Positive drive packaging conveyor system

Abstract

A module builder includes: a packing base plate system comprising a packing base plate belt wound around a front pulley; and a first drive system coupled to the packing base plate system. The first drive system includes a main drive belt coupled to a rear pulley and a front pulley, wherein, in an engaged operating mode, the main drive belt is tensioned to rotate the rear pulley, and in a disengaged operating mode, the main drive belt loses tension to stop the rotation of the rear pulley. The builder includes a second drive system coupled to a baler belt to drive the baler belt into a module forming chamber. The first drive system also includes one or more of a rear lower gate roller, a friction wheel, a packing box roller, an electric clutch, or a motor to engage and drive the main drive belt.

Description

[0001] This application is a divisional application of application number 202010433382.2, filed on May 20, 2020, with the subject matter of "positive drive packaging and conveying system". Technical Field

[0002] This disclosure relates to a packing and conveying system for a circular module builder, and more particularly, to a positive drive packing and conveying system. Background Technology

[0003] Circular module builders, or balers, use belts and rollers to manipulate harvested material into a desired shape. Both circular hay balers and circular module builders for cotton typically use belts under tension that run over a series of rollers to compress the harvested material into a cylindrical shape. In a baling system, the first or subsequent set of belts runs on geared rollers that interact with rollers housed in the module baler's packing box. The second or preceding set of belts is driven individually based on the contact between the packing base belt and the circular module baler (RMB / baler) belt. The belts operate on a set of pulleys and are not mechanically driven, but rather rely on friction. To apply sufficient force to generate enough friction to drive these belts, there is typically a set of cam discs acting on the main vehicle chassis. A common problem with this system is that it requires a specific force to produce movement, and if that force is too small, the belt will not turn, resulting in incorrect baling feed. Another problem is that the position of the front pulleys allows the baler belt joint lace to damage the pulleys when force is generated. If these pulleys fail, they will subsequently damage the baling base belt, leading to complete belt failure or system malfunction. Additional considerations for baler users include baling economy and the reliability of the baling feed.

[0004] Therefore, the packaging and conveying system needs to be improved. Summary of the Invention

[0005] According to one embodiment of this disclosure, a module builder includes: a packing base plate system, wherein the packing base plate system includes a packing base plate belt wound around a front pulley, wherein rotation of the front pulley causes the packing base plate belt to move; and a first drive system coupled to the packing base plate system, the first drive system including a main drive belt coupled to a rear pulley and a front pulley, wherein in an engaged operating mode, the main drive belt is tensioned to rotate the rear pulley, and in a disengaged operating mode, the main drive belt loses tension to stop the rotation of the rear pulley.

[0006] In one example, the module builder also includes: a baler belt capable of operating in the module forming chamber; and a second drive system coupled to the baler belt, wherein the second drive system is configured to rotatably drive the baler belt into the module forming chamber.

[0007] In the second example, the module builder further includes: a packing assembly for storing packing material from a packing roll, wherein the packing assembly is configured to dispense packing material from the packing roll between a baler belt and a packing base belt; and wherein engagement of the packing base belt with the baler belt drives the packing material into the module forming chamber.

[0008] In the third example, the first drive system also includes a rear lower door roller configured to engage and drive the main drive belt.

[0009] In the fourth example, the first drive system also includes a friction wheel configured to engage and drive the main drive belt.

[0010] In the fifth example, the first drive system includes at least one packing box roller that engages and drives the main drive belt.

[0011] In the sixth example, the first drive system includes a plurality of interoperable gears that engage and drive the main drive belt.

[0012] In the seventh example, the first drive system includes a motor operably attached to engage and drive the main drive belt.

[0013] In the eighth example, the packing base plate belt includes multiple packing base plate belts operated by the first drive system.

