Strap welder, strap welding system, and related method

Abstract

Bale strap assemblies for strapping a pressed bale are discussed herein. The bale strap assemblies may include a strap positioning assembly having a plurality of strap assemblies and a return chute assembly having a plurality of return chutes for returning straps to the strap assemblies for strapping the pressed bale. Strap welders located on a bale strapping device contain features to align two end sections of a strap and pre-loading features to expedite discrete steps within a strap dispensing and strap welding cycle.

Description

STRAP WELDER, STRAP WELDING SYSTEM, AND RELATED METHODBACKGROUND

[0001] There are generally three ways in the cotton industry to secure a bale after the bale has been pressed, which include pre-formed steel wires having interlocking ends, flat ribbonsteel bands having their ends inserted into a crimp, and flat thermoplastic strapping material with ends that are frictionally welded together.

[0002] Generally, automatic bale strapping device are categorized as up-packers, wherein baling chambers reside underneath the bale strapping device, often under the floor or ground, and down-packers, wherein baling chambers are located above the bale strapping device. Down-packer-type presses are generally less expensive to purchase and install as much, if not all, of the work is done above ground. However, a down-packer-type press tends to give up some performance advantages, namely, cycle time or bales-per-hour.SUMMARY

[0003] Aspects of the invention include a baling press assembly comprising: a first baling chamber and a second baling chamber, each of the first baling chamber and the second baling chamber being sized and shaped to receive a fibrous material and compressing the fibrous material into a pressed bale; a bale strapping device comprising a frame and a plurality of strap welders mounted to the frame, the bale strapping device being mounted on a loading side of the baling press assembly; a return chute assembly comprising a plurality of spaced apart individual return chutes, each individual return chute comprising a receiving end, an exit end, and a through channel therebetween; each strap welder comprising a frame having a welding module and a dispensing module, and wherein the welding module comprises a stationary weld jaw located adjacent a set wall, a movable weld jaw, and a probe assembly comprising at least one probe having a free end, wherein the probe assembly and the movable weld jaw are mechanically coupled to a carrier that is movable by a linkage system; and wherein the free end is configured to abut the set wall to maintain a gap between the stationary weld jaw and the movable weld jaw to prevent physical contact between the stationary and movable weld jaws.

[0004] The gap can be adjustable to increase or decrease.

[0005] The baling press assembly can further comprise a strap path extending through a length of the frame of the strap welder and a guide block having a channel aligned with thestrap path when in a guiding position and not aligned with the strap path when in a non-guiding position.

[0006] The free end of the probe assembly can contact the guide block when the guide block is in the guiding position.

[0007] The guide block can be prevented from returning to the guiding position when the movable weld jaw is in the welding position.

[0008] The baling press assembly can further comprise a door, the door and the guide block being movable by an actuator.

[0009] The door can be movable between a closed position and an open position, and wherein the door can be prevented from returning to the closed position when the weld jaw is in the welding position.

[0010] A first channel extension can attach to a first end of the door and is spaced from a second channel extension, which can attach to a second end of the door.

[0011] The free end of the probe can push against the guide block before the guide block moves to the non-guiding position and before the movable weld jaw moves to the welding position.

[0012] The guide block can push against the probe assembly while the movable weld jaw is in the welding position.

[0013] The free end can push against the guide block by pressurizing air inside a first cylinder.

[0014] The guide block can push against the probe assembly by pressuring air inside a second cylinder.

[0015] The strap path can define a first direction, and wherein the movable weld jaw can move along a second direction, orthogonal to the first direction.

[0016] The baling press assembly can further comprise a pair of alignment bars located along the strap path.

[0017] the pair of alignment bars can comprise a first alignment bar and a second alignment bar, and wherein part of the strap path can pass between the first alignment bar and the second alignment bar.

[0018] The baling press assembly can further comprise a single alignment bar located above the pair of alignment bars, and wherein part of the strap path passes between the single alignment bar and part of a wall of the strap welder.

[0019] Each of the first and second alignment bars of the pair of alignment bars can have a remote end and an opposite end, an exterior surface, and an interior surface, and wherein the two interior surfaces at the remote end can have a first gap.

[0020] The two interior surfaces of the first and second alignment bars at a location closer to the opposite end than the remote end can have a second gap.

[0021] The second gap can be larger than the first gap.

[0022] A strap can have a first end section and second end section, and wherein the first end section can be held at the first gap and the second end section can be held at the second gap when the guide block is in the guiding position.

[0023] The second end section can locate at the first gap with the first end section when the guide block moves to the non -guiding position and the movable weld jaw moves to a welding position.

[0024] The pair of alignment bars can be mounted to a lever arm and the lever arm can be movable by an actuator.

[0025] The lever arm can be pivotably connected to the frame of the strap welder.

[0026] A weld head kit comprising a frame having the movable weld jaw and the probe assembly mounted thereto can be removable from the frame of the strap welder.

[0027] The dispensing module can comprise a frame and having at least one feeder wheel and a plurality of tension wheels mounted thereto and be removable from the frame of the strap welder.

[0028] A still further aspect of the invention is a strap welder comprising a frame having a welding module and a dispensing module, and wherein the welding module comprises a stationary weld jaw locate adjacent a set wall, a movable weld jar, and a probe assembly comprising at least one probe having a free end, wherein the probe assembly and the movable weld jaw are mechanically coupled to a carrier that is movable by a linkage system; and wherein the free end is configured to abut the set wall to maintain a gap between the stationary weld jaw and the movable weld jaw to prevent physical contact between the stationary and movable weld jaws.

[0029] The gap can be adjustable to increase or decrease.

[0030] A strap path can extend through a length of the frame of the strap welder and a guide block having a channel can align with the strap path when in a guiding position and not aligned with the strap path when in a non-guiding position.

[0031] The free end can contact the guide block when the guide block is in the guiding position.

[0032] The guide block can be prevented from returning to the guiding position when the movable weld jaw is in the welding position.

[0033] The strap welder can further comprise a door and the door and the guide block can be movable by an actuator.

[0034] The strap welder can further comprise a second actuator spaced from the actuator for moving the door.

[0035] The strap welder can further comprise a balance bar having two ends mechanically connected to the actuator and the second actuator.

[0036] The door can be movable between a closed position and an open position, and wherein the door can be prevented from returning to the closed position when the movable weld jaw is in the welding position.

[0037] The free end can push against the guide block before the guide block moves to the non-guiding position.

[0038] The guide block can push against the probe assembly while the movable weld jaw is in the welding position.

[0039] The free end can push against the guide block by pressurizing air inside a cylinder.

[0040] The guide block can push against the probe assembly by pressuring air inside a cylinder.

[0041] The strap path can define a first direction, and wherein the movable weld jaw can be configured to move along a second direction, orthogonal to the first direction.

[0042] The strap welder can further comprise a pair of alignment bars located along the strap path.

[0043] The movable weld jaw can be located on a frame of a weld head kit and the frame of the weld head kit and the movable weld jaw can be removable from the frame of the strap welder as a unit.

[0044] The movable weld jaw can connect to a wrist pin, a connecting rod, and a crank.

[0045] The crank can be rotatable by a driver or a pulley system connected to the driver.

[0046] The movable weld jaw can connect to a carrier by a plurality of connecting links, by at least one flat spring, or by a sleeve.

[0047] The dispensing module can comprise a feeder wheel and a plurality of tension wheels connected to a frame of a strap dispensing kit, and the frame of the strap dispensing kitand the feeder wheel and plurality of tension wheels can be removable from the frame of the strap welder as a unit.

[0048] A still yet further aspect of the invention is a weld head kit comprising: a frame; a first sub-unit comprising a movable weld jaw attached to a carrier mounted to the frame; and a second sub-unit comprising a crank and a connecting rod driven by a driver, wherein the driver, the crank, and the connecting rod are mounted to the frame; and wherein the frame, the first sub-unit, and the second sub-unit are mountable on a frame of a strap welder as a unit and removable from the frame of the strap welder as a unit.

[0049] The weld head kit can further comprise a linkage system mounted to the frame for moving the movable weld jaw.

