of the first processor roll and the second processor roll to achieve the desired amount of maceration of the silage material.

In one aspect of the disclosure, the processor is operable to execute the ration algorithm to calculate a respective amount of other feed materials to be combined with the silage material to define a feed ration for an animal. The respective amounts of the other feed materials may be calculated based on the actual amount of maceration achieved by the mechanical macerator.

Macerating the silage material ruptures the plant cell walls, thereby making the Neutral Detergent Fiber (NDF) fraction of the silage material more digestible for the rumen microbes of the animal. For this reason, maceration of the plant cells may reverse the effects of plant maturity on fiber digestibility. In other words, it is possible to improve the fiber digestibility of a mature plant to be similar to the fiber digestibility of an immature plant by macerating the plant cells.

Although macerating the silage material may improve the fiber digestibility of some forages, it is not always advantageous to macerate all forages to the same level. For example, immature forages may require very little or no maceration of the plant cells because the fiber in immature forage may be highly digestible and there is little to be gained by macerating these plants. On the other hand, the fiber digestibility of mature forages may be significantly increased by maceration of the plant cells. By measuring the nutritive values of the silage material, which is based in part on plant maturity, the degree of maceration needed to optimize digestibility for a specific silage material may be determined, and the mechanical macerator may be controlled to provide this desired degree of maceration to optimize feed ration production.

Referring to the Figures, wherein like numerals indicate like parts throughout the several views, a method of preparing a feed ration <NUM> for an animal <NUM> is described herein. As understood by those skilled in the art, "silage" is a type of fodder or forage material made from green foliage crops that have been preserved by acidification. The acidification is achieved through a fermentation process. Silage may be fed to ruminant animals <NUM>, such as but not limited to cattle, sheep goats, buffalo, deer, etc. The green foliage crops used to make silage may include, but are not limited to, grasses, alfalfa, maize, sorghum, or other cereal plants. The silage material <NUM> may be combined with other feed materials <NUM> to form the feed ration <NUM>. The other feed materials <NUM> may include, but are not limited to, protein supplements such as soybean meal, and cotton seed, energy supplements such as dry corn, effective fiber supplements such as dry alfalfa hay or grass hay crops, and other minerals and micro nutrients.

The process of preparing the feed ration <NUM> (not according to the invention) begins by cutting standing crop material <NUM> in a field to provide a cut crop material <NUM>. The step of cutting the standing crop material <NUM> is generally indicated by box <NUM> in <FIG>. The standing crop material <NUM> may be cut using conventional crop mowing equipment, such as but not limited to, a rotary mower, a rotary bar mower, a sickle mower, etc. The mower may be drawn behind or pushed ahead of a vehicle, such as but not limited to an agricultural tractor. Alternatively, the mower may be mounted to a self-propelled windrower. It should be appreciated that the standing crop material <NUM> may be cut using equipment other than described herein.

After the standing crop material <NUM> has been cut, the cut crop material <NUM> may be allowed to dry in the field to achieve a desired initial moisture content. The step of drying the cut crop material <NUM> in the field is generally indicated by box <NUM> in <FIG>. The desired initial moisture content may vary based on the type of crop material <NUM> and the manner in which the cut crop material <NUM> is stored, described in greater detail below. Generally, the desired initial moisture content is between <NUM>% and <NUM>%. However, it should be appreciated that the desired initial moisture content may vary from the range described herein.

After allowing the cut crop material <NUM> to dry to the desired initial moisture content in the field, the cut crop material <NUM> may be raked into a windrow. The step of raking the cut crop material <NUM> into a windrow is generally indicated by box <NUM> in <FIG>. It should be appreciated that the cut crop material <NUM> may be formed into the windrow during the cutting process. If the cut crop material <NUM> is raked into the windrows after drying, the cut crop material <NUM> may be raked into the windrows using conventional raking equipment, such as but not limited to, a wheel rake, a rotary rake, or a parallel bar or basket rake. The rake may be drawn by a vehicle, such as but not limited to an agricultural tractor. It should be appreciated that the cut crop material <NUM> may be raked into a windrow using equipment other than described herein.

