Bale spreader

Abstract

A bale spreader (10) comprising a cradle (12) for a straw bale, the cradle comprising a base (14) for supporting the straw bale, two sides, a rear and a forward (18) opening, at least one side having a side wall (16), the forward opening (18) comprising at least one bale macerator (20) operable to macerate and project straw forwardly from a straw bale contained within the cradle and out of the forward opening, wherein the bale macerator comprises a shaft (22), rotatable about its longitudinal axis, the shaft having mounted thereon a plurality of rigidly attached spaced apart macerator discs (24), such that rotation of the shaft causes rotation of the discs in the plane of the discs (24), and wherein the diameter of the discs decreases from a maximum in the centre of the forward opening to a minimum at the edges of the forward opening.

Description

[0001] Bale Spreader

[0002] Technical Field

[0003] The present invention relates to a bale spreader, particularly but not exclusively for use in preparing the ground for an interior pig habitat.

[0004] Background and Prior Art

[0005] Bale spreaders are devices that project and spread straw from a straw bale contained within a straw bale cradle. Such devices are commonly used for creating a hay or straw flooring for animals such as cows, either inside in a barn or outside.

[0006] Typically a single bale is held in the cradle, and is encouraged, e.g. by means of a conveyor belt, towards rotating macerators, which act to break up the straw from the bale and simultaneously project the straw to produce a stream of straw that can be directed to be deposited on the ground for preparation of a suitable surface for animals such as cows. They are conveniently mounted on a tractor or forklift, and are raised so that the stream of macerated straw can be so directed to form a uniform carpet of straw for the animals.

[0007] Technical issues arise in relation to loading straw bales into such a cradle, arranging for the internal mechanical elements and ensuring effective maceration and distribution functions.

[0008] EP 0944300 discloses a bale spreader that comprises a cradle for a straw bale, and horizontally mounted and vertically moveable macerators for distribution of the cradle. Typically the macerators are moved upwards to expose a front opening, into which the fresh straw bale may be inserted into the cradle.

[0009] FR 2865346 discloses a bale spreader that is of a similar design but wherein the macerators are arranged on a vertical axis but are not moveable. A fresh straw bale must be placed in the cradle from above. WO 2013 / 108005 discloses a bale spreader wherein the cradle comprises a conveyor floor, to urge the straw bale towards the macerators, which are arranged on a vertical axis. The entire front face of the cradle, including the macerators, are lifted upwards by lifting arms, to allow the entry of a fresh straw bale into the cradle from the open front end.

[0010] However, such bale spreaders are generally quite heavy and bulky and require separate handling of bales to be loaded into the bale spreader.

[0011] Improvements in this area would therefore be desirable.

[0012] Brief Description of the Invention

[0013] In a first aspect, the invention relates to a bale spreader comprising a cradle for a straw bale, the cradle comprising a base for supporting the straw bale, two sides, a rear and a forward opening, at least one side having a side wall, the forward opening comprising at least one bale macerator operable to macerate and project straw forwardly from a straw bale contained within the cradle and out of the forward opening, wherein the bale macerator comprises a shaft, rotatable about its longitudinal axis, the shaft having mounted thereon a plurality of rigidly attached spaced apart macerator discs, such that rotation of the shaft causes rotation of the discs in the plane of the discs, and wherein the diameter of the discs decreases from a maximum in the centre of the forward opening to a minimum at the edges of the forward opening.

[0014] Such a design has been found to be light, mobile, and very effective at chopping up and delivering straw from a straw bale. The differences in the diameter of the discs ensures that they penetrate into the bale to differing degrees, which provides a sequential disintegration of the bale, and ensures that the resistance to rotating the shaft due to penetration of the discs within the bale is minimised, ensuring that the shaft can freely turn even when only a moderate amount of power is available, e.g. when hydraulically operated. The bale spreader is ideally suited for smaller applications, such as for use in pig barns, and can chop up and direct the straw more effectively. The bale macerator may comprise more than one shaft, however, for the purposes of the present invention, a single shaft has been found to be optimal, as it simplifies the construction.

[0015] Preferably the cradle is a v-shaped cradle, the v-shaped cradle being formed by a planar rectangular base and a planar rectangular side wall, the panels together forming a v- shape.

[0016] In a preferred embodiment, the cradle can adopt a loading orientation wherein the base is substantially horizontal and the side wall is substantially vertical, such that a straw bale may be compelled to enter the cradle by scooping the base under the bale so that the bale enters the cradle to be supported by the base via an open side not having a side wall and urged against the side wall; and the cradle can subsequently adopt a spreading orientation wherein the base and the side wall are both at an acute angle to horizontal.

[0017] For example, the spreading orientation may be when both the base and side wall have an angle of around 45° to horizontal, providing the v-shaped cradle.

[0018] Preferably the macerator shaft is inclined at an angle to both the base and the side wall. This is so that the macerator shaft adopts a substantially horizontal orientation when the cradle is in its spreading orientation.

