In order to evaluate the quality of certain fibrous materials, such as cotton, before sale, a sample of the material from each bale is provided to an evaluating agency, typically a division of the USDA. This evaluation called ‘grading’ allows a bale to be sold to customers without the entire product being seen. Further, before large quantities of the fibrous materials are stored for later sale, samples of the material may be obtained to be provided to perspective customers for testing, rather than transporting an entire bale to the perspective customer.
Conventional methods for obtaining a sample from every bale requires intense manual labor with workers having to physically tear one or more samples, typically two, of material from the same bale and insert them into a bag or sleeve. In certain applications, a cutter is used to pre-cut a sample during a bale pressing and forming process for later manual removal by a worker. Not only are workers prevented from completing other tasks while they are obtaining samples, but repeating the same motion for long periods of time may lead to chronic injuries. Further, manually obtaining the samples increases the likelihood that the resulting samples will be nonuniformly sized, will be contaminated by substances on the workers hands, and will be more costly due to the added labor expense.
The present disclosure provides a bale cutter assembly and associated method for automatically cutting a bale of fibrous material to allow for the taking of a sample at a single point from one or two sides of the bale. Generally, the bale is to be cut after the bale has been conveyed from the bale press with the bale retention straps in place.
In one aspect, a system for cutting a bale of fibrous material is provided which includes a transportation mechanism for moving a bale of fibrous material from a first position to a second position; and a plurality of cutter assemblies for creating at least one cut section on the bale as the bale is moved between the first position and the second position.
In another aspect, a system is provided for cutting a bale of fibrous material including an elevator mechanism for lifting a bale of fibrous material from a lower level to an upper level; and a plurality of cutter assemblies for creating a cut section of the bale for obtaining a sample from the bale when the bale is being lifted between the lower level and the upper level. At least one of the cutter assemblies includes a cutting blade.
In yet another aspect, a method is provided for cutting a bale of fibrous material. The method includes moving a bale from a pre-cut position to a post-cut position; moving a first cutter unit against a first side of the bale; and cutting a surface of the first side of the bale to create a cut section of the bale.
In yet another aspect, a method is provided for cutting a bale of fibrous material including moving a first cutter unit against a first side of a bale; and substantially simultaneously moving a second cutter unit against a second side of the bale to cause a pressing surface of the first and second cutter units to apply a controllable force against the bale as the bale is elevated from a first level below the first and second cutter units to a second level above the first level. The method also includes cutting a surface of either the first side or the second side of the bale to create a cut section of the bale as the bale is elevated from the first level to the second level.
Other aspects and variations of the bale cutter assembly summarized above are also contemplated and are more fully understood when considered with respect to the following disclosure.
The detailed description set forth below in connection with the appended drawings is intended as a description of embodiments of the bale cutter assembly provided in accordance with aspects of the present disclosure and is not intended to represent the only forms in which the present disclosure may be constructed or used. The description sets forth the features and the steps for using the bale cutter assembly of the present disclosure in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent functions and structures may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the disclosure. As denoted elsewhere herein, like element numbers are intended to indicate like or similar elements or features.
Obtaining samples from bales before the bales are bagged or otherwise encased in a protective covering ensures that the integrity of such protective covering remains intact. A system for sampling a bale of fibrous material is disclosed in U.S. Publication No. 2009/0188332 A1, Ser. No. 12/360,025, the contents of which are expressly incorporated herein by reference, which was also previously incorporated by reference in provisional application No. 61/308,789. Generally, a sample is formed during the pressing process using a cutting protrusion, such as a blade or knife mounted on a support structure. This cutting protrusion is forced into the fibers, severing them from the cohesive, intertwined body of the bale. Since the sample will be removed, it is practical to cut the sample between the areas where bale retention straps are typically placed. The cut sample typically bulges from the side of the bale when the pressing force is removed since it is not bound to its neighboring fibers contained by bale retention straps.
As shown in
In one embodiment, the terminating ends of rails 103a and 103b extend from an end of the conveyor 103 in a cantilevered arrangement absent of the cylinders, belt driver or the like. A space is maintained between the cantilevered portions of the rails 103a and 103b large enough to allow for a platform 107 of elevator mechanism 106 to be positioned between the cantilevered rails. The platform 107 is configured and sized to receive the bale 102 thereon and to be raised, as further discussed below. The elevator mechanism 106 also includes a bumper stop 108. The bumper stop 108 is provided to impede the momentum of the bale 102 as it moves from the conveyor 103 onto the platform 107. Once the bale has reached the bumper stop 108, the bale 102 is fully seated on the platform 107 and is ready for further processing as described below.
In one embodiment, the elevator mechanism 106 may be any conventional lifting mechanism, for example, a scissor lift mechanism with a support surface may be used to raise and lower the bales. As one of ordinary skill in the art will appreciate, a hydraulic, pneumatic, or electro-mechanical cylinder or motor with a belt/chain may also be used to raise or lower the support platform 107, which may move vertically along rails, guides, tracks, or other suitable transportation means, if needed.
With further reference to
As further described in detail below, each of the plurality of cutter units 114 is mounted at one end at a predetermined position along the lower horizontal support member 118 with the operational or cutting portion of each cutter unit 114 facing inward or toward the center of frame 115. At the other end, the cutter units 114 are each mounted to the upper horizontal support member 119 via an actuation device 120, such as a hydraulic piston, an air cylinder, a mechanical drive or a similar mechanism, located at a corresponding predetermined position. Actuation device 120 creates the “cutting” or “pressing” force for each cutter unit 114 to operate in accordance with the present disclosure, as described below.
