Patent Description:
A baling machine, usually existing of the round or rectangular bale type is used to package crop material into a round or rectangular shape.

A baling machine can be divided up into various areas of components and apparatuses. One of the primary components of the baler is the binding unit usually commonly used to apply a twine / net or a sheeted type material to the bale of product. The binding apparatus can be located on the baler in various locations depending on the type of machine and its use.

Applying binding material to the bale can be a difficult process to achieve high levels of reliability. In particular, problems exist with sheeted materials in that the surface of the material is not of the mesh type and as a result the crop on the bale does not bond with the binding material as efficient as of the mesh type of binding. As a result, the binding sheet type material can often fail to follow the circumference of the bale and may instead follow a rotating component of the baling machine.

In general the machines that can apply this type of sheet binding material, the operator needs to manipulate the intake of crop into the machine as the binding material is being fed into the baling chamber so the incoming crop can enclose the first parts of the sheet material within layers of crop so the sheet binding material is trapped between the crop layers and as a result can successfully follow around the circumference of the bale without leaving the baling chamber.

This intake of crop material to enclose the first parts of the binding material with the crop on the bale is not automated by the machine but instead is solely carried out by the skill of the operator of the machine. This is a difficult process and can also be very unreliable as the operator has to judge the quantity of crop entering the machine and also judge the forward speed correctly of the baling machine. In a standard stop start baler, the driver needs to stop when the baling chamber is full in order to apply the binding material. If the driver stops too early the first part of the binding material will not be enclosed in the bale and the binding material may not follow the bales circumference, if the driver drives forward too far after the baling chamber is full, the first part of the binding material will be enclosed too far beneath the bales surface and excess crop will cover the plastic causing issues at a later stage with the preservation of the crop material and the removal of the binding material. The issues also include incorrect over lap of the binding material, excess crop between the binding layers allowing air or and moisture to enter the bale and /or accumulative issues when trying to remove the binding material from the bale.

Another problem with the binding material of the sheeted plastic type is providing a reliable apparatus to feed the plastic into the chamber, to provide a stretching of the plastic and then to remove some of the braking force at the end of the binding cycle to successfully cut the binding material so the cycle may be successfully started again on the next bale. Due to the elasticity of the binding material, the braking/ stretch of the plastic sheet material must be removed at the end of the cycle in order to prevent excessive contraction of the plastic binding material. If there is excessive contraction of the stretched binding material, reliable feeding of the material at the start of the next bale binding cycle may not be possible.

Commonly, a roller is used to provide a stretch on the binding the material. Either the braking roller is pushed onto the roll of binding material and or the binding material is routed around the braking roller for stretching the binding material. The binding material may be wrapped around the braking roller between <NUM> and <NUM> degrees of contact with the braking roller depending on the machine type.

The applying compressive force from the braking roller pushing onto the circumference of the roll of plastic may be limited because when feeding the binding material at the start of the binding process, it would not be possible to pull the binding material from the roll of binding material due to the high rolling resistance caused by the excessive compressive forces. As a result of this limited compressive force between the braking roller and the roll of binding material, limitations will exist when stretching the binding material at the higher stretch percentages.

The problem presented is, if the force of the braking roller pushing onto the roll of binding material is too great, the binding apparatus will be unable to draw the binding material from the roll of binding so the binding material can enter the baling chamber. If the force of the braking roller pushing on the roll of binding is not sufficient, the release of the braking rotational force at the end of the binding cycle in order to cut the material, the momentum in the roll of binding material will cause the roll of material to rotate after the binding material has been cut and binding cycle has ended. With all of the current binding stretching systems, the stretching roller is always in contact with the binding material either through the binding material passing over, between or around the stretching roller or the stretching roller is pushing on the roll of binding material directly at all times. As a result, if the stretching is excessive or not enough, the binding material passing through the stretching roller can overrun, pull backwards or bind to the stretching roller and as a result, the binding material is not free for the start of the next binding cycle. The systems currently existing have disadvantages of needing to be finely tuning the forces to try and overcome the problems.

Document <CIT> shows a binding system with a braking/ stretching roller and a braking force controlled with a motor. A binding material is in constant contact with the braking/ stretching roller at all stages of the binding cycle. As a result, the system needs to be finely tuned especially at the end of the cycle when cutting the binding material so the binding material does not overrun causing the binding material to fully wrap or become lodged on the braking/ stretching roller.

