Unloader control for a combined cotton harvester and module builder and method of operation of the same Number:6,766,634 from the United States Patent and Trademark Office (PTO) owispatent

Title: Unloader control for a combined cotton harvester and module builder and method of operation of the same

Abstract: A control for an unloader of a cotton module builder or other cotton compactor for controlling unloading and loss of uncompacted or loose cotton from the compactor. The unloader includes an unloading element having a first end, an opposite second end, and an intermediate portion located between the ends. A first cotton driver is positioned and operable for moving cotton over a first portion of the unloading element from the chamber to the intermediate location, and a second cotton driver is positioned and operable for moving the cotton over the unloading element from the intermediate location to the second end. The control includes apparatus for selectably operating the first cotton driver in an unloading direction and apparatus operable during operation of the first cotton driver for detecting passage of a trailing end of the module or mass of compacted cotton.

Patent Number: 6,766,634 Issued on 07/27/2004 to Covington,   et al.

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Inventors:	Covington; Michael J. (Bettendrof, IA), Lemke; Dwight D. (Geneseo, IL), Kuissi; Hyppolite (Moline, IL)
Assignee:	Case Corporation (Racine, WI)
Appl. No.:	10/167,157
Filed:	June 11, 2002

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Current U.S. Class:	56/480 ; 414/111
Current International Class:	A01D 46/08 (20060101); A01D 46/00 (20060101)
Field of Search:	56/474,475,476,477,478,479,480,473.5 414/111 460/119

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References Cited [Referenced By]

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U.S. Patent Documents

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	3209932		October 1965		Schiltz
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	3727777		April 1973		Hanson
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	5192177		March 1993		Cardinal
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	6536197		March 2003		Covington et al.

Primary Examiner: Will; Thomas B.
Assistant Examiner: Torres; Alicia
Attorney, Agent or Firm: Maurer; Brant T. Henkel; Rebecca Stader; John William

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Claims

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What is claimed is:

1. An unloader for a cotton compacting structure including a cotton compacting chamber, the chamber having a floor therein and an open end, the unloader comprising: an unloading element mounted to the compacting structure having a first end located adjacent to the open end of the chamber in position for receiving a mass of compacted cotton from the chamber thereon, a second end opposite the first end, a first surface portion extending between the first end and an intermediate location disposed generally between the first and second ends, a second surface portion extending between the intermediate location and the second end, a first cotton driver extending along the first surface portion, and a second cotton driver extending along the second surface portion; and an unloader control, including apparatus for selectably operating the first cotton driver in an unloading direction for moving a mass of compacted cotton over the first surface portion away from the chamber, and apparatus operable during operation of the first cotton driver for detecting passage of a trailing end of a mass of compacted cotton from the first surface portion and automatically stopping the operation of the first cotton driver in the unloading direction so as to limit loose cotton following the mass of compacted cotton on the first surface portion from passing to the second surface portion, the control preventing resumption of operation of the first cotton driver in the unloading direction until a predetermined condition is present indicative of return of a substantial amount of any loose cotton on the first surface portion to the chamber.

2. The unloader of claim 1, wherein the apparatus operable during the operation of the first cotton driver for detecting passage of the trailing end of the mass of compacted cotton from the first surface portion comprises a pressure sensitive device operable for distinguishing between a pressure corresponding to presence of a mass of compacted cotton and a pressure corresponding to presence of loose cotton.

3. The unloader of claim 1, wherein the apparatus operable during operation of the first cotton driver for detecting passage of a trailing end of a mass of compacted cotton from the first surface portion comprises a switch which contacts a mass of compacted cotton when passing from the first surface portion to the second surface portion, the switch changing from a first operating state to a second operating state when contact with the trailing end of the mass of compacted cotton is broken.

4. The unloader of claim 1 wherein the unloader control includes a processor and circuitry connected to the apparatus for operating the first cotton driver and to the apparatus for detecting passage of a trailing end of a mass of compacted cotton, the processor being operable for controlling the apparatus for stopping the operation of the first cotton driver and preventing resumption of operation of the first cotton driver in the unloading direction, and the processor being further operable for controlling the apparatus for operating the first cotton driver to resume the operation thereof when the predetermined condition indicative of return of loose cotton on the first surface portion to the chamber is present.

5. The unloader of claim 1 wherein the first cotton driver comprises a drag chain.

6. The unloader of claim 1 wherein the second cotton driver comprises a drag chain.

7. An unloader for a cotton compacting structure including cotton compacting chamber, the chamber having a floor therein and an open end, the unloader comprising: an unloading element mounted to the compacting structure having a first end located adjacent to the open end of the chamber in position for receiving a mass of compacted cotton from the chamber thereon, a second end opposite the first end, a first surface portion extending between the first end and an intermediate location disposed generally between the first and second ends, a second surface portion extending between the intermediate location and the second end, a first cotton driver extending along the first surface portion, and a second cotton driver extending along the second surface portion; and an unloader control, including apparatus for selectably operating the first cotton driver in an unloading direction for moving a mass of compacted cotton over the first surface portion away from the chamber, and apparatus operable during operation of the first cotton driver for detecting passage of a trailing end of a mass of compacted cotton from the first surface portion and automatically stopping the operation of the first cotton driver in the unloading direction so as to limit loose cotton following the mass of compacted cotton on the first surface portion from passing to the second surface portion, the control preventing resumption of operation of the first cotton driver in the unloading direction until a predetermined condition is present indicative of return of a substantial amount of any loose cotton on the first surface portion to the chamber, wherein the predetermined condition indicative of return of the loose cotton to the chamber comprises folding at least the first surface portion of the unloading element to a position at least generally facing and tilted downwardly toward the chamber such that a substantial portion of any loose cotton present on the first surface portion will be returned to the chamber.

