Hay bale stacking apparatus

• US 20010006023A1
• Filed: 02/01/2001
• Published: 07/05/2001
• Est. Priority Date: 12/04/1997
• Status: Active Grant

• Current Assignee: God Family & Country LLC
• Original Assignee: Owen J. Brown Jr
• Inventors: Brown, Owen J. Jr.
• Granted Patent: US 6,655,266 B2
• Time in Patent Office: Days
• US Class Current: 100/6
• CPC Class Codes: A01D 85/002 with binding equipment, e.g. binding groups of bales
• CPC Class Codes: A01D 90/08 with bale-forming means additionally used for loading; with means for picking-up bales and transporting them into the vehicle

Abstract

Apparatus for stacking bales of hay into large bundles such as, for example, three bales high and seven bales wide, positions bands about the stacked array to provide a tightly bound, compressed stack of bales. The stacking apparatus compresses the stacked bales during banding with a greater force applied to the same facing portions of the bales as applied during formation of the bales to form a solid, rigid, self-supporting large bundle made up of small bales. Parallel spaced compression zones extending inwardly are formed in the upper and lower rows of bales in the least compressed portion of the bales for receiving the bands which are applied without high tension so as not to damage the hay in holding the bundle of hay bales together. This arrangement prevents the bands from cutting into the hay bales as well as severing the binding of the individual bales, allows the hay bundle to be easily moved by pallet forks, and maintains the banding out of contact with the ground to avoid band damage and deterioration from the elements as well as from rodents. The apparatus is computer controlled and fully automated from the input of individual bales to the discharge of a tightly banded and compressed bundle of hay bales and can be used in “on the go” as the apparatus traverses a field containing the individual hay bales.

Claims

1. Apparatus for stacking a plurality of bound hay bales in a large bundle of hay bales comprising:

intake means for sequentially receiving the bound hay bales and orienting the hay bales in common alignment;

stacking means for receiving each hay bale from said intake means and arranging the aligned hay bales in a vertical stack of hay bales;

compression means for forming inwardly extending, spaced banding zones in a top and a bottom hay bale in the stack of hay bales;

bundling means for forming vertical stacks of hay bales into a bundle of hay bales comprised of vertical stacks of hay bales in side-by-side alignment including top and bottom rows of hay bales;

banding means for tightly wrapping one or more bands around the bundle of hay bales, wherein each of said one or more bands is disposed in a respective banding zone in the top and bottom rows of hay bales in the bundle of hay bales; and

discharge means for removing the bundle of hay bales from the apparatus.

2. The apparatus of

claim 1

wherein each of the hay bales is bound by one or more bindings each aligned with a longitudinal axis of the hay bale, and wherein said one or more bands wrapped around the bundle of hay bales are aligned generally transverse to said one or more bindings on the hay bales.

3. The apparatus of

claim 2

wherein said bindings are disposed about lateral portions of each of the hay bales and said banding zones are disposed in respective upper and lower surfaces of the top and bottom rows of hay bales.

4. The apparatus of

claim 3

wherein each hay bale is bound by a pair of spaced bindings tightly disposed about the hay bale and wherein the bundle of hay bales is tightly wrapped by a pair of spaced bands disposed about the bundle.

5. The apparatus of

claim 4

wherein said bindings are comprised of twine or wire and said bands are comprised of steel strapping.

6. The apparatus of

claim 1

wherein each of said bales is formed by compressing the hay bale along its length in a first direction and tightly wrapping one or more bindings about the hay bale, and wherein said compression means compresses the hay bales arranged in said large bundle in said first direction along the lengths of the hay bales in the top and bottom rows of the bundle.

7. The apparatus of

claim 1

wherein the bundle of hay bales is three bales high and seven bales long.

8. The apparatus of

claim 1

further comprising a hitch disposed on the forward portion of the apparatus and wheels disposed on a lower portion of the apparatus to permit the apparatus to be pulled through a field for stacking hay bales as the apparatus is displaced.

9. The apparatus of

claim 1

wherein said intake means is disposed on a forward portion of said apparatus and includes a first conveyor for moving the hay bales rearwardly in said apparatus, and wherein the hay bales are oriented generally flat when displaced rearwardly.

10. The apparatus of

claim 9

wherein said intake means further includes guide means for directing the hay bales onto said first conveyor.

11. The apparatus of

claim 10

further comprising a vertical lift disposed between said intake means and said stacking means for receiving hay bales from said first conveyor and delivering the hay bales to an upper portion of said stacking means.

12. The apparatus of

claim 11

wherein said vertical lift includes a second conveyor for lifting the hay bales in an upright orientation to an upper portion of said stacking means.

