Patent Description:
Agricultural harvesting machines, such as balers, are used to consolidate and package crop material so as to facilitate the storage and handling of the crop material for later use. In the case of hay or silage, a mower-conditioner is typically used to cut and condition the crop material. In the case of straw, an agricultural combine discharges non-grain crop material from the rear of the combine defining the straw (such as wheat or oat straw) which is to be picked up by the baler. The cut crop material is typically raked into a windrow, and a baler, such as a large square baler or round baler, straddles the windrows and travels along the windrows to pick up the crop material and form it into bales.

A round baler may generally include a frame, supported by wheels, a hydraulic system, a pickup unit to engage and lift the crop material into the baler, a cutting assembly, a main bale chamber for forming a bale, and a wrapping mechanism for wrapping or tying a material around the bale after it has been formed in the main bale chamber. As the baler is towed over a windrow, the pickup unit lifts the crop material into the baler. Then, the crop material may be cut into smaller pieces by the cutting assembly. As the crop material enters the main bale chamber, multiple carrier elements, e.g. rollers, chains and slats, and/or belts, will begin to roll a bale of hay within the chamber. These carrier elements are movable so that the chamber can initially contract and subsequently expand to maintain an appropriate amount of pressure on the periphery of the bale. After the bale is formed and wrapped by the wrapping mechanism, the rear of the baler is configured to open for allowing the bale to be discharged onto the field.

Traditionally, the frame of the baler (see <CIT>) is composed of a single or one-size main frame, which defines the roller fixation points, drives, and tail gate pivot axis. Since the positions of the roller fixation points, drives, and tail gate help to define the bale chamber, the one-size frame thereby also determines the resulting size of the bale which is produced by the bale chamber. Hence, variously sized balers which produce differently sized bales each have a differing frame. As can be appreciated, a manufacturing company may incur additional costs in designing a separate and unique frame for each differently sized baler.

What is needed in the art is a cost-effective frame assembly for an agricultural round baler.

In one exemplary embodiment formed in accordance with the present invention, there is provided a multi-part frame assembly of an agricultural round baler. The frame assembly includes a universal main frame and a pair of interchangeable frame modules removably connected to the main frame. Each frame module of the pair of frame modules includes at least one roller mount configured for mounting the at least one roller and a tail gate mount configured for mounting the tail gate. The pair of frame modules defines a baler size for producing a correspondingly sized round bale such that interchanging the frame modules will produce a different baler size of the baler, without needing to change the main frame.

In another exemplary embodiment formed in accordance with the present invention, there is provided a frame assembly of an agricultural round baler. The agricultural round baler includes at least one roller and a tail gate. The frame assembly includes a main frame and a pair of frame modules removably connected to the main frame. Each frame module of the pair of frame modules includes at least one roller mount configured for mounting the at least one roller and a tail gate mount configured for mounting the tail gate and defining a pivot axis of the tail gate. The pair of frame modules defines a baler size for producing a correspondingly sized round bale.

In yet another exemplary embodiment formed in accordance with the present invention, there is provided an agricultural round baler for baling crop material in a field. The agricultural round baler includes a plurality of rollers defining a bale chamber, a tail gate, and a frame assembly. The frame assembly includes a main frame and a pair of frame modules removably connected to the main frame. Each frame module of the pair of frame modules includes at least one roller mount and a tail gate mount defining a pivot axis of the tail gate. At least one roller of the plurality of rollers is mounted to the at least one roller mount and the tail gate is pivotally mounted to the tail gate mount. The pair of frame modules defines a baler size for producing a correspondingly sized round bale.

One possible advantage of the exemplary embodiment of the frame assembly of the agricultural baler is that the interchangeable frame modules contain all the necessary changes between bale sizes, which significantly reduces the complexity and cost in manufacturing variously sized balers.

The terms "forward", "rearward", "left" and "right", when used in connection with the agricultural baler and/or components thereof are usually determined with reference to the direction of forward operative travel of the towing vehicle, but they should not be construed as limiting. The terms "longitudinal" and "transverse" are determined with reference to the fore-and-aft direction of the towing vehicle and are equally not to be construed as limiting.

