Bale stacker

[0001] This application is a continuation-in-part of application Ser. No. 11/853,523, filed on Sep. 11, 2007, now U.S. Pat. No. 7,610,851, which claims the benefit of U.S. Provisional Patent Application No. 60/825,172, filed Sep. 11, 2006, the entire contents of which applications are hereby incorporated herein by reference.

[0002] This invention is related to a bale stacker for consolidating a number of bales into a bale bundle.

[0003] In recent years, transportation of forage over relatively long distances has been economically viable due to the prices paid for good quality forage in certain areas. Typically, a bale of hay 10 is formed which is about 18 inches wide (W), 14 inches high (H), and 35 inches in length (L) (FIG. 1A). As can be seen in FIG. 1A, the bale customarily rests on a bottom wall (not shown) having an area of L×W, presenting an identical top wall (also having an area of L×W), and exposing two sidewalls, each with an area of H×W. If the forage is to be transported over long distances, it has been found to be convenient to tie a number of individual bales together into relatively large bale bundles.

[0004] The practice of tying a number of individual bales together to form bale bundles has developed in order to permit more economical handling of the forage in connection with its storage and transportation. In the usual current practice, twenty-one bales are stacked in seven vertical stacks of three bales each and then tied together, to form a bale bundle.

[0005] Machines to form bales into bale bundles are known. However, the prior art machines have a number of disadvantages.

[0006] For the foregoing reasons, there is a need for an improved machine for forming bales into bale bundles addressing or mitigating one or more of the disadvantages of the prior art.

[0007] In its broad aspect, the invention provides a bale stacker for forming a number of bales into a bale bundle having a predetermined number of bales. The bale stacker includes a compression chamber extending between an upstream opening and a downstream opening thereof, the bales being receivable in the compression chamber via the upstream opening and formable in the compression chamber into the bale bundle, and the bale bundle being removable from the compression chamber via the downstream opening. The bale stacker also includes a loading chamber in which the bales are positionable in respective columns proximal to the upstream opening, each column comprising a preselected number of bales, and a transfer assembly for moving the columns of said bales from the loading chamber into the compression chamber. The transfer assembly includes a platen for engaging each column of bales respectively, the platen being movable between a retracted position, in which the bales are movable into the loading chamber, and an extended position, in which each respective column of bales is positionable by the platen at least partially in the compression chamber. In addition, the bale stacker includes one or more front doors located at the upstream opening and movable between a closed position, in which the upstream opening is at least partially obstructed by the front doors, and an open position, in which each column of bales is movable respectively through the upstream opening. The bale stacker also includes one or more controlling means for coordinating movement of the front doors with movement of the platen.

[0008] In another of its aspects, the controlling means controls movement of the front doors so that movement of the platen from the retracted position to the extended position results in movement of the front doors from the closed position to the open position respectively, and movement of the platen from the extended position to the retracted position results in movement of the front doors from the open position to the closed position respectively.

[0009] In another aspect, the controlling means includes one or more linkage assemblies linking the transfer assembly and the front doors.

[0010] In another aspect, the front doors each include a front surface adapted for sliding engagement of each bale therewith during movement of each bale into the loading chamber.

[0011] In yet another aspect, the front doors are each movable between a closed position, in which a front surface thereof is disposed for supporting the bales in each column respectively located in the loading chamber, and an open position, in which each column of bales is movable respectively through the upstream opening of the compression chamber.

[0012] In another aspect, the front doors are each movable between a closed position, in which a front surface thereof is formed to guide the bales as they are positioned in respective columns in the loading chamber, and an open position, in which each column of bales is movable respectively through the upstream opening.

[0064] Reference is first made to FIGS. 1B-5 to describe an embodiment of a bale stacker of the invention referred to generally by the numeral 20. The bale stacker 20 is for consolidating a plurality of bales 10 into a bale bundle 22 (FIG. 4D). The bale stacker 20 includes a compression chamber 24 (FIG. 3A) at least partially defined by a floor 26 (FIG. 2), two substantially parallel chamber sidewalls 28, 30 spaced apart from each other by a predetermined distance “D” (FIG. 3B), and a ceiling 32. As can be seen in FIG. 3A, the compression chamber 24 extends between an upstream opening 34 (FIG. 4) and a downstream opening 36 (FIG. 2). Preferably, the bales 10 are receivable in the compression chamber 24 via the upstream opening 34 and the bale bundle 22 is configured to exit the compression chamber 24 via the downstream opening 36, as will be described. It is preferred that the compression chamber ceiling 32 includes a substantially planar rear portion 38 which is positioned substantially parallel to the floor 26. In one embodiment, the compression chamber ceiling 32 also includes a front portion 40 which is positioned upstream from the rear portion 38 (FIG. 3A). Preferably, the front portion 40 is positioned in a non-parallel relationship relative to the floor 26 for engaging the bales 10 as the bales 10 are moved past the front portion 40 in a downstream direction of travel toward the downstream opening 36, so that the bales 10 are compressed between the front portion 40 and the floor 26.

[0065] The downstream direction of travel is schematically indicated by arrow “A” in FIG. 3A.

[0066] It is preferred that the rear portion 38 engages the bales 10 after the bales are moved downstream past the front portion 40 so that the rear portion 38 maintains compression of the bales 10 in a direction which is substantially orthogonal to the floor 26. Preferably, the rear portion 38 is spaced apart from the floor 26 by a distance (“B”) selected so that the bales, when positioned between the rear portion 38 and the floor 26, are compressed to an extent desired, as will be described (FIG. 3A). Such compression is in a direction which is substantially orthogonal to the floor 26.

[0067] It is also preferred that the front portion 40 has a length (“C”) (FIG. 7A) substantially aligned with the downstream direction of travel which is substantially less than one-half of a shorter dimension “H” (FIG. 1A) of the sidewall of each bale 10. (As can be seen in FIG. 1A, the shorter dimension “H” of the sidewall is the shorter of the two dimensions which substantially define the sidewall.) As will be described, the bales 10 preferably are ultimately positioned in the compression chamber resting on one sidewall thereof, with the other sidewall presented upwardly.

