BALE FORMING AND WRAPPING APPARATUS AND METHOD WITH A WEB DETECTING SENSOR

Abstract

A bale forming apparatus forms a round bale, wraps a surface of the bale, and ejects the bale. A discharge gate of a casing is in a bale forming position while the bale is formed. For wrapping the bale, the discharge gate is pivoted into a bale wrapping position. A web detecting sensor detects whether or not provided web is present on the surface of the bale in the casing. This web detecting sensor senses a segment of the bale surface which is visible through a gap between a stationary casing part and the discharge gate being in the bale wrapping position. The wrapped bale is ejected.

Claims

1. A bale forming apparatus comprising: a bale forming device; a casing with a movable discharge gate and a further casing part; and a web providing device, wherein the movable discharge gate is movable with respect to the further casing part between a bale forming position, at least one bale wrapping position, and a bale ejecting position, wherein a or a respective gap between the further casing part and the discharge gate being in the or one bale wrapping position occurs, wherein an aperture between the further casing part and the discharge gate being in the bale ejecting position occurs, wherein the aperture is larger than the or every gap, wherein the bale forming device is arranged to form a bale in the interior of the casing while the discharge gate is in the bale forming position, wherein the web providing device is arranged to provide a web of wrapping material, wherein the bale forming apparatus is arranged to wrap a surface of the bale in the interior of the casing into the provided web while the discharge gate is in the or one bale wrapping position, and wherein the bale forming apparatus is arranged to eject the wrapped bale through the aperture out of the casing when the discharge gate is in the bale ejecting position, wherein the bale forming apparatus further comprises a web detecting sensor arranged to detect whether or not the provided web is present on the surface of the bale in the interior of the casing, and, wherein the web detecting sensor is arranged to sense at least one segment of the bale surface to be wrapped, wherein the or every sensed surface segment is visible through the gap, and to generate an alert if the non-presence of web on the or one sensed surface segment is detected.

2. The bale forming apparatus according to claim 1, wherein the bale forming apparatus is arranged to automatically inhibit the movement of the discharge gate into the bale ejecting position if the web detecting sensor has generated an alert due to detecting the non-presence of web on the or one sensed surface segment.

3. The bale forming apparatus according to claim 1, wherein the bale forming apparatus is arranged to pivot the discharge gate from the or one bale wrapping position into the bale ejecting position only if the web detecting sensor has positively detected the presence of the web on the or every sensed bale surface segment.

4. The bale forming apparatus according to claim 1, wherein the bale forming apparatus further comprises an illumination source which is arranged to illuminate the or every sensed bale surface segment through the provided gap.

5. The bale forming apparatus according to claim 1, wherein the gap occurs along a gap axis and the web detecting sensor comprises an array of sensing cells which are positioned in a sequence parallel to the gap axis, wherein every sensing cell is arranged to detect whether or not a part of the or every bale surface segment is wrapped, and wherein the segment parts are visible through the gap and are positioned in a sequence parallel to the gap axis on the bale surface to be wrapped.

6. The bale forming apparatus according to claim 1, wherein the bale forming apparatus is arranged to move the bale with respect to the casing and thereby with respect to the gap at least while the discharge gate is in the or one bale wrapping position and the bale surface is wrapped, and wherein the web detecting sensor is arranged to subsequently sense through the gap different visible segments of the bale surface to be wrapped.

7. The bale forming apparatus according to claim 1, wherein the discharge gate is movable between the bale forming position, a further bale wrapping position, the bale wrapping position, and the bale ejecting position, wherein a further gap between the further casing part and the discharge gate being in the further wrapping position occurs, and wherein the further gap is smaller than the gap occurring when the discharge gate is in the bale wrapping position.

8. The bale forming apparatus according to claim 1, wherein the bale forming apparatus provides a wrapping chamber in the interior of the casing and is arranged to wrap in the wrapping chamber the surface of the bale, and wherein the web detecting sensor is arranged to sense at least one segment of the surface to be wrapped of the bale in the wrapping chamber through the gap between the further casing part and the discharge gate and through a corresponding gap in the wrapping chamber.

