Tobacco bale slicing apparatus and method

Information

  • Patent Grant
  • 6334447
  • Patent Number
    6,334,447
  • Date Filed
    Tuesday, January 18, 2000
    24 years ago
  • Date Issued
    Tuesday, January 1, 2002
    22 years ago
Abstract
The present application relaxes to a tobacco bale splitting apparatus for splitting a bale of compressed tobacco having a plurality of generally parallel tobacco leaves having stems The present application also relates to a method of splitting a tobacco bale.
Description




The present invention relates to an apparatus for slicing leaf tobacco bales.




Leaf tobacco bales are typically maintained in a highly compressed state which has many advantages over other methods of packing tobacco. One advantage is that the compressed leaves retain moisture longer than they would in a non-compressed state which makes conditioning arid separating the tobacco leaves easier. After tobacco is picked, it is cured in an environment in which the humidity, temperature and other environmental variables are tightly controlled which allows the tobacco to cure without excessive desiccation. Once the proper curing and moisture content is established, the leaves are packed for shipment from the farm or baling site to a processing site. Packing the leaves in leaf bale assemblies maintains the moisture content in a manner superior to wrapping the leaves in sheets so the leaves can be conditioned and separated without undergoing the conventional vacuum conditioning step, the advantages of which will be described hereinbelow. Another advantage to compressing the leaves is that compressed leaves take up less storage space than do non-compressed leaves which results in substantial savings in storage and transportation costs when the tobacco is shipped for later processing. The bale assemblies can also be easily loaded into and out of a vehicle using a forklift and can be stacked, thus requiring less storage space.




This method of packaging tobacco leaves is an improvement over the traditional methods of packing leaves for processing including the conventionally used method of transporting the tobacco leaves wrapped in sheets of material. According to this method, approximately 300 tobacco leaves are placed on a burlap sheet, the sheet is wrapped around the tobacco to form a loose bundle and the bundle is tied. Tobacco packaged in this manner is sometimes referred to as “sheeted tobacco”. This loose method of packing the tobacco exposes the leaf surfaces to the ambient atmosphere which allows water vapor to escape from the leaf at a rate faster than that for compressed leaves and this is a reason why the conventional method of conditioning sheeted tobacco includes a vacuum conditioning step. This loose method of packing in sheets also increases handling and transportation costs and requires greater storage volume prior to processing.




Although this method for packing tobacco in tobacco bale assemblies enables the tobacco producer or processor to reduce transportation costs and better protect the leaves and maintain the moisture content thereof, the tobacco arrives at the processing site for conditioning in a highly compressed state. To make the processing easier, it is often desirable to split the bales into slices before the tobacco is processed. To make the baled leaves more amenable to conditioning, a tobacco bale splitter assembly constructed in accordance with the principles of the present invention can be used for splitting these dense bales into a plurality of slices.




Bale splitter assemblies have been conventionally used for separating bales of “strip” tobacco into smaller slices for processing. Strip tobacco is processed tobacco broken down into small particles with the stems removed. Typical bale splitters use a plurality of prongs which penetrate the strip tobacco bale and separate a slice therefrom. Separating a bale slice from a strip tobacco bale is relatively easy because the tobacco has already been processed and the stems removed. In fact, oftentimes the bale will tend to split along “grains” defined by the compressed tobacco within the bale.




In contrast, conventional bale splitters are not readily adapted to split bales of leaf tobacco in an effective manner. The presence of stems in leaf tobacco bales presents certain difficulties to conventional bale splitters. Bale splitters which penetrate the bale with only one set of prongs and lift off the slice are unsatisfactory because the nature of the leaves and stems will result in an unclean separation. In fact, as the splitter nears the bottom of the bale, the entire remainder of the bale may be lifted instead of separating a slice because of the strength of the stems extending between the slice to be cut and the portion remaining.




Conventional bale splitters which use a pair of cooperating sets of prongs are also unsatisfactory because the two sets penetrate the bale on the same plane. The idea of this type of arrangement is to hold one set of prongs stationary while the other set separates the slice, thereby providing a cleaner separation than would be realized with one set of prongs. However, because the sets of prongs penetrate the bale on the same plane, the stems will intertwine with the two sets and make separation difficult. Due to the intertwining, more power is needed to sever the stems to effect full separation of the slice. In fact, experimentation has shown that the prongs can even bend if enough stems become intertwined.




One method for splitting tobacco leaf bales is to sever a slice from the bale in the vertical direction using a guillotine-like blade. One problem with such an arrangement is that the blade must be kept sharpened for proper use. If the blade is not kept sharpened, the blade will compress and deform the bale on its cutting stroke rather than cut through the bale. This compression and deformation can damage the tobacco and create difficulties in handling the bale. Also, the costs and maintenance associated with such an arrangement is also rather high.




Therefore, it is an object of the present invention to provide a bale slicing apparatus which can effectively separate slices from bales of leaf tobacco. In order to achieve such an object, there is provided a tobacco bale slicing apparatus for slicing a bale of compressed tobacco having a plurality of generally parallel tobacco leaves having stems. The apparatus comprises first bale penetrating structure having a plurality of prongs constructed and arranged to penetrate the bale generally parallel to the flattened tobacco leaves. Second bale penetrating structure has a plurality of prongs constructed and arranged to penetrate the bale generally parallel to the flattened tobacco leaves.




A penetrating structure moving assembly has structure constructed and arranged to (1) move the first penetrating structure generally perpendicularly relative to the flattened tobacco leaves to a first pre-penetrating position wherein the prongs thereof are disposed outside of the bale and at a first level spaced generally perpendicularly to the tobacco leaves from an edge of the bale and corresponding to a desired thickness of a bale slice to be separated from the bale and (2) move the second penetrating structure generally perpendicularly to the flattened tobacco leaves to a second pre-penetrating position wherein the prongs thereof are disposed outside of the bale and at a second level offset relative to the first level in a direction extending generally perpendicularly to the tobacco leaves. The penetrating structure moving assembly has structure constructed and arranged to move the bale penetrating structures from the respective first and second pre-penetrating positions generally parallel to the flattened tobacco leaves to respective first and second penetrated positions wherein the first and second penetrating structure prongs penetrate the bale at the first and second levels so as to define the aforesaid bale slice of the desired thickness and a remaining portion of the bale.




The penetrating structure moving assembly having structure constructed and arranged to move the first and second bale penetrating structures relatively away from one another generally perpendicularly to the flattened tobacco leaves so as to separate the bale slice from the remaining portion of the bale after the first and second penetrating structure prongs have penetrated the bale. A bale slice moving assembly has structure constructed and arranged to move the separated bale slice away from the remaining portion.




According to another aspect of the present invention there is provided a method for slicing a tobacco bale having a plurality of generally parallel flattened tobacco leaves. The method comprises the steps of providing a first bale penetrating structure having a plurality of prongs and a second bale penetrating structure having a plurality of prongs. The first penetrating structure is moved generally parallel to the flattened tobacco leaves so that the prongs thereof penetrate the bale at a first level spaced generally perpendicularly to the tobacco leaves from an edge of the bale and corresponding to a slice of desired thickness to be separated from the bale. The second penetrating structure is moved generally parallel to the flattened tobacco leaves so that the prongs thereof penetrate the bale at a second level offset relative to the first level in a direction extending generally perpendicular to the flattened tobacco leaves. The first bale penetrating structure is moved relatively away from the second bale penetrating structure generally perpendicularly to the flattened tobacco leaves so as to separate the slice of desired thickness from the bale. Then, the slice is moved away from the bale.




