Patent Document

BACKGROUND OF THE INVENTION 
     Cross Reference to Related Application 
     None. 
     Field of the Invention 
     The present invention relates to compaction apparatus, particularly waste paper balers and to control apparatus therefor responsive to timers and to chamber door, loading door, and/or platen position sensors for detecting possible unsafe operation of the baler and for disabling or otherwise preventing hazardous operation modes. 
     SUMMARY OF THE INVENTION 
     The present invention relates to compaction equipment for commercial and industrial trash compaction and waste paper baler equipment utilized in paper recycling, which are important and widely used tools in the field of waste management. It is very desirable that this equipment be both efficient and reliable. As with all powerful mechanical equipment, safety hazards should be eliminated to the maximum extent possible, recognizing that there is a tendency for human operators to be less careful than they should be. 
     Although the invention with which this application is concerned is particularly useful in waste paper balers, this background discussion also concerns itself with trash compactors, since they are both widely used and common forms of equipment. The detailed description below will fully describe balers incorporating the invention. The commercial or industrial waste compactor or baler which will be referred to herein as a “compactor” is found in many situations where there are large volumes of waste to be disposed of in landfills or baled for recycling. Thus, compactors including waste compactors and balers are found in shopping centers, industrial complexes, associated with large discount stores or department stores, and in some residential complexes. 
     The operation and control of balers according to the invention includes features for controlling the starting, stopping, and reversing of the ram used for driving the platen and compressing the waste paper (usually corrugated paper board from packages and cartons). Features such as interlocks and fault detection functions are included which are important to promote and ensure safety at the point of operation of such powerful mechanical equipment. 
     Although operational control of compaction apparatus in years past was usually implemented by simple switches and relays, there has been a tendency in recent years to employ computer microprocessors and somewhat sophisticated computer programs and algorithms stored in computer memory in, or associated with, the microprocessor. 
     U.S. Pat. No. 4,953,109 to Burgis, Pat. No. 5,016,197 to Neumann, et al., and U.S. Pat. No. 5,558,013 to Blackstone, Jr. are examples of trash compaction systems utilizing rather complex computer programs to implement the desired control system (including fullness determination in compaction apparatus). These may be compared with U.S. Pat. No. 3,802,335 to Longo, Pat. No. 4,643,087 to Fenner, et al., and U.S. Pat. No. 6,055,902 to Harrop, et al., which do not employ computer microprocessors but execute simple logic with electrical relays. 
     Compactors including waste compactors and balers are typically exposed to harsh environments including wide ranges of temperatures and potential exposure to power surges. In addition, it is very important that the compaction equipment operate reliably and operate in a safe manner and not be subject to malfunction because of failure or error conditions in its electrical controls. For that reason, there are many users and others who consider that a relatively simply relay based control system has advantages with regard to reliability, durability, and safety over microprocessor controlled by complex software. 
     Compactors of the present invention have advantages of simple electro-mechanical related based control systems as shown in U.S. Pat. No. 6,055,902, disclosure of which is incorporated herein by reference, and at the same time provide an advantage of simple maintainability and low component cost that previous electro-mechanical related based control systems do not provide. 
     Included in the operating and control system are combination magnetic locks and position sensors which operate effectively for locking, releasing, and sensing the position of the loading door and the bale chamber door while reducing the total number of sensors and/or interlocks needed in the system. 
     The present invention departs from the teaching of prior art waste baler paper systems by providing apparatus which is simple, durable, reliable, and capable of being programmed with special features and which provides safe and uncomplicated operation for operating personnel. An important feature of the present invention is the employment of programmable electronic relay networks in a manner to achieve the simplicity and reliability of electrical relay based control systems while achieving the flexibility, programmability, and reduced component costs associated with electro-mechanical relay or solid state relay control networks. 
     In addition to providing the features and advantages referred to above, it is an object of the present invention to provide compaction apparatus such as waste paper balers which have the advantages of simple relay-implemented control systems including a safety interlock feature for the bale chamber door, and the loading door while obtaining the advantages of programming flexibility, increased reliability, and reduced component costs. 
     It is another object of the present invention to utilize combination electromagnetic lock and sensor units for providing control signals to the programmable relay network and receiving control signals from the programmable relay network, thereby reducing the mechanical and electrical elements associated with the control system. 
     It is yet another object of the present invention to provide waste paper balers with controls utilizing programmable relay networks for timing functions which would otherwise require separate timing elements with less adjustability, greater cost, and greater assembly expense. 
     It is a further object of the present invention to provide a programmable relay control system for waste paper balers which maximizes simplicity of operation while assuring that electromagnetic interlocks and other safety features prevent improper or unintended operation which could cause property damage or personal injury. 
    
    
     In addition to the features and advantages of the baler apparatus according to the invention described above, further advantages thereof will be apparent from the following description in conjunction with the appended drawings. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an isometric view of a baler according to the present invention; 
     FIG. 2 is an isometric view of the apparatus of FIG. 1 broken away to show functional elements thereof; 
     FIG. 3 is an enlarged view of the control panel from FIG.  1 . 
     FIGS. 4A through 4E is a diagram of one embodiment of programmable relay configuration for controlling the baler of FIGS. 1 and 2; and 
     FIG. 5 is a schematic circuit diagram showing connections of the programmable relay and other electrical components of the baler of FIGS. 1,  2 , and  3 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     PREFERRED EMBODIMENTS 
     Referring to FIGS. 1,  2 , and  3 , a baler  11  according to the invention is shown having a bale chamber  13  to receive waste which is to be compacted. Hydraulic ram  19  of conventional construction serves to raise and lower a platen  21  to provide the compressing force on the waste material for compaction. A loading door  31  slides in vertical tracks to provide a closeable opening for loading waste into the chamber  13 . In FIG. 1, door  31  is broken away to show the structure behind it but door  31  is shown in its entirety in FIG.  2 . 
     Preferably the loading door  31  is not simply provided with a counterweight and cable mechanism to make it easy to manually raise, but it is rather provided with a gas springs  81  one of conventional form, on each side with characteristics appropriate to overcome the weight of the door and raise it to the upward position at any time when it is not engaged by interlock  78 . Gas spring  81  is a readily available component, used extensively, in the automotive industry for example, and is manufactured by Industrial Gas Springs Ltd and others. Preferably, the gas springs  81  are damped gas springs configured with the loading door  31  so that when it is released from the electromagnetic interlock  78 , it will raise at moderate speed smoothly and softly upward to its fully opened position. While the gas spring arrangement for the loading door is a very desirable feature, the system would be fully operative with some other damped or undamped counterweight or spring arrangement as known in the art. 
     Unloading opening  33  at the front of the baler  11  is closed by a chamber door  35  having a lock  36 . It is opened when it is desired to access a bale for tying and/or for ejecting it. A dump tray  41  in the bottom of the baler chamber is pivoted at its front edge and allowed to rotate up and forwardly to cause ejection of a finished bale. In the center of back  17  of the baler  11  is a vertically extending dump link bar  43  permanently engaged to the platen  21  to move therewith and selectively engageable with the dump tray  41 . In FIG. 2 the baler  11  is shown with the dump tray  41  broken away to show a dump control link  49  extending fore and aft at the bottom of the dump tray  41 . Control link  49  causes the dump tray  41  to be engaged by the dump link bar  43  (but only when dump link bar  43  is allowed to assume a forward with door  35  not closed). Spring  55  on control link  49  serves to urge it forward except when door  35  is closed. 
     From the foregoing description, it will be seen that the dump tray  41  is inactive so long as door  35  is closed, but may be raised by the hydraulic ram to eject a bale due to being coupled to platen  21  when door  35  is closed. Other known embodiments of bale ejection apparatus or as shown in prior patents could be employed with the control apparatus rather than using the preferred embodiment shown and described above. 
     An enlarged view of the preferred control panel arrangement for the apparatus is shown in FIG. 3. A mode selector switch for selecting manual up, manual down, and auto modes of operation is shown at  71 . The function of this switch will be described more fully hereinafter. An off/on/start key switch  73  is positioned below the mode selector switch  71 . A key switch is provided to give control over authorization to operate the baler. Other access control devices such as biometric controls and magnetic card readers could also be used for operator access control for the baler. Electrical operation of switch  73  is more fully explained below. 
     Below the key switch  73  is a stop/pull to raise button  75 . In addition to serving as an emergency stop switch the stop/pull to raise button  75  serves as the control for manually raising the platen to eject a finished bale. It must be manually pulled out and held by an operator for that operation. This is a safety feature that will be further explained in connection with the control system for the baler. A power on light  89  in this preferred embodiment is associated with the mode selector switch  71  but this is an optional feature and a different form of power on light could be provided if desired. 