9. The bale forming apparatus according to claim 8, wherein the bale forming apparatus provides a further chamber in the interior of the casing, is arranged to form the bale with the surface to be wrapped in the further chamber, is arranged to move the bale into the chamber, and is arranged to inject loose material into the further chamber while wrapping the surface of the bale in the wrapping chamber.

10. Method A method for forming at least one bale by using a bale forming apparatus, the bale forming apparatus comprising: a bale forming device; a casing with a movable discharge gate and a further casing part; and a web providing device, wherein the method comprises the steps that of: the bale forming device forming the bale in the interior of the casing while the discharge gate is in a bale forming position; the web providing device providing a web of wrapping material; moving the discharge gate with respect to the further casing part into a bale wrapping position such that a gap between the further casing part and the discharge gate occurs, wrapping a surface of the bale while the bale is in the interior of the casing and while the discharge gate is in the bale wrapping position; moving the discharge gate with respect to the further casing part into a bale ejecting position such that an aperture between the further casing part and the discharge gate occurs, wherein the aperture is larger than the gap; and ejecting the wrapped bale through the aperture out of the casing while the discharge gate is in the bale ejecting position, wherein the bale forming apparatus further comprises a web detecting sensor, wherein the step of wrapping the surface of the bale comprises the steps of: the web detecting sensor sensing at least one segment of the bale surface to be wrapped, wherein the or every sensed surface segment is visible through the gap; the web detecting sensor detecting whether or not the provided web is present on the or every sensed surface segment; and generating an alert if the web detecting sensor detects the non-presence of web on the or at least one sensed surface segment.

11. The bale forming method according to claim 10, wherein the step of generating an alert triggers the event that the movement of the discharge gate into the bale ejecting position is at least temporarily automatically inhibited.

12. The bale forming apparatus according to claim 2, wherein the bale forming apparatus is arranged to pivot the discharge gate from the or one bale wrapping position into the bale ejecting position only if the web detecting sensor has positively detected the presence of the web on the or every sensed bale surface segment.

13. The bale forming apparatus according to claim 2, wherein the bale forming apparatus further comprises an illumination source arranged to illuminate the or every sensed bale surface segment through the provided gap.

14. The bale forming apparatus according to claim 3, wherein the bale forming apparatus further comprises an illumination source arranged to illuminate the or every sensed bale surface segment through the provided gap.

15. The bale forming apparatus according to claim 2, wherein the gap occurs along a gap axis and the web detecting sensor comprises an array of sensing cells positioned in a sequence parallel to the gap axis, wherein every sensing cell is arranged to detect whether or not a part of the or every bale surface segment is wrapped, and wherein the segment parts are visible through the gap and are positioned in a sequence parallel to the gap axis on the bale surface to be wrapped.

16. The bale forming apparatus according to claim 3, wherein the gap occurs along a gap axis and the web detecting sensor comprises an array of sensing cells positioned in a sequence parallel to the gap axis, wherein every sensing cell is arranged to detect whether or not a part of the or every bale surface segment is wrapped, and wherein the segment parts are visible through the gap and are positioned in a sequence parallel to the gap axis on the bale surface to be wrapped.

17. The bale forming apparatus according to claim 4, wherein the gap occurs along a gap axis and the web detecting sensor comprises an array of sensing cells positioned in a sequence parallel to the gap axis, wherein every sensing cell is arranged to detect whether or not a part of the or every bale surface segment is wrapped, and wherein the segment parts are visible through the gap and are positioned in a sequence parallel to the gap axis on the bale surface to be wrapped.

18. The bale forming apparatus according to claim 2, wherein the bale forming apparatus is arranged to move the bale with respect to the casing and thereby with respect to the gap at least while the discharge gate is in the or one bale wrapping position and the bale surface is wrapped, and wherein the web detecting sensor is arranged to subsequently sense through the gap different visible segments of the bale surface to be wrapped.

19. The bale forming apparatus according to claim 3, wherein the bale forming apparatus is arranged to move the bale with respect to the casing and thereby with respect to the gap at least while the discharge gate is in the or one bale wrapping position and the bale surface is wrapped, and wherein the web detecting sensor is arranged to subsequently sense through the gap different visible segments of the bale surface to be wrapped.