In one embodiment, holes 220 are defined at each bottom end 214 of the blocks that are sized and configured to receive the support member 118 therethrough to mount the cutter unit 114 to the frame 115 (see
When activated, the actuation device 120 causes the top end 212 to rotate towards the internal center of the frame 115, and the bottom end 214 to pivot about the horizontal support member 118 to which it is attached. This may be accomplished by allowing the support member 118 to rotate within the holes 220 or else by allowing the support member 118 to rotate on bearing surface 123 on the flange 121 (
Each cutter unit 114 may also include a plurality of cutting blades 224 with at least one cutting blade 224 positioned on each block 202 and 204. The cutting blades 224 are configured to be forced into the fibers, severing them from the cohesive, intertwined body of the bale 102. Each cutting blade 224 is mounted at a location directly adjacent a corresponding cutting blade positioned on the opposing block. However, in a preferred embodiment, only two of the four cutting units are equipped with blades while the other two units merely provide an opposing force to prevent tilting or turning the bale during cutting, as further discussed below. Because blocks 202 and 204 are separated by the length L of space 206, the cutting blades 224 mounted thereto are also separated by the same length. This length L defines the width of the cut. The cutting blades 224 are configured such that a portion of each blade extends, protrudes or is extendible beyond the pressing surface 217, allowing the cutting blade 224 to contact any object that is made to contact the pressing surface 217, such as the bale 102. In one embodiment, each cutting blade 224 may include a mounting member 226 that is configured to be slidably mounted within a slot 228 defined at a predetermined position on the two blocks 202 and 204. The length of the slot 228 is formed perpendicular to the front face 216 of each block, thus, as the mounting member 226 is moved toward the end of the slot 228 closest to the front face 216, the cutting blade 224 is in a fully extended position. Conversely, as the mounting member 226 is moved toward the end of the slot 228 closest to the rear face 218, the cutting blade 224 is in a fully retracted position. One of ordinary skill in the art will appreciate that by sliding the mounting member 226 within the slot 228, the depth of each cut rendered by the cutting blades 224 may be adjusted. In one embodiment, the cutting blades 224 may be circular or rotating blades that can be made to roll across the surface to be cut. The mounting members 226 may traverse within the slots by an actuating air cylinder. Alternatively, the blades may be held stationary (i.e., not rotated and/or not translated within the slots) and the cutting motion on the bale is provided by the elevator mechanism as it raises the bale. In one embodiment, as shown in
It should be understood however that the cutting blades 224 may be any suitable blade, of any suitable geometry that concentrates all or most of the force onto a very small area, resulting in a high amount of pressure, which allows the blade to penetrate the fiber material.
Referring again to
As shown in
As shown in
As shown in
A pusher mechanism 316 is configured to run within a track 318 disposed along the top of the frame 115. When the bale 102 with the cut sections 310 and 312 is lifted to the full extent of the elevator mechanism 106, the pusher mechanism 316 is activated to push the bale 102 from the raised platform 107 to a waiting conveyor (not shown) to be transported away from the bale cutter assembly 100 for further processing.
To facilitate an understanding of the embodiments of the bale cutter assembly 100 and associated method of the present disclosure, it should be understood that, in one embodiment, the bale cutter assembly 100 is intended to operate within the general architecture and operation of a bale sampler, such as the bale sampler disclosed and described in Ser. No. 61/023,812, previously incorporated herein. The bale sampler obtains and packages samples of a fibrous substance from a bale. More specifically, hale sampler may automatically obtain a sufficiently and relatively uniformly sized sample from both sides of a bale at nearly any location along the bale and, if desired, insert the two samples into a bag or two separate bags.
In yet another embodiment, the bale cutter assembly 100 may be incorporated into, and is intended to operate within the general architecture and operation of a bale bagging system, such as the bale bagging system disclosed and described in U.S. Provisional Application Ser. No. 61/033,376, filed Mar. 3, 2008, the contents of which are explicitly incorporated herein by reference for all purposes.
In one exemplary embodiment, a cutting assembly 104 is incorporated into bale bagging system 400 to cut a bale 102 as the bale is raised by elevator mechanism 106 into the bagging chute 423. For clarity, the side view shown in
As shown in
The pusher mechanism 316 is configured to run within the track 318 disposed along the top of the system. When the bale 102 is lifted to the full extent of the elevator mechanism 106, the pusher mechanism 316 is activated to push the bale 102 from the platform 107 to the chute 423 to be transported away from bale cutter assembly 100 for further processing. In an alternative embodiment, once the bale is raised to the appropriate height, it is simply pushed off by the pusher assembly 146.
Although embodiments of the cutting assembly have been specifically described and illustrated, many modifications, combinations, and variations of the embodiments will be apparent to those skilled in the art. Accordingly, it is to be understood that the illustrated embodiments have been set forth only for the purposes of examples, and that the embodiments should not be taken as limiting the disclosure as defined by the following claims. The following claims are, therefore, to be read to include not only the combination of elements which are literally set forth, but all equivalent elements for performing substantially the same function in substantially the same way to obtain substantially the same result. The claims are thus to be understood to include those that have been illustrated and described above, those that are conceptually equivalent, and those that incorporate the ideas of the present disclosure.
This application claims the benefit of U.S. provisional Application No. 61/308,789, filed Feb. 26, 2010, the contents of which are hereby incorporated by reference for all purposes.
Number | Date | Country | |
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61308789 | Feb 2010 | US |