According to yet another aspect of the present invention, there is provided a method for processing a compressed tobacco bale having a plurality of substantially whole, generally parallel flattened tobacco leaves with stems. The method comprises the following steps. Successive portions are removed from the bale to be conditioned. The removed portions are successively supplied in substantially the form removed from the bale to an interior of a rotatable direct conditioning cylinder. The cylinder has a plurality of tobacco separating structures on the interior thereof. The direct conditioning cylinder is continuously rotated so that the tobacco separating structures break up the successively supplied portions by lifting and separating the leaves of the successively supplied portions from one another. The leaves of the successively supplied portions are continuously conditioned in the direct conditioning cylinder by supplying heat and moisture to the leaves while the cylinder rotates. Conditioned leaves are continuously discharged from the direct conditioning cylinder. The method according the present aspect of the invention is not limited to the apparatus described in the following detailed description and it is contemplated that the above-mentioned guillotine-like vertical blade may be used to remove portions from the bale.




Other objects, features, and advantages will become apparent from the following detailed description, the accompanying drawings, and the appended claims.











BRIEF DESCRIPTION OF THE DRAWINGS





FIG. 1

is a perspective view showing a tobacco bale assembly in accordance with the present invention;





FIG. 2

is an end elevational view of a bale splitting assembly in accordance with the present invention showing a bale of tobacco in phantom within the bale splitting assembly;





FIG. 3

is a side elevational view of the bale splitting assembly;





FIG. 4

is a top plan view of the bale splitting assembly with the tobacco bale shown in phantom;





FIG. 5

is a table and time graph describing a sequence of steps that the bale splitting assembly can perform to split the tobacco bale;





FIG. 6

is a block diagram of the conventional method of conditioning and separating tobacco leaves;





FIG. 7

is a block diagram showing a first way the conventional method can be modified to accommodate baled tobacco by incorporating a bale splitting step performed by the bale splitting assembly in a first position and showing the preferred position of an optional inspection step when this first modification of the traditional method is used;





FIG. 8

is a block diagram showing a second way the conventional method can be modified to accommodate baled tobacco by incorporating a bale splitting step performed by the bale splitting assembly in a second position and showing the preferred position of an optional inspection step when this second modification of the traditional method is used;





FIG. 9

is a block diagram of a sequence of steps for performing the preferred method of conditioning and separating baled tobacco leaves which incorporates the bale splitting assembly, a direct conditioning cylinder assembly and an optional inspection step shown in phantom;





FIG. 10

is a schematic representation of a floor plan for effecting the preferred method described in

FIG. 9

for separating and conditioning the tobacco from a tobacco bale showing the optional inspection in phantom; and





FIG. 11

is a block diagram showing a programmable logic control unit controlling the operation of a tobacco splitter assembly in response to a signal from a weigh scale.











DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT SHOWN IN THE DRAWINGS




Referring now more particularly to the drawings, there is shown in

FIG. 1

a perspective view of the preferred embodiment of a tobacco bale assembly, generally designated by the reference numeral


20


which includes a tobacco bale


22


, a bale base member


24


, a bale top member


26


, a bale covering structure


28


and a plurality of elongated bale fastener members


30


. The tobacco bale


22


is comprised of a plurality of compressed whole tobacco leaves arranged with the stems thereof substantially parallel to each other and the leaf surfaces thereof substantially parallel to each other. The force that compresses the whole tobacco leaves into a dense bale is applied in a direction perpendicular to the parallel leaf surfaces. The compressed bale can assume a wide variety of shapes and a wide range of sizes but the preferred shape is cuboid and the preferred size is about forty six inches on each side. A 46″×46″×46″ bale of compressed leaves typically weighs about 1200 pounds. The tobacco bale


22


in

FIG. 1

is placed on the bale base member


24


so that the open and flat leaf surfaces are parallel to the top surface of the base member


24


.




The base member


24


is preferably a right rectangular piece of one inch plywood. The top surface of the base member


24


preferably has essentially the same dimensions as the bottom surface of the bale


22


so the bale completely covers base when placed thereupon. The top member


26


has preferably the same size and structure as the base member


24


and is placed on the top surface of the baled tobacco leaves


22


and the bale covering structure


28


is secured around at least the peripheral sides of the bale assembly


20


, covering the exposed edges of the tobacco leaves. The preferred embodiment of the covering structure


28


is a net-like mesh structure comprised of a flexible and resilient material and the preferred embodiment of the top member


26


is comprised of a plurality of wooden boards which cooperate to form an essentially square planar member the bottom surface of which preferably has the same dimensions as the top surface of the bale


22


. The mesh covering


28


may be secured to the assembly in a plurality of ways including using conventional fasteners such as staples or nails to fasten the same to top member


26


and the base member


24


or it may be shrink-wrapped around the peripheral sides of the bale, or both. The bale covering structure


28


can be one continuous piece or several separate pieces.




The plurality of elongated bale fastener members


30


are wrapped around the bale assembly


20


to hold the top member


26


and the base member


24


tightly against the tobacco bale


22


and maintain the structural integrity of the bale assembly


20


during transport. The elongated bale fastener members


30


are preferably two steel bands that are wrapped around the bale assembly in the substantially parallel configuration shown in FIG.


1


.




The preferred embodiment of a tobacco splitter assembly for splitting the dense bales of tobacco leaves is generally designated


34


and is shown in

FIGS. 2-4

. The tobacco splitter assembly includes a housing structure, generally designated


36


, and an elongated horizontal track assembly, generally designated


38


, extending transversely under and on opposite sides of the housing structure


36


and two vertical track assemblies, generally designated


40


, each of which is rollingly supported on the horizontal track assembly


38


and which are positioned on opposite sides of the housing structure


36


. A bale of tobacco leaves


22


is shown in phantom supported on a longitudinally extending bale conveyor assembly, generally designated by the reference numeral


41


, that forms a middle portion of the housing structure


36


and which extends from a first end of the housing structure


36


to a second end thereof and which is positioned between a plurality of apertured side wall members


43


. Two elongated horizontally extending bale penetrating structures


45




a


and


45




b


, each of which is comprised of a plurality of identical equally spaced parallel linear penetration members


47


, are movably disposed adjacent the housing structure


36


with one set on either side thereof to work on the bale of tobacco


22


. The details of the structures supporting the linear members


47


will be discussed hereinbelow after the general configuration of the horizontal and vertical track assemblies is explained.




The horizontal track assembly


38


includes two parallel coplanar horizontal track members


42


, which are supported and held in spaced relationship by a plurality of identical transverse horizontal track spacer members


44


. The inner side surface of each horizontal track member


42


defines a plurality of roller path structures best seen in the end view of

FIG. 3

including a horizontally extending upwardly facing support roller path


48


and a vertically extending inwardly facing guide roller path


49


.




The two vertical track assemblies


40


are oppositely facing structures which are rollingly supported by a plurality of carrier assemblies on opposite ends of the horizontal track assembly


38


on opposite sides of the housing structure


36


to effect the horizontal movement of each of the vertical assemblies


40


toward and away from the housing structure


36


. Each vertical track assembly


40


includes two parallel vertical track members


50


, a vertical track carrier assembly generally designated


52


, an elongated transverse vertical track end member


54


and an elongated transverse vertical track base structure


56


. The vertical track end members


54


and the vertical track base structures


56


are secured across the top and bottom ends, respectively, of each pair of vertical track members


50


to hold them in parallel spaced relation. Each vertical track end member


54


is further secured to a respective vertical track member


50


by a corner support member


51


. Each vertical track carrier assembly


52


is essentially a horizontally oriented rectangular frame structure that is rolling supported on the horizontal track assembly


38


by a plurality of roller members and to which a pair of vertical track members


50


is rigidly secured.