20. The bale forming apparatus according to claim 4, wherein the bale forming apparatus is arranged to move the bale with respect to the casing and thereby with respect to the gap at least while the discharge gate is in the or one bale wrapping position and the bale surface is wrapped, and wherein the web detecting sensor is arranged to subsequently sense through the gap different visible segments of the bale surface to be wrapped.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0075] FIG. 1 shows the bale forming apparatus of the embodiment with the tailgate in the bale forming position;

[0076] FIG. 2 shows the bale forming apparatus of FIG. 1 with the tailgate in the initial bale wrapping position and with a small gap;

[0077] FIG. 3 shows the bale forming apparatus of FIG. 2 with the tailgate in the final bale wrapping position and with a larger gap;

[0078] FIG. 4 shows the bale forming apparatus of FIG. 1 with the tailgate in the bale ejecting position.

DETAILED DESCRIPTION OF EMBODIMENT

[0079] In the embodiment the invention is used in a continuous round baler as disclosed in WO 2013/157950 A1 and WO 2013/157949 A1 and WO 2013/157948 A1, e.g. A first segment of an endless elastic pressing belt surrounds a bale forming chamber. A second segment of the same pressing belt surrounds a bale wrapping chamber. The pressing belt and thereby both chambers are surrounded by a casing comprising a stationary front housing serving as the further casing part and a pivotal tailgate serving as the movable discharge gate. The tailgate (discharge gate) can be pivoted with respect to the stationary front housing subsequently into four different positions: [0080] a bale forming position, [0081] an initial bale wrapping position serving as the further bale wrapping position, [0082] a final bale wrapping position serving as the bale wrapping position, and [0083] a bale ejecting position.

[0084] The front housing and the tailgate being in the bale forming position entirely cover the pressing belt and thereby both chamberswith the exception of a crop material inlet and the inevitable space between the front housing and the tailgate. A small gap occurs between the front housing and the tailgate being in the initial bale wrapping position. A larger gap occurs between the front housing and the tailgate being in the final bale wrapping position. A segment of the bale surface is visible through this gap. This gap does not occur when the tailgate is in the bale forming position. The tailgate is rigidly but releasable connected with the front housing when the tailgate is in the bale forming position or is in one of the bale wrapping positions.

[0085] This connection is released when the tailgate is to be pivoted into the bale ejecting position. An aperture between the front housing and the tailgate being in the bale ejecting position occurs. This aperture suffices for ejecting a bale out of the wrapping chamber such that the ejected bale drops on the ground GS.

[0086] FIG. 1 to FIG. 4 show the bale forming apparatus of the embodiment with the tailgate being in the bale forming position (FIG. 1), the initial bale wrapping position (FIG. 2), the final bale wrapping position (FIG. 3), and the bale ejecting position (FIG. 4). The bale forming apparatus 1 of the embodiment comprises the following parts: [0087] a towing unit 4 for connecting the baler 1 with a pulling tractor or further propelled vehicle (not shown), [0088] a frame 2, [0089] two ground-engaging wheels 3 which are rotatably mounted at the frame 2, [0090] a crop intake device 5 with an inlet 6 and an outlet 7, [0091] two driven starter rollers 8.1, 8.2 which delimit the crop material inlet from above and from below, [0092] at least one tensioned endless pressing belt 10, [0093] a stationary front housing 15 which serves as the further casing part, [0094] a pivotal tailgate 11 which serves as the movable discharge gate and comprises a tailgate frame 17 connected with the front housing 15 and a pivotal tailgate bottom 18, [0095] a tailgate bottom roller 19 mounted at the free end of the tailgate bottom 18, [0096] a wrapping device 20 with an unrolling station for carrying a supply reel 88 for wrapping material, [0097] two parallel supporting disks 23 which can rotate around a common pivoting axis 25 (perpendicular to the drawing planes of FIG. 1 to FIG. 4), [0098] two pushing rollers 24.1, 24.2 mounted at the circumferential surface of the supporting disks 23, [0099] two pivotal guiding rollers 28.1, 28.2, [0100] a pivotal tensioning device with three guiding rollers, [0101] a pivotal ramp 37, [0102] a pivotal tensioning arm 60 carrying a further guiding roller, and [0103] a web detecting sensor 99 (FIG. 3).