     Key switch  73 , among other things, controls the motor with motor starter  90  which provides power for hydraulic ram  19 . The hydraulic system and valves therefor are conventional and their function will be understood by those skilled in the art so that the details thereof are not shown. In the interest of clarity, details of well known elements of balers and other compaction equipment are not shown and described. 
     The programmable controller for the baler  11  preferably takes the form of a programmable relay  61  (shown in FIG. 5) utilizing relay ladder logic as shown in FIGS. 4A through 4E. For an explanation of relay ladder logic processors refer to U.S. Pat. No. 5,777,869, issued Jul. 7, 1998 to Welch and U.S. Pat. No. 6,018,797, issued Jan. 25, 2000 to Schmidt, et al., incorporated herein by reference, and to the references cited in those patents. A very brief explanation of ladder logic processors will be helpful in describing FIGS. 4A through 4E. As seen in FIGS. 4A through 4E, ladder logic programming, as expected, looks like a ladder. It probably has more similarities to a flow chart than the usual multi-line computer program. There are two vertical lines coming down the program chart, one on the left and one on the right. “Rungs” between the lines have conditionals on the left that lead to outputs on the right as will be apparent in FIGS. 4A through 4E. The most used elements in ladder logic are the relay conditionals −| |− and −/− and the output coils −( )−. The relay conditional with a space means “closed only if energized” while the relay conditional with the slash means “closed if not energized.” The output coil generally means “if its relay is closed energize this output element.” 
     The delay timing notations and other notations in the ladder logic chart of FIGS. 4A through E are self-explanatory. Ladder rung numbers appear at the right margin. 
     The operation of the baler control system will be explained first for the “AUTO” mode. 
     The conditions for the initial set-up are: 
     Mode selector switch  71  is in the center position for “AUTO” mode; 
     Key switch  73  is in the center position for “POWER ON”; 
     Stop button  75  is in the center position for normal operation; 
     Baler chamber door  35  is closed and latched; 
     Platen  21  is fully retracted; 
     Loading door  31  is open; 
     Electromagnetic interlock  78  is energized. 
     The software under which the ladder logic program runs operates in a scanning mode with a scan cycle on the order of ten milliseconds. The program status of the ladder logic program at set-up is as follows. 
     Set-up Program: 
     Rung  1 , I 4  closed, I 5  closed, M 1  energized 
     Rung  2 , I 4  open, I 5  closed, M 2  not energized 
     Rung  3 , I 4  closed, I 5  open, M 3  not energized 
     Rung  4 , M 3  closed, I 8  open, I 1  closed, M 4  not energized 
     Rung  5 , M 3  open, I 8  closed 
     Rung  6 , M 4  open, M 10  closed, T 3  closed, M 5  not energized 
     Rung  7 , M 5  open, I 2  open, T 4  closed, M 6  not energized 
     Rung  8 , M 7  open 
     Rung  9 , M 6  open, I 7  open 
     Rung  10 , M 3  open 
     Rung  11 , I 3  open, I 8  open, I 7  open, M 7  not energized 
     Rung  12 , M 7  open, I 7  open 
     Rung  13 , M 6  open, M 11  closed, Q 1  not energized 
     Rung  14 , Q 1  open, M 3  closed, Q 4  closed, Q 3  not energized 
     Rung  15 , Q 3  open, T 1  not energized 
     Rung  16 , T 1  open, M 9  (S) not energized 
     Rung  17 , I 3  open 
     Rung  18 , M 10  open, M 9  (R) energized 
     Rung  19 , Q 1  closed 
     Rung  20 , Q 1  open, M 1  closed, M 9  open, Q 4  not energized 
     Rung  21 , Q 4  open 
     Rung  22 , M 3  closed, M 7  open 
     Rung  23 , M 3  open, I 3  open 
     Rung  24 , Q 4  open, T 2  not energized 
     Rung  25 , M 3  open, Q 1  open 
     Rung  26 , T 2  open, M 10  not energized 
     Rung  27 , I 7  closed, Q 4  open, M 3  closed 
     Rung  28 , I 1  open, M 11  closed, T 4  closed 
     Rung  29 , Q 1  open, T 3  not energized 
     Rung  30 , M 10  open, I 8  open, M 12  closed, M 11  not energized 
     Rung  31 , M 2  open, T 1  open 
     Rung  32 , M 11  open, T 4  closed, M 12  closed 
     Rung  33 , I 8  open, M 3  open, I 3  open 
     Rung  34 , M 11  closed, Q 2  energized 
     Rung  35 , M 11  open, T 4  not energized 
     Rung  36 , I 8  open, T 4  open, I 1  closed 
     Rung  37 , I 7  open 
     Rung  38 , T 4  open, I 1  open, M 12  not energized 
     Rung  39 , M 12  open 
     For transition to the initial operation mode, the loading door  31  is closed and when the striking plate  79  closes with the electromagnetic interlock  78  the loading door  31  locks. The status of the ladder logic program then becomes AUTO READY OPERATION PROGRAM: 
     Rung  1 , I 4  closed, I 5  closed, M 1  energized 
     Rung  2 , I 4  open, I 5  closed, M 2  not energized 
     Rung  3 , I 4  closed, I 5  open, M 3  not energized 
     Rung  4 , M 3  closed,  18  closed, I 1  closed, M 4  energized 
     Rung  5 , M 3  open, I 8  open 
     Rung  6 , M 4  closed, M 10  closed, T 3  closed, M 5  energized 
     Rung  7 , M 5  closed, I 2  open, T 4  closed, M 6  not energized 
     Rung  8 , M 7  open 
     Rung  9 , M 6  open, I 7  open 
     Rung  10 , M 3  open 
     Rung  11 , I 3  open,  18  closed, I 7  open, M 7  not energized 
     Rung  12 , M 7  open, I 7  open 
     Rung  13 , M 6  open, M 11  closed, Q 1  not energized 
     Rung  14 , Q 1  open, M 3  closed, Q 4  closed, Q 3  not energized 
     Rung  15 , Q 3  open, T 1  not energized 
     Rung  16 , T 1  open, M 9  (S) not energized 
     Rung  17 , I 3  open 
     Rung  18 , M 10  open, M 9  (R) energized 
     Rung  19 , Q 1  closed 
     Rung  20 , Q 1  open, M 1  closed, M 9  open, Q 4  not energized 
     Rung  21 , Q 4  open 
     Rung  22 , M 3  closed, M 7  open 
     Rung  23 , M 3  open, I 3  open 
     Rung  24 , Q 4  open, T 2  not energized 
     Rung  25 , M 3  open, Q 1  open 
     Rung  26 , T 2  open, M 10  not energized 
     Rung  27 , I 7  closed, Q 4  open, M 3  closed 
     Rung  28 , I 1  open, M 11  closed, T 4  closed 
     Rung  29 , Q 1  open, T 3  not energized 
     Rung  30 , M 10  open,  18  closed, M 12  closed, M 11  not energized 
     Rung  31 , M 2  open, T 1  open 
     Rung  32 , M 11  open, T 4  closed, M 12  closed 
     Rung  33 , I 8  closed, M 3  open, I 3  open 
     Rung  34 , M 11  closed, Q 2  energized 
     Rung  35 , M 11  open, T 4  not energized 
     Rung  36 , I 8  closed, T 4  open, I 1  closed 
     Rung  37 , I 7  open 
     Rung  38 , T 4  open, I 1  open, M 12  not energized 
     Rung  39 , M 12  open 
     For start operation, the key switch is turned to the right to the “START” position causing the motor powering the hydraulic ram  19  to start and the platen  21  to begin its descent. The ladder logic program status then becomes AUTO START OPERATION PROGRAM: 
     Rung  1 , I 4  closed, I 5  closed, M 1  energized 
     Rung  2 , I 4  open, I 5  closed, M 2  not energized 
     Rung  3 , I 4  closed, I 5  open, M 3  not energized 
     Rung  4 , M 3  closed, I 8  closed, I 1  closed, M 4  energized 
     Rung  5 , M 3  open, I 8  open 
     Rung  6 , M 4  closed, M 10  closed, T 3  closed, M 5  energized 
     Rung  7 , M 5  closed, I 2  closed, T 4  closed, M 6  energized 