8. The unloader of claim 7 wherein the control allows resumption of operation of the first cotton driver in the unloading direction after the folding of the unloading element.

9. An unloader for a cotton compacting structure including a cotton compacting chamber, the chamber having a floor therein and an open end, the unloader comprising: an unloading element mounted to the compacting structure having a first end located adjacent to the open end of the chamber in position for receiving a mass of compacted cotton from the chamber thereon, a second end opposite the first end, a first surface portion extending between the first end and an intermediate location disposed generally between the first and second ends, a second surface portion extending between the intermediate location and the second end, a first cotton driver extending along the first surface portion, and a second cotton driver extending along the second surface portion; and an unloader control, including apparatus for selectably operating the first cotton driver in an unloading direction for moving a mass of compacted cotton over the first surface portion away from the chamber, and apparatus operable during operation of the first cotton driver for detecting passage of a trailing end of a mass of compacted cotton from the first surface portion and automatically stopping the operation of the first cotton driver in the unloading direction so as to limit loose cotton following the mass of compacted cotton on the first surface portion from passing to the second surface portion, the control preventing resumption of operation of the first cotton driver in the unloading direction until a predetermined condition is present indicative of return of a substantial amount of any loose cotton on the first surface portion to the chamber, wherein the apparatus operable during operation of the first cotton driver for detecting passage of the trailing end of a mass of compacted cotton from the first surface portion comprises an optical detector positioned and oriented for detecting the presence or absence of an object having a height which is at least about equal to a predetermined height of a mass of compacted cotton and greater than an expected height of loose cotton.

10. An unloader for a cotton compacting structure including a cotton compacting chamber, the chamber having a floor therein and an open end, the unloader comprising: an unloading element mounted to the compacting structure having a first end located adjacent to the open end of the chamber in position for receiving a mass of compacted cotton from the chamber thereon, a second end opposite the first end, a first surface portion extending between the first end and an intermediate location disposed generally between the first and second ends, a second surface portion extending between the intermediate location and the second end, a first cotton driver extending alone the first surface portion, and a second cotton driver extending along the second surface portion; and an unloader control, including apparatus for selectably operating the first cotton driver in an unloading direction for moving a mass of compacted cotton over the first surface portion away from the chamber, and apparatus operable during operation of the first cotton driver for detecting passage of a trailing end of a mass of compacted cotton from the first surface portion and automatically stopping the operation of the first cotton driver in the unloading direction so as to limit loose cotton following the mass of compacted cotton on the first surface portion from passing to the second surface portion, the control preventing resumption of operation of the first cotton driver in the unloading direction until a predetermined condition is present indicative of return of a substantial amount of any loose cotton on the first surface portion to the chamber, wherein the unloader control further includes apparatus operable during the operation of the second cotton driver for detecting presence of a leading end of a mass of compacted cotton at or near an end of the second surface portion opposite the first surface portion and changing a condition serving as a signal to an operator to move the cotton compactor in a direction for unloading the mass of compacted cotton from the second surface portion.

11. An unloader for a cotton compacting structure including a cotton compacting chamber, the chamber having a floor therein and an open end, the unloader comprising: an unloading element mounted to the compacting structure having a first end located adjacent to the open end of the chamber in position for receiving a mass of compacted cotton from the chamber thereon, a second end opposite the first end, a first surface portion extending between the first end and an intermediate location disposed generally between the first and second ends, a second surface portion extending between the intermediate location and the second end, a first cotton driver extending along the first surface portion, and a second cotton driver extending along the second surface portion; and an unloader control, including apparatus for selectably operating the first cotton driver in an unloading direction for moving a mass of compacted cotton over the first surface portion away from the chamber, and apparatus operable during operation of the first cotton driver for detecting passage of a trailing end of a mass of compacted cotton from the first surface portion and automatically stopping the operation of the first cotton driver in the unloading direction so as to limit loose cotton following the mass of compacted cotton on the first surface portion from passing to the second surface portion, the control preventing resumption of operation of the first cotton driver in the unloading direction until a predetermined condition is present indicative of return of a substantial amount of any loose cotton on the first surface portion to the chamber, wherein the unloader control includes a processor and circuitry connected to the apparatus for operating the first cotton driver and to the apparatus for detecting passage of a trailing end of a mass of compacted cotton, the processor being operable for controlling the apparatus for stopping the operation of the first cotton driver and preventing resumption of operation of the first cotton driver in the unloading direction, and the processor being further operable for controlling the apparatus for operating the first cotton driver to resume the operation thereof when the predetermined condition indicative of return of loose cotton on the first surface portion to the chamber is present, and wherein the predetermined condition comprises movement of at least the first surface portion to a position for dumping any loose cotton thereon into the chamber.