Another example of prior art is document <CIT>. In this example a braked/ stretch roller is in contact with a binding material and the binding material also wraps around the roller. If the binding material overruns at any point of the binding cycle or breaks at any point of the binding cycle, the plastic will inevitably become entangled and fully wrapped around the braked/ stretch roller. This is a major disadvantage with these known binding systems.

<CIT> discloses a round baler for forming a bale from a crop product. The round baler comprises a first bale forming chamber, a second bale forming chamber and a feeding mechanism. The feeding mechanism comprises among others a drop floor unit comprising a drop floor device, and a feeding path. For adjusting the size of the feeding path the drop floor device is pivotable between a plurality of different positions in each of which the feeding path section is open for conveying the crop through the feeding path section.

It is an object of the invention to provide a method for operating a round baler and a round baler with improved operation control.

For solving the problem a method for operating a round baler and a round baler according to the independent claims <NUM> and <NUM>, respectively, are provided. Further embodiments are referred to in the dependent claims.

According to an aspect of the invention, a method for operating a round baler according to claim <NUM> is provided.

According to another aspect of the invention, a round baler according to claim <NUM> is provided.

In examples related to the first aspect, the control system may be configured to switch the feeding operation when the binding material reaches a predetermined location between <NUM> and <NUM> degrees on the circumference of the bale formed in the main bale forming chamber.

In examples related to the first aspect, the control system may be configured to switch the feeding operation when the binding material reaches a predetermined value corresponding to a point in the circumference of the main bale forming chamber.

In examples related to the first aspect, the control system may be configured to switch the feeding operation as the binding material is wrapping the bale formed in the main bale forming chamber.

In examples related to the first aspect, the control system may be configured to determine the length of the binding material wrapped around the bale, and to switch the feeding operation when the length of the binding material wrapped around the bale reaches a specific length.

In examples related to the first aspect, the method may further comprise: stopping the crop from entering the main bale forming chamber at a predetermined value of a binding cycle for wrapping the bale by the binding material; and covering the binding material by a volume of the crop.

In examples related to the first aspect, the binding material may be provided as at least one of a plastic binding material and a sheet material.

In examples related to the first aspect, the method may further comprise switching the feeding operation by switching a moveable plate in a crop channel.

In operation, the main bale forming chamber is filled to form a bale of crop material. The binding cycle begins prior to the main bale forming chamber reaching a full state, as the binding material is applied onto the bale of crop material; incoming crop encloses a starting end of the binding material into the bale of crop material. At a predefined point, e.g. when the binding material has a specific length and / or the binding material reaches a predefined location on the bales circumference, the control system may switch the crop flow from the main bale forming chamber to the prechamber.

In particular, the process of enclosing a first part of the binding material at a predetermined location on the circumference of the bale may be automated. A minimum quantity of crop needed to enclose the first part of the binding material in the bale's circumference can be defined as part of the automation of the machine's crop flow and baling systems. For example, the length of the binding material wrapped around the bale can be determined. A specific length of the binding material may lead to the conclusion that the binding material has reached the predetermined location so that it is ensured that some crop is arranged on the binding material.

In examples, the control system is configured to change a direction of the flow of the crop material feeding into the main bale forming chamber into the prechamber. The control system may be programmed to alter the direction of flow of the crop material when the binding material is any location from <NUM> to <NUM> degrees on the bale's circumference in the main bale forming chamber.

In examples, the linear length of the binding material is measured as it wraps the bale of crop in the main bale forming chamber. When the binding material reaches a certain predetermined set value which corresponds to a point in the baling chamber's circumference, the control system may alter the direction of the crop from one chamber to the other chamber. As a result, the crop flow is automatically stopped from entering the main bale forming chamber at a predetermined value in the binding cycle and the binding material can be covered by a specific volume of incoming crop which may be automatically controlled by the control system, therefore removing the need for an action by the operator of the machine.

In examples, a predetermined value selected in the control system, which may be linearly linked to a location in the bale chambers circumference, may not be affected by a rotational speed of the main bale forming chamber and / or the prechamber. The rotational speed of the chambers may be directly related to a linear speed at which the binding material enters the main bale forming chamber and follows the bales circumference. As a result, the predetermined point for switching the crop from one of the chambers to the other chamber will remain the same.

In examples, a system to obtain signalled information from the machine may be provided, a calculating process to translate information through formulation and a means for the formulated information to influence the devices on the baling machine to control the crop flow into either of the baler's chambers may be provided.