[0104] The tailgate bottom 18 is pivotal with respect to the tailgate frame 17 around a horizontal pivoting axis 22. The tailgate frame 17 and thereby also the tailgate bottom 18 can pivot with respect to the front housing 11. The or every pressing belt 10 is guided around the deflecting roller 19 at the tailgate bottom 18, around the three rollers at the pivotal tensioning device, around a roller mounted on the tensioning arm 60, around one of the pivotal guiding rollers 28.1, 28.2, and around several further guiding rollers. The wrapping device 20 is mounted at the tailgate frame 17. The starter rollers 8.1, 8.2 and the or every pressing belt 10 belong to a bale forming device 9.

[0105] The baler according to the embodiment operates as follows: [0106] The baler 1 is pulled in the travelling direction TD (in FIG. 1 from right to left) over the ground surface GS. [0107] The intake device 6 picks up loose crop material from the ground GS. [0108] The picked-up loose crop material is conveyed into a drum-shaped bale forming chamber Ch which is delimited by the starter rollers 8.1, 8.2 and by a segment of the or every pressing belt 10. [0109] An increasing round-cylindrical bale B with a circumferential surface and two parallel front faces is formed from the injected loose material in the bale forming chamber Ch and is rotated (in FIG. 1 to FIG. 3 anti-clockwise). The bale forming chamber Ch itself increases and tensions the or every pressing belt 10. [0110] After the measured current diameter of the round-cylindrical bale B has reached a given diameter threshold, e.g. the required final diameter, a pivotal web pusher (not shown) presses a leading segment of a web of wrapping material against the outer surface of the or at least one pressing belt 10. As the belt 10 continues to move, the pressed web is pulled from the supply reel 88 and is injected into the bale forming chamber Ch. The web is injected through the space between the starter roller 8.2 and that segment of the or every belt 10 which is guided around the deflecting roller 19. The discharge gate 11 remains in the bale forming position (FIG. 1). [0111] After the injected web is securely grasped and clamped by the rotated bale B and the or every pressing belt 10, the tailgate bottom 18 is lowered downwards away from the front housing 15. Thereby the tailgate 11 is pivoted from the bale forming position into the initial bale wrapping position (FIG. 2). The space between the roller 8.2 and the belt segment guided around the roller 19 is enlarged such that a small gap is formed (FIG. 2). [0112] Now the partially wrapped bale B is moved out of the bale forming chamber Ch into a drum-shaped bale wrapping chamber Ch positioned above and supported by the tailgate bottom 18. This bale wrapping chamber Ch is surrounded by a further segment of the or every pressing belt 10. For moving the bale B onto the tailgate bottom 18, the supporting disks 23 are jointly rotated around 180 degrees. A pushing roller 24.1 or 24.2 pushes the formed bale B backwards, i.e. away from the intake device 5, onto the tailgate bottom 18. For enabling this movement, the lowered tailgate 11 is slightly moved backwards away from the front housing 15 and is no longer in the initial bale wrapping position but is in the final bale wrapping position (FIG. 3). [0113] An enlarged gap N occurs between the stationary front housing 15 and the pivotal tailgate 11 being in the final bale wrapping position. In the embodiment this enlarged gap N occurs between the deflecting roller 19 at the tailgate bottom 18 on the one side and the lower starter roller 8.2 on the other side, cf. FIG. 3. [0114] The bale B resting on the tailgate bottom 18 is now in the bale wrapping chamber Ch which is surrounded by a further segment of the or every pressing belt 10. The or every pressing belt 10 rotates the bale B resting on the tailgate bottom 18. The web is still pulled from the supply reel 88 and is injected through this gap N into the bale wrapping chamber Ch. The injected web is clamped between the rotated bale B and the or every pressing belt 10 and is pulled from the supply reel 88. [0115] As the bale B has been moved out of the bale forming chamber Ch, the bale forming chamber Ch can take further crop material. While the circumferential surface of the bale B is wrapped while the bale (B) is in the bale wrapping chamber Ch, further crop material is injected into the bale forming chamber Ch and a new bale B is formed, cf. FIG. 3. The baler 1 temporarily carries two bales B, B [0116] When the circumferential surface of the bale B on the tailgate bottom 18 is wrapped into the required number of wrapping material layers, the web is severed and the tailgate 11 is pivoted into the bale ejecting position. Thanks to the tensioning force of the or every pressing belt 10 the wrapped bale B is ejected out of the bale wrapping chamber Ch.