The cut crop material <NUM> may then be collected in the field. The step of collecting the cut crop material <NUM> in the field is generally indicated by box <NUM> in <FIG>. The cut crop material <NUM> may be collected from the field using conventional equipment, such as but not limited to, a forage harvester and a trailer. The trailer may be drawn by another vehicle, such as but not limited to a tractor. The forage harvester gathers the cut crop material <NUM> up from the field, and moves the cut crop material <NUM> through a discharge chute, which discharges the cut crop material <NUM> into the trailer. Once loaded into the trailer, the cut crop material <NUM> may be moved to another location for storage.

In addition to collecting the cut crop material <NUM>, the forage harvester may include a crop processing unit that chops or further cuts the crop material <NUM> into smaller pieces. As such, the cut crop material <NUM> may be further cut or chopped while collecting the cut crop material <NUM> in the field. It should be appreciated that the cut crop material <NUM> may be collected from the field using equipment other than described herein.

Referring to <FIG>, the cut crop material <NUM> may then be stored in an accumulation <NUM> having an oxygen barrier <NUM>. The step of storing the cut crop material <NUM> in the accumulation <NUM> is generally indicated by box <NUM> in <FIG>. The accumulation <NUM> may include configuration that restricts or limits oxygen infiltration into the accumulation <NUM>. For example, the accumulation <NUM> may include a pile of crop material <NUM> disposed in a bunker silo <NUM> (shown in <FIG>), a pile of crop material <NUM> stored in a tower silo, or a compressed bale. As is understood by those skilled in the art, a bunker silo <NUM> generally includes a concrete floor <NUM> with walls <NUM> formed on three sides. The cut crop material <NUM> is piled onto the concrete floor <NUM> in layers and then compressed to remove as much air from the cut crop material <NUM> in the bunker silo <NUM> as reasonably possible. After the cut crop material <NUM> is compressed, the pile or accumulation <NUM> of the cut crop material <NUM> is covered with the oxygen barrier <NUM>. As is understood by those skilled in the art, the cut crop material <NUM> may be formed into a compressed bale. The bale may be formed into a shape, such as but not limited to a parallelepiped rectangular shape, e.g., a large square bale, or a cylindrical shape, e.g., a round bale. The cut crop material <NUM> may be formed into the compressed bale using a round baler, a large square baler, or some other similar baler know to those skilled in the art. Once formed and bound into the bale, the cut crop material <NUM> may then be wrapped with the oxygen barrier <NUM> as is known in the art. A tower silo may alternatively be used, in which the tower silo fully encloses the crop material <NUM> and also acts as the oxygen barrier <NUM> to by blocking air from the crop material <NUM> within the tower silo.

The oxygen barrier <NUM> may include a product that is capable substantially blocking or limiting the flow of air. In one implementation, the oxygen barrier <NUM> is a plastic covering operable to block transfer of oxygen therethrough. The plastic covering may include, but is not limited to, a polyethylene plastic or other similar or equivalent plastic covering. In other embodiments, the oxygen barrier <NUM> is a wall or roof of a structure that blocks transfer or passage of air and/or oxygen therethrough.

With the cut crop material <NUM> disposed in the accumulation <NUM> and covered with the oxygen barrier <NUM>, the cut crop material <NUM> will ferment within the accumulation <NUM> to form a silage material <NUM>. The fermentation process of silage is understood by those skilled in the art. Generally described, the fermentation process involves both aerobic bacteria (oxygen needed) and anaerobic bacteria (no oxygen needed). Aerobic fermentation occurs when the cut crop material <NUM> is positioned in the accumulation <NUM> and/or immediately thereafter, i.e. placed in the bunker silo <NUM> or formed into the bale. The aerobic fermentation consumes what oxygen is available in the accumulation <NUM>. After the aerobic fermentation has consumed the oxygen in the accumulation <NUM>, then the anaerobic fermentation occurs. The complete fermentation process may take approximately four weeks to complete, after which the silage material <NUM> may be stored in the accumulation <NUM> in a generally stable condition for an extended period of time, assuming the introduction of oxygen into the accumulation <NUM> is substantially prevented during the extended storage.

