Patent Description:
A round bale forming apparatus picks up loose crop material from the ground, introduces the crop material into a bale forming chamber, forms from the crop material into a bale, wraps or binds at least one surface of the bale in the bale forming chamber into a web of wrapping material, and ejects the wrapped bale out of the bale forming chamber. Without wrapping the bale surface in the bale forming chamber the ejected bale would fall apart. While a problem in a bale forming and wrapping apparatus, this is a greater problem in a combination bale forming and wrapping machine in which a bound bale is transferred from the baling chamber to a wrapping table located behind the baling chamber. Accordingly, it is important that the operator of the baler can be confident that the web or wrapping material is flowing freely during wrapping or binding in the baling chamber.

It is an advantage of the present invention that it seeks to address these problems.

An alternative solution having the features of the prechacterising portion of claim <NUM> is disclosed in <CIT>.

According to a first aspect of the present invention, a baler comprising a receiving apparatus for receiving a reel of wrapping material, the receiving apparatus including a sensor arrangement for detecting rotation of a reel of wrapping material, the sensor arrangement comprising a displaceable mounting bracket, a rotary element mounted for rotation on the displaceable mounting bracket, the rotary element being provided with a textured surface and a sensor mounted on the displaceable mounting bracket for detecting rotation of the rotary element characterised in that the receiving apparatus further includes a window and that the rotary element of the sensor arrangement extends through the window.

Preferably, the rotary element comprises one or more elements including an angled surface. More preferably, the angled surface is provided by a hemispherical element.

This has as an advantage that the rotary element may easily be displaced during loading of a reel of wrapping material.

Preferably the textured surface comprises one or more regions of surface patterning. More preferably, the surface patterning comprises one or more of a region of raised dots, raised ribs, knurling or dimpling.

Preferably the sensor arrangement further comprises a fixed mounting bracket supporting the displaceable mounting bracket for movement about an axis. More preferably a biasing element acts between the fixed and displaceable mounting brackets. Still more preferably, the biasing element biases the displaceable mounting bracket away from the fixed mounting bracket.

According to a second aspect of the present invention, a combination comprising an agricultural vehicle and a baler in accordance with the first aspect of the present invention towed by the agricultural vehicle.

Preferably, the combination further comprises a control unit, a memory in communication with the control unit, and a user terminal in communication with the control unit, the control unit being configured to receive signals issued by the sensor, to compare the signals from the sensor against a set of values stored in the memory, to determine whether a terminal signal is to be generated and sent to the user terminal to cause the user terminal to generate an alert and as appropriate to send the terminal signal.

More preferably, the control unit is also configured to generate and send a baler signal to cause operation of the baler to cease when a terminal signal is generated and sent.

Reference to terms such as longitudinal, transverse and vertical are made with respect to a longitudinal vehicle axis which is parallel to a normal forward direction of travel (arrow A, <FIG>).

References to terms such as horizontal and vertical are made with respect to the apparatus being located on level, non-sloping ground.

<FIG> shows a semi-schematic diagram of an agricultural baler system <NUM> in which the invention may be employed while baling loose crop material <NUM> from the ground <NUM> into formed bales.

The baler system includes a towing vehicle <NUM> and a baler <NUM>. The towing vehicle <NUM> may include a cab <NUM> wherein an operator may be located, an engine operable to move the towing vehicle, and a power take-off (PTO) <NUM> operable to transfer mechanical power from the engine to the baler <NUM>. The baler <NUM> is hitched to the towing vehicle in any suitable manner, and power for operating the various mechanisms of the baler <NUM> may be supplied by the PTO <NUM> of the towing vehicle <NUM>. One having ordinary skill in the art should appreciate in the context of the present disclosure that the example baler <NUM> is merely illustrative. While a variable chamber round baler is shown to illustrate the general principles of operation of a round baler, it will be understood that the invention is equally applicable to fixed chamber round baler.

The baler <NUM> has a baling chamber <NUM> within which bales of crop material are formed. The loose crop material <NUM> is picked up by a pickup assembly <NUM> and then introduced into the baling chamber <NUM>. The baling chamber rotates the crop material to form a bale.