[0068] Preferably, the front portion 40 is positioned at an angle (i.e., an angle which is not zero) relative to the floor 26, i.e., the front portion 40 is in a non-parallel relationship with the floor. Also, it is preferred that the front portion 40 is positioned in an angle relative to the floor 26 which is between approximately 30 degrees and approximately 75 degrees. Preferably, the front portion 40 is positioned at approximately 45 degrees relative to the floor 26 (FIG. 3A).

[0069] As can be seen in FIGS. 4A-4D, the bales 10 preferably are positioned in the compression chamber 24 in columns 42. The bale stacker 20 preferably includes a loading chamber 44 positioned adjacent to the upstream opening 34 of the compression chamber 24. FIGS. 7A-7D show bales 10 being loaded into the loading chamber 44, and put into the columns 42 in the loading chamber 44. The bales 10 preferably are positioned in the columns 42 as they are loaded into the loading chamber 44, as will also be described.

[0070] As can be seen in FIG. 3A, the bale stacker 20 includes front doors 48 which, when in a closed position, substantially block the upstream opening 34. Similarly, the bale stacker 20 includes one or more rear doors 52 which, when in a closed position, at least partially block the downstream opening 36 (FIG. 3A). (Preferably, there are two rear doors 52, which are shown in an open position in FIG. 3B, and in a closed position in FIG. 3C.) The loading chamber 44 extends between a front surface 54 of the front doors 48, when the front doors 48 are in the closed position (FIG. 3A), and an engagement surface 56 of a platen 58 which is included in a transfer assembly 60.

[0071] The bale stacker 20 preferably also includes the transfer assembly 60. As well as the transfer assembly 60, the bale stacker 20 preferably additionally includes an injector assembly 62 for injecting the bales 10 into the loading chamber 44. The bales 10 preferably are positioned in columns 42 of three bales each in the loading chamber 44 by the injector assembly 62. The manner in which the injector assembly 62 injects the individual bales 10 is shown in FIGS. 7A-7D, and the operation of the transfer assembly 60 to push the columns 42 into the compression chamber 24 is shown in FIGS. 7E-7G.

[0072] In FIG. 7A, the injector assembly 62 is shown in a retracted condition. As can be seen in FIG. 7B, the injector assembly 62 includes first and second hydraulic cylinders 64, 66 which are operably connected to a blade 68. The blade 68 is shown in a retracted position in FIG. 7A, in which the bale is receivable in front of the blade 68. Preferably, the bale 10 is positioned on a table surface 69, as will be described.

[0073] When the injector assembly 62 is activated, the first bale 10 to be positioned in a new column of bales (identified as an “initial bale” in FIG. 7A) is engaged by the blade 68, which, itself moved substantially horizontally to the right (as presented in FIG. 7A) by the first hydraulic cylinder 64, pushes the initial bale across the table surface 69 to the right as illustrated in FIG. 7A, i.e., in the direction indicated by arrow “A1” in FIG. 7A.

[0074] After it has been moved to the edge of the table surface 69, the initial bale is pushed further by the first hydraulic cylinder 64 (via the blade), and engages a curved guide element 70. As can be seen in FIGS. 7A and 7B, after the bale 10 first engages the curved guide element 70, the first hydraulic cylinder 64 continues to push the bale 10 further horizontally, i.e., to the right as shown in FIGS. 7A and 7B. As the bale is pushed further to the right, it rotates in a counterclockwise direction (as shown in FIGS. 7A and 7B), and the blade 68 pivots upwardly accordingly about a pivot point 71.

[0075] The first hydraulic cylinder 64 is shown in FIG. 7B at its maximum extension. Once the first hydraulic cylinder 64 has reached its maximum extension, the second hydraulic cylinder 66 begins to extend. As shown in FIGS. 7B and 7C, the extension of the second hydraulic cylinder 66 in the direction indicated by arrow “A2” (FIG. 7C) causes the blade 68 to pivot upwardly and move along a curved path, as indicated by arrow “A3”. Because of the positioning of the guide element 70, the bale is rotated (in a counterclockwise direction, as shown in FIG. 7B) by approximately 90 degrees as it is pushed upwardly into the loading chamber 44. As can be seen in FIGS. 7A-7C, due to this rotation during loading, the bale 10 is positioned in the loading chamber with the sidewalls thereof facing upwardly and downwardly, and the top and bottom sides facing the platen 58 and the front doors 48 respectively.

[0076] The blade 68 is shown in an extended position in FIG. 7C, in which both the first and second hydraulic cylinders 64, 66 are both extended to the greatest extent possible.

[0077] From the foregoing, it can be seen that the first hydraulic cylinder 64 is positioned to act in a substantially horizontal direction and the second hydraulic cylinder 66 is positioned to act at an angle relative to the horizontal (i.e., in a non-parallel relationship to the table surface), to provide at least partially vertical movement of the blade 68. The second hydraulic cylinder 66 acts in a direction which is not parallel to the direction in which the first hydraulic cylinder 64 acts. Preferably, the second hydraulic cylinder 66 is positioned at an angle of approximately 20 degrees relative to the table top surface.

[0078] Dogs 72 preferably are positioned at or near the top end of the guide element 70. The dogs 72 preferably are spring-loaded or otherwise biased to an open position, the dogs 72 being shown in the open position in FIGS. 7A-7D. Preferably, when the bale is pushed past the dogs 72 as the bale 10 is entering the loading chamber 44, the dogs 72 pivot in the direction indicated by arrow “A3” (FIG. 7A), to permit the bale to pass into the loading chamber 44. It is also preferred that, once the bale is in the loading chamber 44, the dogs 72 promptly return to the open position (as shown in FIG. 7C), and a portion 74 of the bale 10 engages the dogs 72 directly, so that the dogs 72 support the bale 10 (FIG. 7C). In addition, and as shown in FIG. 7C, an upper portion 75 of the bale 10 simultaneously engages the engagement surface 56 of the platen 58. In this way, the bale 10 is supported in the loading chamber 44 after it has been loaded therein.

[0079] A second bale and a third bale (identified as such in FIG. 7D) are subsequently loaded into the loading chamber 44 consecutively by the injector assembly 62 in the same manner as the initial bale. When it is loaded into the loading chamber 44, the second bale is pushed upwardly into the loading chamber 44, causing the initial bale to be displaced upwardly. Similarly, the third bale subsequently is loaded upwardly into the loading chamber 44 by the injector assembly 62 in the same way, moving the second and initial bales upwardly, to result in the column 42 shown in FIG. 7D.

