AU2012207051B2 - Cotton processing systems and components therefor - Google Patents

Abstract

A system for processing round bales of cotton, including: a first conveyor having a loading bay at one end and a transfer bay at the other end; a second conveyor adjacent the first conveyor, the second conveyor having a receiving bay and a feeding bay spaced therefrom, the feeding bay being arranged to convey round bales into a bale feeder for separating cotton; and transfer means arranged to transfer round cotton bales from the transfer bay of the first conveyor to the receiving bay of the second conveyor, the transfer means being adapted to at least transfer bales in wagon wheel form in the transfer bay of the first conveyor to sausage form in the receiving bay of the second conveyor.

Description

1 COTTON PROCESSING SYSTEMS This invention relates to cotton processing systems. For many years raw cotton has been harvested by cotton pickers, then transferred to boll buggies which transport the cotton to presses which in turn press the cotton into large truck/trailer sized packages known as cotton modules. In recent years such modules have been phased out in some areas and cotton is now harvested by cotton pickers which not only pick the cotton but also form it into large round bales in a continuous process while picking and wrapping it in a plastic wrap material about the cylindrical face before unloading the bale ready for transport to a cotton gin. Round bales of cotton are loaded for transport to a cotton gin in much the same manner as cotton modules. In this respect, the round bales are typically arranged end to end in a straight line on the ground to form a "sausage" which is then loaded from one end onto a truck or trailer. The sausage form is important in some cases to ensure that only the outside ends of the two opposite end bales are exposed to the weather and to be ready for loading as a sausage unit. Typically, the truck or trailer has a load supporting deck which is lowered to engage with the sausage near to or on the ground. The deck usually .has a conveyor thereon for conveying the sausage onto the deck and can have a crawler track assembly depending from the underside of the deck for pulling the deck under the sausage as it is conveyed onto the deck by the conveyor in much the same manner as is known for loading cotton modules. It has been found to be difficult to load a cost efficient number of round bales onto a truck using the sausage system. In this respect, a round bale typically has a diameter of about 2250mm and is about 2400mm long and consequently fits 2 well on a standard width truck or trailer deck (which is typically about 2400mm wide) in either a lateral or longitudinal orientation. Notably, although the diameter is initially significantly less than 2400mm, the bales sag under their own weight before, during and after transportation and become somewhat oval in cross section rather than circular, thereby resulting in a major diameter which can extend beyond the sides of the truck or trailer when placed longitudinally thereon. Because of the size of the bales only one sausage of bales can fit longitudinally on a truck or trailer deck but unfortunately, one sausage of bales is little more than a half load from a mass or weight perspective. The sausage form of. transport and storage is similar to that presently used for cotton modules and cotton gins are able to process sausage type loads of bales in much the same manner as modules although there are some difficulties because of the plastic wrap. The present applicant has previously developed a system which allows two rows of cotton bales to be loaded on a deck for transportation to a cotton gin by placing them across the deck, that is, with their axes perpendicular to the direction of travel rather than in the direction of travel or as is known as "wagon wheel" form as described in Australian patent application No. 2010224463. With the wagon wheel system it is more appropriate to store bales in the field before loading in a "wagon wheel" form. While the wagon wheel system of loading allows a significantly higher number of bales to be loaded on the same sized deck, cotton gins are not able to process bales transported and stored in that form as easily as they would like. When processing cotton modules, the first main step at the cotton gin is to pass the module through a feeder which 3 separates the cotton sufficiently so that it feeds into the next processing stage reasonably evenly and constantly. However, bales which enter the feeder with their axes across the direction of travel do not feed evenly because their height increases towards the axis and decreases away from the axis. The present invention is aimed at providing a system for or method of processing round bales of cotton which have been transported with the bales in wagon wheel form. With the foregoing in view, the invention in one aspect resides broadly in a system for processing round bales of cotton, including: a first conveyor having a loading bay at one end and a transfer bay at the other end; a second conveyor adjacent the first conveyor, the second conveyor having a receiving bay and a feeding bay spaced therefrom, the feeding bay being arranged to convey round bales into a bale feeder for separating cotton; and transfer means arranged to transfer round cotton bales from the transfer bay of the first conveyor to the receiving bay of the second conveyor, the transfer means being adapted to at least transfer bales in wagon wheel form in the transfer bay of the first conveyor to sausage form in the receiving bay of the second conveyor. In another aspect the invention resides broadly in a method for processing round bales of cotton, including: transferring bales from a truck or trailer to a first conveyor in wagon wheel form; conveying the transferred bales along the first conveyor in wagon wheel form to a predetermined transfer bay; 4 transferring bales in wagon wheel form from the predetermined transfer bay of the first conveyor to a second conveyor adjacent the first conveyor in sausage form; and feeding bales in sausage form on the second conveyor into a bale feeder for separating cotton. Preferably, the transfer means includes turning means for turning the bales through an angle of about 90 degrees thereby allowing the first and second conveyors to be substantially parallel or even in the same line. Such arrangement would allow the system to be easily installed in at least some existing cotton gins. In a preferred form, the turning means is incorporated in an overhead crane arranged to lift bales from the transfer bay of the first conveyor to the second conveyor. In such form, it is also preferred that the transfer means also include means for rotating the bale to a desired predetermined angular position so that the wrapper can be cut at a desired position. However, in another form, the transfer of bales from the transfer bay of the first conveyor is carried out via a pusher bay where bales which have been turned to the desired orientation for being conveyed in sausage form to the feeder are pushed onto a walking floor type conveyor. Preferably, the system also includes a wrapper removal system for removing the polythene wrapper from the bales before they reach the feeder. In a preferred form, the wrapper removal system includes cutting means for cutting through the polythene wrapper on the bales as they travel along the second conveyor run and grabbing means for grabbing the plastic wrapper and transferring it to a predetermined delivery point. In a preferred form, the cutting means includes a fixed blade mounted in the second conveyor and adapted to slice through the polythene wrapper at the bottom of a bale being conveyed 5 along the second conveyor run. In such form, it is also preferred that the grabbing means includes a grab adapted to grab the wrapper along the top of the able and lift it from the bale as it travels along the conveyor. In another embodiment where the bales pass through a pusher bay, a moving knife is mounted in the floor and arranged to slice through the bottom of the wrapper along its full length while the bale is at rest. In another aspect, the invention resides broadly in apparatus for use in transferring cotton bales from one location to another, the apparatus being adapted for connection to an overhead crane, such as a boom crane or a gantry crane and including: bale grabbing means adapted to grab a bale by engaging the wagon wheel ends of a bale; bale rotating means for rotating the bale about its axis to a desired angular position for removal of a bale wrapper therefrom; and wrapper grabbing means adapted to grab the protective wrapper for removal thereof from the bale. In order that the invention may be more readily understood and put into practical effect, reference will now be made to the accompanying drawings which illustrate a preferred embodiment of the invention and wherein: Fig. 1 is a schematic plan of a system arranged according to the present invention; Fig. 2 is a end elevation of a bale at rest in the pusher bay of the system of Fig. 1; and 6 Fig. 3 is a schematic side elevation of the bale of Fig. 2 about to enter the conveyor with the wrapper almost fully cut. The round bale processing system 10 illustrated in Fig. 1 includes a first conveyor line 11 and a second conveyor line 12 which runs parallel to the first conveyor line. A truck unloading bay 13 is adjacent a conveyor loading bay 14 adjacent the upstream end 15 of the first conveyor line where trucks and semitrailers can stop to have wagon wheel form bales unloaded therefrom. Suitably, an overhead crane (not shown) extends across the truck bay 13 and the conveyor loading bay 14 whereby bales 17 can be simply grabbed whilst on the truck 18 and lifted across and unloaded onto the conveyor 16 in the conveyor loading bay. Trucks can also drive into the truck bay 19 on the opposite side of the loading bay as shown at item 20 for unloading by a front end loader, forklift or the like if desired and be placed on the conveyor at the conveyor loading bay in much the same manner. Bales 15 placed in the conveyor loading bay 14 travel along the conveyor in the direction "A" and can accumulate in the accumulation bay 22. Suitably, the conveyor is a "walking floor" of known type which allows bales to accumulate against each other although other types of conveyors such as belts or the like could be used. Bales move from the accumulation bay into transfer bay 23 where they are automatically weighed and have their identification tags scanned for grower details, variety and other information needed by the cotton gin. It will be seen that the bales entering the transfer bay are still in wagon wheel form after entry. However, bales are lifted from the transfer bay and moved across to conveyor line 12 by an overhead crane 24 (shown schematically) via grab 41.