12. An unloader for a cotton compacting structure including a cotton compacting chamber, the chamber having a floor therein and an open end, the unloader comprising: an unloading element mounted to the compacting structure having a first end located adjacent to the open end of the chamber in position for receiving a mass of compacted cotton from the chamber thereon, a second end opposite the first end, a first surface portion extending between the first end and an intermediate location disposed generally between the first and second ends, a second surface portion extending between the intermediate location and the second end, a first cotton driver extending along the first surface portion, and a second cotton driver extending along the second surface portion; and an unloader control, including apparatus for selectably operating the first cotton driver in an unloading direction for moving a mass of compacted cotton over the first surface portion away from the chamber, and apparatus operable during operation of the first cotton driver for detecting passage of a trailing end of a mass of compacted cotton from the first surface portion and automatically stopping the operation of the first cotton driver in the unloading direction so as to limit loose cotton following the mass of compacted cotton on the first surface portion from passing to the second surface portion, the control preventing resumption of operation of the first cotton driver in the unloading direction until a predetermined condition is present indicative of return of a substantial amount of any loose cotton on the first surface portion to the chamber, wherein the unloader control includes a processor and circuitry connected to the apparatus for operating the first cotton driver and to the apparatus for detecting passage of a trailing end of a mass of compacted cotton, the processor being operable for controlling the apparatus for stopping the operation of the first cotton driver and preventing resumption of operation of the first cotton driver in the unloading direction, and the processor being further operable for controlling the apparatus for operating the first cotton driver to resume the operation thereof when the predetermined condition indicative of return of loose cotton on the first surface portion to the chamber is present, and wherein the unloading element comprises a foldable door arrangement and the predetermined condition is present when the door arrangement is in a folded position in at least partially closing relation to the cotton compacting chamber.

13. A control for an unloader of a cotton compacting apparatus, comprising: a first driver controllably operable for moving a compacted mass of cotton from the cotton compacting apparatus over a surface of the unloader to a first location spaced from the apparatus; a second driver controllably operable for moving the compacted mass of cotton from the first location to an end of the unloader opposite the apparatus; a device positioned and operable for determining passage of a trailing end of the compacted mass from the first location toward the end of the unloader and changing a condition to indicate the passage; and a processor and circuitry for controllably operating the first driver and the second driver, respectively, the processor and the circuitry being operable when the changed condition is present to stop the operation of the first driver for preventing loose cotton on the unloader adjacent the trailing end of the compacted mass from moving past the first location such that the loose cotton can be subsequently returned to the apparatus, the processor and the circuitry preventing resumption of operation of the first driver until a predetermined condition indicative of the return of the loose cotton to the apparatus is present.

14. The control of claim 13 wherein the device positioned and operable for determining passage of the trailing end of the compacted mass from the first location toward the end of the unloader and changing a condition to indicate the passage comprises a contact switch.

15. The control of claim 13 wherein the device positioned and operable for determining passage of the trailing end of the compacted mass from the first location toward the end of the unloader and changing a condition to indicate the passage comprises an optical detector.

16. The control of claim 13 further comprising a device positioned and operable for determining presence of a leading end of the compacted mass at or near the end of the unloader and generating a signal indicative of the presence.

17. The control of claim 13 wherein the device positioned and operable for determining passage of a trailing end of the compacted mass from the first location and changing a condition to indicate the passage comprises a device operable for counting an elapsed time of operation of the first driver or a number of rotations of the first driver.

18. A method of operation of an unloader for removing a compacted mass of cotton from a cotton compacting apparatus, comprising the steps of: providing a first driver controllably operable for moving a compacted mass of cotton from the apparatus over the surface of the unloader to a first location spaced from the apparatus; providing a second driver controllably operable for moving the compacted mass of cotton from the first location to an end of the unloader opposite the apparatus; providing a device positioned and operable for determining when the compacted mass of cotton has passed from the first location and changing a predetermined condition representative thereof; and when the changed predetermined condition is present, stopping the operation of the first driver to limit movement by the first driver of loose cotton from the apparatus past the first location while allowing operation of the second driver, and preventing resumption of the operation of the first driver for moving cotton away from the apparatus until a predetermined condition representative of return of loose cotton present on the unloader to the apparatus is present.

19. A method of operation of an unloader for removing a compacted mass of cotton from a cotton compacting apparatus, comprising the steps of: providing a first driver controllably operable for moving a compacted mass of cotton from the apparatus over the surface of the unloader to a first location spaced from the apparatus; providing a second driver controllably operable for moving the compacted mass of cotton from the first location to an end of the unloader opposite the apparatus; providing a device positioned and operable for determining when the compacted mass of cotton has passed from the first location and changing a predetermined condition representative thereof; and when the changed predetermined condition is present, stopping the operation of the first driver to limit movement by the first driver of loose cotton from the apparatus vast the first location while allowing operation of the second driver, and preventing resumption of the operation of the first driver for moving cotton away from the apparatus until a predetermined condition representative of return of loose cotton present on the unloader to the apparatus is present, wherein the unloader is foldable from an unloading position to a folded position in at least partially closing relation to an open end of the cotton compacting apparatus, and the folding to the folded position comprises the predetermined condition representative of the return of loose cotton present on the unloader to the apparatus.

