Patent Description:
Balers for forming cylindrical bales of agricultural crop bale material are well known, and such bales are usually referred to as "round" bales. The baler has a bale chamber within which a cylindrical bale can be formed, means for feeding bale material into the bale chamber, and an arrangement of pressing elements, for example a series of circumferentially spaced rolls and/or a set of belts supported by rolls, which define a part-cylindrical surface of the bale chamber. As is well known in the art, balers can be of the "fixed chamber" or "variable chamber type", depending on the type of pressing element used. The present invention is applicable to both of these types of baler. The invention is also applicable to combined baler/wrapper machines.

Typically, an agricultural baler is pulled by a tractor and driven by the power take off of the tractor.

The bale material, for example an agricultural crop, is picked up from the ground by a pick-up device. The bale material is optionally processed by a cutting device and then fed into the bale chamber, which comprises a pair of side panels and a number of pressing elements, for example rotating compression rollers and/or belts. The bale material is tumbled within the bale chamber and compressed by the pressing elements forming a cylindrical bale. Once the bale has reached a predetermined size and/or compression the feeding is stopped and the bale is then bound with a binding material, which binds the compressed bale material together under pressure. The finished bale is then ejected from the bale chamber.

In both variable chamber and fixed chamber balers the bale chamber typically has a feed opening through which the bale material is fed into the bale chamber as the bale is formed. The feed opening is typically located between a pair of pressing elements, for example a pair of compression rolls or belt support rolls, which are spaced apart to form the feed opening.

In order to support the bale material and the surface of the partly-formed bale as it moves across the feed opening, a support element is usually provided in or adjacent to the feed opening. The support element typically comprises a fixed plate-like structure that is attached to the side panels of the baler and extends across the width of the feed opening.

During filling of the bale chamber the support element supports the surface of the partly compressed/formed bale as it rotates across the feed opening and helps to prevent bale material falling away from the surface of the bale. If the bale is not supported in this way, bale material may fall away from the surface of the bale and may then be fed back into the bale chamber in lumps, which can affect the shape of the bale. As a result, the bale can be badly formed, for example irregularly shaped and lacking roundness.

The support element partly bridges the gap between the pressing elements on either side of the feed opening and helps to prevent bale material from breaking away from the bale surface during forming of the bale. The support element mat be essential for making well-formed round bales, particularly under circumstances where there is little cohesion in the compacted bale material (for example, when the bale material has a short length) or when the bale material expands easily after compression (for example when the bale material is relatively dry).

It is known to mount the support element to the side panels of the baler with releasable attachment devices, so that the support element can be removed when it is not needed, for example when the bale material has good cohesion and does not expand excessively. In this case, the attachment devices are located in fixed position on the side panels of the baler.

In many balers the bale material is bound using net binding material. Lately balers have been developed that use stretch film binding material to bind the bale.

When film binding material is used certain problems can sometimes arise in relation to the support element. The support element presses against the surface of the rotating bale both during forming of the bale and subsequently during binding of the bale. The film binding material is very sensitive to damage and when it rubs across the surface of support element the film binding material can easily tear. As a result the film binding applied to the surface of the bale can lose its function as a barrier for gas and moisture. The binding function of the film binding material can also be affected, so that the bale is no longer maintained under sufficient compression.

With net binding material these problems do not arise because net binding material is much tougher and it slips more easily over the surface of the support element, so that it is not damaged by rubbing against the support element.

It is an object of the present invention to provide a baler that mitigates one or more of the aforesaid problems.

According to one aspect of the present invention there is provided a baler as defined by one or more of the claims.

The baler includes a plurality of pressing elements for rotating and pressing a mass of bale material in a bale chamber to form a round bale, a feed opening through which bale material can be fed into the bale chamber, and a support element located within the feed opening. The support element is displaceable between a supporting position and a retracted position, wherein the supporting position is located adjacent the bale chamber and the retracted position is located further away from the bale chamber.

The feed opening is located between a pair of said pressing elements.

