Patent Application
20160000016
The invention relates to the field of agricultural balers for producing bales of compressed agricultural crop material. More specifically, the present invention relates to large balers with a heavy flywheel (e.g. 700 kg).
The vast majority of balers does not have its own engine, but is towed by a tractor, and is powered by coupling the power take-off (PTO) shaft of the tractor to an input shaft of the baler. The baler further has a flywheel connected to the input shaft, and a gearbox that drives the various mechanisms in the baler to pick-up the crop from a field, to form the crop into bales and to wrap twine and/or foil around the bales.
A one-way clutch is typically arranged between the PTO shaft and the flywheel to allow the flywheel to rotate faster than the PTO shaft. The baler input shaft can be operatively decoupled from the tractor PTO, e.g. for transportation of the baler from one field to the other.
A large and heavy flywheel is typically required in a baler, especially in so called “large square balers”, or “high density balers” to overcome peak loads encountered by the baler gearbox, which occurs e.g. when the plunger of the baler compresses the crop material in the bale chamber when forming the bales. By using a flywheel with a high inertia and running at a high speed (e.g. 1000 rpm), peak energy for the peak loads can be delivered by the flywheel, which slightly slows down during each compression, and which is accelerated again by the tractor PTO between two compressions.
When all the crop material of one field is processed, the baler is shut down for safety reasons before being transported to another field. When the baler (i.e. the flywheel and the various mechanisms connected thereto) has come to a stop, it is known in the art to keep the flywheel (and the various mechanisms along with it) in a fixed position by using a belt which is tensioned around a section of the flywheel.
It is important to keep the flywheel in a fixed position during transport, because objects or people wearing loose clothing that may come too close to the baler might get caught in the moving parts. This is especially important with heavy flywheels (e.g. 700 kg) and heavy crank arms (e.g. 150 kg), which may cause the flywheel to turn under their weight, or due to acceleration or deceleration of the tractor, or inclination of the road.
It may be even more important to keep the flywheel in a fixed position when an operator is working on the baler, e.g. during maintenance or repair.
As the flywheel becomes larger and heavier, the belt and fastener do not guarantee sufficient safety anymore. Moreover, improper handling of the belt can cause dangerous situations.
It is an object of embodiments of the present invention to provide a baler with a good safety.
In particular, it is an object of embodiments of the present invention to provide a baler with a safe mechanism for holding the flywheel in a fixed position during transport.
In a first aspect, the present invention provides an agricultural baler, comprising a shaft for coupling with a power take-off; a flywheel connected to the shaft; and a brake system comprising a disc brake system and/or a drum brake system adapted for braking the flywheel.
Whereas a belt was useful for holding small flywheels in position, this is not the case anymore for heavy flywheels, having weight of e.g. 700 kg. By adding a brake system comprising a disc brake and/or a drum brake to the baler, a baler with a highly reliable and safe brake system is provided, not only for holding the flywheel in a fixed position, but also for slowing down the flywheel when the baler is switched off. Even when the brake is operated manually, the flywheel can be controlled accurately and securely.
Disc brake systems and drum brake systems are mature components with a well-known reliability, and manageable wear issues. By adding a disc brake system or a drum brake system to the baler flywheel, the safety of the baler is largely increased, not only during transportation or while being parked, but also during maintenance or repair, as the risk that the flywheel would suddenly move because of shocks or vibrations is reduced or suppressed.
A huge advantage of the disc brake system or drum brake system is that it not only guarantees a fixed maintained position of the flywheel, but in addition, can also be used for slowing down a moving flywheel. This was simply not possible with the belt. By offering the ability to actively slow down the baler, instead of having to wait until the baler has come to a full stop by itself, time (e.g. on the field) can be more efficiently used. Alternatively, the safety of the baler operators is increased, especially for those cases where the baler was already torn away before it had come to a complete stop, or late at night, after a hard day of work.
Furthermore, the disc brake system or drum brake system is especially useful in emergency situations, because it allows the flywheel, and the various baler mechanisms, to be stopped much faster than was possible in the past, and moreover, in a safe and reliable way, without damaging the machine, or parts thereof.
An advantage of a disc brake system is that the force exerted by the brake is adjustable. Thus, if desired, a relatively low force can be applied for moderately braking the flywheel, at moderate wear during daily work. But in cases of emergency, the flywheel can be stopped at maximum force, in a minimum amount of time. It is clear that in such cases having a disc brake on the flywheel or not can make the difference between life and death.