Each carrier assembly


52


includes two carrier side support structures


58


and two carrier end structures


60


. Each carrier side support structure


58


is provided with a plurality of support roller members


62


and a plurality of guide roller members


64


. Preferably, each carrier side support structure


58


has three support roller members


62


and two guide roller members


64


. Each pair of carrier end structures


60


holds each member of a pair of oppositely facing carrier side support structures


58


adjacent the roller path structures


48


and


49


so that the support roller members


62


on each side structure


58


is rollingly supported on each horizontal surface


48


on a horizontal track member


42


and each pair of guide roller members


64


rollingly engages an inwardly facing vertical roller path


49


to guide the movement of the plurality of side structures


58


during horizontal movement along the horizontal track assembly


38


in a manner well known in the art. Each carrier end structure


60


is an essentially elongated planar rectangular member which is provided along its top and bottom edges with upper and lower flange members extending perpendicularly outwardly therefrom. The flange members each extend outwardly on the same side of the elongated planar rectangular member and structurally reinforce the same. As seen in

FIG. 3

, each carrier end structure


60


is secured to the side structures


58


so that the flange members


61


extend outwardly toward the ends of the carrier assembly


52


.




Each track carrier assembly


52


is rollingly engaged at opposite ends of the horizontal track assembly


38


on opposite sides of the housing structure


36


. Each vertical track base structure


56


is rigidly connected between median portions of the inner surfaces of oppositely facing pairs of carrier side support structures


58


. Each vertical track end member


54


and each base structure


56


is an elongated, essentially rectangular structure as best seen in FIG.


2


. Each pair of parallel vertical track members


50


is held in parallel coplanar spaced relationship through rigid attachment to the transverse vertical track end member


54


at the upper ends thereof and the transverse vertical track base structure


56


at the lower ends thereof. An elongated inner side of each vertical track member


50


defines a plurality of vertical roller path surfaces including two identical parallel vertically extending opposing surfaces


59


. Each pair of vertical track members


50


is held rigidly upright in a track carrier assembly


52


by the aforementioned rigid attachment to a respective vertical track base structure


56


and by a plurality of carrier support members


66


which are secured in pairs between a lower portion of each vertical track member


50


of each vertical track assembly


40


and each side structure


58


.




A vertical frame assembly


68


is rollingly mounted within each vertical track assembly


40


and each bale penetrating structure


45




a


and


45




b


is rigidly mounted within a vertical frame assembly


68


. Each vertical frame assembly


68


includes a pair of frame side support members


70


, an elongated transverse upper support structure


72


and an elongated transverse lower support structure


74


. An upper support structure


72


is rigidly secured between the upper ends of each pair of the side support members


70


and a lower support structure


74


is rigidly secured between the lower ends of each pair of oppositely facing side support members


70


of each vertical frame assembly


68


and these support structures


72


and


74


cooperate to hold each of the side support members


70


adjacent the two identical parallel vertically extending opposing roller path surfaces


59


on each vertical track member


50


so that a plurality of rollers


63


rotatably attached to the side support members


70


can rollingly engage the vertical track assembly


40


to guide the vertical movement of the vertical frame assemblies


68


with respect to the vertical track assemblies


40


.




An elongated transverse middle support assembly


78


is rigidly secured within each vertical frame assembly


68


to a median portion of the inner surface of each oppositely facing frame side support members


70


. Each middle support assembly


78


is preferably comprised of a pair of identical elongated rectangular planar middle support members


80


each having a pair of identical outwardly perpendicularly extending flange structures which give the support member


80


an essentially U-shaped cross section. The two middle support members


80


which are mounted within the frame assembly


68


with the U-shaped openings directed towards each other to form two identical, aligned elongated openings


82


on opposite sides of the frame assembly


68


, one of which is shown in FIG.


3


. These aligned openings


82


cooperate to form an attachment passage for the plurality of linear members


47


secured to each vertical frame assembly


68


.




Each linear penetration member


47


is preferably an essentially cylindrical structure defining a pointed first end portion


63


, a cylindrical median portion


65


and a threaded second end portion


67


, but the threaded end portion


67


is slightly smaller in diameter than an immediately adjacent cylindrical portion


65


. The linear structures


47


are mounted to the middle support assembly


78


to form the two bale penetrating structures


45




a


and


45




b


by positioning the threaded end


67


of each structure through the aligned openings


82


and placing a bolt member


83


on each threaded end portion. The linear structures


47


are equally spaced along the opening


82


but are offset to one end of the support assembly


78


so that when the vertical frame assemblies


68


are mounted in the oppositely facing vertical track assemblies


40


, none of the linear members


47


which comprise the penetration structure


45


on one of the vertical track assemblies


40


is collinear with any of the linear members


47


which comprise the penetration structure


45


on the opposite vertical track assembly


40


. This is important because this offset configuration of the opposing penetration structures


45




a


and


45




b


, which is best seen in the top plan view of

FIG. 4

, makes it possible for these structures to be positioned over the conveyor assembly


41


at the same time and raised or lowered without the linear members


47


on opposite structures


45




a


and


45




b


coming into contact. This offset relationship is best understood by referring to the top view of the bale splitter assembly in

FIG. 4

which show both of the structures to be positioned over the conveyor assembly


41


at the same time without the linear members


47


on opposite structures


45




a


and


45




b


coming into contact.




Each vertical frame assembly


68


is movably supported within a respective vertical track assembly


40


for vertical movement therein by a vertical movement assembly, generally designated


84


. Each vertical movement assembly


84


is an elongated vertically extending structure capable of linear expansion and contraction and is positioned to be essentially parallel to and essentially equidistant from each track member in a pair of vertical track members


50


on the side thereof away from the housing structure


36


.




Each vertical movement assembly


84


includes an elongated rod member


86


, a casing assembly generally designated


87


, an apertured end member


94


, an upper holder member


96


and a lower holder member


98


. The casing assembly


87


is comprised of a casing body structure


88


, an upper open cap structure


90


and a lower closed cap structure


92


. Each lower holder member


98


is secured to a middle portion of the track base structure


56


so that the member


98


is positioned between the vertical track members


50


on a side of the vertical track assembly facing away from the housing structure


36


. The upper holder member


96


is secured to a middle portion of the upper support structure


72


of the vertical frame assembly


68


so that it is equidistant from the two side support members


70


thereof and on the side of the vertical frame assembly


68


away from the housing structure.




The upper and lower holder members


96


and


98


are vertically aligned and are each provided with a pair of equal diameter aligned transverse throughgoing apertures which receive a pin member


97


to pivotably support the end member


92


and


94


, respectively, on the elongated rod member


86


and the casing body structure


88


, respectively, as will be explained hereinbelow. The upper open cap structure


90


is secured to an upper end of the casing body structure


88


and is provided with an opening to slidably receive the rod member


86


and allow passage of a free end thereof toward and away from of the casing body structure


88


. The lower cap structure


92


seals the lower end of the casing body structure


88


and is provided with a downwardly directed elongated apertured portion to pivotably secure the assembly


87


to the aligned transverse throughgoing apertures on the lower holder member


98


with a pin member


99


in a manner well known in the art. The apertured end member


94


is secured to the free end of the rod member


86


and provides the rod member


86


with an upwardly directed elongated apertured portion to pivotably secure the member


86


to the aligned transverse throughgoing apertures on the upper holder member


96


with a pin member


99


in a manner well known in the art. Each vertical movement assembly


84


moves horizontally with the vertical track assembly


40


to which it is attached as the respective track carrier assembly


52


moves along the horizontal track assembly


38


. As the rod member


86


moves in or out of the case body structure


88


, it lifts or lowers the attached vertical frame assembly


68


and the linear structures


45


attached thereto.




The horizontal movement of the vertical track assemblies


40


along the horizontal track assembly


38


is effected in a similar manner. A pair of identical oppositely directed horizontal movement assemblies


100




a


and


100




b


are positioned beneath the housing structure


36


and are oriented parallel to and slightly above the horizontal track members


42


. The horizontal and vertical assemblies cooperate to define first and second penetrating structure movement assemblies for each of the penetrating structures. In fact, all of the movement assemblies could be considered together as being one penetrating structure movement assembly.