The support element is located between the pair of pressing elements.

The support element may optionally be configured in the supporting position to engage and support the mass of bale material as it rotates within the bale chamber.

The support element may optionally not support or provide a reduced level of support for the mass of bale material as it rotates within the bale chamber.

The support element is configured to be located in the retracted position during at least part of a binding operation, in which binding material is applied to the round bale in the bale chamber, so that the support element does not press on the binding material as it is passed around the bale. This helps to avoid damaging the binding material. The binding material can be a stretch film binding material. The support element can be configured to be located in the supporting position during making of the bale so that it supports the mass of bale material in a bale chamber.

Optionally, the supporting position and the retracted position are separated by a distance D, where D is at least <NUM>, or at least <NUM>.

Optionally, the distance D is in the range <NUM>-<NUM>, or <NUM>-<NUM>, or <NUM>-<NUM>.

Optionally, the bale chamber has a rotational axis that is defined by the longitudinal axis of a round bale in the bale chamber, and the retracted position is located radially further than the supporting position from the rotational axis.

Optionally, the baler includes a binding apparatus for binding the bale in the bale chamber with stretch film binding material.

Optionally, the baler further comprises a support mechanism that enables the movement of the support element between the supporting position and the retracted position.

Optionally, the support mechanism enables linear movement of the support element.

Optionally, the support mechanism enables pivoting movement of the support element, optionally about a pivot axis. Optionally, the pivot axis coincides with a rotational axis of a pressing element. Optionally, the support mechanism includes a lever. Optionally, one end of the lever is connected to the support element. The support element can comprise an elongate body. The elongate body can have a teardrop or oval transverse cross-section. Optionally, the lever is arranged to pivot about the pivot axis. Optionally, the pivot axis can be located in a central portion of the lever. Optionally, the pivot axis is located towards one end of the lever, and preferably towards the end of the lever connected to the support element. Optionally, the pivot axis is arranged parallel with the rotational axis of the pressing element. Optionally, the pivot axis is arranged parallel with a central longitudinal axis of the support element. Optionally, the pivot axis is located on the lever in a position such that the pivot axis does not pass through the elongate body.

Optionally, the support mechanism comprises a control element that controls movement of the support element between the supporting position and the retracted position.

Optionally, the control element comprises a resilient element that provides a biassing force that urges the support element towards the supporting position.

Optionally, the resilient element includes a control mechanism that is configured to adjust the biassing force.

Optionally, the control element comprises an actuator that is operable to move the support element between the supporting position and the retracted position.

Optionally, the baler further comprises a control system that controls operation of the control element.

Optionally, the control system is configured to control operation of the control element, such that the support element is located in the supporting position during a bale making operation when a round bale is formed in the bale chamber, and the support element is located in the retracted position during at least part of a binding operation when a binding material is applied to the round bale in the bale chamber.

Optionally, the control system is configured move the support element from the supporting position to the retracted position at the start of the binding operation or during the binding operation.

Optionally, the control system is configured move the support element from the retracted position to the supporting position at or prior to the start of the bale making operation.

Alternatively, the support element may be resiliently biased towards the supporting position and configured to move from the supporting position to the retracted position against a resilient biassing force.

Optionally, the control system includes a user interface via which a user may control operation of the control system.

Optionally, the baler further comprises a binding mechanism that is configured to apply a binding material to a bale formed in the bale chamber.

Optionally, the baler is a fixed chamber round baler.

Optionally, the pressing elements comprise rotary rollers.

Optionally, the pressing elements comprise flexible belts.

Optionally, the baler is an agricultural baler that is configured for baling an agricultural crop material.

Optionally, the baler includes a pick-up apparatus for picking up bale material from the ground and feeding it to the bale chamber for baling.

According to one embodiment, the baler is a variable chamber baler comprising a plurality of endless belts that extend around two or more of the pressing elements, wherein said belts define the bale chamber. Optionally, the belts are separated widthwise from one another with regard to the width of the bale chamber.