13. The apparatus of

claim 12

further comprising deflection means disposed adjacent an upper end of said second conveyor for engaging and changing the orientation of the hay bales from upright to flat.

14. The apparatus of

claim 13

further comprising displacement means for moving the hay bales from the upper end of said second conveyor to an upper portion of said stacking means.

15. The apparatus of

claim 14

wherein said displacement means also compresses a hay bale along its length as the hay bale is moved to an upper portion of said stacking means.

16. The apparatus of

claim 1

wherein said stacking means includes a vertical plunger for sequentially receiving each hay bale and forming a plurality of hay bales into a vertical stack.

17. The apparatus of

claim 16

wherein said stacking means further includes a fixed support frame coupled to said vertical plunger, and wherein said vertical plunger is incrementally lowered on said fixed support frame with the positioning of each hay bale on a vertical stack of hay bales.

18. The apparatus of

claim 17

wherein said compression means includes first and second spaced vertical compression members and first and second spaced strap guides for respectively engaging a top hay bale and a bottom hay bale in a vertical stack of hay bales for forming upper and lower pairs of spaced banding zones in the vertical stack of hay bales.

19. The apparatus of

claim 18

wherein said compression means further includes first and second pivot arms respectively coupled to said first and second vertical compression members for lowering said vertical compression members into engagement with the top hay bale in a vertical stack of hay bales and for vertically compressing said stack of hay bales.

20. The apparatus of

claim 19

wherein said bundling means further includes a horizontal plunger for sequentially moving a stack of hay bales rearwardly in said apparatus and arranging a plurality of stacks of hay bales in adjacent, side-by-side alignment.

21. The apparatus of

claim 20

further comprising one or more band dispensers for supplying said one or more bands, wherein said horizontal plunger includes means for removing said bands from said band dispensers when said horizontal plunger retracts after moving a stack of hay bales rearwardly in said apparatus.

22. The apparatus of

claim 21

further comprising means for incorporating slack in a band when said horizontal plunger extends to preventing shredding and cutting of the hay and bale binding.

23. The apparatus of

claim 21

further comprising means for engaging a band as the band is removed from a band dispenser and for bending opposed edges of the band for preventing cutting of the hay and said bindings tightly wrapped around each of the hay bales.

24. The apparatus of

claim 23

wherein said means for engaging a band and bending opposed edges of the band includes a roller and beveled die combination through which the band is drawn by retraction of said horizontal plunger.

25. The apparatus of

claim 24

further comprising clamp means for securely engaging said bands as a stack of hay bales is lowered by said vertical plunger for removing the slack from said bands after said horizontal plunger moves to an extended position.

26. The apparatus of

claim 25

wherein said horizontal plunger moves between a retracted position and an extended position for compressing the hay bales and displacing a stack of hay bales rearwardly in said apparatus.

27. The apparatus of

claim 26

wherein said horizontal plunger further displaces a bundle of hay bales rearwardly in said apparatus for discharge from said apparatus when said horizontal plunger moves to said extended position.

28. The apparatus of

claim 27

wherein slack is provided in said one or more bands when said horizontal plunger moves to an extended position to prevent cutting and shredding of the hay and said bindings.

29. The apparatus of

claim 28

wherein said horizontal plunger includes a plurality of vertical panels coupled to at least one hydraulic cylinder, and wherein extension of said at least one hydraulic cylinder causes said vertical panels to engage and displace rearwardly in said apparatus a stack of hay bales.

30. The apparatus of

claim 29

further comprising one or more band guides for wrapping said one or more bands around the bundle of hay bales, wherein each of said band guides is disposed between a pair of adjacent vertical panels and moves vertically with said vertical plunger.

31. The apparatus of

claim 30

further comprising adjustable means for controlling the length of said one or more bands pulled from said one or more band dispensers by said horizontal plunger.

32. The apparatus of

claim 31

wherein said adjustable means for controlling the length of said one or more bands is an adjustable banding length bar.

33. The apparatus of

claim 19

wherein said compression means further includes first and second upper compression members and first and second lower compression members respectively aligned with said first and second vertical compression members and said first and second strap guides for maintaining the upper and lower pairs of banding zones in the bundle of hay bales as the hay bales are moved rearwardly by said horizontal plunger.

34. The apparatus of

claim 33

wherein each band is disposed between and in contact with a hay bale and its associated upper or lower compression member and is maintained in contact with its associated compression member by a hay bale with which it is in contact.

35. The apparatus of

claim 34

wherein a stack of hay bales is disposed on and supported by said first and second strap guides as said stack of hay bales is lowered by said vertical plunger.