     Rung  8 , M 7  open 
     Rung  9 , M 6  closed, I 7  open 
     Rung  10 , M 3  open 
     Rung  11 , I 3  open, I 8  closed, I 7  open, M 7  not energized 
     Rung  12 , M 7  open, I 7  open 
     Rung  13 , M 6  closed, M 11  closed, Q 1  energized 
     Rung  14 , Q 1  closed, M 3  closed, Q 4  closed, Q 3  energized 
     Rung  15 , Q 3  closed, T 1  energized (timing) 
     Rung  16 , T 1  open, M 9  (S) not energized 
     Rung  17 , I 3  open 
     Rung  18 , M 10  open, M 9  (R) not energized 
     Rung  19 , Q 1  open 
     Rung  20 , Q 1  closed, M 1  closed, M 9  open, Q 4  not energized 
     Rung  21 , Q 4  open 
     Rung  22 , M 3  closed, M 7  open 
     Rung  23 , M 3  open, I 3  open 
     Rung  24 , Q 4  open, T 2  not energized 
     Rung  25 , M 3  open, Q 1  closed 
     Rung  26 , T 2  open, M 10  not energized 
     Rung  27 , I 7  open, Q 4  open, M 3  closed 
     Rung  28 , I 1  open, M 11  closed, T 4  closed 
     Rung  29 , Q 1  closed, T 3  energized (timing) 
     Rung  30 , M 10  open, I 8  closed, M 12  closed, M 11  not energized 
     Rung  31 , M 2  open, T 1  open 
     Rung  32 , M 11  open, T 4  closed, M 12  closed 
     Rung  33 , I 8  closed, M 3  open, I 3  open 
     Rung  34 , M 11  closed, Q 2  energized 
     Rung  35 , M 11  open, T 4  not energized 
     Rung  36 , I 8  closed, T 4  open, I 1  closed 
     Rung  37 , I 7  open 
     Rung  38 , T 4  open, I 1  open, M 12  not energized 
     Rung  39 , M 12  open 
     In the descending operation the safety interlock switch  78  will close as the platen  21  descends about three inches and the key switch  73  should by then be released to return to the center or “POWER ON” position. The status in descent operation is: 
     DESCENT OPERATION PROGRAM: 
     Rung  1 , I 4  closed, I 5  closed, M 1  energized 
     Rung  2 , I 4  open, I 5  closed, M 2  not energized 
     Rung  3 , I 4  closed, I 5  open, M 3  not energized 
     Rung  4 , M 3  closed, I 8  closed, I 1  closed, M 4  energized 
     Rung  5 , M 3  open, I 8  open 
     Rung  6 , M 4  closed, M 10  closed, T 3  closed, M 5  energized 
     Rung  7 , M 5  closed, I 2  open, T 4  closed, M 6  energized 
     Rung  8 , M 7  open 
     Rung  9 , M 6  closed, I 7  closed 
     Rung  10 , M 3  open 
     Rung  11 , I 3  open, I 8  closed, I 7  closed, M 7  not energized 
     Rung  12 , M 7  open, I 7  closed 
     Rung  13 , M 6  closed, M 11  closed, Q 1  energized 
     Rung  14 , Q 1  closed, M 3  closed, Q 4  closed, Q 3  energized 
     Rung  15 , Q 3  closed, T 1  energized (timing) 
     Rung  16 , T 1  open, M 9  (S) not energized 
     Rung  17 , I 3  open 
     Rung  18 , M 10  open, M 9  (R) not energized 
     Rung  19 , Q 1  open 
     Rung  20 , Q 1  closed, M 1  closed, M 9  open, Q 4  not energized 
     Rung  21 , Q 4  open 
     Rung  22 , M 3  closed, M 7  open 
     Rung  23 , M 3  open, I 3  open 
     Rung  24 , Q 4  open, T 2  not energized 
     Rung  25 , M 3  open, Q 1  closed 
     Rung  26 , T 2  open, M 10  not energized 
     Rung  27 , I 7  open, Q 4  open, M 3  closed 
     Rung  28 , I 1  open, M 11  closed, T 4  closed 
     Rung  29 , Q 1  closed, T 3  energized (timing) 
     Rung  30 , M 10  open, I 8  closed, M 12  closed, M 11  not energized 
     Rung  31 , M 2  open, T 1  open 
     Rung  32 , M 11  open, T 4  closed, M 12  closed 
     Rung  33 , I 8  closed, M 3  open, I 3  open 
     Rung  34 , M 11  closed, Q 2  energized 
     Rung  35 , M 11  open, T 4  not energized 
     Rung  36 , I 8  closed, T 4  open, I 1  closed 
     Rung  37 , I 7  closed 
     Rung  38 , T 4  open, I 1  open, M 12  not energized 
     Rung  39 , M 12  open 
     The platen  21  will continue to be in the descend mode until the accumulated extend time is equal to the preset value of the extend timer, at which time the platen  21  will start retracting. Since this operation is a matter of timing only, the time during which the force of the platen is applied to compact the trash may vary somewhat. The ladder logic program status for retract operation is: 
     RETRACT OPERATION PROGRAM: 
     Rung  1 , I 4  closed, I 5  closed, M 1  energized 
     Rung  2 , I 4  open, I 5  closed, M 2  not energized 
     Rung  3 , I 4  closed, I 5  open, M 3  not energized 
     Rung  4 , M 3  closed, I 8  closed, I 1  closed, M 4  energized 
     Rung  5 , M 3  open, I 8  open 
     Rung  6 , M 4  closed, M 10  closed, T 3  closed, M 5  energized 
     Rung  7 , M 5  closed, I 2  open, T 4  closed, M 6  energized 
     Rung  8 , M 7  open 
     Rung  9 , M 6  closed, I 7  closed 
     Rung  10 , M 3  open 
     Rung  11 , I 3  open, I 8  closed, I 7  closed, M 7  not energized 
     Rung  12 , M 7  open, I 7  closed 
     Rung  13 , M 6  closed, M 11  closed, Q 1  energized 
     Rung  14 , Q 1  closed, M 3  closed, Q 4  open, Q 3  not energized 
     Rung  15 , Q 3  open, T 1  (timed out) (not energized) 
     Rung  16 , T 1  closed, M 9  (S) energized, T 1  returns to open, M 9  (S) not energized 
     Rung  17 , I 3  open 
     Rung  18 , M 10  open, M 9  (R) not energized 
     Rung  19 , Q 1  open 
     Rung  20 , Q 1  closed, M 1  closed, M 9  closed, Q 4  energized 
     Rung  21 , Q 4  closed 
     Rung  22 , M 3  closed, M 7  open 
     Rung  23 , M 3  open, I 3  open 
     Rung  24 , Q 4  closed, T 2  energized (timing) 
     Rung  25 , M 3  open, Q 1  closed 
     Rung  26 , T 2  open, M 10  not energized 
     Rung  27 , I 7  open, Q 4  closed, M 3  closed 
     Rung  28 , I 1  open, M 11  closed, T 4  closed 
     Rung  29 , Q 1  closed, T 3  energized (timing) 
     Rung  30 , M 10  open, I 8  closed, M 12  closed, M 11  not energized 
     Rung  31 , M 2  open, T 1  closed, T 1  returns to open 
     Rung  32 , M 11  open, T 4  closed, M 12  closed 
     Rung  33 , I 8  closed, M 3  open, I 3  open 
     Rung  34 , M 11  closed, Q 2  energized 
     Rung  35 , M 11  open, T 4  not energized 
     Rung  36 , I 8  closed, T 4  open, I 1  closed 
     Rung  37 , I 7  closed 
     Rung  38 , T 4  open, I 1  open, M 12  not energized 
     Rung  39 , M 12  open 
     The platen  21  will retract until it moves to open the safety interlock  78  or when the accumulated retract time is equal to the preset value in the retract timer. In either case, the motor powering the ram  19  will stop and the electromagnetic interlock  78  will de-energize for three seconds to unlock the loading door  31  allowing it to open. The ladder logic program status is as follows: 
     RETRACT OPERATION PROGRAM: 
     Rung  1 , I 4  closed, I 5  closed, M 1  energized 
     Rung  2 , I 4  open, I 5  closed, M 2  not energized 
     Rung  3 , I 4  closed, I 5  open, M 3  not energized 
     Rung  4 , M 3  closed, I 8  closed, I 1  closed, M 4  energized 
     Rung  5 , M 3  open, I 8  open 
     Rung  6 , M 4  closed, M 10  open, T 3  closed, M 5  not energized, M 10  returns to closed, M 5  energized 
     Rung  7 , M 5  open, I 2  open, T 4  closed, M 6  not energized, M 5  returns to closed 
     Rung  8 , M 7  open 
     Rung  9 , M 6  open, I 7  open 
     Rung  10 , M 3  open 
     Rung  11 , I 3  open, I 8  closed, I 7  open, M 7  not energized 
     Rung  12 , M 7  open, I 7  open 
     Rung  13 , M 6  open, M 11  open, Q 1  not energized 
     Rung  14 , Q 1  open, M 3  closed, Q 4  closed, Q 3  not energized 
     Rung  15 , Q 3  open, T 1  not energized 