According to another embodiment, the baler is a fixed chamber baler comprising a plurality of plurality of rolls that define the bale chamber.

The baler is preferably an agricultural baler that is configured for baling an agricultural crop material. Advantageously, the baler includes a pick-up apparatus for picking up bale material (e.g. crop material) from the ground and feeding it to the bale chamber for baling.

Certain embodiments of the invention will now be described by way of example with reference to the accompanying drawings, wherein:.

<FIG> of the drawings illustrates an agricultural baler <NUM> according to one embodiment of the invention. In this embodiment the baler <NUM> is a fixed chamber round baler. However, it could alternatively be a variable chamber round baler.

The baler <NUM> comprises a wheeled machine that is intended to be drawn behind a tractor or other propelling vehicle. The baler <NUM> includes a frame <NUM>, a drawbar <NUM> and a pair of wheels <NUM>. The baler <NUM> will normally pick up bale material <NUM>, for example crop material that has already been cut or mown, and which is lying on the ground. A pick-up device <NUM> is configured to pick up the bale material <NUM> from the ground and feed it to a rotary feeding device <NUM>, which may optionally include a chopping device comprising a set of rotating knives. The chopped bale material is then fed over a feed chute <NUM> and through a feed opening <NUM> into a cylindrical bale chamber <NUM> in the direction of arrow <NUM>.

The baler <NUM> comprises a housing <NUM> that includes a fixed front part <NUM> that is attached to the frame <NUM> and a pivoting rear part <NUM>. The bale chamber <NUM> is located within the housing <NUM>, approximately half of the bale chamber being located in the front part <NUM> and half in the rear part <NUM>. Thus, the front and rear parts <NUM>, <NUM> of the housing <NUM> each comprise approximately half of the bale chamber <NUM>. The pivoting rear part <NUM> of the housing serves as a tailgate <NUM>, which can be opened by pivoting the tailgate <NUM> about a pivot point <NUM> located towards the upper part of the housing <NUM>. An actuator <NUM>, for example a hydraulic actuator, may be provided for adjusting the position of the tailgate <NUM>. The tailgate <NUM> is shown in a closed condition in <FIG>.

The cylindrical bale chamber <NUM> includes a pair of opposed side panels <NUM> and plurality of pressing elements <NUM>, in this embodiment a set of compression rollers, which are spaced around the circumference of the bale chamber <NUM>. Some of these compression rollers <NUM> are mounted within the fixed front part <NUM> of the bale chamber <NUM>, and some are provided within the pivoting rear part <NUM> of the bale chamber <NUM>. The compression rollers <NUM> are provided with drive means <NUM>, for example drive sprockets, which are driven by a drive chain <NUM> and are configured to be rotated in the same direction, as indicated by the arrows <NUM> in <FIG>. This causes any bale material in the bale chamber <NUM> to rotate in the contrary direction, as indicated by arrow <NUM>. The compression rollers <NUM> may optionally be provided with traction elements <NUM>, for example ribs or studs, which project from the cylindrical surfaces of the compression rollers <NUM> in order to transfer drive effectively to the bale material in the bale chamber <NUM>.

Alternatively, in a variable chamber baler the pressing elements <NUM> may for example comprise a set of belts, chains of similar flexible elongate elements, which may be supported by rolls, sprockets or similar components.

A binding device <NUM> is provided for feeding a binding material, for example a net binding material or a stretch film binding material, into the bale chamber <NUM> to bind a bale B that has been formed in the bale chamber <NUM>.

The feed opening <NUM> is located between a pair of the pressing elements comprising a first pressing element 24a and a second pressing element 24b. In this embodiment the first pressing element 24a is located above the feed opening <NUM>, and the second pressing element 24b is located below the feed opening <NUM>. As the bale material rotates within the bale chamber <NUM> in the direction of arrow <NUM> it rotates initially past the first pressing element 24a and subsequently past the second pressing element 24b.