Each horizontal movement assembly


100


is equidistant from each horizontal track member


42


, but the horizontal movement assembly which is designated


100




a


is positioned slightly above horizontal movement assembly designated


100




b


as is best seen in the end view of FIG.


2


. The structure of assemblies


100




a


and


100




b


is identical. Each horizontal movement assembly


100


is held above the horizontal track assembly


38


between two identical parallel center attachment structures


102


which are positioned between the horizontal track members


42


and are secured to a transverse spacer member


44


and at the lower side portions thereof to identical first and second transverse cross support members


104


. The first and second cross support members


104


are each secured to the inner side surfaces of the horizontal track members


42


but do not interfere with the movement of the track carrier assemblies


52


because the cross support members are under the housing structure


36


outside of the range of motion of the carrier assemblies


52


. Each cross support member has an essentially I-shaped cross sectional configuration which is shown in phantom in FIG.


2


.




Each horizontal movement assembly


100


has a structure similar to that of the vertical movement assemblies


84


and includes a casing body structure


105


, a closed end cap member


107


, an open cap structure


109


, an elongated rod member


111


and an apertured end member


113


. A retainer member


108


which surrounds the body structure


105


of each horizontal assembly


100


engages a plurality of cylindrical support members


109


which are mounted between the parallel center attachment structures


102


to hold the casing body structures


105


of the assemblies


100




a


and


100




b


therebetween. The closed cap structure


107


is secured to and seals one end of the body structure


105


and the open cap structure


109


is secured to the other end thereof and is provided with an opening to slidably receive the rod member


111


and allow linear movement of a free end thereof toward and away from of the casing body structure


105


. An apertured end member


113


is secured to the free end of each rod member and engages a pair of apertured parallel extension structures


110


on an inner linear transverse member


112


attached to a lower portion of each vertical track assembly on a side facing the housing structure


36


. The inner linear transverse member


112


associated with assembly


100




a


is slightly higher that the inner linear transverse member


112


associated with assembly


100




b


so that each assembly


100




a


and


100




b


is substantially parallel to the horizontal tracks


42


. Preferably a pin member is used to secure the aperture on the end member


113


to the aligned apertures on the extension structure


110


in a manner well known in the art. Horizontal movement of each vertical track assembly


40


is effected by the movement of a rod member


111


into or out of the casing body structure


105


which causes the respective track carrier assembly


52


to roll along the horizontal track assembly toward or away from the housing structure


36


.




As shown in

FIG. 2

, the horizontal track structure


38


generally extends under the housing structure


36


in a direction transverse thereto.

FIG. 3

shows a side view of the housing structure


36


in which the structures disposed along the length of the housing structure


36


can be seen. The housing structure


36


includes the conveyor assembly


41


and a plurality of apertured side wall members


43


. The conveyor assembly


41


is held above the horizontal track assembly


38


by a plurality of leg members


114


rigidly attached thereto by a plurality of leg bracket members


116


. The conveyor assembly includes two parallel conveyor side members


118


, a plurality of housing rod members


125


, a plurality of elongated top roller members


120


, a plurality of elongated bottom roller members


122


, an enlarged actuation roller member


124


, an enlarged adjustable roller member


126


and a continuous loop member


128


. The two parallel sides of the frame structure


118


are rigidly held in spaced relation by the plurality of housing rod members


125


. The plurality of elongated top roller members


120


, the plurality of elongated bottom rollers members


122


, the enlarged actuation roller member


124


and the enlarged adjustable roller member


126


are rotatably mounted on the plurality of housing rod members


125


which are secured between opposite sides of the conveyor frame structure


118


to that the plurality of rod members


125


are positioned to rollingly support the continuous loop member


128


. The plurality of top roller members


120


are equally spaced adjacent an upper edge of the frame structure


118


and cooperate with the end rollers


124


and


126


and the loop member


128


to form a support surface for a tobacco bale


22


. The loop member


128


is tautly and rotatably held by the plurality of roller members. The enlarged actuation roller member


124


and the enlarged adjustment roller member


126


support the ends of the loop member


128


and a. pair of bottom roller members


122


support the loop from below. A motor assembly


130


mounted beneath the conveyor assembly


41


rotates the loop member


128


by driving a continuous band structure


132


which frictionally engages the actuation roller


124


in a manner well known in the art. The tightness of the loop member


128


is adjusted by moving the adjustment roller


126


toward or away from the actuation roller


124


to respectively decrease or increase the loop tension.




The conveyor belt assembly


41


serves as a bale slice moving structure and moves the tobacco slice away from the bale. In the preferred embodiment of the invention, the conveyor belt assembly


41


serves both as a bale moving and supporting assembly for moving and supporting the bale and as the bale slice moving structure. It is contemplated, however, that the principles of the present invention may be applied to arrangements where the bale slice moving feature is not performed by an assembly which also supports and moves the bale. For example, the bale penetrating structures may remove slices from the top of the bale and a pusher device may be used to move the bale slice off after it is lifted off the bale. The embodiment disclosed herein is preferred, however, because cost savings are better achieved by performing both moving functions with one assembly. Two apertured side wall members


43


are rigidly attached to and coextensive with the conveyor frame structure


118


so that when the actuation roller


124


is rotated and the loop member


128


rotates in a continuous manner around the various roller members, the top surface of the loop member


128


travels past these apertured wall members


43


. The ends of each apertured side wall member


43


extend angularly outward from the loop member


128


to form a plurality of identical flanged portions


135


of the side wall


43


. This outward flaring of the side walls


43


serves a plurality of purposes, including preventing a tobacco bale that is entering the housing structure


36


from being caught on the side wall


43


. The side walls


43


include a plurality of segments which are joined together at seams


137


. A plurality of apertures


129


are formed in the wall members


43


which are wide enough to allow the linear penetration structures


45




a


and


45




b


to pass freely through the side walls


43


through the full horizontal extent of their range of movement and are elongated in a vertical direction to allow the linear structures


45




a


and


45




b


to move upward and downward through the full vertical extent of their range movement when the structures


45




a


or


45




b


are positioned over the top surface of the conveyor assembly


41


. As can best be seen in

FIGS. 3 and 4

, the apertures in the side wall members


43


on each side of the conveyor assembly


41


and the associated linear members


47


are horizontally offset so that both horizontal penetration structures


45




a


and


45




b


can be raised and lowered independently when they are positioned over the conveyor assembly


41


without coming into contact with one another.




OPERATION OF THE SPLITTER




The movement of each horizontal penetration structure


45




a


and


45




b


is independent of the other and each structure is capable of simultaneous or sequential horizontal and vertical two-dimensional movement because each vertical frame assembly


68


within which each horizontal linear penetration structure


45


is rigidly mounted is movably mounted in one of the vertical track assemblies


40


and each vertical track assembly is in turn rollingly mounted on the horizontal track assembly


38


for horizontal movement toward and away from the housing structure


36


. The vertical movement of either vertical frame assembly


68


and the horizontal movement of either track carrier assembly


52


is effected by the respective movement of a rod member


86


or


111


into or out of a casing body structure


88


or


105


in which it is slidably mounted. Each casing structure


88


or


105


is typically in fluid communication with a fluid pressure source to effect the bi-directional movement of the rod members


86


or


111


, respectively, with respect to the casing body structure


88


or


111


in a manner well known in the art. The housing structure


36


is generally not movable, but the continuous loop member


128


rotatably held therein rotates when the actuation roller member


124


is rotated by the motor assembly


130


. The motor assembly


130


is capable of bi-directional movement, but typically only unidirectional rotation of the loop member


128


is required during the splitting process.