[0014] According to another embodiment of this disclosure, a module builder includes: a baler belt operable in a module forming chamber; a first drive system coupled to the baler belt, wherein the first drive system includes a rear lower gate roller configured to rotatably drive the baler belt into the module forming chamber; a packing base plate system including a packing base plate belt wound on a front pulley, wherein rotation of the front pulley causes the packing base plate belt to move; and a second drive system configured to engage the front pulley to drive the packing base plate system and rotatably move the packing base plate belt, the second drive system being coupled to the rear lower gate roller, wherein in an engaged operating mode, the rear lower gate roller engages the second drive system to rotate the front pulley, and in a disengaged operating mode, the rear lower gate roller disengages from the second drive system to stop the rotation of the front pulley.

[0015] In one example of this embodiment, the drive system further includes a friction wheel coupled to the rear lower door roller to rotatably drive the rear lower door roller.

[0016] In a second example of this embodiment, a packing assembly for storing packing material from a packing roll is also included, wherein the packing assembly is configured to dispense packing material from the packing roll between a baler belt and a packing base belt; and wherein engagement of the packing base belt with the baler belt drives the packing material into a module forming chamber.

[0017] In a third example of this embodiment, the second drive system includes a plurality of interoperable gears to engage and drive the front pulley.

[0018] In a fourth example of this embodiment, the second drive system includes a motor operatively attached to engage and drive the front pulley.

[0019] In a fifth example of this embodiment, the second drive system includes a main drive belt coupled to the rear pulley and the front pulley, wherein in an engaged operating mode, the main drive belt is tensioned to rotate the rear pulley, and in a disengaged operating mode, the main drive belt loses tension to stop the rotation of the rear pulley. In a further improvement, the second drive system includes a drive sprocket coupled to a driven sprocket, wherein the driven sprocket is rotatably coupled to the rear lower door roller. In another improvement, a tensioner is further included, configured to engage the main drive belt in an engaged operating mode to tension the main drive belt. In yet another improvement, the tensioner is partially positioned between the drive sprocket and the driven sprocket.

[0020] In the sixth example of this embodiment, during the engagement operation mode, the baling base plate system pivots to engage the baler belt.

[0021] In the seventh example of this embodiment, the second drive system includes an electric clutch configured to operatively engage the lower door roller. Attached Figure Description

[0022] The foregoing aspects of this disclosure and the ways in which they are obtained will become more apparent and the disclosure itself will be better understood by referring to the following description of embodiments of this disclosure taken in conjunction with the accompanying drawings, in which:

[0023] Figure 1 This is a side view of a cotton harvester;

[0024] Figure 2 This is a cross-sectional side view of the circular module builder;

[0025] Figure 3 These are cross-sectional views of different embodiments of the packaging components of the circular module builder;

[0026] Figure 4a is Figure 3 Bottom perspective view of the packaging base plate system in the embodiment;

[0027] Figure 4b is Figure 3 Bottom perspective view of the packaging base plate system in the embodiment;

[0028] Figure 5 yes Figure 3 A perspective view of one embodiment of the driving system of the embodiment;

[0029] Figure 6 yes Figure 5 Another perspective view of the drive system;

[0030] Figure 7 yes Figure 5 Bottom perspective view of the drive system;

[0031] Figure 8 These are bottom views of the packing base plate system shown in Figures 4a and 4b;

[0032] Figure 9 This is another embodiment of the second drive system.

[0033] The diagrams are arranged in a series, with corresponding labels used to indicate the relevant parts. Detailed Implementation

[0034] The embodiments of this disclosure described below are not intended to be exhaustive or to limit this disclosure to the precise forms described in the following detailed description. Rather, the embodiments were chosen and described so that those skilled in the art can understand and appreciate the principles and practice of this disclosure.

[0035] Figure 1 A harvester 10 according to one embodiment is shown. The harvester 10 shown is a cotton harvester 15. Alternatively, the harvester 10 can be any type of working machine utilizing a baling assembly.

[0036] The harvester 10 includes a chassis 20. The chassis 20 is supported by front wheels 25 and rear wheels 30. The harvester 10 is adapted to move through fields 35 to harvest cotton or other crops. An operating station 40 is supported by the chassis 20. A power module 45 can be supported under the chassis 20. Water, lubricant, and fuel tanks (typically indicated by 50) can be supported on the chassis 20.