[0080] As noted above, the bales 10 are positioned in the column 42 resting on their sidewalls respectively, and the top and bottom sides of each bale face the platen 58 and the front doors respectively. Positioning the bales in this way appears to be advantageous, as will be described.

[0081] As can be seen in FIG. 7C, when the initial bale is positioned in the loading chamber 44, it is supported by the front surface 54 of the front doors 48. The front doors 48 are biased to a closed position, preferably by springs or any other suitable biasing means. As shown in FIG. 7D, when the first column 42 has been loaded in the loading chamber 44, the column 42 is partly held in place by the closed front doors 48. The bottom sides of the bales in the first column engage the front surface 54 of the front doors 48, and rest against the front surface 54.

[0082] As shown in FIGS. 7A-7G, the floor 26 is generally positioned at about 10 degrees relative to the horizontal. This position is selected in order to facilitate movement of the bundle 22 out the downstream opening.

[0083] The transfer assembly 60 is for moving (or pushing) the columns 42 into the compression chamber 24. Preferably, the platen 58 of the transfer assembly 60 includes ridges 76 in its engagement surface 56. The ridges 76 are positioned so that they engage the lower parts of the sidewalls of the bales which are facing the platen 58 when the column 42 is in position in the loading chamber 44 (FIG. 7D). When the column 42 is formed, the bales tend to overhang slightly towards the front. The ridges 76 are positioned as described above so as to counteract this tendency, i.e., the ridges 76 cause the bales in the column 42 to become somewhat better vertically aligned with each other because the ridges engage the lower parts of the sidewalls which face the platen 58 first.

[0084] Once the first column 42 is positioned in the loading chamber 44, the platen 58 is moved in the direction shown by arrow “A4” in FIG. 7E, pushing the first column of bales through the front doors 48. As can be seen in FIG. 7E, once the first column of bales has been pushed past the front doors 48, the first column holds the front doors 48 in an open position. The first column is positioned in FIG. 7E to provide some support for the bales in the immediately following column, as such bales are loaded. In this way, the first column of bales and subsequent columns of bales serve to assist in supporting each column of bales subsequent thereto as each such subsequent column is loaded respectively.

[0085] After the initial and second bales in a column have been loaded, the blade 68 is retracted, i.e., both of the hydraulic cylinders sequentially retract (the second hydraulic cylinder 66 first, and the first hydraulic cylinder 64 next) to their fully retracted positions. However, after the third bale is loaded for a particular column, the blade 68 remains in the extended position, to support the column (FIG. 7D). This has been found to be advantageous because the front edge of the lowermost bale in the column tends to drop down if not supported by the blade 68. The blade 68 remains in the extended position until the column 42 has been pushed into the compression chamber 24.

[0086] FIG. 7F shows the platen 58 after it has pushed (in the direction shown by arrow “A5” in FIG. 7F) a second column of bales (as identified in FIG. 7F) into the compression chamber 24. As can be seen in FIG. 7F, when the second column of bales is pushed into the compression chamber 24, the first column of bales engages the front portion 40 of the compression chamber ceiling 32, causing the first column of bales to be compressed.

[0087] FIG. 7G shows a third column of bales (identified in FIG. 7G) after it has been pushed (in the direction shown by arrow “A6”) into the compression chamber 24. As can be seen in FIG. 7G, when the third column of bales is pushed into the compression chamber 24, the third column pushes the second column of bales further into the compression chamber 24, and the second column of bales in turn pushes the first column further into the compression chamber 24. Also, as the third column is pushed into the compression chamber by the platen 58, the second column engages the front portion 40 of the ceiling 32, which compresses the second column. The first column remains compressed, by the rear portion 38.

[0088] In accordance with customary practice, the bundle 22 preferably includes seven columns of three bales each, i.e., 21 bales in all. A group 78 of 21 bales in seven columns ready to be tied and further compressed (i.e., ready to be consolidated into a cohesive bundle) is shown in FIG. 4. Also, FIG. 4 shows a tying material 80 which defines a pocket into which the seven columns of bales in the group 78 preferably have been pushed, one column at a time, as described above. (The tying material 80 is not shown in FIGS. 7E-7G for clarity of illustration.) The tying material 80 is shown in FIG. 4 prior to its being tied around the bales 78 using a knotter 82. The technique of tying bales and bundles of bales generally, and using knotters therefor, is well-known, and therefore such technique does not need to be described in detail here.

[0089] FIGS. 4A-4D show a series of steps taken after the seventh column (i.e., the final column in the group 78) of bales has been loaded. It will be understood that tying material 80 is present in FIGS. 4A-4D, although the tying material is not shown, for clarity of illustration.

[0090] In FIG. 4A, a seventh column (i.e., the last column in the group 78 shown) is shown in the loading chamber 44. As shown in FIG. 4A, the platen 58 is about to push in the direction shown by arrow “A7”. In FIG. 4B, the platen 58 pushes the seventh column into the compression chamber 24, causing the first column in the group 78 to engage the inside surface 50 of the rear doors 52, which are closed. Accordingly, the group 78 is shown in FIG. 4B positioned in the compression chamber 24, after the seventh column has been pushed into the compression chamber 24. At this point, the compression of the group 78 of bales in the direction of downstream travel (i.e., lengthwise) takes place, i.e., due to the platen 58 pushing the seventh column into the compression chamber 24. The group 78 is tied with tying material 80 (i.e., twine) while such compression is taking place.

[0091] While the group 78 of bales is compressed by the transfer assembly 60, the knotter 82 ties the tying material 80 around the group 78 of bales. Once the tying has been completed, the group of bales 78 has been consolidated into the bale bundle 22.

[0092] It is important for the tying to take place during compression lengthwise because, after such compression, the material in the bales rebounds. It is intended that the rebounding of the material in the bales will exert outward pressure on the tying material 80, thereby causing the tying material 80 to hold the bales together tightly. As is known in the art, it is desirable that the bales be held together in the bundle as tightly as possible.