Once the bale has been formed the formed bale is bound by introducing a web of wrapping material into the baling chamber <NUM>. The web of wrapping material is supplied from a wrapping material reservoir <NUM> to the baling chamber <NUM> by way of a transfer mechanism. Once the bale has been wrapped, the web of wrapping material is severed. The web of wrapping material is severed between the wrapping material reservoir <NUM> and the baling chamber <NUM>. The baling chamber <NUM> continues to rotate to ensure the tail of the web of wrapping material is drawn in into the baling chamber and around the formed bale. Rotation of the baling chamber <NUM> is then ceased and a rear tailgate <NUM> opened to allow ejection of the formed bale. The tailgate <NUM> is then closed before continuing forward movement of the baler system and pick up of crop material for baling.

During wrapping the baler system may cease forward travel to prevent further crop material being introduced into the baling chamber. Alternatively or additionally the pick-up assembly may be disengaged for this purpose.

A user terminal <NUM> communicates with an electronic control unit <NUM>. The user terminal is conveniently located within a cab of the towing vehicle. The electronic control unit <NUM> is also be in electronic or other communication with various components and devices of the baler (and/or the towing vehicle). Conveniently such communication may be enabled by way of a suitable data communication network <NUM> such as one compliant with the ISOBUS standard (a network in conformance to ISO <NUM>). For example, the electronic control unit <NUM> may be in electronic communication with various actuators, sensors, and other devices within (or outside of) the baler. The electronic control unit <NUM> may communicate with various other components (including other controllers) in various known ways, including wirelessly.

Various alternative locations for the electronic control unit may be utilized, including locations on the towing vehicle. It will be understood that one or more electronic control units may be employed and that the electronic control unit(s) <NUM> may be mounted at various locations on the towing vehicle, baler, or elsewhere. The electronic control unit(s) may be a hardware, software, or hardware and software computing device, and may be configured to execute various computational and control functionality with respect to the baler (or towing vehicle).

The electronic control unit <NUM> is also able to access a suitable memory <NUM>. The memory <NUM> may take any suitable form and is in electronic communication with the electronic control unit <NUM>. The memory <NUM> is adapted to store, in any suitable manner such as a database or look up table, reference values for a desired parameter.

The wrapping material located in the wrapping material reservoir <NUM> is in the form of a reel <NUM> of wrapping material. The reel <NUM> of wrapping material may be supported on lower surfaces of a wrapping material reservoir <NUM> or supported within the wrapping material reservoir <NUM> by stubs engaging with a central spindle <NUM> of the reel. In each case a free end of the wrapping material exits the wrapping material reservoir <NUM> and is delivered to a wrapping material delivery mechanism to allow controlled introduction of the wrapping material to the baling chamber <NUM>.

As noted above, during the wrapping operation it is important that the wrapping material continues to be delivered to the baling chamber <NUM>. A number of sensor arrangements are known to monitor the delivery of the wrapping material to the baling chamber <NUM>. It is a problem with a number of these arrangements that they need to be reset on each occasion that a new reel <NUM> of wrapping material is introduced to the wrapping material reservoir <NUM>. For example the sensor arrangement might be located in the pathway needed by an operator to introduce a new reel <NUM> of wrapping material into the wrapping material reservoir requiring the operator first to move the sensor arrangement before then introducing the new reel <NUM> of wrapping material and subsequently resetting the sensor arrangement once the new reel of wrapping material is in position.

Referring now to <FIG>, a sensor arrangement <NUM> in accordance with the present invention is shown. <FIG> shows a side view of a cradle <NUM> within the wrapping material reservoir <NUM>. It can be seen that the cradle <NUM> comprises first and second surfaces <NUM>,<NUM> for supporting the reel <NUM> of wrapping material. A third surface <NUM> at the free end of the second surface provides a lip to the cradle (see also <FIG>).

At the ends side flanges <NUM>,<NUM> are provided at an angle to the first and second surfaces <NUM>,<NUM> to aid in the introduction and removal of the reel <NUM> of wrapping material from the wrapping material reservoir <NUM> by an operator.