7 The grab 41 has two opposed end grab arms 43 and 44 with opposed grab plates 45 and 46 respectively mounted thereon and arranged to grab the bale by clamping it therebetween via contact at its opposed circular (wagon wheel) ends by movement of hydraulic rams 47 and 48. The plates are mounted for rotation relative to the grab arms so that the bale can be rotated about its longitudinal axis. For that purpose, the grab plates 45 and 46 are driven by synchronised hydraulic motors 49 and 50 respectively and controlled by suitable control valves arranged with the crane controls. The grab 41 also has two opposed side grab arms 52 and 53 which are arranged to grab the plastic bale wrapper 54 once it has been cut and drop it into the waste compactor 55 located adjacent the pusher bay. The side grab arms are opened and closed by opposed hydraulic rams 56 and 57 which drive the arms to grip the wrapper and lift it from the bale whereupon the grab is lifted by the crane 24 which then swings it around where it can be released and dropped into the compactor. The crane used to transfer bales from the truck bay 13 to the conveyor loading bay uses a similar grab although it does not need the rotary end plates nor the wrapper grab arms. While moving from the transfer bay, the bales are pivoted through 90 degrees (in the horizontal plane) so that they are placed in conveyor line 12 in sausage form. Conveyor line 12 has a pusher bay 31 at its upstream end where bales being transferred from transfer bay 23 of conveyor line 11 are placed by the overhead crane. Whilst in pusher bay 31, the plastic wrapper is cut by an in-floor cutter system 32 which includes a knife 33 mounted on a cable or chain 30 which moves backwards and forwards in direction "B" as the cable is driven one way or the other by drive unit 34 as can be seen in Fig.2. Other knife systems 8 would be satisfactory and in particular, one where the knife is fixed (although allowed to rotate) while the bale is pushed across the top of the knife by pusher ram 34 as can be seen more clearly in Fig. 2. The pusher ram 34 pushes the bale from the pusher bay onto feed conveyor 38 which conveys it to feeder 39. The feeder is of known type and is arranged to separate the cotton for entry into the rest of the ginning process. It will be appreciated that conveyor 38 could be a belt conveyor, a chain conveyor or a walking floor conveyor if desired. Once the knife 33 has cut the wrapper along the bottom of the bale, the wrapper is grabbed by the side grab arms and dropped into the waste compactor as previously described. It will be appreciated that the wrapper 54 which is applied to the bales by the cotton baler will have an end running across the bale and in some cases, the end portion does not bond well to the previous layer and hangs loose. Such a loose piece of polymer material can contaminate the cotton if it enters the feeder. Consequently, it is desirable to cut the wrapper at a predetermined position so that any hanging end portions remain secured to the wrapper when it is removed and dropped into the waste compactor. The rotating end plates allow for rotation of the bale to the desired predetermined position. It will be appreciated that bales entering the feeder in sausage form will feed at a relatively constant volumetric rate in view of the bale having a relatively constant cross section. However, bales fed into the feeder in wagon wheel form vary substantially in cross-section and do not feed as evenly as desired. Consequently, the present invention provides the advantage of constant feeding for cotton bales which have been transported in wagon wheel form.