[0093] After such lengthwise compression and the tying, the rear doors 52 are opened. This causes the resilient rebounding of the material (i.e., hay) to take place which is directed primarily rearwardly, rather than frontwards. Frontward expansion is not possible at this point because the platen 58 is still in position, engaged with the seventh column.

[0094] It has been found that compression of the bales from top to bottom thereof is generally easier than compression thereof from sidewall to sidewall. This is due to the manner in which the bales are made, and the resilient nature of the hay. For this reason, the bales are positioned in the compression chamber 24 with sidewalls directed upwardly and downwardly. Accordingly, the bundle 22 is more likely to hold its shape better when the bales used to form it are positioned as described.

[0095] When the bales 10 are formed, they are bound with twine or any other suitable tying material, as is known in the art, and each bale has some degree of structural strength, or internal cohesiveness. When consolidating the bales into the bale bundle, it is desirable to compress the bale bundle before tying, because the hay is resilient, and rebounds after tying, and after the compression is released, so that the bales tightly press outwardly against the tying material. This outward expansion or rebounding is important because it is undesirable that bales in a bundle be “loose”, as this may interfere with stacking the bundle, or otherwise working with the bundle. However, over-compression of individual bales can be harmful, especially over an extended period of time, because such over-compression can eliminate or reduce the internal cohesiveness of the bale, and undermine its ability to rebound after compression.

[0096] Accordingly, the extent of compression of each bale, and the direction in which each bale is compressed, preferably is controlled in the bale stacker. Because the bales are more easily compressed in a direction which is from top wall to bottom wall (or vice versa), the bales are positioned on their sidewalls in the loading chamber 44 (i.e., in the columns) and subsequently in the compression chamber. (The bales are also positioned in this way because this is more suitable for the desired dimensions of the bundle after it has been formed.) Conversely, compression of each bale in the other direction (i.e., sidewall to sidewall) is somewhat more difficult, and therefore is limited to the extent caused by the front portion 40 and maintained by the back portion 38.

[0097] The bundles preferably are sized to fit into a high cube van, which has an inside height of approximately 110 inches. Preferably, each bundle is formed so that two bundles (one on top of another) can relatively easily fit into the high cube van. In practice, this means that the bundles preferably should have a height of approximately 52 to 53 inches, or less. Because of this, the rear portion preferably is approximately 51 inches above the floor 26.

[0098] Compression orthogonal to the floor 26 is maintained by the rear portion 38 over an extended period of time. This is advantageous because it results in relatively close control over the ultimate height of the bundle, after consolidation thereof. As indicated above, the height of the bundle preferably is about 52 or 53 inches (or less), for easier loading into a high cube van. However, the lengthwise compression is done over a minimal period of time, e.g., over approximately five seconds, so that the hay will rebound (after tying) to a significant extent in the lengthwise direction. In this way, the desired height of the bundle is substantially maintained, and the hay rebounds generally in the lengthwise direction to a desired extent.

[0099] In FIG. 4D, the platen 58 is shown in a retracted position, so that the first column of the next group of bales (i.e., to be formed into another bundle) may be loaded into the loading chamber 40. Preferably, the bundle 22 shown in FIG. 4D is pushed out of the compression chamber 24 when the subsequent columns of the following group of bales (not shown in FIG. 4D) are pushed into the compression chamber 24 by the platen 58. (Depending on conditions, five or six subsequent columns may be loaded and pushed into the compression chamber before the bundle 22 is pushed out.) The bundle 22 exits via the downstream opening, and rolls down a ramp 83 which preferably is included in the bale stacker 20 to facilitate movement of the bundle 22. Preferably, the ramp has rollers or other means for promoting movement of the bundle down the ramp 83 under the influence of gravity, as is known in the art.

[0100] From the foregoing description, it can be seen that the extent of compression lengthwise is important—i.e., such compression should preferably be only to the desired extent. The distance between the surface 56 of the platen 58, when the transfer assembly 60 is fully extended, and the front surface 50 of the rear doors 52, when the rear doors 52 are closed, preferably is adjustable, so that the conditions of the bales can be taken into account and the lengthwise compression is kept within the desired range. As can be seen in FIGS. 3B and 3C, the surface 50 preferably is on two separate panels 85 formed with mounting elements 87 which are mounted on arms 89 respectively. The mounting elements 87 include holes 91 in which pins 93 are receivable, the mounting elements 87 being temporarily (but securely) attachable to the arms 89 by the pins 93. As can be seen in FIGS. 3B and 3C, the position of the panels 85 on the mounting elements 87 can be changed so that the panels 85 are further out or closer to the arms 89 respectively, as the case may be. Accordingly, the position of the front surface 50 relative to the surface 56 of the platen 58 (when the platen is fully extended) can be varied by attaching the mounting elements 87 at various of the holes 91.

[0101] As indicated above, the bales preferably are provided to the injector assembly 62 on the table surface 69. The bale stacker 20 preferably includes a table assembly 84 (FIG. 5). The table assembly 84 is for transporting bales to the injector assembly 62. The table assembly 84 preferably includes a table 86 having the substantially flat table surface 69. It is preferred also that the table surface 69 is adapted to permit sliding movement of the table 86 under the bale. The table assembly 84 preferably also includes a means 129 for rotating the table 86 about a substantially vertical axis 131 (FIG. 9). As can be seen in FIG. 9, the axis 131 preferably is defined by an axle element 133, to which is attached a sprocket 135 or similar device. The means 129 preferably also includes a motor 137 for rotating the table 86, and a power transmission element 139 connecting the motor and the sprocket 135. As will be appreciated by those skilled in the art, there are many different ways in which rotation of the table 86 could be effected, and the means for rotation 129 illustrated in FIG. 9 is exemplary only.

[0102] It is also preferred that the table assembly 84 includes a bale control device 88 (FIG. 9) for spacing the bales apart from each other on the table surface 69 by an approximate predetermined distance, as will be described. The bale control device 88 causes the bales to be provided to the injector assembly 62 at discrete intervals, thereby preventing the bales from interfering with the operation of the injector assembly 62 by clogging it.