     Rung  16 , T 1  open, M 9  (S) not energized 
     Rung  17 , I 3  open 
     Rung  18 , M 10  closed, M 9  (R) energized, M 10  returns to open 
     Rung  19 , Q 1  closed 
     Rung  20 , Q 1  open, M 1  closed, M 9  open, Q 4  not energized 
     Rung  21 , Q 4  open 
     Rung  22 , M 3  closed, M 7  open 
     Rung  23 , M 3  open, I 3  open 
     Rung  24 , Q 4  open, T 2  not energized (timed out) 
     Rung  25 , M 3  open, Q 1  open 
     Rung  26 , T 2  closed, M 10  energized, T 2  returns to open, M 10  not energized 
     Rung  27 , I 7  closed, Q 4  open, M 3  closed 
     Rung  28 , I 1  open, M 11  open, T 4  closed 
     Rung  29 , Q 1  open, T 3  not energized 
     Rung  30 , M 10  closed, I 8  closed, M 12  closed, M 11  energized, M 10  returns to open 
     Rung  31 , M 2  open, T 1  open 
     Rung  32 , M 11  closed, T 4  closed, M 12  closed 
     Rung  33 , I 8  closed, M 3  open, I 3  open 
     Rung  34 , M 11  open, Q 2  not energized 
     Rung  35 , M 11  closed, T 4  energized (timing) 
     Rung  36 , I 8  closed, T 4  open, I 1  closed 
     Rung  37 , I 7  open 
     Rung  38 , T 4  open, I 1  open, M 12  not energized 
     Rung  39 , M 12  open 
     After the loading door opening mechanism opens the loading door  31 , the electromagnetic interlock  78  will re-energize. The ladder logic program status will be: 
     END OPERATION MODE PROGRAM: 
     Rung  1 , I 4  closed, I 5  closed, M 1  energized 
     Rung  2 , I 4  open, I 5  closed, M 2  not energized 
     Rung  3 , I 4  closed, I 5  open, M 3  not energized 
     Rung  4 , M 3  closed, I 8  open, I 1  closed, M 4  not energized 
     Rung  5 , M 3  open, I 8  closed 
     Rung  6 , M 4  open, M 10  closed, T 3  closed, M 5  not energized 
     Rung  7 , M 5  open, I 2  open, T 4  closed, M 6  not energized 
     Rung  8 , M 7  open 
     Rung  9 , M 6  open, I 7  open 
     Rung  10 , M 3  open 
     Rung  11 , I 3  open, I 8  open, I 7  open, M 7  not energized 
     Rung  12 , M 7  open, I 7  open 
     Rung  13 , M 6  open, M 11  closed, Q 1  not energized 
     Rung  14 , Q 1  open, M 3  closed, Q 4  closed, Q 3  not energized 
     Rung  15 , Q 3  open, T 1  not energized 
     Rung  16 , T 1  open, M 9  (S) not energized 
     Rung  17 , I 3  open 
     Rung  18 , M 10  open, M 9  (R) energized 
     Rung  19 , Q 1  closed 
     Rung  20 , Q 1  open, M 1  closed, M 9  open, Q 4  not energized 
     Rung  21 , Q 4  open 
     Rung  22 , M 3  closed, M 7  open 
     Rung  23 , M 3  open, I 3  open 
     Rung  24 , Q 4  open, T 2  not energized 
     Rung  25 , M 3  open, Q 1  open 
     Rung  26 , T 2  open, M 10  not energized 
     Rung  27 , I 7  closed, Q 4  open, M 3  closed 
     Rung  28 , I 1  open, M 11  open, T 4  closed, M 11  returns to closed 
     Rung  29 , Q 1  open, T 3  not energized 
     Rung  30 , M 10  open, I 8  open, M 12  closed, M 11  not energized 
     Rung  31 , M 2  open, T 1  open 
     Rung  32 , M 11  open, T 4  open, M 12  closed, T 4  returns to closed 
     Rung  33 , I 8  open, M 3  open, I 3  open 
     Rung  34 , M 11  closed, Q 2  energized 
     Rung  35 , M 11  open, T 4  not energized (timed out) 
     Rung  36 , I 8  open, T 4  closed, I 1  closed, T 4  returns to open 
     Rung  37 , I 7  open 
     Rung  38 , T 4  closed, I 1  open, M 12  not energized, T 4  returns to open 
     Rung  39 , M 12  open 
     The “AUTO” operation described above is that which would be used in accumulating waste and compacting it in a series of operations to form a bale. 
     The “MANUAL DOWN” mode of operation described below is used when such is desired, particularly when sufficient waste has been accumulated and compacted to form a bale, so that it can be removed from the baler. The set-up conditions for the “MANUAL DOWN” mode of operation are as follows: 
     Mode selector switch  71  is in the 60 degree down position for “MANUAL DOWN” mode. 
     The key switch is in the center position for “POWER ON”. 
     The stop button  75  is in the center position for normal operation. 
     The baler chamber door  35  is closed and latched. 
     The platen  21  is fully retracted. 
     The loading door  31  is open. 
     The electromagnetic interlock  78  is energized. 
     The set-up status for the ladder logic program is MANUAL DOWN SETUP PROGRAM: 
     Rung  1 , I 4  open, I 5  closed, M 1  not energized 
     Rung  2 , I 4  closed, I 5  closed, M 2  energized 
     Rung  3 , I 4  open, I 5  open, M 3  not energized 
     Rung  4 , M 3  closed, I 8  open, I 1  closed, M 4  not energized 
     Rung  5 , M 3  open, I 8  closed 
     Rung  6 , M 4  open, M 10  closed, T 3  closed, M 5  not energized 
     Rung  7 , M 5  open, I 2  open, T 4  closed, M 6  not energized 
     Rung  8 , M 7  open 
     Rung  9 , M 6  open, I 7  open 
     Rung  10 , M 3  open 
     Rung  11 , I 3  open, I 8  open, I 7  open, M 7  not energized 
     Rung  12 , M 7  open, I 7  open 
     Rung  13 , M 6  open, M 11  closed, Q 1  not energized 
     Rung  14 , Q 1  open, M 3  closed, Q 4  closed, Q 3  not energized 
     Rung  15 , Q 3  open, T 1  not energized 
     Rung  16 , T 1  open, M 9  (S) not energized 
     Rung  17 , I 3  open 
     Rung  18 , M 10  open, M 9  (R) energized 
     Rung  19 , Q 1  closed 
     Rung  20 , Q 1  open, M 1  open, M 9  open, Q 4  not energized 
     Rung  21 , Q 4  open 
     Rung  22 , M 3  closed, M 7  open 
     Rung  23 , M 3  open, I 3  open 
     Rung  24 , Q 4  open, T 2  not energized 
     Rung  25 , M 3  open, Q 1  open 
     Rung  26 , T 2  open, M 10  not energized 
     Rung  27 , I 7  closed, Q 4  open, M 3  closed 
     Rung  28 , I 1  open, M 11  closed, T 4  closed 
     Rung  29 , Q 1  open, T 3  not energized 
     Rung  30 , M 10  open, I 8  open, M 12  closed, M 11  not energized 
     Rung  31 , M 2  closed, T 1  open 
     Rung  32 , M 11  open, T 4  closed, M 12  closed 
     Rung  33 , I 8  open, M 3  open, I 3  open 
     Rung  34 , M 11  closed, Q 2  energized 
     Rung  35 , M 11  open, T 4  not energized 
     Rung  36 , I 8  open, T 4  open, I 1  closed 
     Rung  37 , I 7  open 
     Rung  38 , T 4  open, I 1  open, M 12  not energized 
     Rung  39 , M 12  open 
     Preliminary to starting the MANUAL DOWN operation, the loading door  31  is closed. When striking plate  79  closes with the electromagnetic interlock  78 , the loading door  31  locks. The ladder logic program status is START MANUAL DOWN PROGRAM: 
     Rung  1 , I 4  open, I 5  closed, M 1  not energized 
     Rung  2 , I 4  closed, I 5  closed, M 2  energized 
     Rung  3 , I 4  open, I 5  open, M 3  not energized 
     Rung  4 , M 3  closed, I 8  closed, I 1  closed, M 4  energized 
     Rung  5 , M 3  open, I 8  open 
     Rung  6 , M 4  closed, M 10  closed, T 3  closed, M 5  energized 
     Rung  7 , M 5  closed, I 2  open, T 4  closed, M 6  not energized 
     Rung  8 , M 7  open 
     Rung  9 , M 6  open, I 7  open 
     Rung  10 , M 3  open 
     Rung  11 , I 3  open, I 8  open, I 7  open, M 7  not energized 
     Rung  12 , M 7  open, I 7  open 
     Rung  13 , M 6  open, M 11  closed, Q 1  not energized 
     Rung  14 , Q 1  open, M 3  closed, Q 4  closed, Q 3  not energized 
     Rung  15 , Q 3  open, T 1  not energized 
     Rung  16 , T 1  open, M 9  (S) not energized 
     Rung  17 , I 3  open 
     Rung  18 , M 10  open, M 9  (R) energized 