[0117] One guiding roller 28.1 or 28.2 delimits the two segments of the or every pressing belt 10 which surround the two chambers Ch and Ch.

[0118] The web detecting sensor 99 of the embodiment is mounted at the front housing 15 or at the frame 2, cf. FIG. 3. Thereby the sensor 99 is not moved when the discharge gate 11 is pivoted. The sensor 99 checks and decides whether or not the entire circumferential surface is wrapped into a web of wrapping material while the bale B is in the bale wrapping chamber Ch and the tailgate 11 is in the final bale wrapping position of FIG. 3. The web detecting sensor 99 automatically generates an alert if the web detecting sensor 99 does not detect the presence of web on the bale surface.

[0119] The automatically generated alert triggers at least one of the following measures: [0120] The wrapping procedure is restarted, i.e. performed again. [0121] The tailgate 11 remains in the final bale wrapping position until the web detecting sensor 99 positively detects that the bale surface is wrapped. [0122] An alert is given to the operator. The tailgate 11 is opened (is moved into the bale ejecting position) if a corresponding user input is registered.

[0123] FIG. 3 shows the web detecting sensor 99 which senses the bale surface through the nib N and thereby senses a currently visible segment of the bale surface. As the bale B in the wrapping chamber Ch is rotated, several different segments are visible through the nib None segment after the other. Subsequent visible segments may overlap. The sensor 99 senses this sequence of visible surface segments. The web detecting sensor 99 operates in a distance to the bale B which rests on the tailgate bottom 18 and is currently wrapped.

[0124] The web detecting sensor 99 of the embodiment comprises an image acquisition unit (camera), an illumination source, and an evaluating unit. The illumination source illuminates that bale surface segment which is currently visible through the gap N with light in the visible spectrum or infrared spectrum or ultraviolet spectrum. Thanks to the illumination source the operation of the web detecting sensor 99 does not depend on daylight. The image acquisition unit takes images of that segment of the bale surface which is currently illuminated and is visible through the gap N. The evaluation unit evaluates the images taken by the image acquisition unit and decides whether or not wrapping material is visible in the images. It is possible but not necessary to use a specific kind of wrapping material which is adapted to the web detecting sensor 99. It is also possible that the web detecting sensor 99 is adapted to the or every used kind of wrapping material.

[0125] In the embodiment the web detecting sensor 99 takes and evaluates images while the tailgate 11 is in the bale wrapping position of FIG. 3 and the extended gap N occurs. In one implementation the bale surface with the injected web has already reached the location which is visible through the gap N when the tailgate bottom 18 is pivoted into the final bale wrapping position of FIG. 3. Therefore every image visible through the nib N must show the wrapping material. Otherwise the alert is generated. It is possible that m images (m1) not showing the web are ignored for avoiding a false alert.

[0126] In a further implementation the tailgate bottom 18 is pivoted into the final bale wrapping position of FIG. 3 before the bale surface segment with the front edge of the web has reached a location which is visible through the gap N. At least in this implementation the event is detected that web is pulled from the supply reel 88, e.g. by monitoring a roller which deflects the web and which is mounted outside of the casing 11, 15. Depending on the construction of the baler 1 and on the circumferential velocity of the bale B in the bale wrapping chamber Ch a time period is derived in advance. If the web movement is detected but no wrapping material is visible in at least n images taken after the time period has passed (n>=1 given), the alert is automatically generated. The number n is selected such that delays in moving the web or the wrapped bale surface do not cause a false alert.

[0127] In one application a net or several strands of twine are used as wrapping material and hides the crop material pressed to the bale B. In this application the evaluation unit preferably searches patterns of a fabric (net or twine) in the images. In the images the web as well as crop material are visible.