[0050] Another aspect of the invention is a strap dispensing kit comprising: a frame; a first sub-unit comprising feeder wheel and a plurality of tension wheels mounted to the frame; and wherein the frame and the first sub-unit are mountable on a frame of a strap welder as a unit and removable from the frame of the strap welder as a unit.BRIEF DESCRIPTION OF THE DRAWINGS

[0051] These and other features and advantages of the present devices, systems, and methods will become appreciated as the same becomes better understood with reference to the specification, claims and appended drawings wherein:

[0052] FIG. 1 is a perspective view of an exemplary bale press assembly showing a load side with a bale strapping device having a plurality of strap welders;

[0053] FIG. 2 is a perspective view of the load side of the bale press assembly of FIG. 1 with a strap positioning assembly in an intermediate position;

[0054] FIG. 3 is a perspective view of the load side of the bale press assembly of FIG. 1 with a strap positioning assembly in an intermediate position and a baling chamber exposing a pressed bale;

[0055] FIG. 4 is a side view of the load side of the bale press assembly of FIG. 3;

[0056] FIG. 5 is a side view of the load side of the bale press assembly of FIG. 4 with the bale strapping device in a used position;

[0057] FIG. 6 is a perspective view of a receiving side of an exemplary bale press assembly of the present invention wherein a return chute assembly is in a used position;

[0058] FIG. 7 is a perspective view of a receiving side of an exemplary bale press assembly of the present invention wherein a return chute assembly is in an intermediate position;

[0059] FIG. 8 is a perspective view of the receiving side of the bale strapping assembly of FIG. 7 wherein the return chute assembly is in a stowed position and relocated along a rail to clear the bale press assembly for removal of a strapped bale;

[0060] FIG. 9 is a perspective view of the receiving side of the bale press assembly of FIG. 7 wherein the return chute assembly is in a stowed position and the strapped bale has been removed;

[0061] FIG. 10 is a perspective view of a strap welder provided in accordance with aspects of the invention;

[0062] FIG. 11 is side view of the strap welder of FIG. 10;

[0063] FIG. 12 is an end view of the strap welder of FIG. 11, with the door in the open state;

[0064] FIG. 13 is an end view of the strap welder of FIG. 11, with the door in the closed state;

[0065] FIG. 14 is side view of the strap welder of FIG. 10 in which a guide block is in a retracted position and FIG. 14A is an enlarged view of the central portion of FIG. 14;

[0066] FIG. 15 is side view of the strap welder of FIG. 10 in which the movable weld jaw is in a welding position and FIG. 15A is an enlarged view of the central portion of FIG. 15;

[0067] FIG. 16 is side view of the strap welder of FIG. 10 in which the movable weld jaw is in a welding position, similar to FIG. 15 but from a different viewing perspective, and FIG. 16A is an enlarged view of the central portion of FIG. 16;

[0068] FIG. 17 is a side perspective view of a strap welder and a weld head kit;

[0069] FIG. 18 is a side perspective view of a strap welder and strap feeding and retracting kit;

[0070] FIG. 19 is a side view of the strap welder of FIG. 10 having a strap located at the starting point in the strap path of the strap welder;

[0071] FIG. 20 is a side view of the strap welder of FIG. 19 having the strap dispensed around a pressed bale and the first free end returned to the strap welder;

[0072] FIG. 21 is a side view of the strap welder of FIG. 20 having the strap dispensed around a pressed bale and a second end of the strap created by a cutter;

[0073] FIGs. 22A and 22B show alignment bars used with the strap path to align the edges of a tie strap for welding;

[0074] FIG. 23 is a side view of the strap welder of FIG. 19 having two ends of a strap located in the strap path and ready for welding, and FIG. 23 A is an enlarged view of the central portion of FIG. 23, showing the alignment bars;

[0075] FIG. 24 is a side view of the strap welder of FIG. 19 having two ends of a strap located in the strap path and ready for welding, and FIG. 24A is an enlarged view of the central portion of FIG. 24, showing the alignment bars;

[0076] FIG. 25 is a simplified view of a welding module in accordance with an embodiment of the invention; and

[0077] FIG. 26 is a simplified view of a welding module in accordance with another embodiment of the invention.DETAILED DESCRIPTION

[0078] The detailed description set forth below in connection with the appended drawings is intended as a description of the presently preferred embodiments of baling press assemblies and components thereof provided in accordance with aspects of the present devices, systems, and methods and is not intended to represent the only forms in which the present devices, systems, and methods may be constructed or utilized. The description sets forth the features and the steps for constructing and using the embodiments of the present devices, systems, and methods in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent functions and structures may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the present disclosure. As denoted elsewhere herein, like element numbers are intended to indicate like or similar elements or features.

[0079] Descriptions of technical features or aspects of an exemplary configuration of the disclosure should typically be considered as available and applicable to other similar features or aspects in another exemplary configuration of the disclosure. Accordingly, technical features described herein according to one exemplary configuration of the disclosure may be applicable to other exemplary configurations of the disclosure, and thus duplicative descriptions may be omitted herein.

[0080] FIGs. 1-9 show different views of a baling press assembly 100, which comprises a first baling chamber 102 and a second baling chamber 104 located on a turntable base plate 106 and has a bale strapping device 108 comprising a plurally of strap welders 112. The balingpress assembly 100 shown is a down-packer. However, the bale strapping device 108 in accordance with the present invention is readily adaptable for use with up-packers.

[0081] With reference initially to FIG. 1, a perspective view of a load side of the baling press assembly 100 is shown, which is understood to be the side of the assembly that loads the straps for strapping a pressed bale. The two baling chambers 102, 104 are configured for loading fiber in one of the two chambers and for pressing a load of fiber in the other chamber. Generally, fiber, such as cotton, cotton lint and / or synthetic fiber, to be pressed is loaded into the first baling chamber 102. Simultaneously, while the fiber is loaded in the first baling chamber 102, a quantity of previously loaded fiber is being pressed into a bale in the second baling chamber 104, which is then strapped using the bale strapping device 108 to retain the bale in the pressed state for transportation and delivery.

[0082] After the bale in the second baling chamber 104 is strapped and removed from the baling press assembly 100, the turntable base plate 106 rotates so that the loaded fiber in the first baling chamber 102 is now at the operative position 118 to be pressed into a pressed bale and then strapped using the bale strapping device 108 while cotton lint or fiber is again loaded into the second baling chamber 104, which has now been rotated and is located at the loading position 120. The fiber located in either baling chamber 102 or 104 is only pressed and strapped when that particular baling chamber is rotated to the location where the bale strapping device 108 is located, which may be called the operative position 118 of the baling chamber. Further information regarding the operation of a down-packer assembly with a bale strapping device and a return chute assembly is disclosed in US Pat. No. 7,841,272, the contents of which are expressly incorporated herein by reference.

[0083] The bale strapping device 108 is mounted to the baling press assembly 100, on the loading side of the press base, for attaching a plurality of straps around a bale after the bale has been formed in the baling chamber at the operative position 118 of the chamber. As shown, three strap welders 112 are provided on the frame of the bale strapping device 108 to weld six straps around the pressed bale. This can be implemented by first locating the three strap welders 112 of the bale strapping device 108 at a first welding position to direct a first set of three straps around the bale and then welding the first set of three straps. The bale strapping device 108 is then indexed to a second welding position, such as by sliding the bale strapping device horizontally, so that the three strap welders 112 of the bale strapping device 108 is in position to direct a second set of three straps around the bale to then weld the ends of the second set of three straps. Thus, the bale would be strapped with six total straps using the balestrapping device 108 with only three strap welders 112. In other examples, a different number of strap welders are used to weld a different number of straps. For example, four strap welders can be used to weld four straps at a time and then indexed to weld four additional straps for a total of eight straps.

[0084] As further discussed below, aspects of the present invention utilize a new and inventive bale strapping device 108 with sufficient number of strap welders 112 to perform a single pass weld operation with six straps, or other desired number of straps and strap welders in a single weld pass to complete the desired number of straps around the bale. For example, the invention can utilize four, five, six, seven, or eighter strap welders to perform the desired number welded straps in a single weld operation. Alternatively, the bale strapping device 108 in accordance with aspects of the present invention may be equipped with strap welders that are numbered about half of the final number of straps so that the bale strapping device performs two different weld passes or operations to strap with pressed bale with the desired total number of straps, and wherein the bale strapping device 108 is moved between the first weld operation or pass and the second weld operation to complete the strapping function. Although the present bale strapping device 108 can also perform three welding passes to produce the desired final number of welded straps, it is not preferred due to the added time to perform the third weld pass or operation.

[0085] Note that although the automatic bale strapping device and bale press assembly are described with particular reference to a cotton or fiber baling operation, the baling system may be adapted for baling other suitable materials as well. For example, crushed cardboard boxes, lumber, brick, trash, and used clothing may be pressed and strapped in accordance with aspects of the present invention.