     Rung  19 , Q 1  closed 
     Rung  20 , Q 1  open, M 1  open, M 9  open, Q 4  not energized 
     Rung  21 , Q 4  open 
     Rung  22 , M 3  closed, M 7  open 
     Rung  23 , M 3  open, I 3  open 
     Rung  24 , Q 4  open, T 2  not energized 
     Rung  25 , M 3  open, Q 1  open 
     Rung  26 , T 2  open, M 10  not energized 
     Rung  27 , I 7  closed, Q 4  open, M 3  closed 
     Rung  28 , I 1  open, M 11  closed, T 4  closed 
     Rung  29 , Q 1  open, T 3  not energized 
     Rung  30 , M 10  open, I 8  closed, M 12  closed, M 11  not energized 
     Rung  31 , M 2  closed, T 1  open 
     Rung  32 , M 11  open, T 4  closed, M 12  closed 
     Rung  33 , I 8  closed, M 3  open, I 3  open 
     Rung  34 , M 11  closed, Q 2  energized 
     Rung  35 , M 11  open, T 4  not energized 
     Rung  36 , I 8  closed, T 4  open, I 1  closed 
     Rung  37 , I 7  open 
     Rung  38 , T 4  open, I 1  open, M 12  not energized 
     Rung  39 , M 12  open 
     For MANUAL DOWN START operation, the key switch  73  is turned to the right to the “START” position causing the motor powering the hydraulic ram  19  to start and the platen  21  to begin its descent. The ladder logic program status then becomes: 
     START MANUAL DOWN OPERATION PROGRAM: 
     Rung  1 , I 4  open, I 5  closed, M 1  not energized 
     Rung  2 , I 4  closed, I 5  closed, M 2  energized 
     Rung  3 , I 4  open, I 5  open, M 3  not energized 
     Rung  4 , M 3  closed, I 8  closed, I 1  closed, M 4  energized 
     Rung  5 , M 3  open, I 8  open 
     Rung  6 , M 4  closed, M 10  closed, T 3  closed, M 5  energized 
     Rung  7 , M 5  closed, I 2  closed, T 4  closed, M 6  energized 
     Rung  8 , M 7  open 
     Rung  9 , M 6  closed, I 7  open 
     Rung  10 , M 3  open 
     Rung  11 , I 3  open, I 8  closed, I 7  open, M 7  not energized 
     Rung  12 , M 7  open, I 7  open 
     Rung  13 , M 6  closed, M 11  closed, Q 1  energized 
     Rung  14 , Q 1  closed, M 3  closed, Q 4  closed, Q 3  energized 
     Rung  15 , Q 3  closed, T 1  energized (timing) 
     Rung  16 , T 1  open, M 9  (S) not energized 
     Rung  17 , I 3  open 
     Rung  18 , M 10  open, M 9  (R) not energized 
     Rung  19 , Q 1  open 
     Rung  20 , Q 1  closed, M 1  open, M 9  open, Q 4  not energized 
     Rung  21 , Q 4  open 
     Rung  22 , M 3  closed, M 7  open 
     Rung  23 , M 3  open, I 3  open 
     Rung  24 , Q 4  open, T 2  not energized 
     Rung  25 , M 3  open, Q 1  closed 
     Rung  26 , T 2  open, M 10  not energized 
     Rung  27 , I 7  closed, Q 4  open, M 3  closed 
     Rung  28 , I 1  open, M 11  closed, T 4  closed 
     Rung  29 , Q 1  closed, T 3  energized (timing) 
     Rung  30 , M 10  open, I 8  closed, M 12  closed, M 11  not energized 
     Rung  31 , M 2  closed, T 1  open 
     Rung  32 , M 11  open, T 4  closed, M 12  closed 
     Rung  33 , I 8  closed, M 3  open, I 3  open 
     Rung  34 , M 11  closed, Q 2  energized 
     Rung  35 , M 11  open, T 4  not energized 
     Rung  36 , I 8  closed, T 4  open, I 1  closed 
     Rung  37 , I 7  open 
     Rung  38 , T 4  open, I 1  open, M 12  not energized 
     Rung  39 , M 12  open 
     In the descending operation, the safety interlocks switch  78  will close as the platen  21  descends about three inches and the key switch  73  should by then be released to return to the center or “POWER ON” position. The status in descent operation is DESCENT OPERATION PROGRAM: 
     Rung  1 , I 4  open, I 5  closed, M 1  not energized 
     Rung  2 , I 4  closed, I 5  closed, M 2  energized 
     Rung  3 , I 4  open, I 5  open, M 3  not energized 
     Rung  4 , M 3  closed, I 8  closed, I 1  closed, M 4  energized 
     Rung  5 , M 3  open, I 8  open 
     Rung  6 , M 4  closed, M 10  closed, T 3  closed, M 5  energized 
     Rung  7 , M 5  closed, I 2  open, T 4  closed, M 6  energized 
     Rung  8 , M 7  open 
     Rung  9 , M 6  closed, I 7  closed 
     Rung  10 , M 3  open 
     Rung  11 , I 3  open, I 8  closed, I 7  closed, M 7  not energized 
     Rung  12 , M 7  open, I 7  closed 
     Rung  13 , M 6  closed, M 11  closed, Q 1  energized 
     Rung  14 , Q 1  closed, M 3  closed, Q 4  closed, Q 3  energized 
     Rung  15 , Q 3  closed, T 1  energized (timing) 
     Rung  16 , T 1  open, M 9  (S) not energized 
     Rung  17 , I 3  open 
     Rung  18 , M 10  open, M 9  (R) not energized 
     Rung  19 , Q 1  open 
     Rung  20 , Q 1  closed, M 1  open, M 9  open, Q 4  not energized 
     Rung  21 , Q 4  open 
     Rung  22 , M 3  closed, M 7  open 
     Rung  23 , M 3  open, I 3  open 
     Rung  24 , Q 4  open, T 2  not energized 
     Rung  25 , M 3  open, Q 1  closed 
     Rung  26 , T 2  open, M 10  not energized 
     Rung  27 , I 7  open, Q 4  open, M 3  closed 
     Rung  28 , I 1  open, M 11  closed, T 4  closed 
     Rung  29 , Q 1  closed, T 3  energized (timing) 
     Rung  30 , M 10  open, I 8  closed, M 12  closed, M 11  not energized 
     Rung  31 , M 2  closed, T 1  open 
     Rung  32 , M 11  open, T 4  closed, M 12  closed 
     Rung  33 , I 8  closed, M 3  open, I 3  open 
     Rung  34 , M 11  closed, Q 2  energized 
     Rung  35 , M 11  open, T 4  not energized 
     Rung  36 , I 8  closed, T 4  open, I 1  closed 
     Rung  37 , I 7  closed 
     Rung  38 , T 4  open, I 1  open, M 12  not energized 
     Rung  39 , M 12  open 
     The platen  21  will continue to be in the descent mode until its accumulated extend time is equal to the pre-set value of the extended value at which time the motor powering the ram  19  will stop and the electromagnetic interlock  78  will de-energize to unlock the loading door  31  for three seconds. The ladder logic program for this portion is COMPLETE MANUAL DESCENT OPERATION PROGRAM: 
     Rung  1 , I 4  open, I 5  closed, M 1  not energized 
     Rung  2 , I 4  closed, I 5  closed, M 2  energized 
     Rung  3 , I 4  open, I 5  open, M 3  not energized 
     Rung  4 , M 3  closed, I 8  closed, I 1  closed, M 4  energized 
     Rung  5 , M 3  open, I 8  open 
     Rung  6 , M 4  closed, M 10  closed, T 3  closed, M 5  energized 
     Rung  7 , M 5  closed, I 2  open, T 4  closed, M 6  energized 
     Rung  8 , M 7  open 
     Rung  9 , M 6  closed, I 7  closed 
     Rung  10 , M 3  open 
     Rung  11 , I 3  open, I 8  closed, I 7  closed, M 7  not energized 
     Rung  12 , M 7  open, I 7  closed 
     Rung  13 , M 6  closed, M 11  open, Q 1  not energized 
     Rung  14 , Q 1  open, M 3  closed, Q 4  closed, Q 3  not energized 
     Rung  15 , Q 3  closed, T 1  energized (timed out), Q 3  opens, T 1  not energized 
     Rung  16 , T 1  closed, M 9  (S) energized, T 1  returns to open, M 9  (S) not energized 
     Rung  17 , I 3  open 
     Rung  18 , M 10  open, M 9  (R) energized 
     Rung  19 , Q 1  closed 
     Rung  20 , Q 1  open, M 1  open, M 9  closed, Q 4  not energized, M 9  returns to open 
     Rung  21 , Q 4  open 
     Rung  22 , M 3  closed, M 7  open 
     Rung  23 , M 3  open, I 3  open 
     Rung  24 , Q 4  open, T 2  not energized 
     Rung  25 , M 3  open, Q 1  open 
     Rung  26 , T 2  open, M 10  not energized 
     Rung  27 , I 7  open, Q 4  open, M 3  closed 
     Rung  28 , I 1  open, M 11  open, T 4  closed 
     Rung  29 , Q 1  open, T 3  not energized 
     Rung  30 , M 10  open, I 8  closed, M 12  closed, M 11  energized 
     Rung  31 , M 2  closed, T 1  closed, T 1  returns to open 