After fermentation, the silage material <NUM> is macerated. The silage material <NUM> is macerated with a mechanical macerator <NUM>. The mechanical macerator <NUM> is generally shown in <FIG>. The mechanical macerator <NUM> may include, but is not limited to, a hammer mill, a crushing impact macerator, an opposing plate/belt style macerator, or a differential roll macerator. An example implementation of the mechanical macerator <NUM> is generally shown in <FIG> as a differential roll macerator. However, it should be appreciated that the construction and operation of the mechanical macerator <NUM> may differ from the example implementation shown in <FIG>.

As understood by those skilled in the art, "macerating" or "maceration" is a highly intensive mechanical crop conditioning process in which the physical structure of plant stems are broken down and split into numerals pieces while the leaves and upper stem segments are crushed and pureed, resulting in significant cell wall rupture and the release of intracellular solubles. For example, the degree of cell wall rupture for macerated silage material <NUM> may be between <NUM>% and <NUM>%. As is understood by those skilled in the art, maceration is a much more intensive and extreme form of crop processing than the typical crop conditioning that occurs in traditional crop conditioning units commonly disposed on mowers and other crop cutting implements. As such, it should be appreciated that the maceration of the silage material <NUM> described herein is different and more extensive than, and is not the equivalent of, a typical crop conditioning process that may occur at the time of cutting the crop material <NUM> that is intended to be dried and made into dry hay or the like. A typical crop conditioning process, such as provided by a mower conditioner or other similar apparatus, typically provides less than <NUM>-<NUM>% cell rupture, which is far less than the level of maceration described herein.

The mechanical macerator <NUM> may include a device that macerates the silage material <NUM> through a mechanical process, such as but not limited to, beating, chipping, crushing, bending, cracking, scraping, or shearing the silage material <NUM>. The mechanical macerator <NUM> may include, for example, one or more macerating plates or rollers that move relative to each other, and pass the silage material <NUM> therebetween, whereby the silage material <NUM> is macerated. The mechanical macerator <NUM> may include a power input, such as but not limited to a rotary power input that drives a gear train, or an electric input that drives an electric motor, a hydraulic input that drives a hydraulic motor etc. The power input in turn drives the macerating plates and/or rollers for macerating the silage material <NUM>. It should be appreciated that the mechanical macerator <NUM> may include other components not described herein, and that the specific construction, configuration, and operation of the mechanical macerator <NUM> may vary from the example implementation shown in the Figures and described herein.

Referring to <FIG>, an example implementation of the mechanical macerator <NUM> is generally shown. The example implementation of the mechanical macerator <NUM> includes a first processor roll <NUM> and a second processor roll <NUM>. In the example implementation shown in <FIG> and described herein, the mechanical macerator <NUM> includes a plurality of first processor rolls <NUM>, and a plurality of second processor rolls <NUM>. However, it should be appreciated that the example implementation of the mechanical macerator <NUM> may be implemented with only a single first processor roll <NUM> and a single second processor roll <NUM>.