[0086] The bale strapping device 108 further comprises a strap positioning assembly 124 and a return chute assembly 126. The strap positioning assembly 124 is utilized to move the bale strapping device 108 between different weld positions to perform more than one weld pass or operation to complete the total number of welded straps around the pressed bale. In other words, the strap positioning assembly 124 is configured to index the strap welders 112 of the bale strapping device 108 between more than one position to perform more than one weld pass, such as to move the bale strapping device 108 from a first welding position to dispense and weld a first set of straps to a second welding position to dispense and weld a second set of straps, and so forth to form the desired total number of welded straps around the pressed bale. The plurality of strap welders 112 can be mounted on a frame 116 and the frame can slide backand forth by an actuator to index the strap welders 112 between the first welding position and the second welding position. The frame 116 can also move between a stowed position 136 (FIG. 1), a used position 138 (FIG. 5), and an intermediate position 140 (FIG. 3) therebetween via an actuator. Thus, the strap positioning assembly 124 can slide along a first axis to index and can move up and down along a pivoting axis to move between a used position and a stowed position. In an example, the first axis and the pivoting axis are common.

[0087] The return chute assembly 126 has a plurality of spaced apart individual return chutes 128 (FIGs. 6-9). Each return chute 128 is sized and shaped to direct a strap dispensed by a strap welder 112 to wrap around a pressed bale and return to the strap welder. In an example, the strap end that enters the bale press assembly can return to the strap welder by routing the strap through the return chute so that the strap’s two ends can be welded by the strap welder, as further discussed below. In an example, the return chute assembly 126 has six individual return chutes 128 for directing six different straps around the bale. Preferably, there are the same number of individual return chutes 128 in a return chute assembly 126 as there are total number of straps used to strap the pressed bale. This allows the return chute assembly 126 to operate without having to index between two or more positions to route the straps. With reference to FIG. 8, each return chute 128 has a receiving end 130, an exit end 132, and a through channel 136 therebetween. A strap can enter the receiving end 130, travel in the through channel 136, and then exit out the exit end 132 where it then returns to the strap welder 112 for welding the two ends together, as further discussed below.

[0088] Each strap can be dispensed from a strap welder 112, travel through a respective guide channel 148 of the upper press plate 142 of the baling chamber, the respective return chute 128, and then the respective guide channel 150 of the lower press plate 144 of the baling chamber and then back to the strap welder for welding the two strap ends together. More particularly, the process of strapping a bale can start with FIG. 1, which shows the bale strapping device 108 in a stowed position and the second baling chamber 104 in the down position while the fiber is being pressed inside the second baling chamber. As the pressing is closed to complete, the bale strapping device 108 can move to the intermediate position 140 (FIG. 2) before the second baling chamber 104 lifts to the open position to present a formed bale for strapping. Movement to the intermediate position is analogous to moving the bale strapping device 108 to a forward deployment position and closer to the pressed bale for strapping.

[0089] There are many types of fiber presses, but most are of two kinds. The down-packing described here in which the bale is pressed down in the vertical direction to form a bale and then the pressed bale is ready to be strapped. The other common press is the up-packing type which presses up in the vertical direction to form a bale and then the pressed bale is ready to be strapped. The up-packing press typically has the rotating baling chambers below the floor, but not always. Because the chambers do not move where the equipment must be cleared, the strapper can be placed closer to the bale forming area. The return chutes rotate up and / or to the side to allow the strapped bale to exit the pressing area. The up-packing presses are typically of two model varieties, a door type up-packer, or a door-less up-packer. Both bring their own mounting challenges for strapping equipment. In a typical up-packer assembly, the bale is about 80% formed in the chamber below the floor. Then the upper ram is de-energized to allow the lower ram to push this approximately 80% formed bale up to the “sill”, which presents a physical stop above ground that the bale can be pushed against. Then the approximately 80% formed bale is further pressed by the lower ram against the “sill” to the final desired compression to finish the pressing operation. The strapping device 108 with the plurality of strap welders 112 can then strap the presented pressed bale. The strapping device 108 and strap welders 112 described herein can operate with both up-packers and downpackers.

[0090] FIG. 3 shows the second baling chamber 104 in the raised position to expose the upper press plate or upper press 142 and the lower press plate or lower press 144, as well as the pressed bale 146 located between the two press plates. The upper guide channels 148 on the upper press 142 where the straps enter and the lower guide channels 150 on the lower press 144 where the strap exit are also shown.

[0091] FIG. 4 shows the bale strapping device 108 comprising a plurality of strap welders 112 moved to a used position by one or more actuators. A shock absorber 154 can be incorporated to soften the impact of the bale strapping device 108 when it moves from the intermediate position to the used position. In the example shown, the shock absorber 154 can embody a wheel with a rubber tire 156 and a piston 158. FIG. 5 shows the piston 158 returning to its discharged position to allow each strap welder 112 to move closer to align with the upper and lower guide channels 148, 150 on the upper and lower presses 142, 144 for dispensing a strap and then receiving the dispensed end inside the strap welder for welding the two ends of the strap together, as further discussed below.

[0092] FIG. 6 shows the return chute assembly 126 rotated to the used position, which aligns the receiving end and exit end of each return chute 128 to the upper guide channel 148 and lower guide channel 150 of the upper press and the lower press, respectively. The return chute assembly 126 can also have a stowed position and an intermediate position, like that of the bale strapping device 108. Further, the frame 160 of the return chute assembly 126 can be mounted on a rail 162. The rail can be used to move the return chute assembly 126 away from the pressed bale after the bale has been strapped so that the strapped bale can be removed for off-loading and shipment. After removal, the return chute assembly 126 can slide along the rail 162 to return to the active baling chamber and take part in the strapping process with the bale strapping device 108.

[0093] With reference now to FIG. 10, a perspective view of a strap welder 112 in accordance with aspects of the invention is shown. The strap welder 112 of FIG. 10 may be employed as one of the strap welders of the bale strapping device 108 discussed above and shown in FIGs. 1-4 and elsewhere. The strap welder 112 includes several structures and features designed to reduce the cycle time for each strap welder to propel a thermoplastic strap around a pressed bale and then weld two ends of the strap together via ultrasonic friction weld around the pressed bale. That is, the strap welder 112 in accordance with aspects of the invention is configured to dispense a strap and then weld two ends of the straps at a faster rate than comparable strap welders so that the overall throughput of the baling press assembly 100, i.e., the number of strapped bales, increases due to the faster cycle time on a per hour basis.

[0094] In an example, a strap welder 112 usable with the bale strapping device 108 described hereinabove comprises a dispensing module 164 for dispensing a strap 168 (FIG. 19) and a welding module 166 for welding two ends of the strap. With reference to FIGs. 19-24, the dispensing module 164 is configured to dispense a strap 168 from a strap supply 170 (shown schematically), which can be a roll of a continuous string of a thermoplastic strap. The dispensing module 164, which is more commonly known in the industry as a feed and retract module or “feeder”, includes one or more tension wheels 171, a feeder wheel 174 that is driven by a driver, such as an electric motor, a server motor, an air motor, or a stepper motor, via one or more geared wheels and pulleys for stepping up or down the feeding speed or direct drive and a plurality of relatively smaller or fine adjustment tension wheels 176 to help guide the strap around a bend. The feeder wheel 174 may include one or more seams to promote catching of the strap when feeding the strap into the feed and tract module.

[0095] Although three smaller or fine adjustment tension wheels 176 are shown, as few as one may be used with at least two or more being preferred. The feeder or dispensing module 164, via the feeder and tension wheels, provides the feeding force to push the strap 168 through a strap path 178 (FIG. 20) that spans through the strap welder 112 at a forward end 180 of the strap welder 112. As further discussed below, the strap then travels around a pressed bale and returns to the strap welder to have its two ends frictionally welded.

[0096] The strap 168 has a first end, a free end, or a feed end 182 at a first end section 183 of the strap that is positioned at a starting point 184 on the strap welder 112. Generally, the starting point 184 is the point adjacent a knife or cutter 186 (FIG. 20) for cutting the strap 168 after the strap routes through the upper guide channel 148 (FIG. 3), the return chute assembly 126 (FIG. 6), the lower guide channel 150, and around the bale 146 (shown schematically) and returns to the weld zone 190 (FIG. 21) of the strap welder proximate the weld jaws, as further discussed below.