[0019] This arrangement is particularly advantageous, because the macerator discs with the largest diameter are centrally located, and so will penetrate into the centre of the straw bale. The reduction in the diameter of the macerator discs moving out from the centre then corresponds with the natural reduction in the amount of space available due to the cradle being in a v-shape orientation.

[0020] Typically, the cradle will have a means for urging the bale towards the macerator. This may for example be a number of straw walkers, or auger style rotors.

[0021] As the diameter of the discs decreases from a maximum in the centre of the forward opening to a minimum at the edges of the forward opening, there may be a central disc that has the largest diameter. Alternatively there may a number of larger discs in the centre all with the same diameter. The diameter of the discs may decrease gradually, e.g. a series of 5 discs with a central large disc surrounded by two medium sized discs with two smaller discs on the ends of the shaft. Alternatively there could simply be only two sizes of disc, as long as the larger discs are in the centre and the smaller discs are on the outer portions of the shaft.

[0022] It is highly preferred that the macerator discs, when being rotated in use have a serrated circumference. This may be provided by the discs having a serrated perimeter such as a sawtooth arrangement. However preferably this is provided by a plurality of hingedly attached tools spaced around the circumference, that project outwardly from the circumference during rotation due to the centrifugal force generated by rotation of the shaft. In this arrangement the discs may have a circular diameter. Such tools may be therefore be effectively hidden within the diameter of the disc, enabling the disc to effectively and easily penetrate the bale, whilst also providing an effective maceration of the bale once the disc begins to rotate and the tools project outwardly providing the serrated circumference.

[0023] The bale spreader of the present invention is therefore of a relatively simple and compact design, which is particularly useful for smaller environments such as pig shelters. The variable diameter of the discs also ensures that the straw is broken down and projected effectively.

[0024] The cradle may therefore comprise a single straw bale, or a plurality of bales. The straw bales may be rectilinear, e.g. cuboid or cylindrical in shape for instance. One or two cylindrical straw bales may be conveniently rolled into the cradle through the forward opening. However, it is preferred that the bale spreader contains only one straw bale, as this simplifies the bale loading process and ensures a smaller more compact bale spreader.

[0025] Preferably the cradle comprises a number of stationary blades, that are aligned between and parallel to, the macerator discs. These help to penetrate and break up the bale, as well as help to guide and restrict the movement of the bale towards the forward opening, and complement the rotating macerator discs.

[0026] The bale spreader preferably comprises a mounting bracket, so that it can be operated by a tractor or powered handler. In a second aspect, the invention relates to a method of loading a straw bale into a bale spreader according to any one of the preceding claims, wherein, a straw bale enters the cradle by scooping the bale with the base for supporting the straw bale so that it enters the cradle via an open side not having a side wall. This can be followed by rotating the cradle, so that the base and a side wall are both at an acute angle to horizontal.

[0027] Once loaded, the bale spreader can be activated to macerate the loaded straw bale. Thus, in a third aspect, the invention relates to a method of spreading straw from a bale, the method comprising the steps of carrying out the method according to the second aspect of the invention, followed by initiating rotation of the macerator shaft whilst urging the bale towards the bale macerator.

[0028] The invention will now be illustrated, by way of example, and with reference to the following figures, in which:

[0029] Figure 1 is an end view of a bale spreader according to the present invention in its loading orientation.

[0030] Figure 2 is a perspective view of the bale spreader according to the present invention shown in figure 1 in its loading orientation.

[0031] Figure 3 is a side view of the bale spreader according to the present invention shown in figure 1 in its spreading orientation.

[0032] Figure 4 is a side view of a macerator disc for use with a bale spreader according to the present invention when not rotating.

[0033] Figure 5 is a perspective view of the macerator disc shown in figure 4 when rotating.

[0034] Figure 6 is a side view of a further macerator disc for use with a bale spreader according to the present invention when not rotating.

[0035] Figure 7 is a side view of the macerator disc shown in figure 6 when rotating Turning to the figures, figures 1 and 2 show a bale spreader 10 comprising a cradle 12 for a straw bale, comprising a base 14 an open side 15 and a side wall 16 and a forward opening 18 in its loading orientation. The forward opening 18 comprises a bale macerator 20 comprising a shaft 22, rotatable about its longitudinal axis, the shaft having mounted thereon a plurality of rigidly attached spaced apart macerator discs 24.

[0036] Each macerator disc 24 also comprises a plurality of hingedly attached tools 32 spaced around the circumference, that project outwardly from the circumference during rotation due to the centrifugal force generated by rotation of the shaft. Thus the discs have a circular perimeter at rest, but a serrated perimeter during rotation, as described in more detail below.

[0037] The base 14 is reinforced by a plurality of fingers 28 that pass through the base and extend therefrom, and act to provide a scooping action, described below. The cradle 12 also comprises a number of stationary blades 30 that are aligned between and parallel to, the macerator discs 24.