In <FIG>, the sensor arrangement <NUM> is shown in a first position in which the sensor arrangement <NUM> extends through a window <NUM> in the second surface <NUM> of the cradle <NUM> to contact an outer surface of the reel <NUM> of wrapping material. The reel is urged downward in the cradle by guide means. The guide means conveniently comprises a crossbar <NUM> operated by way of actuators <NUM> located to each side of the wrapping material reservoir <NUM>.

In <FIG>, the sensor arrangement <NUM> is shown in a second position corresponding to the position adopted once a supply of wrapping material has been exhausted from the central spindle <NUM> of the reel of wrapping material. <FIG> also shows an end plate <NUM> against which an end of the reel <NUM> of wrapping material (or an end of the central spindle <NUM>) can abut to ensure the correct placement of the of the reel of wrapping material when loaded into the cradle <NUM>.

With particular reference to <FIG> and <FIG>, the sensor arrangement <NUM> is shown mounted to a first bracket <NUM> fixed on an underside of the second surface <NUM> of the cradle <NUM>. The first bracket <NUM> is substantially U shaped comprising a generally linear central portion <NUM> between first and second side limbs <NUM>,<NUM>. Free ends of the first and second side limbs <NUM>,<NUM> of the first bracket <NUM> are used to secure the first bracket <NUM> to the cradle <NUM> in any suitable manner, for example by welding.

A first pin <NUM> is mounted to extend between the first and second side limbs <NUM>,<NUM> of the first bracket <NUM>. The first pin <NUM> is mounted to be pivotable about its longitudinal axis or to serve as a bearing about which a further element may be rotated.

A second bracket <NUM> is substantially U shaped and comprises a generally linear central portion <NUM> between first and second substantially L-shaped side arms <NUM>,<NUM>. The first and second side arms are such that the central portion <NUM> of the second bracket <NUM> is offset from free ends of the first and second side arms <NUM>,<NUM>.

The free ends of the first and second side arms <NUM>,<NUM> are mounted to the first pin <NUM> for rotational movement with or about the first pin <NUM>.

A second pin <NUM> is provided between the first and second side arms <NUM>,<NUM>, extending between the respective corners of the L-shaped first and second side arms <NUM>,<NUM>. A rotary element <NUM> is mounted for free rotation about the second pin <NUM>.

In the illustrated element the rotary element <NUM> comprises two substantially hemispherical portions <NUM>,<NUM> joined by a central connecting portion <NUM> of diameter less that a diameter of the substantially hemispherical portions <NUM>,<NUM>. In the illustrated embodiment, each of the substantially hemispherical portions <NUM>,<NUM> are provided with a surface texture <NUM>. Other constructions of the rotary element are possible, for example the narrower central connecting portion may be substituted with a connecting portion of equal diameter to that of the substantially hemispherical portions. In such an embodiment the surface texture may be provided instead of or additionally to the surface texture provided on the substantially hemispherical portions.

The surface texture <NUM> may take any suitable form. For example the surface texture <NUM> may take the form of raised dots, raised ribs, knurling or dimpling.

The sensor arrangement <NUM> is further provided with a sensor <NUM> to detect the rotary motion of the rotary element <NUM>. In the illustrated embodiment, the sensor <NUM> is an electronic sensor mounted to the generally linear central portion <NUM> of the second bracket <NUM>. The sensor <NUM> is electronically connected to the electronic control unit <NUM> in any suitable manner. In the illustrated embodiment a physical connector <NUM> is show extending from the sensor <NUM>.

Biasing means are provided between the first bracket <NUM> and the second bracket <NUM> to bias the second bracket <NUM> (and so the rotary element <NUM>) with respect to the first bracket <NUM>. In the illustrated element the biasing means takes the form a spring member <NUM> mounted about the first pin <NUM> between the first bracket <NUM> and the second bracket <NUM>. In the illustrated embodiment, a first free end <NUM> of the spring member <NUM> abuts the first bracket <NUM> and a second free end <NUM> of the spring member is hooked about an upper edge of one of the side arms of the second bracket <NUM>. As can be seen in the illustrated embodiment, the biasing means biases the second bracket <NUM> such that a portion of the rotary element <NUM> carried on the second bracket <NUM> is urged to extend through the window <NUM> in the second surface <NUM> of the cradle <NUM>.