[0097] FIG. 20 shows the strap 168 being fed by the feed wheels 174, 176 of the feeder module 164 around a bale 146 (shown schematically) and then returning to the strap path 178 where the free end or feed end 182 hits a stopper to stop the feeding, which is preferably downstream of the of the starting point 184 to generate an overlapping section 192 of the strap (FIG. 21). In an example, the feeder module uses a servo which rotates an exact controlled amount to then feed out a controlled amount, which is generally larger or a bigger loop than the required length to strap a bale. The strap is then retracted a small amount by the feeder. Alternatively, the strap can be fed until it stops or jams, such as by contacting a stop, a timer could be used, or a sensor could be used to sense the presence of the strap when the feed end of the strap returns to head. The strap then retracts tightly against bale to then be cut and welded at the overlapping section 192.

[0098] The strap 168 is then cut with a cutter 186 (FIG. 20) to form a second end 194, or a second free end, at a second end section 195 of the tie strap 168a. A tie strap 168a is formed from the continuous strap 168 after the strap is cut by the cutter to have two free end sections 183, 195 to be welded together around the bale 146. The two free ends 182, 194 at the two free end sections 183, 195 are staggered or not aligned so as to create an overlapping section 192 at the weld zone 190 (FIG. 20) that will then be frictionally welded by the two weld jaws to weld the tie strap 168a together around the bale, as further discussed below.

[0099] To align the two free ends 182, 194 and the two end sections 183, 195 of the tie strap 168a at the overlapping section 192 for welding, a pair of alignment bars 200 are used toalign the edges of the two end sections 183, 195 of the tie strap 168a, as further discussed below. To retain the strap within the strap path 178 during the strap feeding operation, a single upper alignment bar 198 is used in combination with a wall structure of the welder 112, such as part of the guide path, to retain the strap between the single upper alignment bar 198 and the wall structure, as shown in FIG. 20. Thus, the tie strap 168a is configured to pass between the single upper alignment bar 198 and the guide path wall and between two lower alignment bars 200a, 200b (FIG. 24A). Upon returning to the weld zone 190, both ends of the tie strap pass between the two lower alignment bars 200a, 200b (FIGs. 21 and 24A).

[0100] FIGs. 19-21, from the viewing perspective shown, show the single upper alignment bar 198 and the front or first alignment bar 200a of the lower pairs for supporting the first edge of the tie strap 168a, or the edge that is closest to the viewer. FIG. 23 A more clearly shows the single upper alignment bar 198 and part of the wall of the strap path that together retains the strap during dispensing of the strap around the bale. FIG. 23A also shows the front or first alignment bar 200a of the lower pair of alignment bar. FIG. 24A shows the single upper alignment bar 198, the first alignment bar 200a of the lower alignment pairs, and part of the second alignment bar 200b of the lower pairs of alignment bars, which is positioned behind the far edge of the strap. FIG. 24A also shows the guide block 216 (FIG. 23 A) moved to the nonguiding position or retracted position to then allow the movable weld jaw 196a forward to the welding position, which then pushes the second end section 195 of the tie strap that has just been cut towards the first end section 183.

[0101] Thus, the single upper alignment bar 198 along with the wall of the strap path and the pair of lower alignment bars 200a, 200b can be incorporated to define a gap therebetween to guide the strap during feeding of the strap around the bale and for aligning the edges of the tie strap 168a at the overlapping section 192 of the tie strap 168a for welding, as further discussed below. Once in the position shown in FIG. 24A, the single upper alignment bar 198 and the lower pair of alignment bars 200a, 200b can move away by action of a lever arm 278. As the alignment bars 198, 200a, 200b are mounted to the lever arm 278, movement of the lever arm clears the alignment bars from the weld zone 190 to enable the movable weld jaw 196a to move and weld. The retraction of the alignment bars 198, 200 by the lever arm 278 also clears the way for the welded strap to release from the weld zone. As further discussed below, when the door 240 returns to the closed state (FIG. 13) and the guide block 216 to the guiding position, the guide block 216 and the upper and lower outer door edges contact and push the welded strap laterally to move away from the weld zone 190.

[0102] With reference now to FIG. 22A, the first alignment bar 200a and the second alignment bar 200b of the lower pair of alignment bars 200 are shown, looking down towards the knife or cutter 186, which has a sharp cutting edge 186a. In the view shown, the first end section 183 of the tie strap 168a having the feed end 182 (FIG. 20) is located further away from the cutting edge 186a than the second end section 195 having the second free end 194 of the tie strap. The first end section 183 is the end of the strap that returns to the welder after looping around the pressed bale 146 (FIG. 20) and the second end section 195 is the end of the strap that presents itself to the cutter as the strap advances so that a second free end can be cut. FIG. 23A shows the first and second end sections 183, 195 of the tie strap being spaced from one another by the guide block 216.

[0103] As further discussed below, the guide block 216 is displaceable between a guiding position to guide the strap as the strap is being dispensed around the bale (FIG. 20) and a nonguiding position (FIG. 21, also referred to as retracted position) to provide space for the movable weld jaw 196a to move to the welding position to weld the overlapping section of the strap. The guide block 216 is shown in the guiding position in FIG. 22A, which keeps the two strap sections separated or spaced from one another. The guide block 216 is configured to vacate and move out of the way of the two strap ends 183 195 to a non-guiding position to then allow the movable weld jaw 196a to move to the welding position, which results in the movable weld jaw 196a pushing the second end section 195 towards the first end section 183, which is shown in FIG. 22B. At this point, the two strap ends still cannot be welded together until the alignment bars 200a, 200b vacate the weld zone and provide space for the movable weld head 196a to oscillate against the stationary weld head with the two strap ends located therebetween to be frictionally welded together.

[0104] With reference to FIG. 21, the single upper alignment bar 198 and the pair of alignment bars 200a, 200b are mounted to the lever arm 278, which is pivotably connected to the frame 258 of the welder. An actuator 296 is then connected to the lever arm 278 and actuation of the shaft of the actuator causes the lever arm 278 to move into the weld zone to align the strap ends during feeding of the strap around the bale and out of the weld zone to enable welding. With reference again to FIG. 22B, the alignment bars 200a, 200b are therefore configured to move in the direction of the blunt end 186a of the cutter 186 when the lever arm 278 is moved.

[0105] Each alignment bar of the lower pair of alignment bars 200 has an exterior surface 202 and an interior surface 204, with the reference position of the strap 168a. At the remoteend or handling end 206 of the lower pair of alignment bars 200a, 200b, the interior surfaces 204 of the first and second alignment bars 200a, 200b are provided with varying surfaces 218 to create a strap alignment guide 208. In the example shown, the strap alignment guide 208 has a first alignment gap 210 located between the two interior surfaces 204 of the two alignment bars 200a, 200b at the remote end. The first alignment gap 210 has a first distance that is approximately the same width as the width of the strap, and more preferably is around three thousandths to ten thousandths bigger than the width of the strap. The first gap 210 is configured to guide the first end section 183 of the strap 168a when the first end returns to the welder after looping around the pressed bale.

[0106] Each of the interior surfaces 204 of the two alignment bars 200a, 200b has a recessed section 212 and wherein the two recessed sections of the two bars aligned to define a second alignment gap 214. The second alignment gap has a width with a second distance that is larger than the first distance of the first alignment gap 210. The larger second distance allows the second end section 195 of the strap 168 to readily move into position to be cut as the first end of the strap is fed through the strap path 178 and loop around the bale. The larger second distance at the second alignment gap 214 gives the strap more space to travel during the strap feeding phase of the process and minimizes rubbing between the edges of the strap and the alignment bars.

[0107] After the strap 168 is cut by the cutter 186, as shown in FIG. 21, the second end section 195 is pushed towards the first end section 183 by the movable weld head 196a. This moving together configuration is shown in FIG. 22B. In moving together to be welded, the tie strap 168a at the second end section 195 moves across the two stepped surfaces 218 of the first and second alignment bars 200a, 200b to the narrower first alignment gap 210 so that edges of the first end section 183 and the edges of the second end section 195 align more tightly before the two strap end sections are frictionally welded, which should yield weld profile with the edges of the strap end sections 183 195 more closely stacked or aligned.

[0108] FIG. 23 shows the strap welder 112 with the cutter 186 ready to sever the strap 168 at the second end section 195 to form a second free end 194 and the tie strap 168a (FIG. 21). The guide block 216 is shown in the engaged position and prevents the second end section 195 of the tie strap from merging with the first section 183. Additionally, and as further discussed below, when the guide block 216 is in the engaged position shown, at least one probe or bar 220 on a probe carrier 248 (FIG. 14A and 23A) prevents the movable weld jaw 196a from advancing towards the stationary weld jaw 196b. This in turn prevents potential damage to themovable weld jaw 196a by preventing the possibility that the movable weld jaw 196a may initiate and activate and move against the stationary jaw or the guide block and be damaged thereby. The guide block 216, which is connected to the door 240 (FIG. 23 A), is configured to move or retract away from the weld zone 190 to enable the weld module to then weld the two strap ends together.