In embodiments of the agricultural baler the brake system comprises a drum brake system.
In embodiments of the present invention, the brake system can be a drum brake system. In another embodiment, the brake system can be a disc brake system comprising a drum brake system (e.g. for hand brake purpose). A particular advantage of drum brake systems is that they are less expensive to manufacture than disc brake systems, and they easily incorporate an emergency mechanism, which can be actuated by a different power source than the primary braking system, e.g. by a cable actuation mechanism. The cable may e.g. be connected to a handbrake lever.
In embodiments of the agricultural baler, the disc brake system is a caliper-type disc brake system, comprising a brake disc and a brake caliper.
A particular advantage of a disc brake system and in particular of a caliper-type disc brake system is that it contains less parts than a drum brake system, and is easier to maintain. Other advantages are that the braking force is adjustable and proportional to the pressure placed on the brake pads, and that a disc brake system such as a caliper-type disc brake system cannot block because of lack of self-assist.
In embodiments of the agricultural baler, the brake disc is mounted on the flywheel.
This has the advantage that the braking forces and braking heat can be directly transferred to the flywheel, and stress exerted on the shaft can be reduced.
In embodiments of the agricultural baler, the centre of mass of the brake disc coincides with the centre of mass of the flywheel.
In this way, the flywheel and brake disc are better balanced, which further reduces stresses and wear of the shaft.
An agricultural baler according to embodiments of the present invention may further comprise a gearbox, and the brake caliper may be mounted to the gearbox.
This offers the advantage that the forces acting upon the brake caliper are transferred to the gearbox, which is a rigid and high strength part of the baler, well capable of withstanding these forces, without breaking off, thus enhancing the safety. In addition, vibrations, wear and tolerances can be kept well under control.
An agricultural baler according to embodiments of the present invention may further comprise a handle connected to the brake system via a cable.
The handle may be a handbrake lever for manually stopping the flywheel, or for fixing the position of the flywheel. In an embodiment, the handle has a toothed segment for blocking its position in one of several alternative positions, and a push-button for releasing it from this blocked position. This may be particularly useful as an emergency brake, since it can be operated manually.
In embodiments of the agricultural baler, the brake system comprises a hydraulic brake system, and the baler further comprises a hydraulic circuit fluidly connected to the brake system, and further comprises a brake controller for activating and deactivating the brake system.
In this embodiment, very large forces can be exerted on the brake system, resulting in a very large braking force for the flywheel, which is decelerated much faster, while only minimal effort is required for operating it (a child can operate it). This further improves the safety. Moreover, it allows the activation to be done remotely, e.g. from the tractor, which further increases the safety, because time can be gained by not having to leave the tractor, time which may not be available in case of emergency. Furthermore, the brake controller may communicate with a tractor controller, and may e.g. prohibit baler startup as long as the flywheel brake is active.
An agricultural baler according to embodiments of the present invention may further comprise an emergency stop input device connected to the brake controller, and the brake controller may be adapted for activating the brake system with at least a predetermined braking force.
When receiving a ‘brake’-command from the emergency stop input device, the controller would apply the maximum allowable braking force, so as to bring the flywheel and the various baler functions to a stop as soon as possible.
In embodiments thereof, the agricultural baler further comprises a sensor connected to the brake controller, and is further adapted for detecting if a door of the baler is opened, and for sending a signal to the brake controller for stopping the flywheel when the door is opened.
In this way the flywheel is automatically stopped when a door or a panel of the baler is opened. This again enhances the safety.
In a second aspect, the present invention provides a baler flywheel assembly, comprising a flywheel and a brake system mounted on the baler flywheel, the brake system comprising a disc brake system and/or a drum brake system.
This flywheel assembly is an integrated part of one of the embodiments of the baler according to the invention.
In embodiments of the baler flywheel assembly, the centre of mass of the brake disc substantially coincides with the centre of mass of the flywheel.
In a third aspect, the present invention provides a baler gearbox assembly, comprising a baler gearbox and a baler flywheel assembly according to the second aspect, mounted to the baler gearbox, wherein the brake system is a caliper-type disc brake system comprising a brake disc and a brake caliper, the brake caliper being mounted to the baler gearbox for engaging with the brake disc of the baler flywheel assembly.
This gearbox assembly is a further integrated part of a baler according to embodiments of the invention.