[0037] A harvesting structure 55 can be connected to chassis 20. The harvesting structure 55 shown is configured to remove cotton from field 35. Alternatively, the harvesting structure 55 can be configured to remove other crops. An air duct system 60 can be connected to the harvesting structure 55. A accumulator 65 can be connected to the air duct system 60. The accumulator 65 is configured to receive cotton or other crops from the harvesting structure 55 via the air duct system 60. A feeder 70 can be connected to chassis 20. The feeder 70 is configured to receive cotton or other crops from the accumulator 65. The feeder 70 includes a plurality of rollers 75 configured to compress the cotton or other crops and convey them to a circular module builder 80. The circular module builder 80 has a baler door 28 and a baler front 32.

[0038] Although the circular module builder 80 is shown and described as part of the cotton harvester 15, this disclosure is not limited to this application of the module builder. More specifically, other embodiments contemplated by this disclosure include (but are not limited to) towed circular balers. A towed circular baler may not include the chassis, headstock, air system, and other components shown on the cotton harvester 15. Instead, a towed circular baler may have a suspension mechanism, wheels, and crop pickup assembly coupled to the circular module builder. Those skilled in the art will understand how the teachings of this disclosure can be applied to any circular baler or module builder, and that this disclosure is not limited to the application to the cotton harvester 15 shown and described herein.

[0039] Reference Figure 2 The modular forming chamber 185 may have a plurality of annular belts 190 defining the circumference of the modular forming chamber 185. The plurality of annular belts 190 are supported in a side-by-side arrangement across a support roller arrangement including a plurality of fixed rollers and a plurality of movable rollers. Specifically, the fixed rollers, which advance clockwise from the inlet 195 of the modular forming chamber 185 from the crop, include a lower drive roller 200, a first separation roller 205, a second separation roller 210, an upper drive roller 215, a front upper frame roller 220, a rear upper frame roller 225, a front upper gate roller 230, a rear upper gate roller 235, a rear lower gate roller 240, and a front lower gate roller 245, all of which are connected to facilitate rotation within the circular modular builder 80.

[0040] exist Figure 2 In this configuration, a pair of conventionally laterally spaced belt tensioning or rocker arms 250 are pivotally mounted to a belt tensioning arm pivot 255. Multiple movable rollers, including a first movable roller 260, a second movable roller 265, a third movable roller 270, and a fourth movable roller 275, each having opposite ends and extending therebetween, are rotatably coupled to the laterally spaced belt tensioning arms 250. As shown, one or more of the fixed rollers are driven such that multiple annular baler belts 190 are driven, for example, in a direction such that incoming cotton or other crop is added as a spiral layer to the growing circular module 100 counterclockwise. As the circular module 100 grows within the module forming chamber 185, the laterally spaced belt tensioning arms 250 rotate counterclockwise until a circular module 100 with a predetermined diameter has been formed in the module forming chamber 185.

[0041] The rear of the circular module builder 80 may be a packing assembly 90 that accommodates one or more packing volumes 280. Figure 2In the illustrated embodiment, only one packing roll 280 is shown positioned within the packing assembly 90. However, the packing assembly 90 is configured to stack multiple packing rolls 280 one on top of each other within the packing roll hopper 282. The bottommost packing roll 280 may rest on the front support roller 284 and the rear support roller 286. The front support roller 284 and the rear support roller 286 may be coupled to a bracket (not specifically shown) that allows the front support roller 284 and the rear support roller 286 to move along a linear path toward and away from the lower packing roller 288.

[0042] The packing roll 280 can be packing material sized to cover the outer periphery of the circular module 100. The packing material transitions from the packing roll 280, partially around the front support roller 284, between the front support roller 284 and the lower packing roller 288, and partially around the lower packing roller 188, to the front lower gate roller 245. Once the packing material enters the module forming chamber 185 at the front lower gate roller 245, it follows the annular baler belt 190 around the circumference of the circular module 100 until the outer periphery is substantially covered by the packing material. For hay and forage balers, a cutting assembly (not specifically shown) can then cut the packing material from the packing roll, and the packing material can be attached to the circular module so that it substantially maintains its shape once ejected from the module forming chamber. In the illustrated embodiment, the size of the packing material is suitable for a separate portion of the packing roll 280 that does not require a cutting device, but is adapted to attach to the circular module 100 to maintain its shape once ejected from the module forming chamber 185.