[0109] With reference again to FIG. 10 in addition to FIG. 11, the welding module 166 comprises a weld jaw assembly 196, which has a movable weld jaw 196a and a stationary weld jaw 196b. The movable weld jaw 196a is configured to move between a retracted position when the strap is being dispensed through the strap welder and a welding position to weld two ends of the tie strap together. Movement of the movable weld jaw between the retracted position and the welding position can be along a first axis. The movable weld jaw 196a can also oscillate back-and-forth by a crank shaft that is rotated by a stepper motor to frictionally weld two end sections of the strap together. Oscillation of the movable weld jaw can be along a second axis perpendicular to the first axis, as further discussed below.

[0110] As discussed above, the weld jaw assembly 196 is configured to frictionally weld an overlapping section 192 of the strap 168a located between two weld jaws 196a, 196b. Preferably, the weld jaw assembly 196 is configured to provide a cross-weld on the overlapping section 192 of the strap, which means that the movable weld jaw 196a is configured to move from side edge to side edge of the tie strap to frictionally weld two ends of the strap together (FIG. 25), as further discussed below.

[0111] The movable weld jaw 196a can move between a retracted position shown in FIG. 23 A, in which the guide block 216 is in a guiding position, and a welding position shown in FIG. 24A, in which the guide block 216 is in a non-guiding or retracted position. In an example, the movable weld jaw 196a is mounted on a carriage 226 that is movable by a linkage system 228 that is then operated by an actuator 230. When the guide block 216 is in the guiding position, the movable weld jaw 196a is moved to the retracted position (FIG. 20), spaced from the stationary weld jaw 196b by a greater gap than when in the welding position. In the guiding position, the guide block 216 has a channel for providing a guide path for the strap 168 as the strap is fed around the pressed bale. The presence of the guide block 216 in the guiding position also prevents the movable weld jaw 196a from moving to the welding position. Thus, the guide block 216 can guide the strap and can prevent the movable weld jaw from moving too early against the stationary weld jaw and possibly damage one or both weld jaws.

[0112] FIG. 12 shows the guide block 216 in the retracted or non-guiding position 222 and FIG. 13 shows the guide block 216 in the engaged or guiding position 224. In the retracted position 222 of FIG. 12, the guide block 216 is moved out of the way of the movable weld jaw 196a, as previously discussed. The guide block 216 can be mounted on an elongated rod rail 232 and movable along the rod rail between the retracted position and the engaged position by a pair of solenoid actuators 234. Movement of the guide block 216 is generally orthogonal to the direction of movement of the movable weld jaw 196a. In the viewing perspective of FIG. 12, the movable weld jaw guide block 216 can move to the right to a guiding position and to the left to a non-guiding position. The movable weld jaw 196a (FIG. 11) would move in and out of the page of FIG. 12, towards the viewer to a welding position and away from the viewer to a retracted position.

[0113] In an example, a first channel extension 236 and a second channel extension 238 are connected to a door 240 in a spaced apart configuration. The first and second extensions 236, 238 are configured to cover the feeding slot at both ends of the head to allow the strap to be fed around the bale through a guiding system, and then retract with the door assembly 240, including the guide block 216. However, these components do not need to be tied or integrated together to allow the strap to be retracted to loop size or load as discussed previously. Each of the two channel extensions is generally rectilinear in shape and can be incorporated to extend the strap path 178 when the door 240 and hence the guide block 216 are in the engaged position (FIGs. 11 and 13) to extend the physical route of the strap path during feeding of the strap around the bale. A base block 242 is also connected to the door 240, which is connected to the guide block 216 and laterally extends the guide block 216 away from door. In an alternative example, the guide block 216 can mount directly to the door 240 without the base block 242. The base block 242 can have a bore for accommodating the rod rail 232 and move along the rod rail, which can be generally circular in cross-section but can be practiced with other shaped cross-sections.

[0114] The two solenoid actuators 234 are arranged to move the door 240 to then move the base block 242 to move the guide block 216 between the retracted position 222 of FIG. 12 to the engaged position 224 of FIG. 13, which shows the solenoid actuators de-energized. Movement of the door 240 also moves the first channel extension 236 and the second channel extension 238 located at two ends of the door. To keep the door 240 moving evenly between the open position (FIG. 12) and the closed position (FIG. 13) by the two separate solenoid actuators 234, a balance bar 244 is connected at two ends to mechanical fittings that are thenconnected to the shafts of the two solenoid actuators 234. The balance bar 244 in combination with the door 240 forces the two shafts to move together to simulate a synced movement to then move the door and components connected to the door evenly and squarely. In alternative embodiments, the two shafts can be connected to the door 240 and reinforced to the door to move evenly and squarely without the balance bar.

[0115] FIG. 14 represents a side view of FIG. 12, shown without the door and the guide block for clarity. FIG. 14A is an enlarged view of the central part of FIG. 14, which shows the welding module 166 in enlarged detail. A probe assembly 246 having at least one probe or bar 220, preferably at least two probes or bars 220, is shown connected to a carrier 248, which also has the movable weld jaw 196a mounted thereto. Each of the two probes 220 has a free end that projects forward of the weld jaw surface by a probe weld gap. In other words, the probe free ends are located beyond or forward of the weld jaw surface of the movable weld jaw 196a. The probe free ends are configured to abut or contact the guide block 216 when the guide block is in the guiding position to prevent the movable weld jaw from moving to the welding position during the strap feeding operation (FIG. 23 A). The probe free ends are also configured to abut a structure adjacent the stationary weld jaw 196b to space the two weld jaws 196a, 196b from physically contacting one another to prevent damage and / or excessive wear. Thus, the when the probes 220 contact a set wall or surface adjacent the stationary weld jaw, as further discussed below, a weld gap is defined between the two weld jaws. In an embodiment, the probe weld gap has a length or distance that can be adjusted to control the weld gap or spacing between the two weld jaws 196a, 196b. Alternatively, the stationary weld jaw 196b can be adjusted to adjust the weld gap between the two weld jaws. This also prevents damage when the movable weld head is operated without any strap to weld. The two jaws cannot contact each other.

[0116] FIG. 15 shows the movable weld jaw 196a moved to the welding position for welding portions of the overlapping section 192 of the tie strap 168a at the weld zone 190. Thus, FIG. 15 shows the movable weld jaw 196a moved from the retracted position of FIG. 14 to the welding position, ready for welding the two end sections of the tie strap together at the weld zone 190. FIG. 15A is an enlarged view of the central portion of FIG. 15, which shows the welding module 166 in fuller detail. The actuator 230 moves the linkage system 228 which moves the carrier 248 to move the movable weld jaw 196a towards the stationary weld jaw 196b. A welding gap 250 is located between the two weld jaws, where the overlapping section 192 (FIG. 21) of the tie strap is positioned to be welded by the weld jaws.

[0117] A jaw block 252 is connected to a bracket 254, which is connected to the frame 258 of the strap welder 112. The jaw block 252 can have the fixed weld jaw 196b mounted thereto and a set wall 256. The set wall 256 presents a surface for the two probes 220 to advance against and contact to then set the weld gap 250 between the two weld jaws 196a, 196b. Thus, the two probes 220 are configured to either contact the guide block 216 when the guide block is in the engaged position to protect the movable weld jaw or to contact the set wall 256 on the jaw block 252 to set the weld gap of the two weld jaws during welding, when the guide block is retracted.

[0118] FIG. 16 shows the movable weld jaw 196a in the welding position, similar to FIG.15, but at a different viewing perspective as if the two weld jaws contact but they do not and maintain a weld gap between them. FIG. 16A is an enlarged view of the central section of FIG.16. The probes 220 are shown contacting the set wall 256, as previously discussed, to prevent the two weld jaws from physically contacting. FIG. 16A shows how the weld gap 250 can be adjusted to vary the gap distance from as low as about 0.005” and larger as desired. In some examples, the weld gap can vary by adjusting the position of the fixed weld jaw 196b on the jaw block 252. Additionally or alternatively, the weld gap can vary by adjusting the position of the probe assembly 246 to change the contact point of the two probes against the set wall 256, to change the position of the movable jaw 196a relative to the probe free ends, or combinations thereof.