Referring now to the drawings, and more particularly to <FIG>, there is shown a cross-sectional, side view of a known round baler <NUM> which may be towed by a vehicle <NUM> in a forward direction of travel F. The vehicle <NUM> may be any desired vehicle, such as an agricultural vehicle in the form of a tractor <NUM>.

Crop material is lifted from windrows into the baler <NUM> by a pickup unit <NUM>. The pickup unit <NUM> includes a rotating pickup reel <NUM> with tine bars and tines <NUM>, which move the crop rearward toward a variable bale chamber <NUM>. The reel <NUM> is rotatable in an operating direction for lifting the crop material off of the ground and a reverse direction, i.e., opposite to the operating direction.

The bale chamber <NUM> is configured as a variable bale chamber <NUM> which includes multiple rolls or rollers <NUM>, <NUM>, such as various stationary rollers <NUM> and movable rollers <NUM>, actuators and pivot arms coupled to the movable rollers <NUM>, and at least one belt <NUM>. The rollers <NUM>, <NUM> may comprise a floor roller, starter roller, fixed roller(s), pivot roller(s), stripper roller, and/or follower roller(s). Together, the rollers <NUM>, <NUM> and the belt(s) <NUM> create a round circulating chamber <NUM> which expands in between an empty bale position and a full bale position for engaging and rolling the bale. As the bale grows inside the chamber <NUM> it begins to act upon the belts <NUM> such that the belts <NUM> pull against the pivot arms which in turn causes the movable rollers <NUM> to move upwardly so that the variable bale chamber <NUM> incrementally expands with the size of the bale.

When the bale reaches a predetermined size, the bale is wrapped with a wrapping material (e.g., mesh or twine) by a wrapper. Then, once fully wrapped, the bale is ejected out of the tail gate <NUM>. The tail gate <NUM> may pivot upwardly about pivot axis <NUM> to open the bale chamber <NUM>. Then, the bale rolls out of the bale chamber <NUM> and onto a bale ejector or kicker <NUM>, which pushes the bale rearwardly away from the baler <NUM> so that the tail gate <NUM> may downwardly pivot unencumbered by the ejected bale.

The baler <NUM> can further include an electrical processing circuit <NUM>, e.g. controller <NUM> with a memory <NUM>, for conducting various baling procedures. For instance, the controller <NUM> can be configured for carrying out the bale discharge operation. Hence, the controller <NUM> may open the tail gate <NUM> via accompanying actuators upon sensing a full bale condition by a bale-size sensor.

The baler <NUM> has a main frame <NUM> which supports the various components of the baler <NUM>, including the roller fixation points, drives, and tail gate pivot point <NUM>. The main frame <NUM> is a single or one-size main frame <NUM>. In other words, the main frame <NUM>, which may be a welded construction, is a one-size main frame <NUM> which dictates the size of the bale chamber <NUM>. Thereby, the main frame <NUM> also dictates the size of the bale which is produced by the bale chamber <NUM>. Hence, variously sized balers which produce differently sized bales each have a differing main frame. As can be appreciated, designing a different main frame for each size of bale may place a significant burden on the manufacturing company which manufactures the baler. For instance, designing several main frame structures may take additional design time, test time, and increase the manufacturing tooling investment and complexity.

Referring now collectively to <FIG>, there is shown an embodiment of a round baler <NUM> with a frame assembly <NUM> that includes a standardized or universal main frame <NUM> and a pair of interchangeable frame modules <NUM>, <NUM> for tailoring the baler size of the round baler <NUM>, i.e., the size of the bale produced by the round baler <NUM>. The round baler <NUM> may be substantially similar to the round baler <NUM> as described above, except that the round baler <NUM> includes the frame assembly <NUM> instead of the one-size main frame <NUM>. The frame assembly <NUM> supports the various components of the round baler <NUM>. For instance, the frame assembly <NUM> supports the roller drive architecture including the conveyor <NUM>, e.g. drive chain <NUM>, and sprockets <NUM>, <NUM> coupled to the drive chain <NUM>, fixed and idler rollers <NUM>, <NUM> operably connected to the sprockets <NUM>, and the tail gate <NUM>.