20. An unloader for a cotton compacting structure including a cotton compacting chamber, the chamber having a floor therein and an open end, the unloader comprising: an unloading element mounted to the compacting structure, the unloading element being adjustably angularly positionable relative to the compacting structure and having a first end, a second end, and an intermediate location disposed generally between the first and second ends, the first end being located adjacent to the open end of the chamber in position for receiving a mass of compacted cotton from the chamber thereon and the second end being opposite the first end, the unloading element further including a first surface portion and a second surface portion, the first surface portion extending between the first end and the intermediate location and the second surface portion extending between the intermediate location and the second end, the first surface portion including a first cotton driver extending therealong and the second surface portion including a second cotton driver extending therealong; and an unloader control, including apparatus for selectably operating the first cotton driver in an unloading direction for moving a mass of compacted cotton over the first surface portion away from the chamber, and apparatus operable during operation of the first cotton driver for detecting passage of a trailing end of a mass of compacted cotton from the first surface portion and automatically stopping the operation of the first cotton driver in the unloading direction so as to limit loose cotton following the mass of compacted cotton on the first surface portion from passing to the second surface portion, the control preventing resumption of operation of the first cotton driver in the unloading direction until a predetermined condition is present indicative of return of a substantial amount of any loose cotton on the first surface portion to the chamber.

21. The unloader of claim 20, wherein the apparatus operable during the operation of the first cotton driver for detecting passage of the trailing end of the mass of compacted cotton from the first surface portion comprises a pressure sensitive device operable for distinguishing between a pressure corresponding to presence of a mass of compacted cotton and a pressure corresponding to presence of loose cotton.

22. The unloader of claim 20, wherein the apparatus operable during operation of the first cotton driver for detecting passage of a trailing end of a mass of compacted cotton from the first surface portion comprises a switch which contacts a mass of compacted cotton when passing from the first surface portion to the second surface portion, the switch changing from a first operating state to a second operating state when contact with the trailing end of the mass of compacted cotton is broken.

23. The unloader of claim 20 wherein the unloader control includes a processor and circuitry connected to the apparatus for operating the first cotton driver and to the apparatus for detecting passage of a trailing end of a mass of compacted cotton, the processor being operable for controlling the apparatus for stopping the operation of the first cotton driver and preventing resumption of operation of the first cotton driver in the unloading direction, and the processor being further operable for controlling the apparatus for operating the first cotton driver to resume the operation thereof when the predetermined condition indicative of return of loose cotton on the first surface portion to the chamber is present.

24. The unloader of claim 20 wherein the first cotton driver comprises a drag chain.

25. The unloader of claim 20 wherein the second cotton driver comprises a drag chain.

26. A control for an unloader of a cotton compacting apparatus, comprising: an unloader mounted to a compacting apparatus, the unloader being adjustably angularly positionable relative to the compacting apparatus; a first driver located on the unloader, the first driver controllably operable for moving a compacted mass of cotton from the cotton compacting apparatus over a surface of the unloader to a first location spaced from the apparatus; a second driver located on the unloader, the second driver controllably operable for moving the compacted mass of cotton from the first location to an end of the unloader opposite the apparatus; a device positioned and operable for determining passage of a trailing end of the compacted mass from the first location toward the end of the unloader and changing a condition to indicate the passage; and a processor and circuitry for controllably operating the first driver and the second driver, respectively, the processor and the circuitry being operable when the changed condition is present to stop the operation of the first driver for preventing loose cotton on the unloader adjacent the trailing end of the compacted mass from moving past the first location such that the loose cotton can be subsequently returned to the apparatus, the processor and the circuitry preventing resumption of operation of the first driver until a predetermined condition indicative of the return of the loose cotton to the apparatus is present.

27. The control of claim 26 wherein the device positioned and operable for determining passage of the trailing end of the compacted mass from the first location toward the end of the unloader and changing a condition to indicate the passage comprises a contact switch.

28. The control of claim 26 wherein the device positioned and operable for determining passage of the trailing end of the compacted mass from the first location toward the end of the unloader and changing a condition to indicate the passage comprises an optical detector.

29. The control of claim 26 further comprising a device positioned and operable for determining presence of a leading end of the compacted mass at or near the end of the unloader and generating a signal indicative of the presence.

30. The control of claim 26 wherein the device positioned and operable for determining passage of a trailing end of the compacted mass from the first location and changing a condition to indicate the passage comprises a device operable for counting an elapsed time of operation of the first driver or a number of rotations of the first driver.