[0119] In a preferred embodiment, the probe weld gap is smaller than the thickness of the overlapping section of the strap. Thus, when the movable weld jaw is moved to the welding position adjacent the stationary weld jaw with the overlapping section of the strap located therebetween, the two weld jaws can begin welding the strap without the at least one probe on the probe assembly touching or advancing against the set wall. Thus, using only pressure applied by the linkage system on the movable weld jaw to press the strap between the two weld jaws, the strap can be welded when the movable weld jaw oscillates back-and-forth to from the cross-weld. Weld time is also utilized to control and / or generate the weld. That is, when the weld time for oscillating the movable weld jaw is controlled to operate between 1 and 2 seconds, the cross-welding has been shown to produce acceptable welds for maintaining the bale in a pressed position. As a general rule, a range of time could be used with a variation of pressure. For example, a light pressure would require a relatively longer time to weld, longer than 2 seconds, such as six seconds.

[0120] FIG. 25 shows a top view of the movable weld jaw 196a in a welding position, similar to FIG. 15A but in a simplified view from a top perspective. As shown, the probes 220 (only one shown) of the probe assembly 246 contacts the set wall 256 of the jaw block 252 to maintain a weld gap 250 between the two weld jaws 196a, 196b. In the present embodiment, the movable weld jaw 196a is attached to the carrier 248 via a plurality of connecting links 262, which can be solid metallic structures with openings for connecting to the movable weld jaw and to the carrier via pins, shafts, or rods. Thus, the movable weld jaw 196a is movable relative to the carrier 248 via four pivot points 264. In an example, there can be two pairs of connecting links 262 or four total connecting links. Optionally, only two connecting links are used to connect the weld jaw 196a and the carrier 248. In alternative examples, the connecting links 262 can embody flat springs or leaf springs, which can allow flexing and relative movement between the movable weld jaw 196a and the carrier 248 without the need for pivot points. In still yet other examples and because the movable weld jaw 196a moves very little, albeit at high speed, the connecting links 262 may be solidly or integrally formed with the carrier 248.

[0121] The movable weld jaw 196a is rotated by a connecting rod 266, via a wrist pin 275. The connecting rod 266 is connected to a crank which is connected to a drive shaft 270. Thus, rotation of the drive shaft 270, such as with an electric motor, a server motor, a high speed stepper motor 272, or by one of the listed drivers with a ratio pulley system driven by a belt, will impart a lateral displacement on the crank which then imparts lateral displacing on the connecting rod 266 relative to the drive shaft to cause the movable weld jaw 196a to move side-to-side, in the direction of the double-arrow 268. In practice, the overlapping section 192 of the tie strap 168a would be located at the weld gap 250 and projects in-and-out of the page of FIG. 25. The side-to-side motion 268 of the movable weld jar 196a would therefore create a frictional cross-weld that is angled to the edges of the overlapping section 192 of the tie strap 168a (FIG. 23). A stepper, servo, air-powered, or electric motor running at high speed can generate enough rpm, optionally in combination with a gearing or pulley system, at the weld jaws to produce the desired friction welds.

[0122] FIG. 26 shows an alternative to the welding module of FIG. 25. In the present embodiment, the movable weld jaw 196a is connected to a cylindrical frame or housing 274, which is mounted over a rod or shaft 276 on the probe assembly 246. The shaft 276 located in the cylindrical frame 274 resembles a shaft sliding in a sleeve bearing. The probe assembly 246 is then connected to a carrier 248, which is connected to a linkage system 278. Themovable weld jaw 196a is movable by a connecting rod 266 as discussed above with reference to FIG. 25. Thus, the current configuration allows the movable weld jaw 196a to move relative to the carrier 248 and relative to the stationary weld jaw 196b via a sleeve bearing type configuration to then perform a frictional weld on an overlapping section of the tie strap 168a.

[0123] With reference now to FIG. 17, a weld head kit 280 is shown spaced from the frame 258 of the strap welder 112. The weld head kit 280 is a modular design of a sub-assembly of the strap welder 112 that is configured to quickly exchange or swap out whenever one or more parts located on the strap welder wears or breaks. Thus, rather than troubleshoot and / or repair components on the strap welder 112 and taking the entire baling press assembly 100 (FIG. 1) out of service for an extended period, a technician can quickly replace the entire weld head kit 280 with a new weld head kit 280 and then either repair the removed kit for future re-use or dispose of the removed kit entirely. The use of the weld head kit 280 in accordance with aspects of the present allows the operator to quickly get the strap welder 112 and the baling press assembly 100 back up in service whenever one or more components on the weld head kit 280 break down. The weld head kit 280 is therefore a standalone unit that can be commercialized along with a complete strap welder 112 described elsewhere herein.

[0124] In an example, the weld head kit 280 comprises a frame 282 having a driver 272, which can be a stepper, servo, or electric motor. The driver 272 is connected to a pulley system 284 via a drive belt, which is configured to drive a crank to then drive a connecting rod, as previously discussed. A movable weld jaw 196a can also be provided with the weld head kit 280. The weld jaw 196a can move via a sleeve bearing type system, one or more flat springs, or connecting links, as previously discussed. In some example, a probe assembly 246 having a pair of probes 220 can also be provided with the kit. The probe assembly 246 can be the same as one of the probe assemblies discussed elsewhere herein. The weld head kit 280 is modular and can be assembled and disassembled from the frame 258 of the strap welder using traditional fasteners, shims, washers, and mechanical / electrical connectors as needed.

[0125] In alternative embodiments, a weld head kit 280 can have fewer or more components than described hereinabove and shown in FIG. 17. For example, the kit can have all of the components mentioned except for a driver, which can be re-used from the older removed kit for use on the newly replaced kit. The driver, which can be a stepper motor, a servo motor, an electric motor, or an air-powered motor, could also be set up as a direct drive to omit the need for any step up or step down components.

[0126] With reference now to FIG. 18, a strap dispensing kit or feeder kit 286 is shown spaced from the frame 258 of a strap welder 112. Like the weld head kit 280 of FIG. 17, the strap dispensing kit 286 is a modular design of a sub-assembly of the strap welder 112 that is configured to quickly exchange or swap out whenever one or more parts located on the strap welder wears or breaks. Thus, rather than troubleshoot and / or repair components located on the strap welder and taking the entire baling press assembly down for an extended period, a technician can quickly replace the entire strap dispensing kit or feeder 286 with a new strap dispensing kit 286 and then either repair the removed kit for future re-use or dispose of the removed kit entirely. The use of the strap dispensing kit 286 in accordance with aspects of the present allows the operator to quickly get the strap welder 112 back up in service whenever one or more components on dispensing module of the strap welder break down. The strap dispensing kit 286 is therefore a standalone unit that can be commercialized along with a complete strap welder 112 described elsewhere herein.

[0127] In an example, the strap dispensing kit 286 comprises a frame 288 having a smooth feeder wheel 174, two or more tension wheels 176, a drive pulley system 290 for turning the feeder wheel 174, a down ratio belt gearbox having a large wheel 292 and a reduced wheel 294. The strap dispensing kit 286 is modular and can be assembled and disassembled from the frame of the strap welder using traditional fasteners, shims, washers, and mechanical / electrical connectors.

[0128] In alternative embodiments, a strap dispensing kit 286 can have fewer or more components than described hereinabove. For example, the kit can use a different drive system with fewer wheels or different ratios, or can be driven directly by a driver without any step up or step down components.

[0129] As described herein, aspects of the invention include a strap welder comprising a probe assembly 246 having at least one probe 220 with a free end, which is understood as an end that is not attached or connected to any other component. The free end of the at least one probe extends beyond a weld surface of the movable weld jaw 196a by a probe weld gap. Thus, when a guide block, which is attached to a door 240, is in the engaged position or when the door is in the closed position, the movable weld jaw 196a is prevented from contacting the guide block by the presence of the free end of the at least one probe, which projects forward of the weld surface of the movable weld jaw and therefore contacts the guide block before the movable weld jaw can contact the guide block.

[0130] Also as described herein, aspects of the invention include a strap welder comprising a probe assembly 246 having at least one probe 220 with a free end, which is understood as an end that is not attached or connected to any other component. When the guide block 216 is in a non-guiding position or retracted position and the movable weld jaw 196a is in a welding position, the at least one probe 220 and / or the probe assembly 246 having the at least one probe provides a physical presence that prevents the guide block 216 returning to the engaged or guiding position. The presence of the at least one probe 220 and / or the probe assembly 246 therefore prevents the guide block 216 from contacting and possibly damaging the movable weld jaw 196a when in the weld jaw is in the welding position. As the guide block 216 is mounted to the door 240, the at least one probe 220 and / or the probe assembly 246 also prevents the door from moving from the open position to the closed position when the movable weld jaw is in the welding position.