     Rung  32 , M 11  closed, T 4  closed, M 12  closed 
     Rung  33 , I 8  closed, M 3  open, I 3  open 
     Rung  34 , M 11  open, Q 2  not energized 
     Rung  35 , M 11  closed, T 4  energized (timing) 
     Rung  36 , I 8  closed, T 4  open, I 1  closed 
     Rung  37 , I 7  closed 
     Rung  38 , T 4  open, I 1  open, M 12  not energized 
     Rung  39 , M 12  open 
     Loading door opening mechanism opens the loading door  31  and after three seconds, the electromagnetic interlock  78  will re-energize. The status preparatory to opening the chamber door to tie the finished bale is as follows: 
     BEGIN MANUAL DOOR OPERATION 
     Rung  1 , I 4  open, I 5  closed, M 1  not energized 
     Rung  2 , I 4  closed, I 5  closed, M 2  energized 
     Rung  3 , I 4  open, I 5  open, M 3  not energized 
     Rung  4 , M 3  closed, I 8  open, I 1  closed, M 4  not energized 
     Rung  5 , M 3  open, I 8  closed 
     Rung  6 , M 4  open, M 10  closed, T 3  closed, M 5  not energized 
     Rung  7 , M 5  open, I 2  open, T 4  closed, M 6  not energized 
     Rung  8 , M 7  open 
     Rung  9 , M 6  open, I 7  open 
     Rung  10 , M 3  open 
     Rung  11 , I 3  open, I 8  open, I 7  open, M 7  not energized 
     Rung  12 , M 7  open, I 7  open 
     Rung  13 , M 6  open, M 11  closed, Q 1  not energized 
     Rung  14 , Q 1  open, M 3  closed, Q 4  closed, Q 3  not energized 
     Rung  15 , Q 3  open, T 1  not energized 
     Rung  16 , T 1  open, M 9  (S) not energized 
     Rung  17 , I 3  open 
     Rung  18 , M 10  open, M 9  (R) energized 
     Rung  19 , Q 1  closed 
     Rung  20 , Q 1  open, M 1  open, M 9  open, Q 4  not energized 
     Rung  21 , Q 4  open 
     Rung  22 , M 3  closed, M 7  open 
     Rung  23 , M 3  open, I 3  open 
     Rung  24 , Q 4  open, T 2  not energized 
     Rung  25 , M 3  open, Q 1  open 
     Rung  26 , T 2  open, M 10  not energized 
     Rung  27 , I 7  closed, Q 4  open, M 3  closed 
     Rung  28 , I 1  open, M 11  open, T 4  closed, M 11  returns to closed 
     Rung  29 , Q 1  open, T 3  not energized 
     Rung  30 , M 10  open, I 8  open, M 12  closed, M 11  not energized 
     Rung  31 , M 2  closed, T 1  open 
     Rung  32 , M 11  open, T 4  open, M 12  closed, T 4  returns to closed 
     Rung  33 , I 8  open, M 3  open, I 3  open 
     Rung  34 , M 11  closed, Q 2  energized 
     Rung  35 , M 11  open, T 4  not energized (timed out) 
     Rung  36 , I 8  open, T 4  closed, I 1  closed, T 4  returns to open 
     Rung  37 , I 7  open 
     Rung  38 , T 4  closed, I 1  open, M 12  not energized, T 4  returns to open 
     Rung  39 , M 12  open 
     In preparation for removing a finished bale, the chamber door is opened and the finished bale is tied before instituting the “MANUAL UP” mode. 
     For operation of the baler control system in the “MANUAL UP” mode, the conditions for the initial set-up are: 
     Mode selector switch  71  is in the  60  degree UP position selecting “MANUAL UP”. 
     The key switch  73  is in the center position for “POWER ON”. 
     The stop button  75  is in the center position for normal operation. 
     The bale chamber door  33  is open and the finished bale is tied. 
     The platen  21  is extended to the top of the finished bale. 
     The loading door  31  is open. 
     The status of the ladder logic program then becomes: 
     MANUAL UP SET-UP PROGRAM 
     Rung  1 , I 4  closed, I 5  open, M 1  not energized 
     Rung  2 , I 4  open, I 5  open, M 2  not energized 
     Rung  3 , I 4  closed, I 5  closed, M 3  energized 
     Rung  4 , M 3  open, I 8  open, I 1  closed, M 4  energized 
     Rung  5 , M 3  closed, I 8  closed 
     Rung  6 , M 4  closed, M 10  closed, T 3  closed, M 5  energized 
     Rung  7 , M 5  closed, I 2  open, T 4  closed, M 6  not energized 
     Rung  8 , M 7  open 
     Rung  9 , M 6  open, I 7  open 
     Rung  10 , M 3  closed 
     Rung  11 , I 3  open, I 8  open, I 7  open, M 7  not energized 
     Rung  12 , M 7  open, I 7  open 
     Rung  13 , M 6  open, M 11  closed, Q 1  not energized 
     Rung  14 , Q 1  open, M 3  open, Q 4  closed, Q 3  not energized 
     Rung  15 , Q 3  open, T 1  not energized 
     Rung  16 , T 1  open, M 9  (S) not energized 
     Rung  17 ,I 3  open 
     Rung  18 , M 10  open, M 9  (R) energized 
     Rung  19 , Q 1  closed 
     Rung  20 , Q 1  open, M 1  open, M 9  open, Q 4  not energized 
     Rung  21 , Q 4  open 
     Rung  22 , M 3  open, M 7  open 
     Rung  23 , M 3  closed, I 3  open 
     Rung  24 , Q 4  open, T 2  not energized 
     Rung  25 , M 3  closed, Q 1  open 
     Rung  26 , T 2  open, M 10  not energized 
     Rung  27 , I 7  closed, Q 4  open, M 3  open 
     Rung  28 , I 1  open, M 11  closed, T 4  closed 
     Rung  29 , Q 1  open, T 3  not energized 
     Rung  30 , M 10  open, I 8  open, M 12  closed, M 11  not energized 
     Rung  31 , M 2  open, T 1  open 
     Rung  32 , M 11  open, T 4  closed, M 12  closed 
     Rung  33 , I 8  open, M 3  closed, I 3  open 
     Rung  34 , M 11  closed, Q 2  energized 
     Rung  35 , M 11  open, T 4  not energized 
     Rung  36 , I 8  open, T 4  open, I 1  closed 
     Rung  37 , I 7  open 
     Rung  38 , T 4  open, I 1  open, M 12  not energized 
     Rung  39 , M 12  open 
     The “MANUAL UP” operation, which also causes ejection apparatus (described elsewhere) to eject the finished bale from the baler, is initiated by the key switch  73  being turned to the right (“START”) position. The motor starter  90  will then start the motor but the platen  21  will not move. The status for the ladder logic program will be: 
     MANUAL UP STOP OPERATION PROGRAM 
     Rung  1 , I 4  closed, I 5  open, M 1  not energized 
     Rung  2 , I 4  open, I 5  open, M 2  not energized 
     Rung  3 , I 4  closed, I 5  closed, M 3  energized 
     Rung  4 , M 3  open, I 8  open, I 1  closed, M 4  energized 
     Rung  5 , M 3  closed, I 8  closed 
     Rung  6 , M 4  closed, M 10  closed, T 3  closed, M 5  energized 
     Rung  7 , M 5  closed, I 2  closed, T 4  closed, M 6  energized 
     Rung  8 , M 7  open 
     Rung  9 , M 6  closed, I 7  open 
     Rung  10 , M 3  closed 
     Rung  11 , I 3  open, I 8  open, I 7  open, M 7  not energized 
     Rung  12 , M 7  open, I 7  open 
     Rung  13 , M 6  closed, M 11  closed, Q 1  energized 
     Rung  14 , Q 1  closed, M 3  open, Q 4  closed, Q 3  not energized 
     Rung  15 , Q 3  open, T 1  not energized 
     Rung  16 , T 1  open, M 9  (S) not energized 
     Rung  17 , I 3  open 
     Rung  18 , M 10  open, M 9  (R) not energized 
     Rung  19 , Q 1  open 
     Rung  20 , Q 1  closed, M 1  open, M 9  open, Q 4  not energized 
     Rung  21 , Q 4  open 
     Rung  22 , M 3  open, M 7  open 
     Rung  23 , M 3  closed, I 3  open 
     Rung  24 , Q 4  open, T 2  energized (timing) 
     Rung  25 , M 3  closed, Q 1  closed 
     Rung  26 , T 2  open, M 10  not energized 
     Rung  27 , I 7  closed, Q 4  open, M 3  open 
     Rung  28 , I 1  open, M 11  closed, T 4  closed 
     Rung  29 , Q 1  closed, T 3  energized (timing) 
     Rung  30 , M 10  open, I 8  open, M 12  closed, M 11  not energized 
     Rung  31 , M 2  open, T 1  open 
     Rung  32 , M 11  open, T 4  closed, M 12  closed 
     Rung  33 , I 8  open, M 3  closed, I 3  open 
     Rung  34 , M 11  closed, Q 2  energized 
     Rung  35 , M 11  open, T 4  not energized 