31. A method of operation of an unloader for removing a compacted mass of cotton from a cotton compacting apparatus, comprising the steps of: providing an unloader, the unloader being mounted to a cotton compacting apparatus and adjustably angularly positionable relative thereto; providing a first driver, the first driver located on the unloader and controllably operable for moving a compacted mass of cotton from the apparatus over the surface of the unloader to a first location spaced from the apparatus; providing a second driver, the second driver located on the unloader and controllably operable for moving the compacted mass of cotton from the first location to an end of the unloader opposite the apparatus; providing a device positioned and operable for determining when the compacted mass of cotton has passed from the first location and changing a predetermined condition representative thereof; and when the changed predetermined condition is present, stopping the operation of the first driver to limit movement by the first driver of loose cotton from the apparatus past the first location while allowing operation of the second driver, and preventing resumption of the operation of the first driver for moving cotton away from the apparatus until a predetermined condition representative of return of loose cotton present on the unloader to the apparatus is present.

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Description

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TECHNICAL FIELD

This invention relates generally to an unloader control for a combined cotton harvester and module builder, and more particularly, to an unloader control operable for automatically detecting a condition representative of passage of a compacted cotton module from the module builder and controlling and limiting subsequent unloading of loose cotton therefrom, and a method of operation of the control.

BACKGROUND ART

It is well known for a cotton harvester to have a basket for receiving and holding the harvested cotton, and in some instances, apparatus in the basket for compacting the cotton for increasing the basket capacity. Typically, when the basket is full, or it is otherwise desired to unload the basket, the basket is positioned at an appropriate height and a door or gate on one side or end is pivoted outwardly from the basket and the contents are conveyed from the basket over the door or gate by drag chains or the like and unloaded or dumped into a waiting vehicle such as a truck or trailer for transport to another location such as a gin, or into a module builder which is separate from the harvester and operable for compacting the cotton into a densely compacted unitary cotton module. Reference in this regard, Buehler et al. U.S. Pat. No. 5,584,762, issued Dec. 17, 1996 to Case Corporation, which discloses a well known cotton harvester having a basket with a compactor and an unloading door; and Haney et al. U.S. Pat. No. 4,184,425, issued Jan. 22, 1980 to Cotton Machinery Company, Inc., which discloses a typical known separate cotton module builder.

Presently, it is desired to provide the capability to densely compact the harvested cotton into a unitary module on the harvesting machine as the cotton is being harvested, so as to eliminate the intermediate steps of compacting the cotton in a basket of the harvester then transporting either the collected cotton to a module builder or the module builder to the cotton and unloading the cotton into the module builder, and then further compacting the cotton into a cotton module. In the combined harvesting and module building machine, it is preferably desired to compact the cotton periodically in a module building chamber as it is received from the harvesting apparatus. In some instances, when the module is complete, it may still be desirable or necessary to continue harvesting until a row or section of a field is complete. As a result, a significant amount of loose or uncompacted cotton may be present in the module building chamber of the machine. This loose cotton can present a problem, as it will be present in the module building chamber and at least some part of it is likely to be unloaded with the module, which may be undesirable.

Therefore, what is sought is an unloader for a cotton module builder of a combined cotton harvester and module builder, and a control and method for operating the unloader, which effectively and conveniently contains and recovers loose cotton that may pass from a chamber of the module builder as a compacted cotton module is unloaded therefrom, such that the loose cotton is not lost and can be incorporated into a subsequent cotton module, or unloaded at a different time, as desired. The unloader will also have utility for use with the baskets of conventional cotton harvesters.

SUMMARY OF THE INVENTION

According to one preferred aspect of the invention, an unloader control for a cotton module builder or basket which provides many of the desired features discussed above, is disclosed. The preferred unloader includes an unloading element such as a door, gate, or ramp mounted to the module builder, the unloading element having a first end located adjacent to an open end of a cotton compacting chamber of the module builder in position for receiving a cotton module therefrom, an opposite unloading or second end from which the module is unloaded, and an intermediate portion or location between the ends. A first cotton driver is positioned and operable for moving cotton over a first portion of the unloading element from the chamber to the intermediate location, and a second cotton driver is positioned and operable for moving the cotton over the unloading element from the intermediate location to the second end. According to one preferred aspect of the invention, the control includes apparatus for selectably operating the first cotton driver for moving the cotton in an unloading direction over the first unloader portion toward the second portion, and apparatus operable during operation of the first cotton driver for detecting or determining passage of a trailing end of a cotton module or other mass of compacted cotton from the first unloader portion and automatically stopping the operation of the first cotton driver so as to limit loose cotton following the module or compacted mass from passing to the second unloader portion, the control preferably preventing resumption of operation of the first cotton driver in the unloading direction until a predetermined condition is present indicative of return of a substantial amount of any loose cotton on the first unloader portion to the chamber.

According to another preferred aspect of the present invention, the control includes a device positioned and operable for determining passage of a trailing end of a cotton module or other compacted mass of cotton from the first unloader portion or the intermediate location toward the second end of the unloader and changing a condition or state to indicate the passage, and a processor and circuitry for controllably operating the first driver and the second driver, respectively, the processor and the circuitry being operable when the changed condition is present to stop the operation of the first driver for preventing loose cotton on the unloader following the trailing end of the module or mass from moving past the first driver or intermediate location onto the second unloader portion such that loose cotton following the module or compacted mass can be subsequently returned to the compacting chamber, the processor and the circuitry preventing resumption of operation of the first driver in the unloading direction until a predetermined condition indicative of the return of the loose cotton to the chamber is present.