The tobacco splitter assembly


34


can be controlled manually by a human operator through a plurality of switch assemblies which enable the operator to control the horizontal and vertical movement of each penetrating structure


45




a


and


45




b


and the rotation of the loop member


128


. In the preferred embodiment, however, the movements of the penetrating structures


45




a


and


45




b


and the loop member


128


are controlled and coordinated by a programmable computer control unit called a programmable logic control (PLC)


175


which cooperates with a plurality of electronic and electromechanical devices including a bale position sensor in the form of a photo-electric eye assembly, and a plurality of proximity switches, but a human operator or inspector is provided with a switch or other means for temporarily taking over control of the processing operations from the PLC and thereby interrupting the operation of the tobacco splitter assembly and the plurality of devices cooperating therewith to correct a fault in the tobacco splitting process. The photo-electric eyes and the proximity switches are not shown in the drawings but their use to control one or several industrial processing devices is well known in the art.




The process of splitting a tobacco bale


22


begins by cutting and removing the elongated bale fastener members


30


, the bale covering structure


28


and the bale top and base members,


26


and


24


, respectively, as described hereinbelow and placing the bale


22


on a first end of the conveyor surface. The bale can be placed on the first end of the conveyor surface directly or through the cooperation of a separate bale feeding device. Specifically, a feed conveyor assembly


146


, shown schematically in

FIG. 10

, is typically and preferably used to feed a series of unsplit bales into the tobacco splitter assembly


34


as will be explained below when the use of the splitter assembly


34


in the conditioning process is discussed. Because the tobacco bales are approximately 1200 pounds, a forklift is typically used to place the tobacco bale on the feed conveyor assembly. The PLC


175


can be used to control and coordinate both the tobacco splitter assembly and the feed conveyor assembly so that the feed conveyor assembly moves a tobacco bale into the tobacco splitter assembly


34


when the splitter is ready to receive the same. After the feed conveyor assembly places a bale on the continuous loop member


128


, a control signal from the PLC activates the motor assembly


130


on the conveyor assembly and rotates continuous loop structure


128


until a signal from a photoelectric eye assembly, which detects the position of the bale within the housing structure


36


, indicates that the bale


22


has advanced into the housing structure


36


until it is approximately centered with respect to the plurality of elongated vertically extending non-aligned apertures in each of the side walls


43


. The phantom tobacco bale


22


shown in

FIGS. 2 and 4

is in the centered position. A control signal from the PLC then switches off the motor assembly


130


and a series of subsequent control signals guides the penetration structures


45




a


and


45




b


through a series of movements to split the bale


22


.




The operation of the tobacco splitter assembly


34


to split a compressed bale


22


of tobacco into slices will now be described with reference to a particular example described in tabular and graphic form in FIG.


5


. The programmable logic control unit


175


can be and preferably is programmed to perform the sequence of steps listed in FIG.


5


.

FIG. 5

describes both the timing of a sequence of mechanical movements of the two horizontally extending penetration structures


45




a


and


45




b


after the bale has been centered on the splitter assembly


34


and the timing of the rotation of the loop member


128


to move a slice out of the splitter. It should be reemphasized that the PLC


175


could be programmed to perform more than just these steps and, more specifically, could be used to control other equipment at the same time that it is programmed to and being used to control the tobacco splitter assembly


34


. The bale splitting assembly


34


can be used to split a bale


22


into a slices of the desired thickness. The thickness of the slices is set or determined by a plurality of proximity switches in a manner well known in the art.




It is assumed for the purposes of this example that a tobacco bale


22


has been loaded into the splitter


34


and is in the position shown in phantom in

FIGS. 2-4

to be split by the structures


45




a


and


45




b


and that the continuous loop member


128


is motionless when the listed operations of

FIG. 5

commence. It is also assumed the two horizontal structures


45




a


and


45




b


are initially positioned immediately before operation


1


in

FIG. 5

is commenced as far from the bale conveyor assembly


41


in the horizontal direction as possible and that the second horizontal structure


45




b


is at a vertical penetrating position above the bale conveyor surface equal to the desired thickness of the slice of the tobacco bale


22


. The preferred bale slice thickness is nine and one half inches so the initial penetrating position of structure


45




b


is 9.5 inches above the top surface of the conveyor surface upon which the bale


22


is resting.




The initial penetrating position of the other penetration structure


45




a


immediately prior to the commencement of operation


1


in

FIG. 5

is also important and is preferably two and one half inches above the height of the lower structure


45




b


because each time the bale


22


is sliced, the opposing penetration structures


45




a


and


45




b


penetrate opposite sides of the bale preferably at substantially the same time. It will be recalled that the compressed leaves in the bale are flat and arranged so that the leaf surfaces and the leaf stems are parallel. The bale is placed in the tobacco splitter assembly


34


so that the leaf surfaces are parallel to the top surface of the conveyor assembly to enable the penetration structures


45




a


and


45




b


to be inserted between the cleavage planes formed by the leaf layers to slice the bale. Consequently, if the horizontal distance between the penetration structures


45




a


and


45




b


is too small, the flat, compressed parallel leaves are sheared by the action of the structures


45




a


and


45




b


penetrating the bale from opposite directions, which may damage the leaves, and an excess amount of power is required to penetrate the bale. Also, when the structures are too close together, the leave stems may intertwine with the prongs, thereby inhibiting clean slicing and, in the worst case, causing bending of the penetrating prongs. If the penetration structures


45




a


and


45




b


are horizontally too far apart, the bale is not sliced cleanly. The preferred height differential of 2.5 inches minimizes this undesirable shearing and reduces power consumption. Because the preferred height differential of the two horizontal structure


45




a


and


45




b


is two and one half inches, the first horizontal structure


45




a


is initially set at a height of 12 inches above the top surface of the conveyor assembly loop member


128


before simultaneous penetration commences.




In

FIG. 5

the word “push” refers to a movement of a rod member


86


or


111


out of the casing body structure


88


or


105


, respectively, in which it is held to raise one or both sets of penetration structures


45


or to move one or both of the vertical track structures


40


away from the housing structure


36


; and the word “pull” refers the movement of the rod


86


or


111


back into the casing body


88


or


105


, respectively, to lower one or both penetration structures


45


or to move one or both of the vertical track structures


40


toward the housing stricture


36


. Column


1


in

FIG. 5

describes the operation performed by splitter, column


2


indicates the distances traversed by each of the penetration structures


45




a


or


45




b


during the operation, column


3


gives the total time required for each operation and columns


4


-


6


is a timing diagram of the operations listed in column one where time is given in seconds along the top of columns


4


,


5


and


6


.




As indicated in

FIG. 5

, operations


1


and


2


occur simultaneously and involve inserting the first


45




a


and second


45




b


penetration structures into the bale simultaneously until each penetration structure


45


has penetrated the bale


22


. The maximum horizontal movement of each structure


45




a


and


45




b


in a direction toward the bale conveyor assembly


41


is shown in

FIGS. 2-4

and is determined in the preferred embodiment by the extent to which each of the rod members


111


can slide into a respective casing body structure


105


of the horizontal movement assembly


100


in which it is held.

FIGS. 2 through 4

also show the position of the two penetration structures


45




a


and


45




b


after the completion of these first two simultaneous operations and before operation


3


has commenced. The simultaneous insertions which occur during the first and second operations are achieved by pulling both of the penetration structures


45


a preferred distance of approximately 48 inches from their initial or starting positions described above. The time required to complete this movement is preferably approximately 4.5 seconds. The simultaneity of these first two operations is indicated by the fact that the time lines for operations


1


and


2


shown in column


4


are of equal length and by the fact that the time line for operation


1


is directly below that for operation


2


.