[0043] exist Figure 2 In one aspect of the packing assembly 90 shown, the packing material is stretched as it extends between the lower packing roller 288 and the front lower gate roller 245. More specifically, one or more of the front support roller 284, the rear support roller 286, and the lower packing roller 288 can be powered to feed the packing material from the packing roll 280 into the module forming chamber 185. Furthermore, the packing material can be clamped between the front support roller 284 and the rear support roller 286 and the lower packing roller 288 as it is fed from the packing roll 280 into the module forming chamber 185.

[0044] Power rollers 284, 286, and 288 feed packing material toward the front lower gate roller 245 at a feed rate. The feed rate may be slightly less than the speed required to match the rotational speed of the circular module 100. In a non-limiting example, the circular module may have a circumference of 23 feet, thus requiring approximately 23 linear feet of packing material per revolution. However, the packing assembly 90 may have a feed rate of only 22 linear feet per revolution. In this embodiment, the packing material is stretched as it moves between the lower packing roller 288 and the front lower gate roller 245 as it transitions from the packing roll 280 to the module forming chamber 185.

[0045] Stretching the packing material during the transition from the packing assembly 90 to the module forming chamber 185 provides a tightly packed circular module 100 with high density, thus enabling the transport of large quantities of harvested crops. Furthermore, the packing material compresses the circular module 100 to maintain its proper shape. Properly covering the outer surface of the circular module 100 also prevents moisture from penetrating it. However, if the packing material is not evenly distributed around the outer surface, the circular module 100 may deform and unravel, or become soaked with water or the like.

[0046] exist Figure 2 In one aspect of the illustrated embodiment, the lower baling roller 288 may be rotatably coupled to the circular module builder 80 at the front baler 32 or at the first and second walls of the baler door 28. When the baling material is stretched between the lower baling roller 288 and the front lower door roller 245, the central portion of the lower baling roller 288 may deflect toward the front lower door roller 245 in response to the tensile force applied by the baling material. This deflection or bending of the lower baling roller 288 may result in uneven distribution of the baling material onto the circular module 100. More specifically, when the baling material is distributed onto the surface of the circular module 100, the central portion of the baling material may be tighter than the edge portions, and vice versa.

[0047] Return to reference Figure 1 After forming and packaging the circular module 100, the module processing system 330 can receive the circular module 100. The module processing system 330 temporarily supports the circular module 100 and then discharges it from the harvester 10.

[0048] In operation, the harvester 10 is driven through field 35 to harvest cotton or other crops. The harvesting structure 55 shown picks cotton from cotton plants in field 35. Alternatively, the harvesting structure 55 may detach cotton from cotton plants. The cotton is conveyed to a accumulator 65 via an air duct system 60. The accumulator 65 holds the cotton until a predetermined cotton height is reached, and then conveys the cotton to a feeder 70. In an exemplary embodiment, the accumulator 65 feeds cotton to the feeder 70 approximately four times for each circular module 100 produced. When the feeder 70 receives the cotton, multiple rollers 75 are activated to distribute the cotton onto a feed conveyor belt, which conveys the cotton to a circular module builder 80. The circular module builder 80 compresses the cotton using a circular baler belt 90, simultaneously forming the module 100.

[0049] After the circular module builder 80 receives compressed cotton, multiple annular baler belts 190 rotate the cotton into the circular module 100. Once the circular module builder 80 has received sufficient cotton from the feeder 70, the circular module can be wrapped and the circular module 100 can be ejected onto the module handling system 330. The module handling system 330 supports the circular module 100 and then discharges it from the harvester 10. The harvester 10 is adapted to move through the field 35 to harvest cotton.