The first processor roll <NUM> and a second processor roll <NUM> are rotatably attached to a frame <NUM> and are arranged in parallel with each other. The first processor roll <NUM> and the second processor roll <NUM> are spaced apart from each other to define a roll gap <NUM> therebetween. At least one of the first processor roll <NUM> and the second processor roll <NUM> is moveable relative to the other of the first processor roll <NUM> and the second processor roll <NUM> to change or adjust the roll gap <NUM> therebetween. The first processor roll <NUM> and the second processor roll <NUM> may be attached to and supported by the frame <NUM> in a suitable manner. Additionally, at least one of the first processor roll <NUM> and the second processor roll <NUM> may include an adjustment mechanism attaching it to the frame <NUM> to enable relative movement therebetween to adjust the roll gap <NUM>. The specific construction and operation of the adjustment mechanism are not pertinent to the teachings of this disclosure, are understood by those skilled in the art, and are therefore not described in detail herein.

Each of the first processor roll <NUM> and the second processor roll <NUM> are rotatable about a respective central longitudinal axis. The first processor roll <NUM> and the second processor roll <NUM> may be configured to rotate in opposite rotational directions. For example, the first processor roll <NUM> may be configured to rotate in a counter-clockwise direction <NUM> as viewed on the page of <FIG>, whereas the second processor roll <NUM> may be configured to rotate in a clockwise direction as viewed on the page of <FIG>. Each of the first processor roll <NUM> and the second processor roll <NUM> are operable to rotate at a respective rotational speed. As such, the first processor roll <NUM> may rotate at a first rotational speed, and the second processor roll <NUM> may rotate at a second rotational speed that is different from the first rotational speed. The difference between the first rotational speed and the second rotational speed defines a differential roll speed.

The first processor roll <NUM> and the second processor roll <NUM> are operable to receive the silage material <NUM> through an inlet <NUM> of the roll gap <NUM>, and macerate the silage material <NUM> as the silage passes through the roll gap <NUM> with the first processor roll <NUM> and the second processor roll <NUM> rotating at their respective rotational speeds. The amount of maceration of the silage material <NUM> is dependent, at least partially, upon the distance of the roll gap <NUM> and the differential roll speed between the first processor roll <NUM> and the second processor roll <NUM>. The silage material <NUM> is discharged from the roll gap <NUM> through an outlet <NUM> of the roll gap <NUM>.

A nutrition sensor <NUM> is positioned adjacent the inlet <NUM> of the roll gap <NUM>. The nutrition sensor <NUM> is operable to sense data related to nutritive levels of the silage material <NUM>. The nutritive levels or values of the silage material <NUM> may include, but are not limited to, a Neutral Detergent Fiber (NDF) value, an Acid Detergent Fiber (ADF) value, a Crude Protein (CP) value, and an Ash or mineral content value. It should be appreciated that the nutrition sensor <NUM> may sense data related to these or other nutritive values which may then be used to determine or calculate the actual nutritive values. Alternatively, the nutrition sensor <NUM> may sense the actual nutritive values directly. The nutrition sensor <NUM> may include any sensor or combination of sensors, test equipment, chemicals, cameras, etc., necessary to sense the data related to the nutritive levels. The specific configuration and operation of the nutrition sensor <NUM> is dependent upon the specific types of nutritive values sensed, are understood by those skilled in the art, and are therefore not described in detail herein.

The mechanical macerator <NUM> further includes a macerator sensor <NUM>. The macerator sensor <NUM> is positioned adjacent to the outlet <NUM> of the roll gap <NUM>. The macerator sensor <NUM> is operable to sense data related to an actual amount of maceration achieved by the first processor roll <NUM> and the second processor roll <NUM>. The macerator sensor <NUM> may sense data related to the actual amount of maceration that may then be used to determine or calculate the actual amount of maceration achieved, or may directly sense the actual amount of maceration achieved. The macerator sensor <NUM> may include, for example, a camera or other similar device that captures and image of the silage material <NUM> exiting the roll gap <NUM>. The image may then be analyzed by a ration controller <NUM> to determine the actual amount of maceration of the silage material <NUM>. It should be appreciated that the macerator sensor <NUM> may be implemented in some other manner not shown or described herein.