Operation


3


immediately follows the simultaneous completion of Operations


1


and


2


. Operation


3


raises the first penetration structure


45




a


a preferred distance of 18 inches by pushing it for 2.4 seconds. The push is accomplished by the linear movement of the rod member


86


which is associated with the structure


45




a


out of its casing structure


88


to lift the respective vertical frame assembly. Thus, during this third operation the two penetration structures


45


cooperated to split a slice off of the bale


22


; viz., the first penetration structure


45




a


raises an upper portion of the bale


22


a preferred distance of eighteen inches, although a range of ten to eighteen inches could be used, while the second penetration structure


45




b


holds a lower portion of the bale to be sliced off against the loop member


128


. The second penetration structure


45




b


therefore remains motionless during the time period in which operation


3


is executed. The second penetration structure


45




b


is then retracted during operation


4


a distance of 48 inches by pushing it for a period of approximately 6.3 seconds so that the newly formed slice can be moved out of the tobacco splitter assembly


34


through the opposite end at which it entered by activating the continuous loop member


128


for 5 seconds during operation


5


. Typically a conveyor mechanism downstream of the tobacco splitter assembly


34


is activated by the PLC


175


or by a switching device when the slice is moved out from the tobacco splitter assembly


34


which conveyor mechanism receives and transports the slice toward a plurality of devices which separate and condition the leaves, as will be described hereinbelow.




Following the completion of operation


4


, the second penetration structure


45




b


is back in the same position it was in immediately prior to the commencement of operation


1


; in other words, this second structure


45




b


is now in position to begin the bale slicing cycle again. Before this can happen, however, the bale


22


must be placed back on the loop member


128


and the first penetration structure


45




a


moved back into its original position. This occurs during operations


6


through


8


. Operation


6


lowers the first penetration structure


45




a


thirty inches by pulling it for 2.8 seconds. The unsplit portion of the bale is placed back on the loop member


128


during Operation


7


, which follows the completion of Operation


6


; during Operation


7


, the first penetration structure


45




a


retracts 48 inches by being pushed for 6.3 seconds horizontally away from the housing structure


36


. The remainder of the bale


22


is prevented from being pulled off the top surface of the loop member


128


by the side walls


43


. Finally, the first penetration structure


45




a


is raised in Operation


8


by pushing it for


1


.


6


seconds over a 12-inch distance. The splitter


34


is now ready to repeat these eight operations shown in

FIG. 5

until the bale


22


on loop member


128


is completely split and the last slice of a particular bale leaves the tobacco splitter assembly


34


. When the last slice leaves the splitter, a control signal from the PLC


175


activates the feed conveyor which places the next bale on the loop member


128


of the tobacco splitter assembly


34


and the above described splitting procedure is repeated.




Although this preferred method described in

FIG. 5

of using the splitter assembly


34


to slice a tobacco bale produces slices having a thickness of approximately 9.5 inches, the proximity switches of the splitter can be used in a manner well known in the art to produce slices of any desired thickness. Thus, the horizontal height assumed by the penetration structures


45




a


and


45




b


is controlled by a plurality of proximity switches in a manner well known to one skilled in the art so the PLC


175


can be programmed to produce slices of any desired thickness. The sequence and timing of the above described operations can be varied by reprogramming the programmable logic control unit or by the intervention of a human operator monitoring the splitting assembly and the other devices cooperating therewith during a tobacco splitting and conditioning operation. Therefore it is within the scope of this invention to enable the PLC


175


to control and coordinate a plurality of devices that operate with the tobacco splitter assembly


34


in a tobacco conditioning process. It is also within the scope of the invention to program the PLC


175


to control the entire tobacco conditioning process, including the operation of the splitter assembly


34


. The PLC controlled system can be interrupted by a human operator monitoring the tobacco processing and then PLC controlled operations can be resumed thereafter at any time at the discretion of the operator.




USING THE SPLITTER IN THE CONDITIONING PROCESS




It is frequently desired to condition and separate leaves of tobacco and a plurality of methods for the same are well known in the prior art. Tobacco farmers typically deliver their tobacco to market in sheets. Tobacco buyers frequently bale this sheeted tobacco into 1200 pound bales after it has been purchased from the tobacco farmers because baling the sheeted tobacco reduces freight costs and storage space requirements. The tobacco splitter assembly


34


described hereinabove and the conditioning and separating method illustrated in

FIGS. 9 and 10

provide a means to slice bales of whole tobacco and condition the slices of whole leaves in a process that utilizes a direct conditioning cylinder, which is described hereinbelow. It should be noted that the tobacco splitter assembly and the conditioning and separating method illustrated in

FIGS. 9 and 10

can be used to slice, separate and condition other forms of tobacco leaves including tobacco in strip form, but the splitter


34


and the method of

FIGS. 9 and 10

also provide the tobacco processor with the capability of slicing baled whole leaf tobacco and separating and conditioning the same using a direct conditioning cylinder. The direct conditioning cylinder which is used in this method is also described hereinbelow. Before these are considered, however, the traditional or conventional method of processing tobacco will be examined.




Methods for conditioning and separating the loosely bundled sheeted leaves are well know and a block diagram for the conventional method for performing the same is shown in FIG.


6


. If the leaf tobacco arrives for conditioning in compressed bales


22


incorporated into tobacco bale assemblies


20


as described above, then the preferred method for conditioning and separating the leaves is given in

FIGS. 9 and 10

. A block diagram for this preferred method of conditioning and separating the baled leaf tobacco


22


is shown in FIG.


9


and the preferred representation of a floor plan for effecting this preferred method is disclosed in FIG.


10


. The traditional method of conditioning and separating leaves will be discussed first, then the preferred method for conditioning and separating the baled tobacco leaves


22


incorporated into the bale assemblies


20


will be examined and then the preferred modifications of the traditional method will be considered which modifications will enable the traditional system to be modified to advantageously process baled tobacco.




For a plurality of reasons, it is also frequently necessary and desirable to inspect the tobacco leaves before they begin the conditioning process or as they are being conditioned. An important reason why tobacco is inspected is to ensure that all tobacco that is about to be conditioned or is being conditioned is of an acceptable grade. Typically during the conditioning process, tobacco from a plurality of bales is moistened, separated into individual leaves or leaf parts and blended together. When the tobacco arrives for conditioning in tightly compressed bales, it is not possible to inspect the leaves in the bale as it would be if the leaves arrived for conditioning loosely packed in sheets. If baled tobacco of unknown quality is to be conditioned, it is possible that soil or tobacco of an unacceptable grade has been included in the bale. If these impurities are blended in with acceptable tobacco during the conditioning process, a great deal of waste can occur and therefore it is desirable to inspect the tobacco as is enters the conditioning process and human inspectors are typically and preferably employed to do this. Consequently, when either a modified form of the traditional method is used or the preferred method of

FIGS. 9 and 10

is used to condition baled tobacco, it is preferable to include human inspectors in the process if tobacco of unknown quality is being conditioned and to modify the procedures accordingly. Therefore, phantom block representations of inspectors


170


are included in the drawings to indicate where in the process the inspection would preferably take place and although the presence of inspectors is optional, it is to be understood that in the preferred embodiment of each method, it is preferable to have an inspector present when a particular method is used to process tobacco of unknown quality and purity and to provide the inspector with control means for temporarily taking over control of the process from the PLC


175


and for halting the processing in the event that sub-grade tobacco, soil or other undesirable material is detected to prevent the same from being blended with other tobacco.