[0131] Also as described herein, aspects of the invention include a strap welder comprising a probe assembly 246 having at least one probe 220 and wherein the probe is configured to contact a set wall 256 on a jaw block 252 of the stationary weld jaw 196b to maintain a weld gap between the two weld jaws. The weld gap can be adjusted to reduce or increase in length. Incorporating the weld gap prevents the two weld jaws from coming together to undesirably wear. Maintaining an appropriate weld gap also produces a better frictional weld than when the weld gap is overly tight.

[0132] In a still further aspect of the invention, when a guide block 216 is in a guiding position and a door 240, to which the guide block 216 is connected, is in a closed position or state to facilitate guiding a strap 168 around a bale, the probe assembly 246 having at least one probe 220 can begin to load or press, i.e., pre-loading, against the guide block 216 before the guide block begins to move to the non-guiding position or retracted position. This pre-loading configuration allows the movable weld jaw 196a, which is connected to the probe assembly, to move to the welding position faster compared to waiting for the guide block to first move to the non-guiding position before activating to move to the welding position. By pre-loading, this allows the two weld jaws 196a, 196b to get into the welding position at the weld zone sooner to begin welding compared to when the movable weld jaw waits for the guide block to first retract before the movable weld jaw activates to move to the welding position.

[0133] In a still further aspect of the invention, when the two weld jaws are in the welding position to weld a tie strap, the guide block 216 can begin to load or press, i.e., pre-loading, against the at least one probe 220 and / or the probe assembly 246 before the welding is completeand the movable weld j aw 196a returns to the retracted position. This pre-loading configuration allows the door 240 and the guide block 216 to move to the closed position and the guiding position, respectively, faster compared to waiting for the movable weld jaw 196a to first move to retracted position before activating the door to move to the closed position and the guide block to move to the guiding position. This pre-loading configuration allows the door 240 to push the tie strap out from the weld area quicker when the door is moved from the open position or state to the closed position compared to when the door and the guide block wait for the movable weld jaw 196a to first retract before activating to move to the closed position and the guiding position, respectively.

[0134] In an example, pre-loading of the door and / or guide block and pre-loading of the probe and / or probe assembly comprises pressuring an air actuator cylinder with air pressure before the prior sequence or operation is complete.

[0135] Example Embodiments

[0136] The following are numbered example embodiments of the apparatuses, devices, systems, and methods related to bailing press assemblies and strap welders. The below listing of examples or any other examples disclosed herein may be combined in whole or in part. Elements of the examples disclosed herein are not limiting.

[0137] Example 1. A baling press assembly comprising: a baling chamber, the baling chamber being sized and shaped to receive a fibrous material and compressing the fibrous material into a pressed bale; a bale strapping device comprising a frame and a plurality of strap welders mounted to the frame, the bale strapping device being mounted on or proximate a baling press assembly to strap a presented formed bale; a return chute assembly comprising a plurality of spaced apart individual return chutes, each individual return chute comprising a receiving end, an exit end, and a through channel therebetween; each strap welder comprising a frame having a welding module and a dispensing module, wherein the welding module comprises a stationary weld jaw located adjacent a set wall, a movable weld jaw, and a probe assembly comprising at least one probe having a free end, wherein the probe assembly and the movable weld jaw are mechanically coupled to a carrier that is movable by a linkage system, and wherein dispensing module comprises a frame and having at least one feeder wheel and a plurality of tension wheels mounted to the frame of the dispensing module; and wherein the free end is configured to abut the set wall to maintain a gap between the stationary weld jaw and the movable weld jaw to prevent physical contact between the stationary and movable weld jaws.

[0138] Example 2. Wherein the gap is adjustable to increase or decrease.

[0139] Example 3. The baling press assembly can further comprise a strap path extending through a length of the frame of the strap welder and a guide block having a channel aligned with the strap path when in a guiding position and not aligned with the strap path when in a non-guiding position.

[0140] Example 4. The baling press assembly wherein the free end can be configured to contact the guide block when the guide block is in the guiding position.

[0141] Example 5. The baling press assembly wherein the guide block can be prevented from returning to the guiding position when the movable weld jaw is in the welding position.

[0142] Example 6. The baling press assembly can further comprise a door, the door and the guide block can be movable by an actuator.

[0143] Example 7. The baling press assembly wherein the door can be movable between a closed position and an open position, and wherein the door can be prevented from returning to the closed position when the movable weld jaw is in the welding position.

[0144] Example 8. The bailing press assembly wherein a first channel extension can be attached to a first end of the door and can be spaced from a second channel extension, which is attached to a second end of the door.

[0145] Example 9. The bailing press assembly wherein the guide block can be fastened to the door.

[0146] Example 10. The bailing press assembly wherein the guide block comprises a channel for guiding a strap.

[0147] Example 11. The bailing press assembly can further comprise a stop surface spaced form the channel, and wherein the probe assembly can be configured to contact the stop surface to prevent movement of the movable weld jaw into contact with the stationary weld jaw.

[0148] Example 12. The baling press assembly wherein the free end can be configured to push against the guide block before the guide block moves to the non-guiding position and before the movable weld jaw moves to the welding position.

[0149] Example 13. The baling press assembly wherein the guide block can be configured to push against the probe assembly while the movable weld jaw is in the welding position.

[0150] Example 14. The baling press assembly wherein the free end can be configured to push against the guide block by pressurizing air inside a first cylinder.

[0151] Example 15. The baling press assembly wherein the guide block can be configured push against the probe assembly by pressuring air inside a second cylinder.

[0152] Example 16. The baling press assembly wherein the strap path defines a first direction, and wherein the movable weld jaw is movable along a second direction, orthogonal to the first direction.

[0153] Example 17. The bailing press assembly wherein the guide block can be movable in the second direction.

[0154] Example 18. The bailing press assembly can further comprise a door, and wherein the door defines part of the strap path.

[0155] Example 19. The bailing press assembly wherein the guide block can be mounted on the door.

[0156] Example 20. The baling press assembly can further comprise a pair of alignment bars located along the strap path.

[0157] Example 21. The baling press assembly wherein the pair of alignment bars can comprise a first alignment bar and a second alignment bar, and wherein part of the strap path passes between the first alignment bar and the second alignment bar.

[0158] Example 22. The baling press assembly can further comprise a single alignment bar located above the pair of alignment bars, and wherein part of the strap path passes between the single alignment bar and part of a wall of the strap welder.

[0159] Example 23. The baling press assembly wherein each the first and second alignment bars of the pair of alignment bars has a remote end and an opposite end, an exterior surface, and an interior surface, and wherein the two interior surfaces at the remote end has a first gap.

[0160] Example 24. The baling press assembly wherein the two interior surfaces of the first and second alignment bars at a location closer to the opposite end than the remote end has a second gap.

[0161] Example 25. The baling press assembly wherein the second gap can be larger than the first gap.

[0162] Example 26. The baling press assembly wherein a strap has a first end section and second end section, and wherein the first end section can be held at the first gap and the second end section can be held at the second gap when the guide block is in the guiding position.

[0163] Example 27. The baling press assembly wherein the second end section can be located at the first gap with the first end section when the guide block moves to the non-guiding position and the movable weld jaw moves to a welding position.

[0164] Example 28. The bailing press assembly wherein a cutter has a body with a length, a blunt end at a first end of the body and a cutting edge located at a second end of the body, and wherein the body can be configured to translate in a direction parallel to a lengthwise axis of the first or the second alignment bar.

[0165] Example 29. The bailing press assembly wherein the pair of alignment bars are mounted to a lever arm and the lever arm is movable by an actuator.

[0166] Example 30. The bailing press assembly wherein the lever arm can be pivotably connected to the frame of the strap welder.

[0167] Example 31. The bailing press assembly wherein a weld head kit comprising a frame having the movable weld jaw and the probe assembly mounted thereto is removable from the frame of the strap welder.

[0168] Example 32. The bailing press assembly wherein the dispensing module can be removable from the frame of the strap welder.