In a fourth aspect, the present invention provides a tractor and baler combination, comprising an agricultural baler according to the first aspect; a tractor having a PTO connectable to the shaft of the baler for accelerating the flywheel of the baler and wherein the tractor further comprises a tractor controller circuit for sending a command to the brake controller for activating the brake system.
This allows commands for stopping the flywheel to be sent by the tractor driver remotely, without having to step towards the baler. This is faster, safer, and more convenient. Such brake controller may also incorporate additional functionality such as checking if the brake is deactivated before allowing the PTO shaft to be coupled.
Particular and preferred aspects of the invention are set out in the accompanying independent and dependent claims. Features from the dependent claims may be combined with features of the independent claims and with features of other dependent claims as appropriate and not merely as explicitly set out in the claims.
These and other aspects of the invention will be apparent from and elucidated with reference to the embodiment(s) described hereinafter.
The invention will be further elucidated by means of the following figures.
The drawings are only schematic and are non-limiting. In the drawings, the size of some of the elements may be exaggerated and not drawn on scale for illustrative purposes.
Any reference signs in the claims shall not be construed as limiting the scope.
In the different drawings, the same reference signs refer to the same or analogous elements.
The present invention will be described with respect to particular embodiments and with reference to certain drawings but the invention is not limited thereto but only by the claims. The drawings described are only schematic and are non-limiting. In the drawings, the size of some of the elements may be exaggerated and not drawn on scale for illustrative purposes. The dimensions and the relative dimensions do not correspond to actual reductions to practice of the invention.
Furthermore, the terms first, second and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequence, either temporally, spatially, in ranking or in any other manner. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the invention described herein are capable of operation in other sequences than described or illustrated herein.
Moreover, the terms top, under and the like in the description and the claims are used for descriptive purposes and not necessarily for describing relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the invention described herein are capable of operation in other orientations than described or illustrated herein.
It is to be noticed that the term “comprising”, used in the claims, should not be interpreted as being restricted to the means listed thereafter; it does not exclude other elements or steps. It is thus to be interpreted as specifying the presence of the stated features, integers, steps or components as referred to, but does not preclude the presence or addition of one or more other features, integers, steps or components, or groups thereof. Thus, the scope of the expression “a device comprising means A and B” should not be limited to devices consisting only of components A and B. It means that with respect to the present invention, the only relevant components of the device are A and B.
Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments.
Similarly it should be appreciated that in the description of exemplary embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims following the detailed description are hereby expressly incorporated into this detailed description, with each claim standing on its own as a separate embodiment of this invention.
Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those in the art. For example, in the following claims, any of the claimed embodiments can be used in any combination.
In the description provided herein, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.
Where in embodiments of the present invention reference is made to “rectangular baler” reference is made to an agricultural baler for making cuboid bales.
Where in embodiments of the present invention reference is made to “high density bales”, bales with a density higher than 100 kg/m3, for example higher than 190 kg/m3 are meant.
In the present invention, “centre of gravity” and “centre of mass” are used as synonyms.
Where in embodiments of the present invention reference is made to a “brake system”, reference is made to a device for slowing or stopping the rotation of a wheel while it is in motion. In this application reference is made to disc brake systems (such as the caliper-type of disc brake systems), as well as drum brake systems. The caliper-type of disc brake comprises a brake disc and a caliper, the brake caliper comprising two brake pads to be forced to the sides of the disc.
Agricultural balers, of the type that can be towed and powered via a tractor PTO are known in the art. Referring to the drawings,
A plunger 13 reciprocates in a fore-and-aft direction within the bale chamber 80, at least within a first part thereof. Biomass fed via the feeder duct 28 is thereby compacted, e.g. compressed or otherwise treated, so as to form bales in the above-described operation of the agricultural baler 70. Cuboid shaped bales, also known as “rectangular bales” are formed. The formed bales may then be moved forward by the reciprocating motion of the plunger 13 to shift serially and incrementally along the bale chamber 80 towards a discharge outlet, wherefrom the bales may eventually be ejected. The baler 70 may furthermore comprise components such as a knotter mechanism for automatically tying the completed bales with e.g. twine or similar lineal object to make them self-supporting, for example for shipping and storage. Once tied, the bales are discharged from the discharge outlet of the bale chamber 80 onto a discharge 31 in the form of a chute, generally designated 31, for gently lowering the bales near ground level.