As may be seen from <FIG>, an operator loads a new reel <NUM> of wrapping material onto an open end of the cradle <NUM>. The reel <NUM> of wrapping material is then slid along the cradle. As reel <NUM> of wrapping material is advanced within the cradle <NUM> a leading edge of the reel encounters a leading hemispherical surface of the rotary member causing the rotary element <NUM> to be deflected out of the cradle <NUM>. Further advancing of the reel <NUM> of wrapping material causes it to abut the closed end of the cradle <NUM>. The reel <NUM> of wrapping material is now in position to allow correct location of a leading edge of a web of the wrapping material on introduction to the transfer mechanism ready for baling. No additional setting of the sensor arrangement is required by the operator since the rotary element is already urged into an outer surface of the reel <NUM> of wrapping material in the cradle <NUM>.

It will be understood that contours other than the hemispherical contour of the illustrated embedment that are conducive to sliding or acting like a ramp for the leading edge of the reel <NUM> of wrapping material to push the rotary element <NUM> into position may also be used for the rotary element <NUM>.

During the binding operation wrapping material is drawn from the reel <NUM> of wrapping material causing the reel <NUM> of wrapping material to rotate about the central spindle <NUM>. Rotation of the reel <NUM> of wrapping material causes the rotary element <NUM> to be rotatably driven about the second pin <NUM> and for such rotation to be detected by the sensor <NUM>. The sensor <NUM> can then send a confirmatory signal to the electronic control unit <NUM>.

In use, the electronic control unit <NUM> initiates a binding cycle (step <NUM>) to draw wrapping material from the reservoir. Rotation of the reel <NUM> of wrapping material causes rotation of the rotary element <NUM> in turn causing a signal to be sent from the sensor <NUM> to the electronic control unit <NUM>. The electronic control unit <NUM> compares the sensor signal to be compared against a reference value stored in the memory <NUM> (step <NUM>). If the sensor signal corresponds to a reference value indicative of reel rotation the electronic control unit <NUM> allows the binding cycle to continue in the normal manner.

If no signal (because rotation of the reel <NUM> of wrapping material has ceased for any reason) or a signal not corresponding to a reference value stored in the memory <NUM> is received, the electronic control unit <NUM> will generate a signal causing the binding cycle to cease for example by causing rotation of the baling chamber <NUM> to cease and an alert signal to be sent to the user terminal <NUM> to cause the user terminal <NUM> to alert the operator to the reason for ceasing of the binding cycle (step <NUM>). Alternatively the electronic control unit <NUM> may only cause the alert signal to be sent to the user terminal <NUM> to generate an alert indicating the reason that the operator ought to take action to cause the binding cycle to cease. In either case, the alert may take the form of a visual indication, an audible indication or both.

Thus in the case where the supply of wrapping material is exhausted there will no longer be movement of the rotary element. As the supply of wrapping material is consumed the geometry of the rotary element and biased lever arm ensures even, reliable contact with the surface of the reel of wrapping material, even as the diameter of the reel of wrapping material is reduced.

In the illustrated embodiment, relative movement between the spindle of the reel of wrapping material and the sensor arrangement occurs due to the wrapping material being removed from the reel thereby reducing the overall diameter of the reel of wrapping material. However the relative movement will also occur by modification of the degree of displacement of the displaceable mounting bracket towards the reel of wrapping material where the reel spindle is supported by stubs at the side of the wrapping material reservoir.

Claim 1:
A baler (<NUM>) comprising a receiving apparatus for receiving a reel (<NUM>) of wrapping material, the receiving apparatus including a sensor arrangement (<NUM>) for detecting rotation of a reel of wrapping material, the sensor arrangement (<NUM>) comprising a displaceable mounting bracket (<NUM>), a rotary element (<NUM>) mounted for rotation on the displaceable mounting bracket (<NUM>), the rotary element (<NUM>) being provided with a textured surface (<NUM>) and a sensor (<NUM>) mounted on the displaceable mounting bracket for detecting rotation of the rotary element (<NUM>) characterised in that the receiving apparatus further includes a window (<NUM>) and that the rotary element (<NUM>) of the sensor arrangement (<NUM>) extends through the window (<NUM>).