According to another preferred aspect of the invention, the unloader portions comprise components of a door, gate, or ramp arrangement unfoldable from a generally upstanding folded position in at least partially closing relation to an open end of the cotton compacting chamber, to an unfolded position forming a ramp or bridge between the chamber and a surface such as the ground onto which a cotton module or other compacted mass of cotton is to be unloaded, at least the first unloader portion being tiltable downwardly toward the chamber during folding to the folded position so as to return or dump loose cotton present on the unloader into the chamber, the folding comprising an unloading or module complete condition serving as the predetermined condition indicative of the return of the loose cotton to the chamber.

According to another aspect of the invention, the control includes a device positioned and operable for determining presence of a leading end of a cotton module or other compacted mass of cotton at or near the second or unloading end of the unloader and generating a signal indicative of the presence, to allow an operator to begin moving the module builder or other compactor in a direction opposite the unloading direction at a speed corresponding to the speed of the compacted cotton moving along the unloader, to safely unload the compacted cotton from the unloader onto the receiving surface.

Preferred cotton drivers include, but are not limited to, powered drag chains, belts, rollers, and other apparatus operable for moving a cotton module or other relatively dense mass of compacted cotton along an unloader.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a simplified side elevational view of a representative combined cotton harvesting and module building machine including an unloader which includes a foldable door arrangement and an unloader control constructed and operable according to the present invention, the door arrangement being shown in a folded position;

FIG. 2 is another side view of the machine of FIG. 1 showing the module builder tilted to an unloading position and the door arrangement of the unloader in an unfolded position, with a module of compacted cotton and a quantity of loose cotton on the door arrangement shown in phantom;

FIG. 3 is a fragmentary perspective view of the unloader showing a representative cotton driver thereof;

FIG. 4 is a simplified fragmentary side view of the machine of FIG. 1, showing unloading of the cotton module onto the unloader;

FIG. 5 is another simplified fragmentary side view of the machine of FIG. 1, showing the module in position for being unloaded onto a surface such as the ground and the loose cotton forward of the module;

FIG. 6 is another simplified fragmentary side view of the machine of FIG. 1, showing unloading of the module onto the surface and the position of the loose cotton on the unloader;

FIG. 7 is another simplified fragmentary side view of the machine showing the module unloaded and the loose cotton remaining on the unloader;

FIG. 8 is another simplified fragmentary side view of the machine showing the folding door arrangement of the unloader in a partially folded position for returning the loose cotton to the module builder;

FIG. 9 is a fragmentary side view of the unloader showing apparatus of the unloader control operable during operation of a first cotton driver for detecting passage of a trailing end of a cotton module or mass of compacted cotton from a first surface portion of the unloader;

FIG. 10 is a simplified schematic representation of aspects of a preferred control for the unloader of FIGS. 1-9;

FIG. 11 is a simplified schematic representation of aspects of another preferred control for the unloader;

FIG. 12 is a simplified rear view of the unloader showing alternative apparatus of the control operable during operation of a first cotton driver for detecting passage of a trailing end of a cotton module or mass of compacted cotton from a first surface portion of the unloader;

FIG. 13 is a simplified schematic representation of aspects of another preferred control for the unloader;

FIG. 14 is a high level flow diagram showing preferred steps of operation of the control of the unloader of FIGS. 1-13;

FIG. 15A is a high level flow diagram showing preferred steps of operation of the unloader of FIGS. 1-13;

FIG. 15B is a continuation of the high level flow diagram of FIG. 15A; and

FIG. 15C is a continuation of the high level flow diagram of FIGS. 15A and 15B.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings, in FIGS. 1 and 2, a representative self-propelled mobile cotton harvesting machine 10 is shown, including a cotton module builder 12 for building a cotton module from cotton as it is harvested by machine 10. Cotton harvesting machine 10 includes a plurality of cotton harvesting row units 14 mounted transversely across a forward end 16 of machine 10 in the conventional manner, for removing cotton from cotton plants of a cotton field as machine 10 is driven in a forward direction over the field. After the cotton is removed from the cotton plants by row units 14, the cotton is conveyed through a cotton conveyor structure 18 from the row units 14 to module builder 12. Module builder 12 includes and defines a generally rectangular cotton compacting chamber 20 enclosed at its bottom by a floor 22, at its forward end by a forward wall 24, and on its sides by side walls 26, walls 24 and 26 extending upwardly from floor 22. A cotton compactor 28 is disposed in chamber 20 above floor 22 and is movable upwardly and downwardly toward floor 22 for compacting cotton received in chamber 20 from cotton conveyor structure 18 into a compacted, unitary cotton module 30, illustrated in FIG. 2 in phantom being unloaded from module builder 12.