36. The apparatus of

claim 35

wherein said first and second strap guides position first and second bands respectively on said first and second lower compression members.

37. The apparatus of

claim 36

wherein said first and second strap guides connect said first and second bands respectively to said banding means.

38. The apparatus of

claim 37

wherein each of said first and second strap guides includes a respective strap guide hinge coupled to an end of a strap guide and engaging a respective band supported by its associated strap guide for providing clearance of the band from a hay bale disposed on said strap guide during vertical displacement of said strap guide.

39. The apparatus of

claim 33

wherein said banding means wraps first and second bands around a stack of hay bales as said stack is formed by said vertical plunger and wraps said first and second bands around a bundle of stacked hay bales as said bundle is formed by said horizontal plunger.

40. The apparatus of

claim 39

wherein each of said first and second lower compression members includes a respective trough for receiving and allowing a band to move freely within a compression zone during banding of a bundle of hay bales as said horizontal plunger moves forward and aft in a reciprocating manner.

41. The apparatus of

claim 40

wherein said banding means includes first and second dispensers for letting out said first and second bands as hay bale stacks and a bundle of hay bales are formed.

42. The apparatus of

claim 41

wherein said banding means further includes first and second splicing and severing means for securing said first and second bands tightly about a bundle of hay bales and severing said bands.

43. The apparatus of

claim 20

wherein said bundling means further includes back gates disposed in an aft portion of the apparatus for limiting rearward displacement of a bundle of hay bales by said horizontal plunger in forming a compressed bundle of hay bales.

44. The apparatus of

claim 43

wherein said discharge means includes means for opening said back gates when a bundle of stacked hay bales is formed by said horizontal plunger for permitting discharge of the bundle from said apparatus by rearward displacement of said horizontal plunger.

45. The apparatus of

claim 44

wherein said means for opening said back gates includes a plurality of hydraulic cylinders coupled to said back gates for displacing said back gates between closed and opened positions.

46. The apparatus of

claim 45

wherein said plurality of hydraulic cylinders include a first pair of extension cylinders each coupled to a respective back gate and a second pair of swing cylinders also each coupled to a respective back gate, wherein said extension cylinders move said gates between retracted and extended positions and said swing cylinders move said gates between closed and open positions.

47. The apparatus of

claim 46

further comprising control means for first extending said extension cylinders in moving said gates to the extended position and then extending of said swing cylinders in moving said gates to the open position in opening said back gates, and for reversing the operating sequence of said extension and swing cylinders in closing said back gates.

48. The apparatus of

claim 47

further comprising releasable latch means for locking said back gates in the closed position.

49. The apparatus of

claim 48

wherein said discharge means further includes a pivoting floor disposed in a lower aft portion of said apparatus for lowering a bundle of hay bales to a support surface as the bundle is removed from the apparatus.

50. The apparatus of

claim 49

wherein said discharge means further includes a hydraulic cylinder coupled to said pivoting floor for lowering said pivoting floor to permit removal of a bundle of hay bales from the apparatus and for raising the pivoting floor following removal of the bundle.

51. The apparatus of

claim 50

wherein said horizontal plunger further compresses the stacks of hay bales in a horizontal direction by urging the stacks of hay bales against said back gates when said back gates are closed.

52. The apparatus of

claim 51

further comprising control means for controlling the force of compression applied to the stacks of hay bales by said horizontal plunger.

53. The apparatus of

claim 52

wherein said control means includes a manually adjustable pressure relief valve coupled to said first hydraulic cylinders coupled to said back gates.

54. The apparatus of

claim 53

further comprising latch means for engaging and maintaining said pivoting floor in a fully upraised position for supporting a bundle of hay bales prior to discharge of said bundle from the apparatus.

55. The apparatus of

claim 1

further comprising a computer for controlling the operation of said intake, stacking, compression, bundling, banding and discharge means.

56. The apparatus of

claim 55

further comprising an operator controlled manual reset for allowing an operator to interrupt and re-initiate operation of the apparatus.

57. The apparatus of

claim 56

further comprising first detection means for detecting a hay bale in said intake means.

58. The apparatus of

claim 57

wherein said first detection means includes a first photo sensor.

59. The apparatus of

claim 58

further comprising second detection means for detecting a hay bale in said vertical elevator.

60. The apparatus of

claim 59

wherein said second detection means includes a second photo sensor.

61. The apparatus of

claim 60

wherein said stacking means includes a third photo sensor for determining the number of hay bales in a vertical stack of hay bales.

62. The apparatus of

claim 61

wherein said third photo sensor further determines the number of vertical stacks of hay bales in a bundle of hay bales.