     Rung  36 , I 8  open, T 4  open, I 1  closed 
     Rung  37 , I 7  open 
     Rung  38 , T 4  open, I 1  open, M 12  not energized 
     Rung  39 , M 12  open 
     When the key switch  73  is released to return to the center or “POWER ON” position, the controller is ready for manual raising of the platen and the status of the ladder logic program is: 
     MANUAL UP READY PROGRAM 
     Rung  1 , I 4  closed, I 5  open, M 1  not energized 
     Rung  2 , I 4  open, I 5  open, M 2  not energized 
     Rung  3 , I 4  closed, I 5  closed, M 3  energized 
     Rung  4 , M 3  open, I 8  open, I 1  closed, M 4  energized 
     Rung  5 , M 3  closed, I 8  closed 
     Rung  6 , M 4  closed, M 10  closed, T 3  closed, M 5  energized 
     Rung  7 , M 4  closed, I 2  open, T 4  closed, M 6  energized 
     Rung  8 , M 7  open 
     Rung  9 , M 6  closed, I 7  open 
     Rung  10 , M 3  closed 
     Rung  11 , I 3  open, I 8  open, I 7  open, M 7  not energized 
     Rung  12 , M 7  open, I 7  open 
     Rung  13 , M 6  closed, M 11  closed, Q 1  energized 
     Rung  14 , Q 1  closed, M 3  open, Q 4  closed, Q 3  not energized 
     Rung  15 , Q 3  open, T 1  not energized 
     Rung  16 , T 1  open, M 9  (S) not energized 
     Rung  17 , I 3  open 
     Rung  18 , M 10  open, M 9  (R) not energized 
     Rung  19 , Q 1  open 
     Rung  20 , Q 1  closed, M 1  open, M 9  open, Q 4  not energized 
     Rung  21 , Q 4  open 
     Rung  22 , M 3  open, M 7  open 
     Rung  23 , M 3  closed, I 3  open 
     Rung  24 , Q 4  open, T 2  energized (timing) 
     Rung  25 , M 3  closed, Q 1  closed 
     Rung  26 , T 2  open, M 10  not energized 
     Rung  27 , I 7  closed, Q 4  open, M 3  open 
     Rung  28 , I 1  open, M 11  closed, T 4  closed 
     Rung  29 , Q 1  closed, T 3  energized (timing) 
     Rung  30 , M 10  open, I 8  open, M 12  closed, M 11  not energized 
     Rung  31 , M 2  open, T 1  open 
     Rung  32 , M 11  open, T 4  closed, M 12  closed 
     Rung  33 , I 8  open, M 3  closed, I 3  open 
     Rung  34 , M 11  closed, Q 2  energized 
     Rung  35 , M 11  open, T 4  not energized 
     Rung  36 , I 8  open, T 4  open, I 1  closed 
     Rung  37 , I 7  open 
     Rung  38 , T 4  open, I 1  open, M 12  not energized 
     Rung  39 , M 12  open 
     In order to raise the platen causing the finished bale to eject, an operator must be at the control panel on the side of the baler where the operator is out of the path of the ejected bale and is in a position to see that the ejection of the bale onto an appropriate carrier is provided for in a safe manner. The operator must pull out on the (STOP/PULL TO/RAISE) stop button  75  causing the platen to retract only as long as the operator continues to hold out on the stop/pull to/raise button. For the platen to raise, the ladder logic program has the following status: 
     MANUAL UP RAISE PLATEN OPERATION PROGRAM 
     Rung  1 , I 4  closed, I 5  open, M 1  not energized 
     Rung  2 , I 4  open, I 5  open, M 2  not energized 
     Rung  3 , I 4  closed, I 5  closed, M 3  energized 
     Rung  4 , M 3  open, I 8  open, I 1  closed, M 4  energized 
     Rung  5 , M 3  closed, I 8  closed 
     Rung  6 , M 4  closed, M 10  closed, T 3  closed, M 5  energized 
     Rung  7 , M 5  closed, I 2  open, T 4  closed, M 6  energized 
     Rung  8 , M 7  open 
     Rung  9 , M 6  closed, I 7  open 
     Rung  10 , M 3  closed 
     Rung  11 , I 3  closed, I 8  open, I 7  open, M 7  not energized 
     Rung  12 , M 7  open, I 7  open 
     Rung  13 , M 6  closed, M 11  closed, Q 1  energized 
     Rung  14 , Q 1  closed, M 3  open, Q 4  closed, Q 3  not energized 
     Rung  15 , Q 3  open, T 1  not energized 
     Rung  16 , T 1  open, M 9  (S) energized 
     Rung  17 , I 3  closed 
     Rung  18 , M 10  open, M 9  (R) not energized 
     Rung  19 , Q 1  open 
     Rung  20 , Q 1  closed, M 1  open, M 9  closed, Q 4  energized 
     Rung  21 , Q 4  open 
     Rung  22 , M 3  open, M 7  open 
     Rung  23 , M 3  closed, I 3  closed 
     Rung  24 , Q 4  open, T 2  energized (timing) 
     Rung  25 , M 3  closed, Q 1  closed 
     Rung  26 , T 2  open, M 10  not energized 
     Rung  27 ,I 7  closed, Q 4  open, M 3  open 
     Rung  28 , I 1  open, M 11  closed, T 4  closed 
     Rung  29 , Q 1  closed, T 3  energized (timing) 
     Rung  30 , M 10  open, I 8  open, M 12  closed, M 11  not energized 
     Rung  31 , M 2  open, T 1  open 
     Rung  32 , M 11  open, T 4  closed, M 12  closed 
     Rung  33 , I 8  open, M 3  closed,  13  closed 
     Rung  34 , M 11  closed, Q 2  energized 
     Rung  35 , M 11  open, T 4  not energized 
     Rung  36 , I 8  open, T 4  open, I 1  closed 
     Rung  37 ,I 7  open 
     Rung  38 , T 4  open, I 1  open, M 12  not energized 
     Rung  39 , M 12  open 
     If the button is released, the platen will stop and the status of the ladder logic program will be: 
     STOP PLATEN RAISE OPERATION PROGRAM 
     Rung  1 , I 4  closed, I 5  open, M 1  not energized 
     Rung  2 , I 4  open, I 5  open, M 2  not energized 
     Rung  3 , I 4  closed, I 5  closed, M 3  energized 
     Rung  4 , M 3  open, I 8  open, I 1  closed, M 4  energized 
     Rung  5 , M 3  closed, I 8  closed 
     Rung  6 , M 4  closed, M 10  closed, T 3  closed, M 5  energized 
     Rung  7 , M 5  closed, I 2  open, T 4  closed, M 6  energized 
     Rung  8 , M 7  open 
     Rung  9 , M 6  closed, I 7  open 
     Rung  10 , M 3  closed 
     Rung  11 , I 3  open, I 8  open, I 7  open, M 7  not energized 
     Rung  12 , M 7  open, I 7  open 
     Rung  13 , M 6  closed, M 11  closed, Q 1  energized 
     Rung  14 , Q 1  closed, M 3  open, Q 4  closed, Q 3  not energized 
     Rung  15 , Q 3  open, T 1  not energized 
     Rung  16 , T 1  open, M 9  (S) not energized 
     Rung  17 , I 3  open 
     Rung  18 , M 10  open, M 9  (R) not energized 
     Rung  19 , Q 1  open 
     Rung  20 , Q 1  closed, M 1  open, M 9  closed, Q 4  not energized 
     Rung  21 , Q 4  open 
     Rung  22 , M 3  open, M 7  open 
     Rung  23 , M 3  closed, I 3  open 
     Rung  24 , Q 4  open, T 2  energized (timing) 
     Rung  25 , M 3  closed, Q 1  closed 
     Rung  26 , T 2  open, M 10  not energized 
     Rung  27 , I 7  closed, Q 4  open, M 3  open 
     Rung  28 , I 1  open, M 11  closed, T 4  closed 
     Rung  29 , Q 1  closed, T 3  energized (timing) 
     Rung  30 , M 10  open, I 8  open, M 12  closed, M 11  not energized 
     Rung  31 , M 2  open, T 1  open 
     Rung  32 , M 11  open, T 4  closed, M 12  closed 
     Rung  33 , I 8  open, M 3  closed, I 3  open 
     Rung  34 , M 11  closed, Q 2  energized 
     Rung  35 , M 11  open, T 4  not energized 
     Rung  36 , I 8  open, T 4  open, I 1  closed 
     Rung  37 , I 7  open 
     Rung  38 , T 4  open, I 1  open, M 12  not energized 
     Rung  39 , M 12  open 
     When the accumulated retract time is equal to the reset value in the retract timer, the motor powering ram  19  will stop concluding the “MANUAL UP” operation. The status of the ladder logic program will be: 
     MANUAL UP END OPERATION PROGRAM 
     Rung  1 , I 4  closed, I 5  open, M 1  not energized 
     Rung  2 , I 4  open, I 5  open, M 2  not energized 
     Rung  3 , I 4  closed, I 5  closed, M 3  energized 
     Rung  4 , M 3  open, I 8  open, I 1  closed, M 4  energized 
     Rung  5 , M 3  closed, I 8  closed 