[0038] The bale spreader 10 also comprises a mounting bracket 26 so that it can be mounted on a tractor or powered handler or similar mounting vehicle.

[0039] In use, the bale spreader 10 is mounted on a tractor or similar vehicle and a straw bale 40 enters the cradle by scooping the bale with the base 14 for supporting the straw bale with the fingers 28 so that it enters the cradle 12 via the open side 15 with the cradle in the orientation shown in figures 1 and 2.

[0040] The bale spreader is then tipped to adopt its spreading orientation as shown in figure 3.

[0041] Once in place in the cradle, a device for urging the bale 40 is employed to urge the straw bale towards the forward opening 18 whilst the shaft 22 begins to rotate, e.g. driven by a hydraulic system. This may be by use of a straw walker or one or more augers for example.

[0042] The bale 40 encounters the central macerator disc 24 with the largest diameter first, which can then begin to penetrate into the centre of the bale 40. Subsequently the smaller diameter macerator discs 24 also begin to penetrate the bale as it is urged towards the macerator 20.

[0043] Figure 4 shows in more detail an example of a macerator disc 24 when it is at rest. The disc comprises a number of hingedly attached tools 32, which in this case are flails rotatably attached to the disc 24 by chains. When the disc 24 begins to rotate, then the centrifugal force projects the flails outwardly, as shown in figure 5. Thus, the bale can be urged onto the disc 24 when it is not rotating, so that some of the disc can penetrate into the bale. Once the disc then begins to rotate the tools 32 will project outwardly of the disc and macerate the bale.

[0044] Figure 6 shows an alternative type of macerator disc 24, wherein a plurality of hingedly attached rigid arms 32 are provided. When at rest as shown in figure 6, the rigid arms do not project outwardly of the disc 24. Thus, the bale can be urged onto the disc 24 when it is not rotating, so that some of the disc can penetrate into the bale. Once the disc 24 then begins to rotate the tools 32 will project outwardly of the disc and macerate the bale, as shown in figure 7. The rigid arms can then begin macerating the bale.

Claims

Claims1. A bale spreader comprising a cradle for a straw bale, the cradle comprising a base for supporting the straw bale, two sides, a rear and a forward opening, at least one side having a side wall, the forward opening comprising at least one bale macerator operable to macerate and project straw forwardly from a straw bale contained within the cradle and out of the forward opening, wherein the bale macerator comprises a shaft, rotatable about its longitudinal axis, the shaft having mounted thereon a plurality of rigidly attached spaced apart macerator discs, such that rotation of the shaft causes rotation of the discs in the plane of the discs, and wherein the diameter of the discs decreases from a maximum in the centre of the forward opening to a minimum at the edges of the forward opening.

2. A bale spreader according to claim 1 wherein the bale macerator comprises a single macerator shaft.

3. A bale spreader according to claim 1 or claim 2, wherein the cradle can adopt a loading orientation wherein the base is substantially horizontal and the side wall is substantially vertical, such that a straw bale may be compelled to enter the cradle by scooping the base under the bale so that the bale enters the cradle to be supported by the base via an open side not having a side wall and urged against the side wall; and the cradle can subsequently adopt a spreading orientation wherein the base and the side wall are both at an acute angle to horizontal.

4. A bale spreader according to claims 2 and 3, wherein the longitudinal axis of the bale macerator shaft is substantially horizontal when the cradle is in its spreading orientation.

5. A bale spreader according to any one of the preceding claims that comprises a means for compelling the straw bale towards the forward opening.

6. A bale spreader according to any one of the preceding claims, wherein there is a central macerator disc, located at the centre of the forward opening having the greatest diameter of the macerator discs.

7. A bale spreader according to any one of the preceding claims, wherein the macerator discs when rotating in use have a serrated circumference.

8. A bale spreader according to claim 7, wherein the serrated circumference is provided by a plurality of hingedly attached tools spaced around the circumference, that project outwardly from the circumference during rotation due to the centrifugal force generated by rotation of the shaft.

9. A bale spreader according to any one of the preceding claims, wherein the cradle comprises a number of stationary blades, that are aligned between and parallel to, the macerator discs.

10. A bale spreader according to any one of the preceding claims, comprising a mounting bracket for attachment to a mechanised apparatus.

11. A method of loading a straw bale into a bale spreader according to any one of the preceding claims, wherein, a straw bale enters the cradle by scooping the bale with the base for supporting the straw bale so that it enters the cradle via an open side not having a side wall.

12. A method according to claim 11 , followed by rotating the cradle, so that the base and a side wall are both at an acute angle to horizontal.

13. A method of spreading straw from a bale, the method comprising the steps of carrying out the method according to claim 11 or claim 12, followed by initiating rotation of the macerator shaft whilst urging the bale towards the bale macerator.

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