[0050] Now refer to Figure 3 Figures 4a and 4b illustrate different embodiments of the packing assembly 302. More specifically, the packing assembly 302 may have a packing roll hopper 304 similar to the packing roll hopper 282 described above. The packing roll hopper 304 may be provided for storing multiple packing rolls, wherein the bottommost packing roll contacts the upper front packing roller 306 and the support roller 308. Both the upper front packing roller 306 and the support roller 308 are rotatably connected to the front baler section 32 of the circular module builder 80 or the first and second walls of the baler door 28. The upper front packing roller 306 is rotatably connected to the front baler section 32 or the first and second side walls of the baler door 28 about a first axis 310, and the support roller 308 is rotatably connected to the front baler section 32 or the first and second side walls of the baler door 28 about a support axis 312. The first axis 310 and the support axis 312 are both defined by fixed portions passing through the first and second sidewalls of the baler front 32 or the baler door 28. The first axis 310 and the support axis 312 may not move relative to the first and second sidewalls of the baler front 32 or the baler door 28, or relative to the circular module builder 80.

[0051] The baling assembly 302 may also have a lower baling roller 314 positioned adjacent to the upper front baling roller 306. The lower baling roller 314 is rotatably connected between a first bracket 316 and a second bracket 318. The first bracket 316 is pivotally connected about a bracket axis 320 to a first wall of the baler front 32 or the baler door 28, and the second bracket is pivotally connected about a bracket axis 320 to a second wall of the baler front 32.

[0052] The lower packing roller 314 can be positioned in the first position around the bracket axis 320 (e.g., Figure 3 Pivoting between the first position (shown) and the second position. In the first position, the outer surface of the lower packing roller 314 is positioned adjacent to the outer surface of the upper front packing roller 306. More specifically, in the first position, the packing material can be clamped between the upper front packing roller 306 and the lower packing roller 314 at clamping point 406 (see Figure 4). Clamping the packing material between the upper front packing roller 306 and the lower packing roller 314 allows the rotational speed of the rollers 306, 314 to partially control the feed rate, as described in more detail below.

[0053] exist Figure 3 In one aspect of the embodiment, the outer surfaces of the upper front packing roller 306 and the lower packing roller 314 may be coated with a material that grips the packing material (e.g., rubber). The outer surfaces of rollers 306, 314 can then control the feed speed of the packing material to the lower front gate roller 245, preventing the packing material from slipping between them. In other words, when the packing material is clamped between the respective rollers 306, 314 at clamping point 406 and as it travels from the packing roll toward the module forming chamber 185, the outer surfaces of rollers 306, 314 can frictionally engage with the packing material. In this configuration, the tensile force generated on the packing material between the lower front gate roller 245 and the lower packing roller 314 is insufficient to cause the packing material to slip between the upper front packing roller 306 and the lower packing roller 314.

[0054] In one embodiment, a biasing member (not shown), such as a spring, may be positioned between the first bracket 316 and the second bracket 318 and the corresponding first and second walls of the baler front 32 or baler door 28, so that the lower baling roller 314 pivots about the bracket axis 320 toward the front upper baling roller 306. The force applied to the brackets 316, 318 by the biasing member increases the clamping force on the baling material, thereby reducing the possibility of the baling material slipping therebetween during periods of high tensile force.

[0055] The biasing member can be any type of spring, etc., known in the art, and is not limited to any particular type. More specifically, the biasing member can generate force by any type of mechanical, pneumatic, hydraulic, electrical, etc. In one non-limiting example, the biasing member 402 is a helical spring. In another example, the biasing member is a hydraulic, pneumatic, or electric actuator. Those skilled in the art will understand that many different types of biasing members 402 can be used to bias a pivoting member about an axis, and this disclosure is not limited to any particular one.