Importantly, machine 10 includes an unloader 32 constructed and operable according to the present invention for unloading cotton modules such as module 30 from chamber 20, and also for optionally picking up and loading cotton modules into chamber 20. Unloader 32 preferably comprises a folding door arrangement controllably operable for movement between a folded or closed position (FIG. 1) in closing relation to an open rear end 34 of module builder 12, and an unfolded or unloading position (FIG. 2) in concert with tilting of module builder 12, for unloading modules such as module 30, and for optionally picking up cotton modules, as desired.

Unloader 32 includes a primary door segment 36 having a proximal or first end 38 pivotally mounted to machine 10 or module builder 12 adjacent to open rear end 34 by a pivot 40, and a distal or second end 42 opposite first end 38. Primary door segment 36 is pivotally movable between a folded or closed position (FIG. 1) in at least partially closing or covering relation to rear end 34, and an unfolded or open position (FIG. 2) at least substantially parallel to floor 22. Unloader 32 includes a secondary door segment 44 having a proximal end 46 pivotally mounted to second end 42 of primary door segment 36 at an intermediate location between module builder 12 and a free end 50 of secondary door segment 44 by a pivot 48. Secondary door segment 44 is pivotally movable between a folded or closed position in generally side-by-side or overlaying relation to primary door segment 36 (FIG. 1), and an unfolded or unloading position aligned so as to be at least substantially coplanar with and in end-to-end relation to primary door segment 36 and floor 22.

A pair of primary door drivers 52 are pivotally connected between module builder 12 and primary door segment 36, and are operable for pivotally moving primary door segment 36 between the closed or folded position and the open or unfolded position. Primary door drivers 52 each include a fluid cylinder 54 located beside one of the side walls 26 of module builder 12 and pivotally connected at one end by a pivot 56 to module builder 12, and pivotally connected by a pivot 58 to a riser 60 attached to and extending outwardly from primary door segment 36 at a location generally between first end 38 and second end 42. Fluid cylinders 54 are retracted for positioning primary door segment 36 in the closed or folded position, as shown in FIG. 1, and are extended, as shown in FIG. 2, for positioning primary door segment 36 in the open or unfolded position.

Unloader 32 includes a pair of secondary door drivers 62 connected between primary door segment 36 and secondary door segment 44 and operable for pivotally moving secondary door segment 44 between its folded position and its unfolded or unloading position, secondary door drivers 62 each including a fluid cylinder 64 located beside door segments 36 and 44, cylinders 64 each including one end connected by a pivot 66 to door segment 36 and an opposite end pivotally connected by a pivot 68 to one end of a link element 70 pivotally connected at an opposite end by a pivot 72 to door segment 44. As will be explained, link elements 70 importantly are pivotable through a predetermined range of pivotal positions including a position as shown in FIGS. 1 and 2 extending outwardly in at least generally perpendicular relation to door segment 44, and a position generally parallel to door segment 44 (not shown) to facilitate smooth unfolding and folding of door segments 36, 44 of unloader 32.

Here, it should be noted that a compacted cotton module, such as module 30, formed and built within module building chamber 20 by module builder 12 can have a variety of shapes and sizes, as desired or required for a particular application, which shape and size will be primarily defined by the dimensions of chamber 20. Currently, a full cotton module built by a typical known cotton module builder will have width and height dimensions each of about 7 to 8 feet, and a length dimension of about 32 feet. Such cotton modules are typically built by a module builder using cotton harvested by a separate harvesting machine and brought to and deposited in the module builder. In contrast, in the present application, as noted above, module builder 12 is located on and works in conjunction with cotton harvesting machine 10 for producing cotton modules from the cotton as it is being harvested. Cotton fields can be hilly and include irrigation ditches between the rows of cotton plants, as well as naturally made ditches, swales, rivulets and the like, which can present a difficult terrain to be traversed by machine 10 during the harvesting operation. As a result, such that machine 10 is not unduly heavy and unmanageable, and has a size that is not too large and can meet current height and width restrictions on agricultural machines allowed on public roads, chamber 20 is only sufficiently large to produce a cotton module 30 of half the length of the conventional modules discussed above, or about 7 to 8 feet wide by about 7 to 9 feet tall by 16 feet long. A cotton module built by module builder 12 having these dimensions can be expected to weigh as much as 11,000 pounds.

In order to safely unload a cotton module of the above size and weight, it has been found that the unloading apparatus, such as unloader 32, should be oriented at no more than about a 25.degree. angle to a surface lower than module builder 12 onto which the module is to be unloaded. For a cotton harvesting machine with a module building capability such as machine 10, floor 22 of module builder 12 can be expected to be 4 feet or higher above a ground surface on which machine 10 is located and onto which a cotton module is to be deposited. Thus, to provide an inclined path or ramp for unloading the module onto the lower surface at less than about a 25.degree. angle, either a relatively long ramp must be used, or at least the rear end of the module builder lowered to allow using a shorter ramp. In the present instance, which is a preferred version, module builder 12 is not lowered, so unloader 32 is relatively long when unfolded, primary door segment 36 being about 8 feet long, and secondary door segment 44 being about 11 feet long for a combined length of about 19 feet. Here, it should be understood that other sizes and geometries are also contemplated according to the present invention. In regard to the present embodiment, however, it should be appreciated that for a relatively long ramp such as provided by unloader 32, and the significant weight of cotton modules such as module 30 to be conveyed thereover, door segments 36 and 44 by necessity must be of relatively strong construction, and as a result, relatively heavy. Thus, when being unfolded and folded, wherein door segments 36 and 44 are extended in essentially cantilever relation to module builder 12, substantial loading of pivots 40, 48, 56, 58, 66, and 68, as well as fluid cylinders 54 and 64 will be encountered, which loads have been observed to be sufficient to bend cylinders similar to cylinders 54 and 64.