A support element <NUM> is located within the feed opening <NUM>. In this embodiment the support element is located just below the first support element 24a in the upper part of the feed opening <NUM>. It is positioned close to the outer circumference of a bale B formed in the bale chamber <NUM>. The support element is positioned to support the bale material forming the bale B, when the bale is either partly-formed or fully-formed, to help prevent bale material falling away from the surface of the bale B as it travels across the feed opening <NUM> between the first pressing element 24a and the second pressing element 24b.

In this embodiment the support element <NUM> comprises an elongate body, for example in the form of an elongate beam that extends across the width of the bale chamber and it has a transverse cross-sectional shape resembling an oval or raindrop having a convex outer surface. The transverse cross-section can be perpendicular to a longitudinal axis of the support element <NUM>. The outer surface is smooth and the shape of the support element <NUM> is designed to allow the surface of the bale to run smoothly over the support element <NUM> with low friction. The support element <NUM> may however have other shapes, for example it may comprise a flat or curved plate or a beam having a different transverse cross-sectional shape, for example square, rectangular, elliptical or a combination of straight and/or curved surfaces.

As illustrated more clearly in <FIG>, the support element <NUM> is configured to move between a supporting position shown in solid lines in which it is positioned close to the outer circumference of the bale B to support the bale material during forming of a bale, and a retracted position <NUM>' shown in broken lines in which it is displaced away from the outer circumference of the bale B. Typically, the support element <NUM> may move through a distance D in the range <NUM>-<NUM> centimetres between the supporting position <NUM> and the retracted position <NUM>'.

As illustrated for example in <FIG>, <FIG> the support element <NUM> may be supported by a support mechanism <NUM> that allows the support element <NUM> to move between the supporting position <NUM> and the retracted position <NUM>'. Various different types of support mechanism <NUM> may be provided as illustrated in the figures.

For example, in a first embodiment as illustrated in <FIG> the support mechanism <NUM> may comprise a pivot support mechanism that allows the support element <NUM> to pivot between the supporting position shown in solid lines and the retracted position shown in broken lines. In this embodiment the support mechanism <NUM> comprises a lever <NUM> that is connected at a first end thereof to the support element <NUM> and is supported for pivoting movement about a pivot axis 35a to enable movement of the support element <NUM> towards and away from a bale B in the bale chamber. In the example of <FIG> the pivot axis 35a coincides with the rotational axis of the first pressing element 24a. An advantage of having the pivot axis 35a coincide with the rotational axis of the first pressing element 24a is that the distance between the first pressing element 24a and the support element <NUM> does not change as the support element <NUM> moves between supporting position and the retracted position <NUM>'. Typically, the pivot axis 35a is located in a central portion of the lever <NUM>.

The pivot axis 35a may alternatively be located elsewhere such that it does not coincide with the rotational axis of the first pressing element 24a. This is illustrated in a second embodiment, which is shown in <FIG>. The embodiment of <FIG> includes the support mechanism <NUM> comprising a pivot support mechanism that allows the support element <NUM> to pivot between the supporting position shown in solid lines and the retracted position <NUM>' shown in broken lines. In this embodiment the support mechanism <NUM> comprises the lever <NUM>, which is connected at a first end thereof to the support element <NUM>, and is supported for pivoting movement about a pivot axis 35a to enable movement of the support element <NUM> towards and away from a bale B in the bale chamber. The pivot axis 35a of the lever is arranged parallel to the rotational axis of the first pressing element 24a. The pivot axis 35a can be located towards one end of the lever <NUM>, and preferably towards the end of the lever that is connected to the support element <NUM>. The pivot axis 35a is located to enable the support mechanism <NUM> to enlarge the distance between the bale B and the support element <NUM>. Typically, this can be achieved by locating the pivot axis 35a on the lever in a position that is adjacent to, but outside of, the support element <NUM>. That is, the pivot axis 35a does not pass through the elongate body <NUM>. The pivot axis 35a is arranged parallel to the elongate body <NUM>.