Referring now to the block diagram representation of the conventional method for conditioning loose tobacco in

FIG. 6

, it is shown that this traditional method includes a vacuum conditioner unit


134


, a dump feeder


136


, an ordering cylinder


138


, a control feeder


140


and a weigh belt


142


. The first step of the conditioning process in the conventional procedure is to place or feed a batch of the tobacco into a vacuum chamber within the vacuum conditioner unit


134


. A vacuum is created within the vacuum conditioner unit


134


which is communicated to the tobacco in the vacuum chamber and which removes essentially all of the ambient atmospheric gases surrounding the tobacco and subjects the batch of tobacco to a strong vacuum. This vacuum is strong enough to effect the atmosphere within the pores of the leaves. Next, a carefully controlled amount of conditioned ambient atmospheric gasses having a carefully controlled temperature and moisture content is fed into the vacuum chamber of the vacuum conditioner unit


134


and maintained there for a predetermined period of time to make the leaves more pliable.




After the completion of this vacuum conditioning step, the batch of tobacco is removed from the vacuum conditioning unit


134


and placed in a blending line where it may be blended with tobacco leaves from a plurality of other batches. The leaves are then conveyed to the dump feeder


136


, sometimes referred to as a bulk feeder, which feeds the mixed blended tobacco leaves into the ordering cylinder


138


, which is frequently referred to as a conditioning cylinder. Ordering cylinders


138


are well known in the art and typically include a drum portion which is rotatably mounted therein and which rotates about a downwardly sloping axis so that the tobacco which has been fed into the proximal end thereof advances to the distal end thereof by the combined action of the rotation and gravity. The bulk feeder


136


feeds the tobacco leaves into an inner peripheral portion of the open proximal end of the ordering cylinder


138


where a plurality of spikes mounted on the inner periphery break up the large clumps of leaves as they rotate with the drum portion until the leaves fall through the open turning cylinder. A flow of conditioned heated air is introduced into the conditioning cylinder


138


at the upper inner periphery thereof that further conditions the leaves as they advance through the rotating cylinder. An optional spray apparatus may be provided at the distal end of the ordering cylinder


138


to ensure that the leaves contain the proper amount of moisture when they exit the cylinder. Upon leaving the ordering cylinder


138


, the leaves go to the weigh belt feeder where they are further broken up and fed to a weighing belt device which weighs the leaves and controls the rate of flow of the leaves as they exit the conditioning system and makes the leaf flow of the conditioned and loosened leaves more even. This controlled flow of leaves is then sent for further processing.




The preferred method for conditioning and separating the baled whole tobacco leaves is shown in

FIGS. 9 and 10

. The concept of splitting cases of tobacco in strip form, that is, with the stem removed, and conditioning the same using a direct conditioning cylinder has been known for many years. The tobacco splitting assembly


34


disclosed herein, however, is can split bales of whole leaf tobacco into slices and the method of separating and conditioning baled tobacco leaves illustrated in

FIGS. 9 and 10

using a direct conditioning cylinder can also be used to condition and separated whole leaf tobacco, including baled whole leaf tobacco and sheeted whole leaf tobacco.




Two important differences in the preferred method over the traditional method are that the vacuum conditioner unit


134


and the conventional ordering cylinder


138


have been eliminated and a direct conditioning cylinder


144


and the tobacco splitter assembly


34


have been included. Eliminating the vacuum conditioning unit is advantageous because the units are expensive to buy and maintain and vacuum conditioning typically takes a proportionately large amount of time and consumes a large quantity of energy. Conditioning an entire bale of tobacco typically requires about one half of one hour. The direct conditioning cylinder includes at least one rotating cylinder which may be provided about an interior rotating surface thereof with a plurality of axially inwardly extending internal projections such as spikes, paddles, blades or similar structures to lift and drop the slices and fragments of baled tobacco to separate them. The rotating cylinder rotates about a downwardly sloping longitudinal axis to gravitationally advance the tobacco to the distal or delivery end thereof during rotation. The interior of the direct conditioning cylinder can further include a plurality of steam or water conduits that can be variously located to communicate heat, moisture or conditioning chemical agents to the rotating tobacco.




The direct conditioning cylinder


144


differs from the ordering cylinder


138


in several ways including the fact that the heated air which conditions the tobacco enters the direct conditioning cylinder


144


at the lower periphery thereof rather than at the upper periphery as it does in the ordering cylinder


138


. The direct conditioning cylinder


144


is preferably used in tandem with the tobacco splitter assembly


34


because breaking up the compressed bales into slices makes conditioning and separating them easier.




The preferred procedure for conditioning the baled leaf tobacco includes the splitter assembly


34


and the direct conditioning cylinder


144


and the details of this procedure can be understood by reference to the schematic of the floor plan in

FIG. 10

, which procedure typically commences with the following steps: the steel bands


30


, the top member


26


and bale covering structure


28


are removed from the tobacco bale assembly


20


and the bale


22


and the base member


24


are lifted, typically by a forklift with rotatable clamps, and placed onto the feed mechanism called the feed conveyor


146


. During this movement of the bale


22


and the base member


24


, the lift rotates the bale and base member so that the base member


24


is now on top of the bale. Once the bale and base member are released by the clamps of the forklift, the base member


24


is removed by hand and the bale is now ready to be moved into the tobacco splitter assembly


34


. After the base member is removed the feed conveyor


146


moves the bale


22


to the entrance of the tobacco splitter assembly


34


and places it on the bale conveyor assembly which transports the bale


22


to the center of the splitter mechanism


34


in position to be split. The bale


22


is placed on the feed conveyor


146


so that the leaf surfaces are parallel to the surface of the feed conveyor on which it rests. This orientation positions the cleavage planes formed by the leaves essentially horizontally so the bale can be split without damaging the leaves.




The bale


22


is split in the manner set forth above in the section under the heading “Operation of the Splitter” into a plurality of slices which leave the tobacco splitter assembly


34


one at a time. The tobacco splitter assembly


34


slices the bale repeatedly until the last slice leaves the assembly


34


, whereupon the next bale


22


enters the tobacco splitter assembly


34


. The speed at which the slices leave the tobacco splitter assembly


34


is predetermined by an operator


180


who programs a desired flow rate of slices into the PLC


175


. Specifically, a scale conveyor


148


, also known as a weigh scale, which is positioned downstream of the tobacco splitter assembly


34


weighs each slice of the tobacco bale


22


and sends a control or feedback signal back to the PLC


175


; the PLC


175


then, based on the selected flow-rate of the tobacco into the direct conditioning cylinder


144


chosen by the operator


180


, determines when the following slice should leave the splitter assembly


34


. Controlling the operation of a machine using a feedback signal sent from a weigh scale to a PLC is well known in the art. The size of the slice is also within the control of the operator


180


who can reprogram the PLC


175


and the optimum slice thickness is determined by many factors. Cooperation between the nature of the slice and the capacity of the direct conditioning cylinder


144


allows the tobacco to be conditioned without extensive damage to the leaves as frequently occurred in previous methods. Alternatively, the flow-rate of tobacco can also be regulated by programming the PLC


175


to convey a tobacco slice out of the tobacco splitter assembly


34


at predetermined time intervals. Hence, a tobacco slice could exit the tobacco splitter assembly


34


and be directed to the direct conditioning cylinder


144


at regular time intervals and this time interval could be changed at the discretion of the PLC programmer.





FIG. 11

shows a block diagram of the PLC


175


controlling the operation of the tobacco splitter assembly


34


and a feedback signal going from the weigh scale


148


to the PLC


175


to indicate the rate at which tobacco slices leave the splitter assembly


34


. The double headed arrow between the PLC


175


and the tobacco splitter assembly indicate that it is possible for the PLC to receive feedback signals from the splitter. The double headed arrow between the PLC and the weigh scale indicate that it is also possible for the operator to program the PLC to send control signals to the weigh scale. The dotted lines from the operator


180


to the PLC


175


indicate that the operator can predetermine the rate at which slices leave the splitter by programming the PLC


175


. The broken line from the inspector


170


to the PLC


175


indicates that the inspector


170


can interrupt the PLC


175


if necessary.