The ration controller <NUM> is coupled to and in communication with the nutrition sensor <NUM> and the macerator sensor <NUM>. Additionally, the ration controller <NUM> is operable to control and/or adjust the roll gap <NUM> and the differential roll speed. The ration controller <NUM> may alternatively be referred to as a computing device, a computer, a controller, a control module, a module, etc. The ration controller <NUM> is operable to receive data from the nutrition sensor <NUM> and the macerator sensor <NUM>, and control the operation of the first processor roll <NUM> and the second processor roll <NUM>. The ration controller <NUM> includes a processor <NUM>, a memory <NUM>, and all software, hardware, algorithms, connections, sensors, etc., necessary to manage and control the operation of the mechanical macerator <NUM>. As such, a method may be embodied as a program or algorithm operable on the ration controller <NUM>. It should be appreciated that the ration controller <NUM> may include any device capable of analyzing data from various sensors, comparing data, making the necessary decisions required to control the operation of the mechanical macerator <NUM> and executing the required tasks necessary to control the operation of the mechanical macerator <NUM>.

As used herein, "controller" is intended to be used consistent with how the term is used by a person of skill in the art, and refers to a computing component with processing, memory <NUM>, and communication capabilities, which is utilized to execute instructions (i.e., stored on the memory <NUM> or received via the communication capabilities) to control or communicate with one or more other components. In certain embodiments, a controller may be configured to receive input signals in various formats (e.g., hydraulic signals, voltage signals, current signals, CAN messages, optical signals, radio signals), and to output command or communication signals in various formats (e.g., hydraulic signals, voltage signals, current signals, CAN messages, optical signals, radio signals).

The ration controller <NUM> may be in communication with other components on the mechanical macerator <NUM>, such as hydraulic components, electrical components, input devices, etc. The ration controller <NUM> may be electrically connected to these other components by a wiring harness such that messages, commands, and electrical power may be transmitted between the ration controller <NUM> and the other components. Although the ration controller <NUM> is referenced in the singular, in alternative embodiments the configuration and functionality described herein can be split across multiple controllers using techniques known to a person of ordinary skill in the art.

The ration controller <NUM> may be embodied as one or multiple digital computers or host machines each having one or more processors, read only memory (ROM), random access memory (RAM), electrically-programmable read only memory (EPROM), optical drives, magnetic drives, etc., a high-speed clock, analog-to-digital (A/D) circuitry, digital-to-analog (D/A) circuitry, and any required input/output (I/O) circuitry, I/O devices, and communication interfaces, as well as signal conditioning and buffer electronics.

The computer-readable memory <NUM> may include any non-transitory/tangible medium which participates in providing data or computer-readable instructions. The memory <NUM> may be non-volatile or volatile. Non-volatile media may include, for example, optical or magnetic disks and other persistent memory. Example volatile media may include dynamic random access memory (DRAM), which may constitute a main memory. Other examples of embodiments for memory include a floppy, flexible disk, or hard disk, magnetic tape or other magnetic medium, a CD-ROM, DVD, and/or any other optical medium, as well as other possible memory devices such as flash memory.

The ration controller <NUM> includes the tangible, non-transitory memory <NUM> on which are recorded computer-executable instructions, including a ration algorithm <NUM>. The processor <NUM> of the ration controller <NUM> is configured for executing the ration algorithm <NUM>. The ration algorithm <NUM> implements a method of macerating the silage material <NUM>.

The ration controller <NUM> receives data from the nutrition sensor <NUM> related to the nutritive levels of the silage material <NUM> entering the mechanical macerator <NUM> through the inlet <NUM> of the roll gap <NUM>. The step of sensing the data related to the nutritive levels of the silage material <NUM> is generally indicated by box <NUM> in <FIG>. The nutrition sensor <NUM> sensors data related to the nutritive levels or values of the silage material <NUM> prior to the silage material <NUM> being macerated. The ration controller <NUM> may use the data from the nutrition sensor <NUM> to calculate or otherwise determine the actual nutritive values of the silage material <NUM> prior to maceration.