In the embodiments of <FIG> and <FIG>, the support element <NUM> is urged towards the bale B by a control element <NUM>, which in these embodiments comprises a hydraulic actuator that is connected between a second end of the lever <NUM> and an anchor point (not shown) of the frame of the baler. By activating the actuator <NUM> the support element <NUM> may be moved towards and away from a bale B in the bale chamber as required.

In a third embodiment illustrated in <FIG> the support mechanism <NUM> again comprises a lever <NUM> that is connected at a first end to the support element <NUM> and is supported for pivoting movement about a pivot axis 35a to enable movement of the support element <NUM> towards and away from a bale B in the bale chamber. The position of the support element <NUM> relative to the bale B is controlled by a control element <NUM>, which in this embodiment comprises a hydraulic actuator that is connected to the second end of the lever <NUM>. The actuator <NUM> is connected to a hydraulic control circuit comprising a pair of hydraulic control lines 38a,b. A hydraulic accumulator <NUM> is connected to the first control line 38a and allows movement of the support element in response to variations in the profile of the rotating bale B. A gauge <NUM> senses the hydraulic pressure in the first control line 38a, allowing operation of the actuator <NUM> to be monitored.

In a fourth embodiment illustrated in <FIG> the support mechanism <NUM> may alternatively comprise a sliding support mechanism <NUM> that enables sliding movement of the support element <NUM> between the supporting position and the retracted position. The sliding support mechanism <NUM> may be configured to allow sliding movement of the support element <NUM> along either a straight linear path or a curved path. The sliding support mechanism <NUM> may include a control element <NUM>, for example a hydraulic actuator, that controls movement of the support element <NUM> between the supporting position and the retracted position. The hydraulic actuator <NUM> is connected to a hydraulic control circuit similar to that shown in <FIG>.

Other types of support mechanism <NUM> may alternatively be provided.

In any of the various embodiments of the invention described herein, the support mechanism <NUM> may include a control element <NUM> that controls movement of the support element <NUM> between the supporting position and the retracted position. The control element <NUM> may comprise a passive control element or an active control element. A passive control element may, for example, comprise a resilient control element, for example a spring or a pneumatic piston and cylinder. An active control element may comprise an actuator, for example an electrical, mechanical or hydraulic actuator. The actuator may be controlled to move the support element <NUM> between the supporting position and the retracted position.

If a passive control element is provided, for example a resilient control element such as a spring, it may be configured to urge the support element <NUM> from the retracted position towards the supporting position. The resilient control element may thus be configured to press the support element <NUM> against the cylindrical surface of a bale in the bale chamber, but can move towards and away from the bale chamber in response to undulations in the surface of the bale. Thus, in <FIG> and <FIG> the hydraulic actuator <NUM> may be replaced by a spring.

If an active control element is provided, for example an actuator, it may be configured to move the support element <NUM> to the supporting position during one part of the bale making process and to move the support element <NUM> away from the supporting position to the retracted position during another part of the bale making process. For example, the control element may be configured to move the support element <NUM> to the supporting position while a bale is being formed in the chamber, and subsequently It may be configured to move the support element <NUM> to the retracted position during binding of the bale in the bale chamber, so that the support element <NUM> does not come into contact with the binding material. If stretch film binding material is used, this will help to avoid tearing and other problems that may arise from contact between the binding material and the support element <NUM>.

Alternatively, the control element <NUM> may be configured to hold the support element <NUM> in the supporting position during a first part of the binding process, for example while the binding material is being wrapped initially around the bale, and subsequently it may be configured to move the support element <NUM> to the retracted position, for example while the binding is completed by adding additional layers of binding material to the surface of the bale.

In another embodiment the active control element <NUM> may comprise a controllable resilient support element, for example a hydraulic actuator. In that case, the resilient force provided by the active control element may be controlled, so that the support element <NUM> is pressed against the surface of a bale in the bale chamber with different forces at different times according to the stage of the bale making process. For example, the support element <NUM> may be pressed against the surface of the bale with a first force during formation of the bale, and it may be pressed against the surface of the bale with a second force during binding of the bale, where the second force is less than the first force. The support element <NUM> will then provide a reduced support function during the binding process and will be less likely to cause tearing of the binding material.