[0056] Now refer to Figure 5 , Figure 6 and Figure 7The diagram illustrates a first drive system 502. The first drive system 502 may have a drive sprocket 504 connected to a driven sprocket 506 via a chain, belt, etc. Furthermore, a tensioner 510 may be partially positioned between the drive sprocket 504 and the driven sprocket 506 to ensure proper chain tension is maintained between the sprockets 504 and 506. In a non-limiting embodiment, the drive sprocket 504 may be rotatably connected to the rear lower gate roller 240 or any other roller of the modular forming chamber 185. In this embodiment, the tooth ratio of the sprockets 504 and 506 may determine the feed rate of the packing assembly 302 relative to the rotational speed of the rollers of the modular forming chamber 185. In another non-limiting embodiment, the drive sprocket 504 may be rotatably connected to a second drive system 509, which may be any type of system, such as mechanical, pneumatic, hydraulic, or electrical, that engages with and rotates the drive sprocket 504.

[0057] exist Figure 5 , Figure 6 and Figure 7 In one form, the second drive system 509 includes a first roller 511 offset from the second roller 517 and a tensioner belt 515 wound around the first roller 511 and the second roller 517 to drive the drive sprocket 523. The belt is tensioned by the roller 513 when the packing base plate is engaged. Other forms of the second drive system 509 may include a friction wheel driven packing system, one or more gears, chains, and sprocket arrangements engaged with the shaft 521 or the drive sprocket 523 to generate input motion, one or more packing box rollers, and an electric clutch, to name just a few.

[0058] exist Figure 7 In this configuration, the first roller 511 includes a shaft 521 operatively attached to a drive sprocket 523, which is connected to a driven sprocket 525 via a series of teeth on each of the intermeshing sprockets 523, 525. The driven sprocket 525 includes a shaft 527 operatively connected to a rear pulley 529. The rear pulley 529 receives a tensioner belt 531 wound around the rear pulley 529 and the packing base pulley 533 to drive a shaft 535 of a second packing base pulley 537. The packing base system 520, further described below, includes one of the second packing base pulleys 537 associated with the respective packing base belts, wherein each of the second packing base pulleys 537 is assembled with a shaft 535 extending across the width of the packing base system 520.

[0059] Driven sprocket 506 may have a shaft (not specifically shown) that connects driven sprocket 506 to drive gear 512 of first drive system 502. Drive gear 512 may also contact upper front packing roller 306, which in turn selectively contacts lower packing roller 314.

[0060] When rollers 306 and 314 are in the first position, the rotational movement of the rear lower gate roller 240 causes the drive sprocket 504 to rotate. The rotation of the drive sprocket 504 is transmitted to the driven sprocket 506 via the chain 508. From the driven sprocket 506, the shaft causes the drive gear 512 to rotate. The drive gear 512 causes the corresponding front upper packing roller 306 and lower packing roller 314 to rotate. The rotation of the drive sprocket 504 also activates the second drive system 509, causing the shaft 535 and the second packing base plate pulley 537 to rotate.

[0061] Although drive gear 512 is described as being powered via a mechanical linkage with the rear lower gate roller 240, drive gear 512, or the front upper packing roller 306 and lower packing roller 314, can be powered independently. More specifically, hydraulic, pneumatic, electric, or other motors can be directly coupled to any of the aforementioned rollers, gears, or sprockets to provide rotational power. In this embodiment, the controller can communicate with the motor of the corresponding roller, gear, or sprocket to determine the feed rate generated by the packing assembly 302.

[0062] The packing base plate system 520 is partially positioned between the packing assembly 302 and the module forming chamber 185. Multiple continuous packing belts 522, etc., can be positioned on the packing base plate 520. The packing belts 522 and the packing base plate 520 can guide the packing material partially from the packing roll to the front lower gate roller 245 and ultimately to the module forming chamber 185.

[0063] The support roller 308 may not be directly connected to the first drive system 502. Instead, the support roller 308 can rotate freely as the packing roll placed on it rotates. In other words, the support roller 308 can be an idler roller supporting the packing roll while allowing the packing roll to rotate as the packing material is fed into the module forming chamber 185. Furthermore, the support roller 308 may be spaced apart from the upper front packing roller 306 to provide a bracket or the like between the rollers 306 and 308 to allow the packing roll to be placed thereon. The rollers 306 and 308 can maintain proper positioning of the packing roll while facilitating rotation guided by the first drive system 502.