[0103] The manner in which the table assembly 84 transports bales to the injector assembly 62 is shown in FIGS. 6A-6C. In FIG. 6A, a first bale (identified as such) is moved in the direction shown by arrow “A8” by a baler (not shown) along a chute 90 onto the table 86. (As will be described, the bale stacker 20 may be used with a baler or otherwise.) As can be seen in FIG. 6A, the table 86 preferably rotates in a counterclockwise direction, as indicated by arrow “A9”. The table 86 preferably includes an inner guide element 92 and an outer guide element 94 which serve to channel the bales toward the injector assembly 62. The guide elements 92, 94 are stationary relative to the moving table 86.

[0104] As can be seen in FIGS. 6A, 6B, and 6C, the first bale and a second and a third bale preferably are placed on the table surface 69 spaced apart an approximate predetermined distance from each other. (As described below, the transportation of the bales by the table 86 to the injector assembly 62 preferably is controlled at least in part by the bale control device 88 in any event.) The path taken by the bales is generally indicated by arrows in FIG. 6B, and as can be seen in FIG. 6C, the net result is that a sidewall of the first bale 10 is positioned for engagement with the blade 68 of the injector assembly 62. The injector assembly 62 preferably includes a bale stop 96 which moves in concert with the blade 68, as will be described. The bale stop 96 also partially controls the movement of bales to the injector assembly 62.

[0105] The use of the bale control device 88 (referred to hereinafter as a spacer bar) and the bale stop 96 to control the movement of bales on the table is shown in FIGS. 8A-8D, 9, and 10A-10E. As can be seen in FIGS. 8A and 8B, the spacer bar has an elongate body 98. In FIG. 8B, a leading bale is moved by the table 86 underneath an upstream end 101 of the body 98. The leading bale is shown in FIG. 8C as having been received in the injector assembly 62, and is positioned in front of the blade 68. In the meantime, after the leading bale moves past a downstream end 103 of the body 98, a first following bale moves underneath the upstream end 101 of the body 98 (FIG. 8C). At the same time, a second following bale is placed on the table 86 (FIG. 8C).

[0106] In FIG. 8D, because the first hydraulic cylinder 64 of the injector assembly 62 is extended at least somewhat, the bale stop 96 prevents the first following bale from proceeding further, and consequently interfering with the operation of the injector assembly. Because the downstream end 103 of the body 98 is positioned on the first following bale, the upstream end 101 is positioned to prevent the second following bale from proceeding further towards the injector assembly 62, as will be described. As can be seen in FIG. 8D, a third following bale is unable to proceed onto the table, because the second following bale is (at the point shown in FIG. 8D) bumping into the second following bale. The relative positions of the bale control device 88 and the bale stop 96, when the blade is in the extended position, are shown in FIG. 9. (The second hydraulic cylinder 66 in the injector assembly 62 has not been shown in FIG. 9 for clarity of illustration.)

[0107] The operation of the spacer bar (or bale control device) 88 is shown in FIGS. 10A-10E. As can be seen in FIG. 10A, the body 98 of the spacer bar 88 is pivotable about a pin 105. The body 98 is pivotable between a first position (FIG. 10B), in which the upstream end 101 is raised to permit the leading bale to pass underneath the upstream end 101 and the downstream end 103 is correspondingly lowered, and a second position (FIGS. 10C and 10D), in which the downstream end 103 is raised to engage the leading bale. When the downstream end 103 is so raised, the upstream end 101 is correspondingly lowered. As can be seen in FIGS. 8A-8D and 10A-10E, the table surface 69 is adapted to move relative to the bale while the bale is restrained by the upstream end 101, and the table surface 69 ultimately moves the bale past the upstream end 101. As described above, the bale may be held under the downstream end 103 for some time because the bale is held substantially stationary relative to the spacer bar 88 by the bale stop 96, i.e., the bale engages the bale stop 96 when the bale stop is in its path. However, once the bale stop 96 is moved out of the path of the bale, the bale is moved by the table 86 away from the spacer bar 88, and into position in front of the blade 68 of the injector assembly 62.

[0108] Preferably, the spacer bar 88 includes a shoe 107 mounted on a pin 109 extending from a bracket 111 positioned at the upstream end 101. Preferably, the shoe is pivotable between an up position (FIG. 10D) and a down position (FIGS. 10A-10C, 10E) about the pin 109. The shoe 107 has an engagement surface 112, and is biased by a biasing means 113 (preferably, a spring) to the down position.

[0109] As can be seen in FIG. 10A, when the body 98 is positioned midway between its first and second positions, an initial bale engages the shoe 107 beneath a midway point 115 on the engagement surface 112, so that the bale engages the shoe 107 and slides underneath the shoe 107, causing the body's upstream end 101 to pivot upwardly, and also consequently causing the downstream end 103 to pivot downwardly to a corresponding extent. Preferably, the body 98 is balanced so that, when neither of the ends 101, 103 is engaged with a bale, the body 98 is positioned in the midway position shown in FIG. 10A.

[0110] As shown in FIG. 10B, when the body 98 is in the first position, the shoe 107 permits the bale to pass underneath the upstream end 101. The shoe 107 preferably engages the top side of the bale as it passes underneath the upstream end 101.

[0111] As can also be seen in FIG. 10B, the downstream end 103 is configured so that the bale pushes the downstream end 103 upwardly to the second position, when the bale engages the downstream end 103. In FIG. 10C, the body 98 is shown in the second position thereof, with the downstream end 103 lightly engaged with the top side of the initial bale. The upstream end 101 is lowered to a corresponding extent, with the result that the first following bale engages the shoe engagement surface 112 at a point above the midway point 115. In this situation, instead of the first following bale sliding underneath the shoe 107, the first following bale engages the shoe 107, and causes the shoe 107 to pivot upwardly to the up position (FIG. 10D). With the body 98 and the shoe 107 in this position, the bale is stopped from proceeding, as it can be seen that the first following bale cannot pass underneath the upstream end 101 when the shoe is positioned relatively low with respect to the bale's top side. The table surface 69 continues to move underneath the bale relative to the bale's bottom side, creating a relatively light pressure causing the bale to press forwardly, i.e., past the upstream end 101.

[0112] Finally, FIG. 10E shows that, once the initial bale moves past the downstream end 103, the upstream end 101 is moved upwardly by the shoe 107. This takes place because the shoe 107 presses down on the bale as it returns to the position to which it is biased, causing the upstream end to move upwardly. In this position, the first following bale engages the shoe 107 at a point below the midway point 115, so that the first following bale can push the upstream end upwardly, and pass underneath the upward end 101.