     Rung  6 , M 4  closed, M 10  open, T 3  closed, M 5  not energized, M 10  returns to closed 
     Rung  7 , M 5  open, I 2  open, T 4  closed, M 6  not energized 
     Rung  8 , M 7  open 
     Rung  9 , M 6  open, I 7  open 
     Rung  10 , M 3  closed 
     Rung I 1 , I 3  open, I 8  open, I 7  open, M 7  not energized 
     Rung  12 , M 7  open, I 7  open 
     Rung  13 , M 6  open, M 11  closed, Q 1  not energized 
     Rung  14 , Q 1  open, M 3  open, Q 4  closed, Q 3  not energized 
     Rung  15 , Q 3  open, T 1  not energized 
     Rung  16 , T 1  open, M 9  (S) not energized 
     Rung  17 , I 3  open 
     Rung  18 , M 10  closed, M 9  (R) energized, M 10  returns to open 
     Rung  19 , Q 1  closed 
     Rung  20 , Q 1  open, M 1  open, M 9  open, Q 4  not energized 
     Rung  21 , Q 4  open 
     Rung  22 , M 3  open, M 7  open 
     Rung  23 , M 3  closed, I 3  open 
     Rung  24 , Q 4  open, T 2  not energized (timed out) 
     Rung  25 , M 3  closed, Q 1  open 
     Rung  26 , T 2  closed, M 10  energized, T 2  returns to open, M 10  not energized 
     Rung  27 ,I 7  closed, Q 4  open, M 3  open 
     Rung  28 , I 1  open, M 11  closed, T 4  closed 
     Rung  29 , Q 1  open, T 3  not energized 
     Rung  30 , M 10  closed, I 8  open, M 12  closed, M 11  not energized, M 10  returns to open 
     Rung  31 , M 2  open, T 1  open 
     Rung  32 , M 11  open, T 4  closed, M 12  closed 
     Rung  33 , I 8  open, M 3  closed, I 3  open 
     Rung  34 , M 11  closed, Q 2  energized 
     Rung  35 , M 11  open, T 4  not energized 
     Rung  36 , I 8  open, T 4  open, I 1  closed 
     Rung  37 , I 7  open 
     Rung  38 , T 4  open, I 1  open, M 12  not energized 
     Rung  39 , M 12  open 
     When the operator has followed the procedures above, the finished bale should be ejected completing the “MANUAL UP” operation and concluding the cycle so that the “AUTO” mode can be initiated again as described above. 
     FIG. 5 is a schematic circuit diagram showing the hard wired connections of the programmable relay with other electrical components of the baler of FIGS. 1 and 2. Programmable relay  61  is the part of the controller for the baler and is a conventional solid-state electronics device readily available and well known as indicated by the referenced patents. 
     Electrical outputs of programmable relay  61  are labeled Q 1 , Q 2 , Q 3 , and Q 4 . Output Q 1  supplies a control signal to motor starter  90  for the motor powering hydraulic ram  19  for raising and lowering platen  21  (ram  19  and platen  21  being shown in FIG.  1 ). An overload protector  91  is shown in circuit with motor starter  90 . 
     Output Q 4  controls the interlock solenoid shown schematically at  77 . Output Q 3  controls the hydraulic extend valve solenoid shown schematically at  93  and output Q 2  controls the hydraulic retract valve solenoid shown schematically at  95 . 
     Programmable relay  61  is provided with power terminals L and N receiving AC power from transformer secondary  85  having a fuse  87  in series therewith for protection thereof As shown at  73 , off/on/start key switch is configured to provide power from transformer secondary  85  to all elements of the circuit of FIG. 5 in all positions except the off position. Power on condition is indicated by power on light  89 . The three-phase power system for the motor of hydraulic ram  19  is conventional and not shown in detail. 
     Safety interlock switch  81  is connected to Input  6 . Mode select switch  71  is connected to Inputs  4  and  5 , being closed to both at the center position. 
     The off/on/start key switch  73  also has a contact and connection to Input  2 . The pull to raise/stop button  75  has contacts connecting input  3  and  4  respectively. 
     Other operation features may not be readily apparent from the foregoing description. They include the following. 
     If the stop button is pushed in while the motor is on and if the loading door is closed, the motor will stop and the electromagnetic interlock will de-energize to unlock the loading door. The loading door opening mechanism will open the loading door as it does whenever the electromagnetic interlock is de-energized. The magnetic door interlock will remain un-energized for three seconds and then re-energize. 
     If the stop button is pushed in while the motor is off and if the loading door is closed, the electromagnetic interlock will de-energize to unlock the loading door. The loading door opening mechanism will open the loading door. The electromagnetic interlock will remain un-energized for three seconds and then re-energize. 
     If the key switch is moved to the “off” position, all control voltage is off and there is no power to the programmable relay. 
     If the stop/pull to raise button is pulled out while the motor is running, and if the platen is extended and if the loading door is closed, the platen will shift direction and retract until the accumulated retract time is equal to the preset value in the retract timer. The motor then will stop and the electromagnetic interlock will de-energize to unlock the loading door. The loading door opening mechanism will open the loading door. The electromagnetic interlock will remain un-energized for three seconds and then re-energize. 
     If the stop/pull to raise button is pulled out while the motor is off and if the key switch is in the “POWER ON” position and if the platen is extended and if the loading door is closed, the motor will start and the platen will retract until the accumulated retract time is equal to the preset value in the retract timer. The motor will stop and the electromagnetic interlock will be energized to unlock the loading door. The loading door opening mechanism will open the loading door. The electromagnetic interlock will remain un-energized for three seconds and then re-energized. 
     From the foregoing discussion, it will be seen that the control circuit and the programmable relay provide for both expected and unexpected operator actions at the control panel thereby preventing problems with a control system function that could require supervisory activity beyond the operator&#39;s ability. 
     From FIGS. 1,  2 ,  3 ,  4 A-E, and  5  it will be seen that the control system of the programmable relay and associated components serve to effectively provide all of the functions of the baler including waste acceptance, compaction, and bale ejection in a safe and efficient manner with a minimum of complexity using a relatively small number of interlocking and locking devices. 
     While the control program and circuit described above is explained in relation to cooperation with a particular form of bale dump tray and ejection mechanism coupling the bale dump tray and the baler platen, its usefulness is not limited to this particular form of baler and ejection mechanism but is suitable with or adaptable to other forms of compaction apparatus. 
     In addition to the alternative forms of implementation of the apparatus shown, suggested, or described above, it will be apparent to those skilled in the art that other modifications and variations to the apparatus can be employed and accordingly the scope of the invention is not to be limited to the variations explicitly described but is rather to be determined by reference to the appended claims.

Technology Category: b