In examples, signalled information may be obtained and recorded from the chambers' rotational speed. In addition or alternatively, signalled information may be obtained from the main bale forming chamber concerning the pressures within the main bale forming chamber of compressing the crop material into a bale and signalled information may be recorded concerning the bale size within the main bale forming chamber.

In examples, a calculating process may be applied to provide simultaneous calculation from the signals received from the chambers. When a predetermined value is reached for the bale pressure and / or the bale size, the binding unit may be activated by the control system. The binding material is then fed into the main bale forming chamber. As the binding material is fed into the main bale forming chamber, further signalled information may be relayed back to the control system. The signalled information may then be processed and a formulation process may take place to calculate the length of the binding material entering the main bale forming chamber. When a predetermined value is reached, the control system may send a signal to change the crop flow direction from one chamber to the other chamber.

In examples, the switching of the crop flow from one chamber to the other chamber when the binding material has reached a predetermined set value may be automated by the baler's systems.

In examples, the crop may be switched from the main bale forming chamber to the prechamber with a moveable plate in a crop channel. Signalled information may be related back to a processor of the control system, and the processor may engage in a process to translate the signalled information into positional information to relay the position of the plate in the crop channel. The signalled information may later be relayed to the processor concerning the bale size and / or the density of the bale. At a predetermined value for the bale density and / or the bale size, the processor may relay information to start the binding process. Signalled information may be relayed back from the binding unit's feeding roller to determine the length of binding material entering the main bale forming chamber. The signalled information received by the baler's processor may be calculated using formulation resulting in a linear length of the binding material entering the main bale forming chamber being determined. When a preselected length of binding material has entered the main bale forming chamber, the processor may signal to the control system to move the crop to the prechamber.

In examples, the control system starts the binding of the bale prior to the bale reaching its <NUM>% (full) size and density, resulting in the binding material reaching a designated radial position on the circumference of the bale as the bale reaches the full <NUM>% in size and density as preselected parameters by the control system followed by the process of the crop switching paths to the prebale forming chamber.

In examples, the control system may automatically adjust (correction process by the control system) the starting bale size and density (<<NUM>%) of the bale control the starting of the binding and therefore at <NUM>% bale size and density, the binding material is seated on a preselected radial point on the bales circumference as such point the crop passage is altered from the main bale forming chamber into the prebale forming chamber.

In examples, the starting of the binding at a starting bale size and density (<<NUM>%) can be altered / corrected automatically by the control system depending on the result of the previous bale, the control system automatically calculates the finished size and density of the bale post binding cycle resulting in a corrective calculation to start the next binding cycle at a later % bale size and or density or at an earlier % bale size and density depending on the final bale size and density calculation of the bale post binding cycle.

In examples, the control system may automatically calculate and adjust the starting bale size and density for the binding to start resulting in a final bale size that is consistent with the initial parameters inputted into the control to have a final bale of product that is comparable in size and density to the actual parameters inputted or preset on the balers control system.

Following, further embodiments are described by referring to figures. In the figures show:.

<FIG> shows a schematic representation of a baling machine <NUM> of the nonstop type. The baling machine <NUM> is provided with a prechamber <NUM> in which a preformed bale is prepared in the process of forming a bale from crop <NUM>. There is a first feeding channel <NUM> configured to feed the crop <NUM> picked up by a crop pickup mechanism <NUM> to the prechamber <NUM>.

There is a second feeding channel <NUM> for feeding or guiding the crop <NUM> into a main baling forming chamber <NUM>. In the main bale forming chamber <NUM> a full bale of crop material is prepared.

A crop cutting device <NUM> is provided. A crop switching plate <NUM> can be pivoted on the rear side of the crop cutting device <NUM> for guiding the crop <NUM> to at least one of the prechamber <NUM> and the main bale forming chamber <NUM>.

The feeding of the crop <NUM> is conducted by a feeding mechanism <NUM>.

While according to <FIG> the crop <NUM> is fed to the main bale forming chamber <NUM>, the crop <NUM> is fed to the prechamber <NUM> according to <FIG> when the crop switching plate <NUM> is in a different position compared to <FIG>.

A binding apparatus <NUM> is provided for the baling machine <NUM>. The binding apparatus <NUM> is provided with a roll <NUM> of binding material. A binding material pathway <NUM> is provided. A tail end <NUM> of the binding material is on the circumference of the bale <NUM>.

Further, a feeding roller <NUM> is provided for the binding apparatus <NUM>.

Referring to <FIG>, further aspects are described, specifically with respect to the binding apparatus <NUM> provided in a binding unit <NUM>.