The main frame <NUM> may comprise a welded construction of one or more component. The upper portion on each side of the main frame <NUM> may include a recess or cutout for accommodating the frame module <NUM>, <NUM>. The main frame <NUM> may comprise any desired material, such as metal and/or plastic.

Each frame module <NUM>, <NUM> is removably connected to the main frame <NUM>. For example, each frame module <NUM>, <NUM> may include one or more receiving holes <NUM> for receiving corresponding fastener(s), such as bolts and/or screws, that removably attach each respective frame module <NUM>, <NUM> to the corresponding sides of the main frame <NUM>. The left and right frame modules <NUM>, <NUM> may substantially mirror one another, except that the left frame module <NUM> may include additional mounting features for supporting the roller drive architecture of the round baler <NUM>. For example, both frame modules <NUM>, <NUM> may include at least one roller mount <NUM>, <NUM> for mounting any desired roller <NUM>, <NUM>, a tail gate mount <NUM> defining the pivot point <NUM>, i.e., axis, of the tail gate <NUM>, a side panel mount <NUM> for mounting a respective side panel of round baler <NUM>, and a lift-hook mounting point <NUM> for receiving a lift hook to lift the round baler <NUM>. The left frame module <NUM>, as viewed in the forward direction of travel, further includes a chain mount <NUM> to which the chain sprocket <NUM> and drive chain <NUM> are mounted. Thereby, the frame modules <NUM>, <NUM> may collectively support the drive chain <NUM>, sprockets <NUM>, <NUM>, fixed and idler rollers <NUM>, <NUM>, and the tail gate <NUM>. As can be appreciated, the body of each frame module <NUM>, <NUM> may comprise one or more components and any desired material. The frame modules <NUM>, <NUM> may correspond to a <NUM> meter-sized baler (<NUM> foot-sized baler).

The at least one roller mount <NUM>, <NUM> of each frame module <NUM>, <NUM> mounts at least one roller <NUM>, <NUM>. The at least one roller mount <NUM> may include two fixed-roller mounts <NUM> for respectively mounting two fixed rollers <NUM> and a single idler roller mount <NUM> for mounting the idler roller <NUM>. Hence, the roller mounts <NUM>, <NUM> may define and set the roller fixation points of the fixed and idler rollers <NUM>, <NUM>. Each fixed roller mount <NUM> may comprise an open recess and/or accompanying brackets for receiving and connecting the fixed rollers <NUM> to the body of the frame module <NUM>, <NUM>. The idler roller mount <NUM> may comprise an opening and/or accompanying bracket for connecting the idler roller to the body of the frame module <NUM>, <NUM>. As can be appreciated, the set locations of the rollers <NUM>, <NUM> on the frame modules <NUM>, <NUM> in part determines the size of bale which is producible by the round baler <NUM>.

The tail gate mount <NUM> may be connected to the upper, rear end of each frame module <NUM>, <NUM>. The tail gate mount <NUM> defines the pivot axis <NUM> of the tail gate <NUM>, which thereby helps to define the overall size of the bale which may be ejected by the round baler <NUM>. Each tail gate mount <NUM> may comprise a through hole, within a designated portion, e.g. plate, of the frame module <NUM>, <NUM>, for receiving a mounting bar of the tail gate <NUM>.

The side panel mount <NUM> of each frame module <NUM>, <NUM> may be located adjacent to the tail gate mount <NUM>. As shown, each side panel mount <NUM> may comprise a bracket which extends outwardly from the surface of the frame module <NUM>, <NUM>. Yet, the side panel mounts <NUM> may or may not extend beyond the surface of the frame module <NUM>, <NUM>. The side panel mounts <NUM> may mount any desired side panels which correspond to a desired baler size.

Each lift-hook mounting point <NUM> is located at the top of each frame module <NUM>, <NUM>. Each lift-hook mounting point <NUM> may comprise a receiving hole, within a designated portion, e.g. plate, of the frame module <NUM>, <NUM>, for receiving a respective lift hook in order to lift the round baler <NUM>. It should be appreciated that each frame module <NUM>, <NUM> may or may not include a lift-hook mounting point <NUM>.