[0113] As can be seen in FIGS. 11A and 11B, the compression chamber ceiling 32 is movable between a compression position (FIG. 11A) and a released position (FIG. 11B). In the released position, the ceiling 32 is located approximately three to four inches above the ceiling 32 when it is in the compression position.

[0114] This feature is useful when, for example, the bundle 22 is to be removed from the compression chamber 24, but there are no additional bales available for processing. Such a situation may arise, for example, when the bales in a particular field have been collected, and no bales remain in such field. In particular, this feature of the invention is useful where, for example, the bale stacker 20 is used for consolidating bales from different farmers, i.e., the operator of the bale stacker is working on a contract basis, and mixing of bales from different fields is undesirable.

[0115] As can be seen in FIG. 11A, the ceiling 32 preferably is mounted to a frame 117 of the bale stacker via a parallel linkage which includes pins 119, 121, 123 and 125. As can be seen in FIGS. 11A and 11B, the movement of the ceiling 32 from the compression position to the released position and vice versa is effected by movement of a lever 127. The movement from the compression position to the released position is upwardly and generally toward the rear, as indicated by arrow A10. It can be seen in FIGS. 11A and 11B that, after moving the ceiling 32 to the released position, the bundle 22 can be pulled out of the compression chamber (e.g., by a tractor) relatively easily.

[0116] In use, the bale stacker is positioned as required. The bale stacker 20 preferably is mounted on wheels, and may be towed to a location where bales are fed to it, for example, via the chute 90. Alternatively, the bale stacker 20 may be towed in a field, with a device (e.g., a suitable conveyor) adapted to pick up bales directly in the field.

[0117] The bales are placed on the table 86, and as described, the spacer bar 88 and the bale stop 96 are used to control the flow of the bales to the injector assembly 62 so that the bales are fed to the injector assembly one at a time, when the blade 68 is retracted and ready to receive the next bale. The injector assembly 62 loads the bales one at a time into the loading chamber 44, to form columns 42 of three bales each. Each column 42 is separately pushed into the compression chamber 24 by the transfer assembly 60. With the seventh (and final) column for a particular group of bales 78 which is to be formed into a bundle, the push given to such seventh column by the transfer assembly (when the column is pushed into the compression chamber) serves to compress the entire group of twenty-one bales lengthwise. Such lengthwise compression is to a predetermined extent.

[0118] In addition, as each column is pushed past the front portion 40 of the ceiling 32, the front portion compresses the column orthogonally relative to the floor 26 of the compression chamber 24. Such compression is intended to be limited to a certain extent, in order that the internal cohesiveness of the bales might not be adversely affected by such compression. After the column 42 moves past the front portion 40, compression thereof orthogonal to the floor is maintained by the rear portion 38.

[0119] The group 78 is tied off while it is being compressed as described, so that the bales in the group 78 are consolidated into the bale bundle 22. Before the platen 58 is retracted, the rear doors 52 are opened, to permit a resilient expansion of the hay in the bundle 22 towards the downstream opening, generally in the downstream direction. Subsequently, the platen 58 is fully retracted, so that the subsequent columns of bales for the next group of bales may be loaded into the loading chamber 44. When the subsequent columns of the next group of bales are pushed into the compression chamber, they in turn push the bale bundle 22 out of the compression chamber, via the downstream opening. Preferably, the bundle 22 rolls down the ramp 83 under the influence of gravity. After the bundle 22 has exited the compression chamber 24, the rear doors 52 are closed, in preparation for the lengthwise compression of the next group of bales.

[0120] Additional embodiments of the invention are shown in FIGS. 12A-16B. In FIGS. 12A-16B, elements are numbered so as to correspond to like elements in FIGS. 1B-11B.

[0121] An alternative embodiment of a bale stacker 220 of the invention is shown in FIGS. 12A-16B. The bale stacker 220 is for forming a number of bales 10 into the bale bundle 22 having a predetermined number of bales 10. Preferably, the bale stacker 220 includes a compression chamber 224 extending between an upstream opening 234 and a downstream opening 236 thereof (FIGS. 12A, 12B). The bales 10 are receivable in the compression chamber 224 via the upstream opening 234 and are formable in the compression chamber 224 into the bale bundle 22. The bale bundle 22 is removable from the compression chamber 224 via the downstream opening 236. Also, the bale stacker 220 preferably includes a loading chamber 244 in which the bales 10 are positionable in respect of columns 242 proximal to the upstream opening 234. Each column 242 includes a preselected number of bales 10, as will be described. The bale stacker 220 preferably also includes a transfer assembly 260 for moving the columns 242 of bales 10 from the loading chamber 244 into the compression chamber 224. In one embodiment, it is preferred that the transfer assembly 260 includes a platen 258 for engaging each column 242 of bales respectively. It is also preferred that the platen 258 is movable between a retracted position (FIG. 12A), in which the bales 10 are movable into the loading chamber 244, and an extended position (FIG. 12B), in which each respective column 242 of bales 10 is positionable by the platen 258 at least partially in the compression chamber 224. Preferably, the bale stacker 220 also includes one or more front doors 248 located at the upstream opening 234 and movable between a closed position (FIG. 14A), in which the upstream opening 234 is at least partially obstructed by the front doors 248, and an open position (FIG. 13A), in which each column 242 of bales 10 is movable respectively through the upstream opening 234. In addition, the bale stacker 220 preferably also includes one or more controlling means 273 for coordinating movement of the front doors 248 with movement of the platen 258.

[0122] In one embodiment, the controlling means 273 controls movement of the front doors 248 so that movement of the platen 258 from the retracted position to the extended position results in movement of the front doors 248 from the closed position to the open position respectively, and movement of the platen 258 from the extended position to the refracted position results in movement of the front doors 248 from the open position to the closed position respectively (FIGS. 12A, 12B).

[0123] The controlling means are for controlling movement of the front doors relative to movement of the platen, i.e., for coordinating movement of the front doors with movement of the platen. It will be appreciated by those skilled in the art that the controlling means 273 may include various arrangements of various components. For instance, in one embodiment, the controlling means 273 may include one or more hydraulic cylinders controlled by limit switches and a PLC computer.