63. The apparatus of

claim 62

wherein said banding means includes means for curving opposed edges of said bands for avoiding cutting and shredding of the hay bales by said bands.

64. The apparatus of

claim 63

wherein said means for curving the opposed edges of said bands includes, in combination, a roller and a die, and wherein said die includes a bevelled edge for bending the edges of said bands when drawn between said roller and die.

65. The apparatus of

claim 1

wherein said horizontal plunger includes first and second coupled hydraulic cylinders connected to said vertical panels, wherein said first cylinder displaces the stacks of hay bales rearwardly in said apparatus and said first and second cylinders compress the stacks of hay bales forming the bundle of hay bales.

66. The apparatus of

claim 65

further comprising a pressure supply line and control valve means coupled to said first and second hydraulic cylinders for providing hydraulic fluid under pressure to said first cylinder for extending said first cylinder in displacing the stacks of hay bales rearwardly in said apparatus, wherein said first cylinder extends said second cylinder, whereupon said pressure supply line and said control valve means provide hydraulic fluid under pressure to said first and second cylinders for extending said cylinders together for compressing the stacks of hay bales in forming a compressed bundle of hay bales.

67. The apparatus of

claim 66

wherein said control valve means directs hydraulic fluid to a piston side of said second cylinder as said first cylinder extends said second cylinder.

68. The apparatus of

claim 67

wherein said first and second cylinders are retracted by said control valve means providing hydraulic fluid under pressure to a rod side of said first cylinder following compression of the bundle of hay bales, and wherein a first larger portion of hydraulic fluid flows from a piston side of said first and second cylinders to a rod side of said second cylinder during retraction of said first cylinder, and wherein a second smaller portion of said hydraulic fluid returns to a hydraulic reservoir during retraction of said first hydraulic cylinder.

69. A method for forming a bundle of hay bales, wherein each of said hay bales is formed by applying a compressive force to the hay bale along a first direction followed by positioning bindings around the hay bale in a tight-fitting manner, said method comprising the steps of:

arranging a plurality of hay bales in a vertical stack and compressing the stack of hay bales in a second vertical direction;

arranging a plurality of vertical stacks of hay bales in closely spaced, side-by-side alignment in forming a bundle of hay bales;

compressing said bundle of hay bales in a third horizontal direction, wherein said third horizontal direction is aligned with said first direction in which the individual bales are compressed when formed; and

tightly wrapping banding around said bundle of hay bales while said hay bales are being compressed vertically and horizontally without damaging the hay in said bales or severing the bindings disposed about said hay bales.

70. The method of

claim 69

wherein the step of compressing a stack of hay bales includes forming upper and lower recessed compression zones respectively disposed in a respective upper and lower surface of top and bottom hay bales in said stack of hay bales.

71. The method of

claim 70

wherein said compression zones are linear and parallel and are arranged in spaced relation on the upper and lower surfaces of the top and bottom hay bales.

72. The method of

claim 71

wherein said banding is placed in said upper and lower recessed compression zones during wrapping of the banding around said bundle.

73. The method of

claim 72

further comprising the step of engaging the banding in said recessed compression zones for maintaining the banding in position in said compression zones.

74. The method of

claim 73

wherein the steps of vertically and horizontally compressing the hay bale includes compressing hay bales along their respective lengths.

75. The method of

claim 74

further comprising the step of severing said banding and securely splicing opposed ends of the severed banding together as said banding is tightly wrapped around said bundle of hay bales.

76. The method of

claim 75

further comprising the step of bending opposed edges of said banding prior to tightly wrapping said banding around said bundle of hay bales to avoid cutting and shredding of the hay bales and the bindings disposed about the hay bales.

77. The method of

claim 76

further comprising the step of providing slack in said banding prior to tightly wrapping the banding around said bundle of hay bales to prevent cutting and shredding of the hay and the bindings disposed about the hay bales.

78. The method of

claim 77

further comprising the step of removing a predetermined length of banding from a banding dispenser prior to wrapping the banding around said bundle, wherein said predetermined length is adjustable.

79. The method of

claim 78

further comprising the step of selectively adjusting a horizontal compression force used to horizontally compress said bundle of hay bales.

80. The method of

claim 79

further comprising the step of discharging said bundle of hay bales into a field following formation of said bundle.

81. The method of

claim 80

wherein said bundle of hay bales is formed from seven closely spaced, side-by-side stacks of hay bales, and wherein each of said stacks is comprised of three hay bales in vertical alignment.