To effect the tilting of module builder 12 to a desired angle of inclination relative to a surface onto which a cotton module is to be unloaded, or from which a cotton module is to be loaded, machine 10 includes at least one and preferably two tilt drivers 74 suitably mounted and located for tilting module builder 12 about a pivot 76 located adjacent to rear end 34. The preferred tilt driver 74 shown in FIGS. 1 and 2 is a conventional fluid cylinder including an upper end connected by a pivot 78 to a forward end of module builder 12 and an opposite end (not shown) pivotally connected to machine 10 beneath the forward end of module builder 12.

To effect forward to rearward movement of a cotton module such as a module 30 from module building chamber 20 and onto primary door segment 36, floor 20 includes at least one cotton driver 80 which preferably is a conventional drag chain operable in a forward to rearward direction for dragging or urging a cotton module within chamber 20 rearwardly, and operable in the opposite direction for moving or urging the module forwardly. Similarly, primary door segment 36 includes at least one cotton driver 82 and secondary door segment 44 includes at least one cotton driver 84, cotton drivers 82 and 84 each also preferably comprising a forwardly and rearwardly operable drag chain. Cotton drivers 80, 82, and 84 are preferably independently operable using conventional hydraulic motors, electric motors, or by connection to an engine of machine 10 or other motive source in any suitable manner.

Referring to FIG. 3, secondary door segment 44 is shown, including a plurality of spaced drag chains of cotton driver 84, which is representative also of cotton drivers 80 and 82. In this regard, it should be noted that other drivers, such as belts, caterpillars, rollers, and the like may be used as any of drivers 80, 82, and 84. It should also be noted that FIG. 3 shows a wheel 86 mounted to free end 50, for facilitating easy forward and rearward movement of secondary door segment 44 as it is being unfolded and folded, and also as a cotton module is being unloaded from or loaded into cotton module builder 12, and, likewise, that other elements, such as skids, slides, rollers, or the like, could be used to facilitate movement of free end 50 over the ground or another surface 88, as desired. Still further in reference to FIG. 3, it should be noted that pivot stops 90 are provided on secondary door segment 44 for preventing link element 70 from pivoting in the rearward direction beyond the outwardly extending position shown, and similarly, a stop 92 is provided for preventing pivotal movement of the link element in the opposite direction past about parallel to door segment 44, stops 90 and 92 being provided to achieve desired pivotal action of link elements 70 as will be explained.

Turning to FIGS. 4-8, preferred steps will be described for the unloading of a cotton module, such as cotton module 30, from chamber 20. Referring to FIG. 4, operation of cotton drivers 80 and 82 is initiated to begin moving module 30 in the rearward direction, denoted by arrow A, through open rear end 34 of module builder 12 to second end 42 of primary door segment 36. At the same time, or when module 30 is nearing or moving onto secondary door segment 44, operation of cotton driver 84 can be initiated. Referring also to FIG. 5, module 30 will then be conveyed along door segments 36 and 44 such that a rear end 94 of module 30 is brought into contact with surface 88. Referring also to FIGS. 6 and 7, at this time, machine 10 is moved in the forward direction, denoted by arrow B, at a speed substantially corresponding to the rearward speed of movement of module 30, such that module 30 is unloaded onto surface 88, without being damaged.

Referring again to FIGS. 4-6, as noted previously, often, when a cotton module is complete, it will be desirable to continue harvesting, to the end of a row or field or section of a field, the thus harvested cotton being allowed to collect in module builder 12 primarily above the module in locations such as spaces between augers or other components of cotton compactor 28, as well as spaces thereabove. When a module such as module 30 is unloaded from module builder 12, at least some of this loose cotton, denoted at 96, will be scraped from the top of the module and will fall therefrom and from cotton compactor 28 onto floor 22 and be carried or moved by cotton drivers 80 from module builder 12 in following or trailing relation to the module being unloaded. Often, it is desired to return the loose cotton to module builder 12 for compaction into a subsequently built module, or for later unloading at another location.

Also referring to FIGS. 7-9, a preferred manner of returning loose cotton 96 to module builder 12 essentially involves retaining loose cotton 96 on, or preventing passage thereof from, primary door segment 36 over an intermediate location 98 between door segment 36 and secondary door segment 44 to door segment 44 after passage of a module such as module 30 thereto (FIG. 9), then at least partially folding unloader 32 such that door segment 36 is oriented so as to extend downwardly toward open end 34 of module builder 12 such that loose cotton 96 will slide or fall therein. Referring more particularly to FIG. 9, to prevent passage of loose cotton 96 from primary door