[0128] In a further application a plastic sheet or film is used as the wrapping material. In this case the evaluating unit preferably decides whether the or some images show plastic sheet or crop material. If no plastic sheet is detected, the alert is generated. Preferably the decision is made on the basis of the color of the bale surface and/or of the plastic sheet. It is also possible that the texture of the bale surface is classified by evaluating the images.

[0129] In one embodiment the user (operator) enters the expected color of crop material and/or the color of the used plastic sheet. In a further implementation these colors are given in advance to the evaluating unit, e.g. as a part of a software program.

[0130] The gap N extends along a gap axis (perpendicular to the travelling direction TD and to the drawing plane of FIG. 3). In one embodiment the web detecting sensor 99 comprises one image acquisition unit. In a further application several sensing cells (image acquisition units) are positioned in a sequence along the gap axis. Every sensing cell takes images from one part of that bale surface segment which is currently visible through the gap N. The segment parts together cover the entire currently visible bale surface segment. Adjacent segment parts may overlap. Every sensing cell delivers signals to the evaluating unit. The image acquisition unit evaluates the images for the segment parts and decides for every segment part if the images from this segment part shows wrapping material or does not show wrapping material. The decision result can distinguish from segment part to segment part of the same segment, i.e. for different segment parts sensed at the same time. Thanks to the array of sensing cells the evaluating unit can not only decide whether or not wrapping material is at all on the bale surface but can also determine if the entire width of the circumferential surface is wrapped with wrapping material (the desired wrapping result) or only a part of the circumferential surface is wrapped.

[0131] Reference signs used in the claims will not limit the scope of the claimed invention. The term comprises does not exclude other elements or steps. The articles a, an, and one do not exclude a plurality of elements. Features specified in several depending claims may be combined in an advantageous manner.

TABLE-US-00001 LIST OF REFERENCE SIGNS 1 bale forming apparatus 2 frame of the bale forming apparatus 1, carries the wheels 3 3 ground-engaging wheels of bale forming apparatus 1 4 front end with towing unit 5 intake device for crop material, comprises inlet 6 and outlet 7 6 inlet of intake device 5 7 outlet of intake device 5 8.1, stationary driven starter rollers, delimit from above and from 8.2 below the crop material inlet guiding into the bale forming chamber Ch, belong to the bale forming device 9 9 bale forming device, comprises at least one endless belt 10 and the starter rollers 8.1, 8.2 10 endless belt(s), belong to the bale forming device 9, surround the bale forming chamber Ch and the bale wrapping chamber Ch 11 pivotal tailgate, serves as the pivotal discharge gate, comprises the tailgate frame 17 and the tailgate bottom 18 15 stationary front housing 17 tailgate frame 18 tailgate bottom, pivotal with respect to the tailgate frame 17 around the axis 22 19 tailgate bottom roller, mounted at tailgate bottom 18 20 wrapping device, mounted at the tailgate frame 17, comprises an unrolling station for carrying a supply reel 88 for wrapping material 22 pivoting axis of the tailgate bottom 18 with respect to the tailgate frame 17 23 supporting disks, carries the pushing rollers 24.1, 24.2 24.1 pushing roller, pushes the second bale B 24.2 further pushing roller, pushes the first bale B 25 common rotating axis of both supporting disks 23 28.1, pivotal guiding rollers 28.2 32 coupling device, comprises the disk engaging hook 33 and the disk locking cylinder 83 33 disk engaging hook of the coupling device, can engage one coupling pin 34.1, 34.2, 34.3 34 coupling pins which can be coupled with the disk engaging hook 33 35 retarding device for the supporting disks 23 36 fixed guiding roller above the starter roller 8.1 37 pivotal ramp 60 pivotal tensioning arm for the pressing belt(s) 10 88 supply reel for wrapping material 99 web detecting sensor, comprises an image acquisition unit, an evaluating unit, and optionally an illumination source B first bale B second bale Ch bale forming chamber, surrounded by a segment of the or every pressing belt 10 Ch bale wrapping chamber above the tailgate bottom 18, surrounded by a further segment of the or every pressing belt 10 GS ground surface over which the baler 1 moves N gap between front housing and tailgate 11, occurs when the tailgate 11 is in the final bale wrapping position TD travelling direction of the bale forming apparatus 1