Once the ration controller <NUM> knows the nutritive levels of the silage material <NUM>, the ration controller <NUM> may determine a desired amount of maceration of the silage material <NUM> based on the nutritive levels of the silage material <NUM>. The step of determining the desired amount of maceration of the silage material <NUM> is generally indicated by box <NUM> in <FIG>. The desired amount of maceration of the silage material <NUM> is dependent at least upon the actual nutritive values of the silage material <NUM> and the animal <NUM> to which the feed ration <NUM> is to be fed. For example, immature silage material <NUM> may require little maceration to achieve a desired feed quality, whereas very mature silage material <NUM> may require significant maceration to achieve the desired feed quality.

Once the ration controller <NUM> has determined the desired amount of maceration for the silage material <NUM>, the ration controller <NUM> may position or control the roll gap <NUM> and the respective rotational speeds of the first processor roll <NUM> and the second processor roll <NUM> to an initial setting or position to achieve the desired amount of maceration of the silage material <NUM>. The amount of maceration increases with a decrease in the distance of the roll gap <NUM>. Additionally, the amount of maceration increases with an increase in the differential roll speed. The initial setting for the roll gap <NUM> and the differential roll speed may be dependent upon the specific configuration of the mechanical macerator <NUM>, the type of crop material <NUM>, etc. The ration controller <NUM> may maintain a plurality of different predefined initial settings for the roll gap <NUM> and the differential roll speed to achieve different levels of maceration in the memory <NUM>.

Once the first processor roll <NUM> and the second processor roll <NUM> are positioned in their initial settings to achieve the desired amount of maceration of the silage material <NUM>, the silage material <NUM> is fed into the mechanical macerator <NUM> through the inlet <NUM> of the roll gap <NUM> and macerated. The step of macerating the silage material <NUM> is generally indicated by box <NUM> in <FIG>. The silage material <NUM> is discharged through the outlet <NUM> of the roll gap <NUM> after being macerated by the first processor roll <NUM> and the second processor roll <NUM>.

The ration controller <NUM> receives data from the macerator sensor <NUM> related to an actual amount of maceration achieved by the first processor roll <NUM> and the second processor roll <NUM>. The step of sensing data related to the actual amount of maceration achieved is generally indicated by box <NUM> in <FIG>. As described above, the macerator sensor <NUM> may sense an actual amount of maceration, or sense data that may be used to calculate or determine the actual amount of maceration of the silage material <NUM>.

The ration controller <NUM> may then compare the actual amount of maceration of the silage material <NUM> to the desired amount of maceration of the silage material <NUM> to determine if the actual amount of maceration of the silage material <NUM> is within a defined range of the desired amount of maceration of the silage material <NUM>, or if the actual amount of maceration of the silage material <NUM> is not within the defined range of the desired amount of maceration of the silage material <NUM>. The step of comparing the actual maceration to the desired maceration is generally indicated by box <NUM> in <FIG>. The defined range may include a range above and/or below the desired amount of maceration of the silage material <NUM>. A level of maceration within the defined range indicates an acceptable level of maceration. A level of maceration above or greater than the defined range may indicate excessive or unnecessary amounts of maceration. A level of maceration below or less than the defined range may indicate an unacceptable or insufficient amount of maceration.

If the ration controller <NUM> determines that the actual level of maceration of the silage material <NUM> achieved by the mechanical macerator <NUM> is within the defined range of the desired amount of maceration, generally indicated at <NUM> then the roll gap <NUM> and/or the differential roll speed do not need to be adjusted, and the mechanical macerator <NUM> may continue operation at the initial settings.