9 It will also be appreciated that the present system supports on-farm storage of cotton bales and regulated transport to the cotton gins as bales are required for processing thus decreasing the area required for storage at the cotton gins. It will of course be realised that while the above has been given by way of illustrative example of the invention, all modifications and variations thereto as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of this invention as is described herein.

Claims (13)

1. A system for processing round bales of cotton, including: a first conveyor having a loading bay at one end and a transfer bay at the other end; 5 a second conveyor adjacent the first conveyor, the second conveyor having a receiving bay and a feeding bay spaced therefrom, the feeding bay being arranged to convey round bales into a bale feeder for separating cotton; and transfer means arranged to transfer round cotton bales from 0 the transfer bay of the first conveyor to the receiving bay of the second conveyor, the transfer means being adapted to at least transfer bales in wagon wheel form in the transfer bay of the first conveyor to sausage form in the receiving bay of the second conveyor. 5

2. A method for processing round bales of cotton, including: transferring bales from a truck or trailer to a first conveyor in wagon wheel form; conveying the transferred bales along the first conveyor 20 in wagon wheel form to a predetermined transfer bay; transferring bales in wagon wheel form from the predetermined transfer bay of the first conveyor to a second conveyor adjacent the first conveyor in sausage form; and feeding bales in sausage form on the second conveyor into 25 a bale feeder for separating cotton.

3. A system or method according to claim 1 or claim 2 wherein the transfer means includes turning means for turning the bales through an angle of about 90 degrees thereby allowing the first 11 and second conveyors to be substantially parallel or even in the same line.

4. A system or method according to claim 3 wherein the turning 5 means is incorporated in an overhead crane arranged to lift bales from the transfer bay of the first conveyor to the second conveyor.

5. A system or method according to claim 4 wherein the transfer 0 means also include means for rotating the bale to a desired predetermined angular position so that the wrapper can be cut at a desired position.

6. A system or method according to claim 1 or claim 2 wherein 5 the transfer means includes a pusher bay where bales which have been turned to the desired orientation for being conveyed in sausage form to the feeder are pushed onto a walking floor type conveyor. .0

7. A system or method according to any one of the preceding claims including a wrapper removal system for removing a polythene wrapper from the bales before they reach the feeder.

8. A system or method according to claim 7 wherein the wrapper 25 removal system includes cutting means for cutting through the polythene wrapper on the bales as they travel along the second conveyor run and grabbing means for grabbing the plastic wrapper and transferring it to a predetermined delivery point. 30

9. A system or method according to claim 8 wherein the cutting means includes a fixed blade mounted in the second conveyor and arranged to slice through the polythene wrapper at the bottom of a bale being conveyed along the second conveyor run. 12

10. A system or method according to claim 9 wherein the grabbing means includes a grab adapted to grab the wrapper along the top of the bale and lift it from the bale as it travels along the conveyor.

11. A system or method according to claim 7 wherein the cutting means includes a moving knife mounted in the floor and arranged to slice through the bottom of the wrapper along its full length while the bale is at rest.

12. A system according to any one of the preceding claims including apparatus adapted for connection to an overhead crane, such as a boom crane or a gantry crane and including: bale grabbing means adapted to grab a bale by engaging the wagon wheel ends of a bale; bale rotating means for rotating the bale about its axis to a desired angular Position for removal of a bale wrapper therefrom; and wrapper grabbing means adapted to grab the protective wrapper for removal thereof from the bale.

13. A system, method or apparatus for processing round bales of cotton substantially as herein described with reference to the accompanying drawings. cDWY010 4 -Amd--March2016