In <FIG> bale chamber rollers <NUM> are depicted applied for forming the bale <NUM>.

A braking apparatus structure <NUM> is provided.

There are binding material guide rollers <NUM>.

The binding unit <NUM> is provided with a frame <NUM>. With respect to the binding unit <NUM>, a binding apparatus grouping mechanism <NUM> and a binding material cutting mechanism <NUM> are provided.

A part <NUM> of the binding material is entering the main bale forming chamber <NUM> between one of the bale chamber rollers <NUM> and the circumference of the bale <NUM>.

The binding material is provided by a roll of binding material <NUM>. The binding material is moved along a path <NUM> when leaving the roll of binding material <NUM>.

A stretch roller <NUM> (stretching / braking roller) is provided.

A secondary force depicted by reference numeral <NUM> is applied to the stretch roller <NUM>.

There is a braking roller <NUM> of the braking apparatus structure <NUM> for providing a braking mechanism.

A primary force depicted by reference numeral <NUM> is applied to the stretch roller <NUM>.

There is a primary force monitoring device <NUM>.

A connecting rod <NUM> is connecting an actuator for braking in the brake mechanism.

Further, a binding material feeding roller <NUM> is provided.

<FIG> shows a schematic representation of a binding apparatus, wherein the binding apparatus is provided with a braking mechanism, within the braking mechanism the stretch roller locates in the parked / binding roll recharge position. In this state, the binding unit <NUM> is in a switch over state, the braking mechanism <NUM> is lifted into a home position so the binding material roll can be recharged when the binding material <NUM> goes empty.

<FIG> shows a schematic representation of a binding apparatus, wherein the braking mechanism is shown, within the braking mechanism the stretch roller locates in the binding feed position, located away from the binding material. The binding unit <NUM> is now engaged in the working mode, the roll of binding material <NUM> is in position and the braking mechanism <NUM> is lifted from the binding materials surface so the binding material can be pulled from the roll and fed into the baling chamber <NUM>. The binding material follows a path <NUM> from the circumference of the binding material roll over the guiding rollers <NUM>, between the plastic grouping sys-tem <NUM>, through the binding systems feeding rollers and cutting mechanism and in-to the baling chamber <NUM>.

<FIG> shows a schematic representation of the binding apparatus, wherein the braking mechanism is shown, within the braking mechanism the stretch roller locates in the binding completion position. The primary braking apparatus is removed from the stretching roller locates, the roll of binding material <NUM> is in position and the primary braking mechanism <NUM> is lifted from the braking roller so the binding material can be cut by the binding unit <NUM> knife unit <NUM>.

<FIG> shows a schematic representation of the binding apparatus, wherein the braking mechanism is shown, within the primary braking apparatus <NUM> is removed from the braking roller and the secondary braking force <NUM> is removed by the lifting of the braking roller <NUM> from being in contact with the binding material <NUM>.

Claim 1:
A method for operating a round baler, comprising
- providing a nonstop baler type machine (<NUM>);
- controlling a feeding mechanism (<NUM>) for feeding of crop into a prechamber (<NUM>) and a main bale forming chamber (<NUM>) by a control system of the baler;
- in a feeding operation, feeding the crop (<NUM>) through a first feeding channel (<NUM>) into the prechamber (<NUM>); and
- switching the feeding operation by the control system, thereby, stopping feeding the crop (<NUM>) into the prechamber (<NUM>) and starting feeding the crop (<NUM>) through a second feeding channel (<NUM>) into a main bale forming chamber (<NUM>) of the baler;
characterized by
obtaining signaled information from the main bale forming chamber (<NUM>) concerning pressures within the main bale forming chamber (<NUM>) of compressing the crop (<NUM>) into a bale and recording signaled information concerning the size of the bale within said main bale forming chamber (<NUM>);
starting the binding of the bale by the control system prior to the bale reaching its full size
so that the binding material is reaching a designated radial position on the circumference of the bale as the bale reaches the full <NUM>% in size and density
by providing a binding material for wrapping the bale formed in the main bale forming chamber (<NUM>);
stretching the binding material by a stretching means comprising a stretch roller when wrapping the bale within the main bale forming chamber (<NUM>);
applying an external braking force to the stretch roller to provide a braking effect while in contact with the binding material;
releasing the stretching and the braking force at the end of the binding cycle; and
switching from the feeding operation towards the main bale forming chamber (<NUM>) to the feeding operation towards the prechamber (<NUM>) in response to a binding material parameter reaching a predetermined parameter value by the control system.