As discussed above, the left frame module <NUM> may additionally include one or more mounting features for mounting the roller drive architecture, e.g. drive chain <NUM> and sprockets <NUM>, <NUM>, of the round baler <NUM>. For example, the left frame module <NUM> may further include a chain mount <NUM> and a downwardly extending protrusion <NUM> upon which the chain mount <NUM> is connected. The chain mount rotatably supports the chain sprocket <NUM>. The chain mount <NUM> may be located at the bottom of the frame module <NUM>, underneath the roller mounts <NUM>, <NUM>. The chain mount <NUM> may comprise a rod that extends outwardly from the body of the frame module <NUM>. More particularly, the chain mount <NUM> extends outwardly and perpendicularly from the protrusion <NUM>. The chain mount <NUM> may further include one or more brackets and/or fasteners for securing the chain sprocket <NUM> to the frame module <NUM>. The protrusion <NUM> may be a part of the body of the frame module <NUM>, or alternatively, the protrusion may be a separate component which is affixed to the body of the frame module <NUM>. The protrusion <NUM> may be in the form of a beam connected to the body of the frame module <NUM>. The protrusion <NUM> may comprise any desired material. It should be appreciated that the left frame module <NUM> may include more than one chain mount <NUM> may include any desired number of sprockets <NUM>, <NUM> for support the drive chain <NUM> and/or driving any desired number of rollers <NUM>, <NUM>.

Referring now to <FIG>, there is shown another embodiment of a pair of frame modules <NUM>, <NUM>. The pair of frame modules <NUM>, <NUM> may be substantially similar to the frame modules <NUM>, <NUM>, except that the frame modules <NUM>, <NUM> have a differing mounting architecture in order to procedure a differently sized baler for producing a correspondingly sized bale. For example, the frame modules <NUM>, <NUM> may have an extended body that is taller than the body of the frame modules <NUM>, <NUM>. Also, for example, the frame modules <NUM>, <NUM> may have a differently located idler roller mount <NUM>. Furthermore, the left frame module <NUM> may not include a protrusion <NUM>; and hence, the chain mount <NUM> may be located within the body of the frame module <NUM>. The frame modules <NUM>, <NUM> may correspond to a <NUM> meter-sized baler (<NUM> foot-sized baler). Like elements between the frame modules <NUM>, <NUM>, <NUM>, <NUM> have been identified with like reference characters except with the <NUM> series designation for the frame modules <NUM>, <NUM>.

Since the frame modules <NUM>, <NUM> contain all the necessary changes between bale sizes, the frame modules <NUM>, <NUM> reduce the complexity and cost in manufacturing variously sized balers. A desired set of frame modules <NUM>, <NUM>, <NUM>, <NUM> may be connected to the main frame <NUM> at the time of manufacture of the baler <NUM>, or the frame modules <NUM>, <NUM> may be interchanged with another set of frame modules <NUM>, <NUM> after the sale of the baler <NUM>. For example, a farmer may alter the size of his current baler <NUM> by buying new frame modules <NUM>, <NUM> and accordingly interchanging the existing frame modules <NUM>, <NUM> with the new frame modules <NUM>, <NUM> to achieve a desired baler size. As can be appreciated, the farmer may also need to alter the belt sizes in order to achieve a differently sized bale chamber for producing a correspondingly sized bale.

Claim 1:
An agricultural round baler (<NUM>) for baling crop material in a field, comprising:
a plurality of rollers (<NUM>, <NUM>) defining a bale chamber;
a tail gate (<NUM>); and
a frame assembly (<NUM>), comprising:
a main frame (<NUM>), and
in characterized that:
the frame assembly (<NUM>) further comprising a pair of frame modules (<NUM>, <NUM>) defining a baler size for producing a correspondingly sized round bale, the pair of frame modules (<NUM>, <NUM>) being removably connected to the main frame (<NUM>), each frame module (<NUM>, <NUM>) of the pair of frame modules (<NUM>, <NUM>) comprising at least one roller mount (<NUM>, <NUM>) and a tail gate mount (<NUM>) defining a pivot axis of the tail gate (<NUM>),
wherein at least one roller (<NUM>, <NUM>) of the plurality of rollers (<NUM>, <NUM>) is mounted to the at least one roller mount (<NUM>, <NUM>),
wherein the tail gate (<NUM>) is pivotally mounted to the tail gate mount (<NUM>).