[0124] It is preferred that the controlling means 273 includes one or more linkage assemblies 241 linking the transfer assembly 260 and the front doors 248. As will be described, the linkage assembly 241 is a mechanical linkage. The linkage assembly has a cost advantage over a controlling means which includes one or more hydraulic cylinders, as will be appreciated by those skilled in the art. However, as indicated above, the controlling means are not necessarily driven or moved by movement of the platen 258 or other components of the transfer assembly 260.

[0125] Preferably, the transfer assembly 260 includes a cam surface 243 extending between a first end 245 and a second end 247 thereof movable with the platen 258 (FIG. 15B). In one embodiment, the linkage assembly 241 preferably includes a roller 249 adapted for rolling engagement with the cam surface 243 and an arm portion 251 extending between a back end 253 thereof, disposed proximal to the front door 248, and a front end 255 thereof, disposed distal to the front door 248. The arm portion 251 is connected to the front door 248 (FIG. 15A). In one embodiment, the arm portion 251 is pivotable about an axis 257 between a first position (FIG. 15A), in which the front door 248 is located thereby in the closed position, and a second position (FIG. 15B), in which the front door 248 is located thereby in the open position. Preferably, the cam surface 243 is configured so that movement of the platen 258 between the retracted and the extended positions thereof causes the arm portion 251 to pivot between the first and second positions respectively, and also causes corresponding movement of the front doors 248 between the closed and open positions respectively.

[0126] The problem which the bale stacker 220 addresses is described as follows. In the first embodiment of the bale stacker 20 (described above), the first column of bales for a particular bale bundle engage the front surface 54 of the front doors 48 (FIGS. 7C, 7D). However, as can be seen in FIGS. 4A-4D, 7E-7F, and 9, once the first column is pushed past the front doors 48, the front doors 48 are held open by the first column and successive columns positioned at the front end of the compression chamber, until the bale bundle is completed.

[0127] Accordingly, when the second and subsequent columns are loaded into the loading chamber, the immediately preceding column is located at the front end of the compression chamber. In the bale stacker 20, the bales in the second and subsequent columns in a particular bale bundle therefore are slidingly engaged with the bales in the immediately preceding column, when the second and subsequent columns are moved into the loading chamber 44 of the bale stacker 20. In this situation, however, the bales being loaded sometimes are caught on the bales in the immediately preceding column. This can result in the bales being turned as they are loaded into the loading chamber 44, due to catching on the bales in the immediately preceding column. When this happens, the generally straight, generally upward path of the bale being loaded is interrupted. It will be appreciated by those skilled in the art that the bale which is being loaded may be turned sufficiently that the loading chamber becomes blocked thereby. Such jamming is to be avoided, to the extent possible, because productivity is adversely affected when time must be spent to clear the blocked loading chamber. In practice, this problem is generally only occasional, however, it can be frequent if the hay in the bales is relatively wet. For instance, the hay may be relatively damp due to prevailing weather conditions.

[0128] In the bale stacker 220, this problem is addressed, or at least mitigated. The front doors 248 address the issue in two ways. First, the front surfaces 254 preferably are relatively smooth, and are positioned so that the bales being loaded into the loading chamber 244 are slidingly engageable therewith.

[0129] Second, the front doors 248 return to the closed position after a column is pushed into the compression chamber. As can be seen, for example, in FIGS. 12D and 12E, when the platen 258 moves from the extended position (FIG. 12D) to the retracted position (FIG. 12E), the front doors 248 are moved from the open position to the closed position respectively. In this way, the front doors 248 are returned to the closed position after each column of bales is pushed from the loading chamber into the compression chamber.

[0130] Accordingly, each front door 248 preferably includes the front surface 254 thereof adapted for sliding engagement of each bale therewith during movement of each bale into the loading chamber 244. From the foregoing, it can be seen that, because the front doors 248 are positioned so that bales slidingly engage the front surfaces 254 of the doors 248 as the bales are loaded into the loading chamber 244, the problem of bales becoming jammed in the loading chamber is substantially addressed.

[0131] As can be seen in FIG. 14B, the loading chamber 244 preferably is positioned at an angle to the horizontal (i.e., higher at the front than the back), so that each bale (and each column of bales), while in the loading chamber, is at least partially supported by the front doors 248.

[0132] Also, the front doors 248 preferably are formed to at least partially guide the bales as they are moved into the loading chamber 244. For instance, in one embodiment, the front surfaces 254 are substantially flat, and guide bales upwardly as the bales are loaded into the loading chamber.

[0133] As can be seen in FIGS. 12A-12H, the platen 258 preferably includes one or more body elements 261 with surfaces 263 thereof which are substantially flat and smooth (i.e., to define a plane), and also substantially parallel to the front surfaces of the front doors 248. Preferably, the body elements 261 define gaps 265 therebetween (FIGS. 12A, 12C, 12E). The gaps 265 enable tying material 280 (FIG. 12H) to be drawn around the bales as they are compressed, so that the bales can be tied while compressed, to form the bale bundle. Any suitable means for moving the platen 258 between the extended and the retracted positions may be used. For instance, in one embodiment, the platen 258 preferably is moved between the extended and retracted positions by one or more hydraulic cylinders.

[0134] In one embodiment, the axis 257 is located proximal to the front end 255 of the arm portion 251 (FIGS. 16A, 16B). As can be seen in FIGS. 15A-16B, the roller 249 preferably is mounted on the arm portion 251 and the arm portion 251 is pivotably mounted to a frame 259 (FIGS. 15A, 15B) of the bale stacker 220 so that the cam surface 243 moves relative to the roller 249 when the platen 258 moves between the retracted and extended positions thereof.

[0135] Those skilled in the art would be aware of various arrangements of the components of the linkage assembly which would be suitable. In one embodiment, the cam surface 243 includes a first portion 269 which is substantially parallel to the direction of travel of the platen 258 between the retracted and extended positions, and a second portion 271 which is positioned at a predetermined angle relative to the first portion 269 (FIGS. 16A, 16B). The arm portion 251 and the front door 248 attached thereto are formed so that, when the roller 249 engages the first portion 269, the front door 248 is held in the open position. Also, when the roller 249 moves from the first portion 269 to the second portion 271, the front door 248 moves from the open position and toward the closed position. The front door 248 reaches the closed position when the roller 249 reaches the end of its path along the second portion 271 of the cam surface 243, as shown in FIGS. 15A and 16A.