[0064] As shown in Figures 4a, 4b and Figure 8 As further shown, the baling base system 520 includes a plurality of baling base frame supports 130 that provide support for the baling base belt 522, which is located below a circular module builder or annular baler belt 190 that moves along the baling base belt 522, the rear lower gate roller 240, and the front lower gate roller 245, as will be understood by those skilled in the art. The baling base system 520 moves generally longitudinally along the length of the harvester 10 in response to an actuator (not shown). The bale moves between the baling base belt 522 and the module builder belt to wrap the cotton to provide cotton modules.

[0065] The packing base plate system 520 is configured for longitudinal movement and rotation about a four-bar linkage having a first rotation axis 140, a second rotation axis 142, a third rotation axis 144, and a fourth rotation axis 146. The first rotation axis 140 is located at one end of a bar 148 rotatably connected to a fixed frame member 150. The second rotation axis is located at the other end of bar 148. The third rotation axis 144 is located at one end of a bar 152 rotatably connected to a second bar 154. The fourth rotation axis 146 is located at the other end of bar 152 and also marks the rotation axis of the second bar 154.

[0066] The second rod 154 extends from axis 146 to rod 118 and is coupled to an actuator (not shown), which is coupled to fixed bracket 158. Movement of the actuator causes rod 118, and thus the baling base plate system 520, to engage and disengage from the annular baler belt 190.

[0067] In one embodiment, the actuator is a hydraulic actuator coupled to a valve (not shown), the function of which is controlled by a controller, such as a processor device, to move a hydraulic cylinder to initiate a packing cycle when instructed. The controller includes: a memory configured to store program instructions; and a processor device configured to execute the stored program instructions to adjust the position of the hydraulic cylinder.

[0068] The packing base plate system 520, including the frame support 130, moves generally along the longitudinal axis defined by the plane of the belt 522. However, due to its four-bar linkage configuration, the second bar 154 subsequently moves the lower door roller 240 in both the longitudinal direction and the upward or inclined direction. An actuator pushes the second bar 154, thus pushing the bar 118 forward to the engaged position shown in Figures 4a and 4b. When packing is complete, the actuator pulls the bar 118 to the disengaged position, and the packing base plate system 520 returns to the unengaged position.

[0069] The rod 118 also supports a plurality of packing fingers 160 that are fixedly connected to and extend from the rod 118. Upward movement of the rod 118 also guides the packing fingers 160 upward.

[0070] The second drive system 509 uses a positive drive source. In the illustrated embodiment, the baling base system 520 comprises a single set of baling base belts 522, compared to a conventional system that includes two sets of baling base belts working together. In the illustrated embodiment, the rear lower gate roller 240 is used to generate the input motion. The preferred embodiment is driven by the rear lower gate roller 240, but any roller in the baler system can be used to generate the input motion. The tensioner belt 515 is tensioned when the baling base system 520 engages for baling cycles and loses tension to stop belt rotation once the baling base system 520 disengages. The input motion is then transformed via a gear and belt system to drive the rear pulley 529 of the baling base system 520. The second drive system 509 does not require any frictional contact between the baling base belt 522 and the baler belt 190 to generate rotation of the baling base belt 520. Without friction, the front or second pulley 537 is positioned to reduce or eliminate damage caused by the connecting parts of the annular baler belt 190 (sometimes referred to as the baler belt joint). The tensioner belt 53 can be tensioned by an automatic tensioning system, which will allow for changes in size over time and use within the system.

[0071] An alternative embodiment is a friction wheel driven packing system. In this embodiment, a wheel of some material (plain steel, rubber, anti-slip type, or rough surface texture, etc.) contacts the lower gate roller 240 to generate input motion. When the packing base plate system 520 engages, the friction wheel drives the packing base plate pulleys 533, 537 in a manner similar to the embodiment shown. This can be achieved through a series of belts, chains and sprockets, gears, or a directly driven shaft.