Large balers 70, especially rectangular balers 70 for producing high-density bales have a flywheel 2 with a relatively large diameter (e.g. in the range of 75 to 130 cm, e.g. 110 cm) and heavy weight (e.g. in the range of 300 to 1000 kg, e.g. 700 kg) for obtaining a high inertial mass or energy equivalent. When all crop material of one field is compacted into bales, the baler 70 is temporarily stopped, e.g. by decoupling or disabling the tractor PTO. While running freely, the flywheel 2 will slow down until it stops, and the related functions, such as the pick-up, packer or stuffer mechanism are deactivated along with the flywheel 2. When the baler 70 is stopped, e.g. temporarily on the field before being transported to another field, or e.g. permanently when parked in a barn, or e.g. for maintenance in a garage, it is important that the flywheel 2 cannot accidentally rotate, e.g. under the weight of the crank 6, or e.g. due to shocks or vibrations.
It is known in the art to block the flywheel by means of a belt, e.g. made from leather, but the use of such a belt has several disadvantages, e.g. the belt is subject to wear, and cannot and should not be tensioned while the flywheel 2 is still moving. A more reliable mechanism for holding the flywheel 2 is therefore desired.
While looking for a more reliable mechanism for holding a flywheel 2 (especially a large and heavy flywheel 2), the inventors came up with the idea of adding a brake system 40 comprising a disc brake system 40 and/or a drum brake system 40 to the flywheel 2. As far as known to the inventors, no agricultural balers 70 with such a brake system for keeping the flywheel 2 in a fixed position, exist yet. Balers 70 may have other brakes, such as brakes for stopping a wrapping roll, or brakes for stopping the conveyer, but these brakes are required for its normal operation. A brake system 40 (according to embodiments of the invention) mounted to the flywheel 2 is not required for its normal operation. On the contrary, whereas disc brake systems 40 and drum brake systems 40 are known and very much used for stopping moving vehicles, such as automobiles and trains, they are not used in the field of agricultural balers 70 for stopping the flywheel 2. There is a general acceptance in the field of agricultural balers 70 that balers 70 have a flywheel 2 with a large inertia, which needs a significant time to come to a complete stop. Everyone also knows and it is generally accepted that it may be dangerous to approach a baler 40 before it has come to a full stop.
By providing a brake system 40, not only the problem of holding a large and heavy flywheel 2 in a fixed position is solved, but in addition, the brake system 40 adds the ability to actively slow down the flywheel 2 when the baler 70 is switched off. This has the advantage that the switch-off of the baler 70 may be considerably faster and the use of the baler 70 may be considerably safer.
Such a baler flywheel arrangement is schematically illustrated in
It is noted that
Several embodiments are described next. In
Caliper-type disc brakes 40 have the advantage (e.g. over drum brake systems (40)) that the braking can be better controlled, because the braking force is proportional to the pressure placed on the brake pad 58 by the braking system 40, e.g. via any brake servo, braking pedal or lever, and a caliper-type disc brake system 40 cannot block because of lack of self-assist. Drum brake systems (40) may be cheaper.
Common to all embodiments is the brake disc 41 having a smooth, e.g. machined side portion adapted for contacting brake pads 58. The brake caliper 51 is preferably mounted to the gearbox 46 (see
The brake caliper 51 of
Instead of providing a single caliper 51, it is also possible to provide multiple, e.g. two or three or more brake calipers 51. This has the advantage that the total braking force exerted upon the flywheel 2 can be increased, and consequently that the time needed to stop the flywheel can be decreased. By distributing the brake calipers 51 at 180° (in case of two calipers), or at 120° angular distance (in case of three calipers), etc, the forces exerted upon the shaft 3 during braking may also be reduced, because the friction forces exerted upon the brake disc 41 would be approximately equal in size, but having different directions, thus forming no net force, but a moment. Another advantage would of course be that in case of failure or malfunction of one of the brake calipers, the others would still function, thus increasing the safety of the baler.
In the examples shown in
| Number | Date | Country | Kind |
|---|---|---|---|
| BE2013/0118 | Feb 2013 | BE | national |
This application is the US National Stage filing of International Application Serial No. PCT/EP2014/0053068 filed on Feb. 18, 2014 which claims priority to Belgian Application BE2013/0118 filed Feb. 21, 2013, each of which is incorporated herein by reference in its entirety.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2014/053068 | 2/18/2014 | WO | 00 |