[0136] It will be understood that the linkage assemblies 241 mounted on each side of the bale stacker 220 are the same in all material respects, except that they are mirror images of each other.

[0137] As can be seen in FIGS. 13B and 14B, the linkage assembly 241 preferably includes an upper arm portion (identified as 251a in FIGS. 13B and 14B for convenience) and a lower arm portion (identified as 251b in FIGS. 13B and 14B for convenience). Preferably, the upper and lower arm portions 251a, 251b are connected by a connecting rod 267 which strengthens the linkage assembly, as it urges the upper and lower arm portions 251a, 251b to move substantially simultaneously.

[0138] It will also be understood that the upper and lower arm portions are the same in all material respects.

[0139] Those skilled in the art will appreciate that a variety of arrangements may be used for moving bales into the loading chamber 244. However, in one embodiment, the bale stacker 220 preferably includes an injector assembly 262 (FIG. 12H) for moving the bales into the loading chamber 244 and positioning the bales in columns respectively therein.

[0140] In addition, it will be appreciated by those skilled in the art that the bales may be fed to the injector assembly 262 using various devices or methods. In one embodiment, the bale stacker 220 preferably also includes a table assembly 284 for transporting each bale consecutively to the injector assembly 262 and positioning each bale respectively for movement thereof by the injector assembly 262.

[0141] In use, the bales preferably are positioned on the table assembly 284 consecutively (i.e., one at a time). The methods and devices which may be used to position the bales consecutively on the table assembly 284 are well known in the art, and it is therefore unnecessary to describe such methods and devices in detail. Preferably, each bale is positioned by the table assembly 284 in the injector assembly 262 consecutively, so that each bale preferably is then loaded into the loading chamber 244 consecutively. The bales may be positioned consecutively in the injector assembly in the manner described above, in connection with the bale stacker 20. As described above, the bales preferably are loaded into the loading chamber 244 by the injector assembly one at a time to form a three-bale column. Preferably, the loading chamber 244 is at least partially defined by the platen 258 and the front surfaces 254 of the front doors 248, and the loading chamber 244 is substantially filled by the column of three bales.

[0142] Because the bale bundle ultimately is preferably formed of a total of 21 bales (i.e., seven columns of three bales each), it is expeditious to form each column of three bales in the loading chamber. However, it will be understood that the columns of bales may include any suitable numbers of bales, as required.

[0143] In FIG. 12A, the bale stacker 220 is shown after a bale bundle (not shown) has been formed and pushed out of the compression chamber 224. The platen 258 is in the refracted position, and the bales of the first column in the next bale bundle are receivable in the loading chamber 244.

[0144] In FIG. 12B, the platen 258 is shown in the extended position, for illustrative purposes.

[0145] The first column 242 of three bales is shown positioned in the loading chamber 244 in FIG. 12C. It will be understood that the bales 10 in the column 242 preferably are loaded into the loading chamber 244 by the injector assembly 262. Each bale preferably is pushed generally upwardly (i.e., in the direction indicated by arrow “M” in FIG. 12H) into the loading chamber 244 by the injector assembly 262 in the manner described above in connection with the bale stacker 20. However, the column 242 is positioned in the loading chamber 244 using any suitable means.

[0146] In FIG. 12D, the first column (identified in FIG. 12D as 242a for convenience) has been moved rearwardly, from the loading chamber 244 into the compression chamber 224, by the platen 258 as it moves from the retracted position (FIGS. 12A, 12C) to the extended position (FIGS. 12B, 12D). The direction of such movement is indicated by arrow “N” in FIG. 12D.

[0147] FIG. 12E shows the platen 258 returned to the retracted position, i.e., after the platen 258 has moved from the extended position to the retracted position. The direction of such movement is indicated by arrow “P” in FIG. 12E. As shown in FIG. 12E, upon the platen 258 returning to the retracted position, the next column of bales is receivable in the loading chamber 244.

[0148] In FIG. 12F, the second column of bales (identified as 242b in FIG. 12F for convenience) is shown being positioned in the compression chamber 224 by the platen 258. The platen 258 is shown in the extended position in FIG. 12F. As the column 242b is pushed into the compression chamber 224 (i.e., in the direction indicated by arrow “Q” in FIG. 12F), the column 242b engages column 242a, and pushes column 242a rearwardly.

[0149] FIG. 12G shows the columns needed to form the bale bundle positioned in a group 278 in the compression chamber 224. As can be seen in FIG. 12G, when the platen 258 pushes the final column for the bale bundle to be formed (such final column being identified as 242g in FIG. 12G for convenience) into the compression chamber 22, rear doors 252 are closed. The platen 258 is shown in the extended position in FIG. 12G. Preferably, after the final column for a particular bale bundle is positioned in the compression chamber, the platen 258 pushes further rearwardly (i.e., to a position rearward of the extended position), to compress all the bales in the bale bundle while the bale bundle is tied off.

[0150] The group 278 of 21 bales in seven columns ready to be tied and further compressed (i.e., ready to be consolidated into a cohesive bundle) is also shown in FIG. 12H. Also, FIG. 12H shows a tying material 280 which defines a pocket into which the seven columns of bales in the group 278 preferably have been pushed, one column at a time, as described above. (The tying material 280 is not shown in FIGS. 12A-12G for clarity of illustration.) The tying material 280 is shown in FIG. 4 prior to its being tied around the bales 278 using a knotter 282. The technique of tying bales and bundles of bales generally, and using knotters therefor, is well-known, and therefore such technique does not need to be described in detail here.

[0151] Any element in a claim that does not explicitly state “means for” performing a specified function, or “step for” performing a specific function, is not to be interpreted as a “means” or “step” clause as specified in 35 U.S.C. §112, paragraph 6.

[0152] It will be appreciated by those skilled in the art that the invention can take many forms, and that such forms are within the scope of the invention as claimed. Therefore, the spirit and scope of the appended claims should not be limited to the descriptions of the preferred versions contained herein.