The slices go directly from the tobacco splitter assembly


34


by means of a plurality of conveyor mechanisms into the direct conditioning cylinder


144


where they are conditioned and separated into individual leaves. In the floor plan shown in

FIG. 10

, a slightly inclined conditioner conveyor


150


moves the tobacco from the weigh scale


148


to the proximal, or intake, end of the direct conditioning cylinder


144


. The preferred angle of inclination of the conditioner conveyor is about 20 degrees.




After completion of the conditioning process, the conditioned tobacco exits the direct conditioning cylinder


144


and is propelled by a slightly inclined conveyor


154


to an oscillator


156


and a flow-regulating feeder


158


. The preferred angle of inclination of the conveyor


154


is about nineteen degrees. A carefully controlled amount of the tobacco then passes out of the flow-regulating feeder


158


along the conveyor


159


to a weigh belt


160


which feeds a controlled amount of the conditioned tobacco to a picking conveyor


162


for picking. The speed of the flow-regulating feeder


158


is controlled by the weigh belt


160


and the PLC


175


according to a set-point selected by the operator.




A plurality of structures are positioned to feed or refeed tobacco into the conditioning process without going through the tobacco splitter assembly


34


. A portable conveyor assembly


152


is positioned to feed tobacco downstream of the tobacco splitter assembly


34


and upstream of the weigh scale assembly


148


. Preferably the moving surface of the portable conveyor assembly


152


is inclined. A floor sweeper


164


is used to feed tobacco back to the conditioner conveyor


150


. A refeed assembly


166


is also positioned to refeed tobacco back to the conditioning conveyor


118


along the same plurality of conveyors


159


used by the floor sweeper


164


.




Although the preferred method for conditioning and separating the leaves of baled tobacco is that illustrated in

FIGS. 9 and 10

, many of the existing processing sites for conditioning tobacco are of the traditional type shown in

FIG. 6

which incorporate the vacuum unit


134


and the ordering cylinder


138


. Therefore, it is frequently desirable to have a method for modifying traditional conditioning facilities to allow them to be used for processing the baled tobacco


22


incorporated in the tobacco bale assembly


20


. Because the traditional facilities incorporate the use of vacuum conditioning units


134


therein instead of direct conditioning cylinders


144


, a method for processing baled tobacco by modifying a conventional processing plant would include vacuum conditioning either the split or unsplit baled tobacco as a step in the process.




As mentioned previously, inspecting the tobacco prior to or during the conditioning process is often necessary regardless of the method used to condition and separate the leaves in order to ascertain whether or not the tobacco contained in the bales is of an acceptable. Because tobacco arrives for conditioning in compressed bales


22


incorporated in the bale assemblies


20


, it is impossible to visually inspect the tobacco until the bales have been split apart and so the possibility exists that tobacco of an unacceptable grade or clumps of soil or sand have been incorporated into a tobacco bale. Therefore it is important for an inspector


170


to examine the grade and purity of the tobacco after it is split and for the inspector


170


to have the ability to halt the processing equipment when a problem is discovered so that the substandard tobacco or the impurities can be prevented from blending with the acceptable grade tobacco.




When the modified traditional procedure is used, the tobacco may be split before or after vacuum conditioning, depending on the layout of the plant, among other factors. If the tobacco splitter assembly


34


is incorporated into the process prior to, or upstream of, the vacuum conditioning step


134


, the inspection step


170


is preferably performed prior to vacuum conditioning


134


as indicated in

FIG. 8

by the position of the inspection step


170


which is shown in phantom. If the facility has been set up to vacuum condition the bale of tobacco


22


prior to splitting, it is preferred to have the inspection take place after vacuum conditioning and after the splitting, but prior to placing the tobacco into the ordering cylinder


138


. This embodiment is shown in

FIG. 7

with the inspection step


170


shown in phantom. When the tobacco bale


22


is conditioned and separated using the preferred method shown in

FIGS. 9 and 10

which incorporates the direct conditioning cylinder, the inspection preferable occurs prior to the tobacco entering the direct conditioning cylinder


144


and more preferably still, the inspection


170


takes place prior to the tobacco arriving at the weigh scale


148


. This preferred position is shown in phantom in both

FIGS. 9 and 10

.




It is to be understood that the foregoing detailed description is provided to illustrate the structural and functional principles of the present invention and is not intended to be limiting. To the contrary, the present invention is intended to encompass any alterations, modifications, and equivalents within the scope of the appended claims.




It should be noted that the appended claims do not contain limitations expressed in the ‘means for performing a specified function’ format of 35 U.S.C. § 112, ¶6. This is to clearly point out that the applicant does not intend the claims to be interpreted under 35 U.S.C. § 112, ¶6, so as to be limited solely to the structures disclosed in the present application and their structural equivalents.



Claims
  • 1. A method for splitting a tobacco bale having a plurality of substantially whole, generally parallel flattened tobacco leaves with sterns comprising:providing a first bale penetrating structure having a plurality of prongs and a second bale penetrating structure having a plurality of prongs; moving said first penetrating structure generally parallel to the flattened tobacco leaves so that said prongs thereof penetrate the bale at a first level spaced generally perpendicularly to the tobacco leaves from an edge of the bale and corresponding to a slice of desired thickness to be separated from the bale; moving said second penetrating, structure generally parallel to the flattened tobacco leaves so that said prongs thereof penetrate the bale at a second level offset relative to said first level in a direction extending generally perpendicular to the flattened tobacco leaves; moving said first and second bale penetrating structures relatively away from one another generally perpendicularly to the flattened tobacco leaves so as to separate the slice of desired thickness from the bale, and then moving the slice away from the bale.
  • 2. A method according to claim 1, wherein moving said penetrating structures relative away from one another so as to separate the slice from the bale comprises moving said second bale penetrating structure generally upwardly to lift the remaining portion of the bale while said first bale penetratingly structure remains stationary and prevents the bale slice from moving upwardly so as to separate the bale slice from the bottom of the bale;said moving the slice away from the bale comprising moving the slice out from under the remaining portion of the bale; said method further comprising: after moving the bale slice out from under the remaining portion of the bale, moving said first bale penetrating structure out from under the remaining portion; then lowering the second bale penetrating structure so as to lower the remaining portion of the bale to a bale supporting surface; thereafter moving the second bale penetrating structure out from under the remaining portion of the bale.
  • 3. A method according to claim 2, wherein said bale penetrating structures penetrate the bale from opposite sides and further comprising;before moving either of said penetrating structures, moving the tobacco bale relative to said penetrating structures until the bale is positioned between said penetrating structures.
  • 4. A method according to claim 3, further comprising:during moving the tobacco bale relative to said penetrating structures, sensing the position of the bale and stopping the movement of the bale upon sensing that the bale is substantially centered with respect to said bale penetrating structures.
  • 5. A method according to claim 3, wherein said sensing is performed by a photoelectric eye.
  • 6. A method according to claim 3, wherein said method is computer controlled.
Parent Case Info

This is a division of application Ser. No. 09/163,182, filed Sep. 30 1998, now abandoned. Which claims the benefit of Provisional Application No. 60/061,404, filed Sep. 30, 1997.

US Referenced Citations (9)
Number Name Date Kind
3948277 Wochnowski et al. Apr 1976 A
3978868 Thiele et al. Sep 1976 A
4004594 Wochnowski et al. Jan 1977 A
4222397 Brackman et al. Sep 1980 A
4628948 Beard et al. Dec 1986 A
4733676 Fisk et al. Mar 1988 A
5117844 Spicer et al. Jun 1992 A
5193556 Lasch et al. Mar 1993 A
5240013 Johnson et al. Aug 1993 A
Foreign Referenced Citations (2)
Number Date Country
0 101 271 Feb 1984 EP
0 511 196 Oct 1992 EP
Provisional Applications (1)
Number Date Country
60/061404 Sep 1997 US