[0072] Alternatively, a separate, independent motor or any other type of drive input may be used to drive the packing base plate system 520 and the packing base plate belt 522. In another embodiment, the drive input may include rollers in the packing box.

[0073] Figure 9Another embodiment of the second drive system 909 is shown. The second drive system 909 also uses input from the rear lower gate roller 240 (not shown) to generate rotation. The second drive system 909 includes an electric clutch 1000, which initially rotates but is not engaged while the rear lower gate roller 240 rotates. When the baling cycle begins, an electrical signal (current) is sent to the electric baling clutch to engage the clutch. The clutch then generates input rotation via a telescopic drive shaft to the secondary baling base drive, thereby rotating the baling base belt 522 (not shown). The telescopic drive shaft allows the baling base to move across its range during engagement and disengagement movements. When the baling base cycle disengages, the electrical signal is turned off, and the clutch disengages, thereby stopping the rotation of the secondary drive and the primary baling base belt. In this embodiment, since the direction needs to be reversed, the baler belt and the baling base belt travel in the same direction, so the baling clutch is directly driven by a set of gears. A set of belts, chains, and sprockets, or some other type of drive, generating input to the clutch from different locations in the circular module builder 80, can be used.

[0074] Although this disclosure has been described with reference to at least one embodiment, further modifications may be made to this disclosure within its spirit and scope. Therefore, this application is intended to cover any variations, uses, or applications of this disclosure using its general principles. Furthermore, this application is intended to cover deviations from this disclosure that fall within known or conventional practice in the field to which this disclosure pertains and fall within the limitations of the appended claims.

Claims

1. A module builder comprising: a baling machine belt operable in a module forming chamber; a first drive system coupled to the baling machine belt, wherein the first drive system includes a rear lower door roller configured to rotationally drive the baling machine belt into the module forming chamber; a pack bottom system including a pack bottom belt wound around a front pulley, wherein rotation of the front pulley moves the pack bottom belt; and a second drive system configured to engage the front pulley to rotationally move the pack bottom system and the pack bottom belt, the second drive system coupled to the rear lower door roller, wherein in an engaged mode of operation the rear lower door roller engages the second drive system to rotate the front pulley and in a disengaged mode of operation the rear lower door roller disengages from the second drive system to stop rotation of the front pulley.

2. The module constructor of claim 1, wherein, the drive system further includes a friction wheel coupled to the rear lower door roller to rotationally drive the rear lower door roller.

3. The module builder of claim 1, further comprising: a pack assembly storing a pack roll of packing material, wherein the pack assembly is configured to dispense the packing material from the pack roll between the baling machine belt and the pack bottom belt; and wherein engagement of the pack bottom belt with the baling machine belt drives the packing material into the module forming chamber.

4. The module constructor of claim 1, wherein, the second drive system includes a plurality of gears operable with one another to engage and drive the front pulley.

5. The module constructor of claim 1, wherein, the second drive system includes a motor operatively attached to engage and drive the front pulley.

6. The module constructor of claim 1, wherein, the second drive system includes a main drive belt coupled to a rear pulley and the front pulley, wherein in an engaged mode of operation the main drive belt is tensioned to rotate the rear pulley and in a disengaged mode of operation the main drive belt loses tension to stop rotation of the rear pulley.

7. The module constructor of claim 6, wherein, the second drive system includes a drive sprocket coupled to a driven sprocket, wherein the driven sprocket is rotationally coupled to the rear lower door roller.

8. The module builder of claim 7, further comprising: a tensioner configured to engage the main drive belt to tension the main drive belt in an engaged mode of operation.

9. The module constructor of claim 8, wherein, the tensioner is positioned partially between the drive sprocket and the driven sprocket.

10. The module constructor of claim 1, wherein, the pack bottom system pivots to engage the baling machine belt during an engaged mode of operation.

11. The module constructor of claim 1, wherein, the second drive system includes an electrically driven clutch configured to operatively engage the rear lower door roller.

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