If the ration controller <NUM> determines that the actual level of maceration of the silage material <NUM> achieved by the mechanical macerator <NUM> is not within the defined range of the desired amount of maceration, generally indicated at <NUM>, then the ration controller <NUM> may adjust the mechanical macerator <NUM>, i.e., adjust the roll gap <NUM> and/or the differential roll speed, to an adjusted setting to bring the actual level of maceration achieved by the mechanical macerator <NUM> into the defined range of the desired amount of maceration. The step of adjusting the mechanical macerator <NUM> is generally indicated by box <NUM> in <FIG>. This process may be repeated until the actual level of maceration achieved by the mechanical macerator <NUM> is within the defined range of the desired amount of maceration. It should be appreciated that the step of adjusting the mechanical macerator <NUM> may include other processes not specifically described in detail herein, and which are dependent upon the specific type and style of macerator being used. Examples of adjusting the mechanical macerator may include, but are not limited to, adjusting a time of maceration, adjusting a speed of maceration, adjusting a number of engaged macerators, adjusting a crush pressure, etc. For example, adjusting the mechanical macerator <NUM> may include, but is not limited to, macerating the forage material for a longer period of time until the desired amount of maceration is achieved.

As noted above, the mechanical macerator <NUM> may be adjusted by changing the roll gap <NUM> and/or by changing the differential roll speed. In order to change the roll gap <NUM>, one of the first processor roll <NUM> and the second processor roll <NUM> is moved relative to the other of the first processor roll <NUM> and the second processor roll <NUM> to adjust the roll gap <NUM> therebetween. In order to adjust the differential roll speed, the respective rotation speed of one of the first processor roll <NUM> and the second processor roll <NUM> is changed relative to the other of the first processor roll <NUM> and the second processor roll <NUM>.

Once the desired amount of maceration is achieved by the mechanical macerator <NUM>, generally indicated at <NUM>, the ration controller <NUM> may calculate a respective amount of other feed materials <NUM> to be combined with the silage material <NUM> to define the feed ration <NUM> for the animal <NUM> based. The step of calculating the respective amounts of the other feed materials <NUM> is generally indicated by box <NUM> in <FIG>.

Once the respective amounts of the other feed materials <NUM> is calculated, the macerated silage material <NUM> may be mixed with the other feed materials <NUM> to form the feed ration <NUM> for the animal <NUM>. The step of mixing the silage material <NUM> with the other feed materials <NUM> is generally indicated by box <NUM> in <FIG>. After mixing the silage material <NUM> with the other feed materials <NUM>, the feed ration <NUM> may then be fed to an animal <NUM>. The step of feeding the animal <NUM> is generally indicated by box <NUM> in <FIG>.

Claim 1:
A mechanical macerator for macerating silage material (<NUM>), the mechanical macerator (<NUM>) comprising:
a macerating mechanism operable to macerate the silage material (<NUM>)
a nutrition sensor (<NUM>) positioned relative to the macerating mechanism and operable to sense nutritive levels of the silage material (<NUM>);
a ration controller (<NUM>) coupled to the nutrition sensor (<NUM>), and including a processor and a memory having a ration algorithm stored thereon, wherein the processor is operable to execute the ration algorithm to:
receive data from the nutrition sensor (<NUM>) indicating the nutritive levels of the silage material (<NUM>);
determine a desired amount of maceration of the silage material (<NUM>) based on the nutritive levels of the silage material (<NUM>);
control the macerating mechanism to achieve the desired amount of maceration of the silage material (<NUM>), wherein macerating the silage material (<NUM>) includes high intensity crop processing of the silage material (<NUM>) resulting in cell wall rupture and the release of intracellular solubles of the silage material (<NUM>), characterized in that, the mechanical macerator further comprising a macerator sensor (<NUM>) coupled to the ration controller (<NUM>), wherein the macerator sensor (<NUM>) is operable to sense an actual amount of maceration achieved by the macerating mechanism, and the processor is operable to execute the ration algorithm to receive data from the macerator sensor (<NUM>) indicating an actual amount of maceration achieved by the macerating mechanism.