The baler may include a control system <NUM> that is configured to control operation of the active control element <NUM>, for example an actuator. The control system <NUM> may for example be configured to control the timing of any movements of the support element <NUM> between the supporting position and the retracted position, and/or the distance D through which the support element <NUM> is moved between the supporting position and the retracted position.

An embodiment of a control system is illustrated schematically in <FIG>. In this embodiment the support mechanism <NUM> is similar to the embodiment shown in <FIG> and described above. However, the control system may alternatively be employed with any suitable support mechanism <NUM> including for example those shown in <FIG>.

As illustrated in this embodiment, the control system <NUM> may include a machine controller <NUM>, for example an electronic control device, that is configured to receive input signals from one or more sensors and/or from the operator, and to provided control signals to one or more components of the baler to control the operation thereof. For example, in this embodiment the machine controller <NUM> is connected via control lines <NUM> to one or more actuation and control sensors <NUM>, an rpm sensor <NUM> associated with one of the pressing elements <NUM>, a bale density sensor <NUM> associated with the tailgate actuator <NUM>, the control element <NUM> of the support mechanism <NUM> and an rpm sensor <NUM> associated with the rotary feeding device <NUM>. The machine controller <NUM> is also connected via a control line <NUM> to a tractor display and data entry device <NUM>, for example an operator interface. It will be appreciated that one or more of the input and output devices mentioned above may be omitted and/or that one or more of additional input and output devices may also be provided.

During operation of the baler <NUM>, bale material <NUM> is picked up from the ground by the pick-up device <NUM> and fed by the feeding device <NUM> into the bale chamber <NUM> through the feed opening <NUM>. The against the surface of the bale material is rotated by the rotating compression rollers <NUM> and starts to tumble, forming a cylindrical bale B. As more material is fed into the bale chamber <NUM> the material is pressed towards the center of the bale chamber <NUM> by the rotating compression rollers <NUM>, thereby compressing the bale B.

When the bale material is sufficiently compressed and/or when the bale has reached a required size as sensed for example by a sensor attached to the tailgate actuator <NUM>, the feeding of bale material into the bale chamber <NUM> is stopped and a binding material, for example a net binding material or a stretch film binding material, is fed from a binding device <NUM> into a gap between the pressing elements <NUM> and the surface of the bale B, and is wrapped around the compressed bale material as the bale continues to rotate in the bale chamber. usually, in the case of film binding material, several layers of film are applied to the surface of the bale to form the binding. The binding serves to keep the bale material under compression and in shape after the bale B is ejected from the bale chamber <NUM>.

Once the bale has been bound the tailgate <NUM> is opened by pivoting about the pivot axis <NUM> under control of the actuator <NUM>, to let the bale B roll out of the bale chamber <NUM>. The pressing elements <NUM> continue to rotate to help eject the bale B from the bale chamber <NUM>. After ejecting the bale B, the tailgate <NUM> is closed and the baling process is repeated.

Claim 1:
A baler including a plurality of pressing elements (<NUM>) for rotating and pressing a mass of bale material (<NUM>) in a bale chamber (<NUM>) to form a round bale (B), a feed opening (<NUM>) through which bale material (<NUM>) can be fed into the bale chamber (<NUM>), the feed opening (<NUM>) is located between a pair of said pressing elements (24a,24b), and characterized by a support element (<NUM>) located within the feed opening (<NUM>) between the pair of pressing elements (24a,24b), wherein the support element (<NUM>) is displaceable between a supporting position and a retracted position, wherein the supporting position is located adjacent the bale chamber (<NUM>) and the retracted position is located further away from the bale chamber (<NUM>), wherein the support element (<NUM>) is configured to be located in the retracted position during at least a part of a binding operation, in which binding material is applied to the round bale (B) in the bale chamber.