82. Apparatus for wrapping strapping about an article, said apparatus comprising:

grasping means for securely engaging and maintaining an end of the strapping in a fixed position;

movable guide means for engaging the strapping in a sliding manner and wrapping the strapping in a tight-fitting manner about the article;

first displacement means for engaging an intermediate portion of the strapping and positioning said intermediate portion of the strapping immediately adjacent the end of the strapping engaged by said grasping means; and

splicing and severing means for splicing said intermediate portion to the end of the strapping and for severing the strapping, whereupon the strapping remains tightly wrapped around the article.

83. The apparatus of

claim 82

wherein said grasping means, said first displacement means and said splicing and severing means are disposed in a housing, and wherein said housing includes an elongated, linear slot with the strapping extending from said movable guide means into said housing through the slot therein.

84. The apparatus of

claim 83

wherein said grasping means includes a fetcher arm and a strap gripper and first and second gripper feet disposed on respective opposed sides of and engaging respective opposed surfaces of the strapping.

85. The apparatus of

claim 84

wherein said fetcher arm engages and pulls the intermediate portion of the strapping through the slot in said housing to a position immediately adjacent the end of the strapping.

86. The apparatus of

claim 85

wherein said first displacement means includes a first hydraulic cylinder coupled to said fetcher arm for moving said fetcher arm in a reciprocating manner.

93. The apparatus of

claim 94

wherein said second displacement means includes a hydraulic cylinder.

94. The apparatus of

claim 95

wherein said splicing and severing means includes a die and cutter combination for splicing said intermediate portion of the strapping to the end of the strapping and for severing the strapping.

95. The apparatus of

claim 82

further comprising first and second grasping means, first and second movable guide means, first and second displacement means and first and second splicing and severing means for simultaneously wrapping first and second strappings about an article.

92. The apparatus of

claim 92

further comprising second displacement means coupled to said fetcher arm for moving said fetcher arm out of the path of said movable guide means when said first horizontal cylinder is extended and for moving said fetcher arm in the path of said movable guide means whereupon said fetcher arm engages said intermediate portion of the strapping.

87. The apparatus of

claim 88

further comprising transport means for displacing said guide means horizontally and vertically in a path about the circumference of the article.

88. The apparatus of

claim 89

wherein said guide means includes a roller engaging the strapping for facilitating removal of the strapping from said guide means.

89. The apparatus of

claim 90

wherein said slot in said housing is aligned with said movable guide means.

90. The apparatus of

claim 91

wherein said guide means further includes an elongated linear member disposed intermediate said movable guide means and the slot in said housing, and wherein said elongated linear member includes an elongated aperture therein, wherein the strapping is disposed in and is displaced along and through said elongated aperture.

91. The apparatus of

claim 92

wherein said elongated aperture, said roller and the slot in said housing are in common alignment.

96. A hydraulic system for forming a plurality of articles arranged in stacks into a large bundle and for compressing said bundle by displacing a plunger in a reciprocating manner, said hydraulic system comprising:

a hydraulic pressure supply line coupled to a hydraulic fluid tank;

first and second hydraulic cylinders each having a respective piston side and rod side, wherein the rod side of each of said cylinders is connected to the plunger and said cylinders extend and retract together;

directional control valve means coupling said pressure supply line to said first cylinder for extending said first cylinder in forming the articles arranged in stacks into the large bundle of articles when said directional control valve means is activated, wherein extension of said first cylinder extends said second cylinder; and

sequence valve means coupled to said first and second cylinders and to said direction al control valve means for determining when the hydraulic pressure for extending said first cylinder exceeds a predetermined value as the stacks of articles are arranged in a large bundle and for directing hydraulic fluid under pressure to the piston side of said second hydraulic cylinder for also extending said second cylinder and compressing the bundle of stacked articles with said first cylinder;

wherein said directional control valve means directs hydraulic fluid under pressure to the rod side of said first cylinder after the bundle of stacked articles is compressed when said directional control valve means is deactivated for retracting said first hydraulic cylinder and wherein said directional control valve means further directs hydraulic fluid from the piston sides of said first and second cylinders to the rod side of said second cylinder for reducing the flow of hydraulic fluid between said cylinders and said hydraulic fluid tank during extension and retraction of said hydraulic cylinders.

98. The hydraulic system of claim 99 wherein said pilot check valve means is closed when the hydraulic pressure exceeds said predetermined value to allow for extension of said second cylinder by hydraulic fluid directed under pressure to the piston side of said second cylinder.

97. The hydraulic system of

claim 98

further comprising pilot check valve means connected between said second cylinder and said directional control valve means for directing hydraulic fluid into the piston side of said second cylinder when said second cylinder is extended by said first cylinder.