[0169] Example 33. A strap welder for use with a bailing press assembly, the strap welder comprising: a frame having a welding module and a dispensing module, and wherein the welding module comprises a stationary weld jaw locate adjacent a set wall, a movable weld jar, and a probe assembly comprising at least one probe having a free end, wherein the probe assembly and the movable weld jaw are mechanically coupled to a carrier that is movable by a linkage system; wherein the dispensing module comprises a frame having at least one feeder wheel and a plurality of tension wheels mounted to the frame; and wherein the free end is configured to abut the set wall to maintain a gap between the stationary weld jaw and the movable weld jaw to prevent physical contact between the stationary and movable weld jaws.

[0170] Example 34. The strap welder wherein the gap can be adjustable to increase or decrease.

[0171] Example 35. The strap welder can further comprise a strap path extending through a length of the frame of the strap welder and a guide block having a channel aligned with the strap path when in a guiding position and not aligned with the strap path when in a non-guiding position.

[0172] Example 36. The strap welder wherein the guide block can be movable in a direction transverse to the strap path.

[0173] Example 37. The strap welder wherein the guide block can be attached to a door, and wherein the door defines at least part of the strap path.

[0174] Example 38. The strap welder wherein the free end can be configured to contact the guide block when the guide block is in the guiding position.

[0175] Example 39. The strap welder wherein the guide block can be prevented from returning to the guiding position when the movable weld jaw is in the welding position.

[0176] Example 40. The strap welder can further comprise a door, the door and the guide block being movable by an actuator.

[0177] Example 41. The strap welder can further comprise a second actuator spaced from the actuator for moving the door.

[0178] Example 42. The strap welder can further comprise a balance bar having two ends mechanically connected to the actuator and the second actuator.

[0179] Example 43. The strap welder wherein the door can be movable between a closed position and an open position, and wherein the door is prevented from returning to the closed position when the movable weld jaw is in the welding position.

[0180] Example 44. The strap welder wherein the free end can be configured to push against the guide block before the guide block moves to the non-guiding position.

[0181] Example 45. The strap welder wherein the guide block can be configured to push against the probe assembly while the movable weld jaw is in the welding position.

[0182] Example 46. The strap welder wherein the free end can be configured to push against the guide block by pressurizing air inside a first cylinder.

[0183] Example 47. The strap welder wherein the guide block can be configured to push against the probe assembly by pressuring air inside a second cylinder.

[0184] Example 48. The strap welder wherein the strap path defines a first direction, and wherein the movable weld jaw is configured to move along a second direction, orthogonal to the first direction.

[0185] Example 49. The strap welder can further comprise a pair of alignment bars located along the strap path.

[0186] Example 50. The strap welder wherein the pair of alignment bars comprises a first alignment bar and a second alignment bar, and wherein part of the strap path passes between the first alignment bar and the second alignment.

[0187] Example 51. The strap welder can further comprise a single alignment bar located above the pair of alignment bars, and wherein the single alignment bar and a wall of the strap welder defines a guide channel for a strap.

[0188] Example 52. The strap welder wherein each of the first and second alignment bars has a remote end and an opposite end, an exterior surface, and an interior surface, and wherein the two interior surfaces at the remote end has a first gap.

[0189] Example 53. The strap welder wherein the two interior surfaces of the first and second alignment bars at a location closer to the opposite end than the remote end have a second gap-

[0190] Example 54. The strap welder wherein the second gap can be larger than the first gap-

[0191] Example 55. The strap welder wherein a strap has a first end section and second end section, and wherein the first end section is held at the first gap and the second end section is held at the second gap when the guide block is in the guiding position.

[0192] Example 56. The strap welder wherein the second end section can be located at the first gap with the first end section when the guide block moves to the non-guiding position and the movable weld jaw moves to a welding position.

[0193] Example 57. The strap welder can further comprising a cutter, the cutter has a body with a length, a blunt end at a first end of the body and a cutting edge located at a second end of the body, and wherein the body is configured to translate in a direction parallel to a lengthwise axis of the first or the second alignment bar.

[0194] Example 58. The strap welder wherein the movable weld jaw can be located on a frame of a weld head kit and the frame of the weld head kit and the movable weld jaw are removable from the frame of the strap welder as a unit.

[0195] Example 59. The strap welder wherein the movable weld jaw can be connected to a wrist pin, a connecting rod, and a crank.

[0196] Example 60. The strap welder wherein the crank can be rotatable by a driver or a pulley system connected to the driver.

[0197] Example 61. The strap welder wherein the movable weld jaw can be connected to a carrier by a plurality of connecting links, by at least one flat spring, or by a sleeve.

[0198] Example 62. The strap welder wherein the dispensing module can be connected to a frame of a strap dispensing kit, and the frame of the strap dispensing kit and the feeder wheel and plurality of tension wheels are removable from the frame of the strap welder as a unit.

[0199] Example 63. The strap welder wherein the single alignment bar can be fixed from moving and the pair of alignment bars is translatable.

[0200] Example 65. The strap welder wherein the movable weld jaw can be translatable by a probe carrier.

[0201] Example 66. The strap welder wherein the movable weld jaw can be mounted to the probe carrier by a plurality of connecting links or flat springs,

[0202] Example 67. The strap welder wherein the frame can be attached to a bale strapping device of a bailing press assembly.

[0203] Example 68. The strap welder wherein the bailing press assembly comprises: a baling chamber, the baling chamber being sized and shaped to receive a fibrous material and compressing the fibrous material into a pressed bale; and a return chute assembly comprising a return chute, the return chute comprising a receiving end, an exit end, and a through channel therebetween.

[0204] Example 69. The strap welder wherein the strap welder can be a first strap welder and further comprising a second strap welder and a third strap welder mounted to the bale strapping device.

[0205] Example 70. The strap welder wherein the return chute can be a first return chute and further comprising a second return chute and a third return chute mounted to the return chute assembly.

[0206] Example 7E A weld head kit comprising: a frame; a first sub-unit comprising a movable weld jaw attached to a carrier mounted to the frame; and a second sub-unit comprising a crank and a connecting rod driven by a driver, wherein the driver, the crank, and the connecting rod are mounted to the frame; and wherein the frame, the first sub-unit, and the second sub-unit are mountable on a frame of a strap welder as a unit and removable from the frame of the strap welder as a unit.

[0207] Example 72. The weld head kit can further comprise a linkage system mounted to the frame for moving the movable weld jaw.

[0208] Example 73. A strap dispensing kit comprising: a frame; a first sub-unit comprising feeder wheel and a plurality of tension wheels mounted to the frame; and wherein the frame and the first sub-unit are mountable on a frame of a strap welder as a unit and removable from the frame of the strap welder as a unit.

[0209] Example 74. A strap welder for use with a bailing press assembly, the strap welder comprising: a frame having a welding module and a dispensing module, wherein the welding module comprises a stationary weld jaw and a movable weld jar; wherein the dispensing module comprises a frame having at least one feeder wheel; and wherein a guide block ismovable to a guiding position to guide a strap and moveable to a non-guiding position to allow welding of two strap ends between the movable weld jaw and the stationary weld jaw.

[0210] Methods of making and of using the bale press or bale press assembly, strap welder, and components thereof are within the scope of the present invention.

[0211] Although exemplary embodiments of a baling press assembly and components thereof, including methods for strapping a bale and for making a baling press and strap assemblies have been described, it will be appreciated by one of ordinary skill in the art that modifications may be made to such devices, assemblies, and methods while still remaining within the scope of the appended claims. For example, although an exemplary embodiment of a bale strapping device of the present invention includes three strap welders mounted on the strap positioning assembly and six return chutes mounted on the return chute assembly, the bale strapping device may be modified to include a variety of strap assemblies and return chutes to provide the appropriate number of necessary straps. Further modifications include incorporating a pre-load configuration for various sub-steps in order to speed up the overall strap dispensing and welding process. Alignment bars having alignment interior surfaces can also be incorporated to align two strap end sections of a tie strap in order to generate a clean aligned weld.

Claims

WHAT IS CLAIMED IS:

1. A baling press assembly comprising: a baling chamber, the baling chamber being sized and shaped to receive a fibrous material and compressing the fibrous material into a pressed bale; a bale strapping device comprising a frame and a plurality of strap welders mounted to the frame, the bale strapping device being mounted on or proximate a baling press assembly to strap a presented formed bale; a return chute assembly comprising a plurality of spaced apart individual return chutes, each individual return chute comprising a receiving end, an exit end, and a through channel therebetween; each strap welder comprising a frame having a welding module and a dispensing module, wherein the welding module comprises a stationary weld jaw located adjacent a set wall, a movable weld jaw, and a probe assembly comprising at least one probe having a free end, wherein the probe assembly and the movable weld jaw are mechanically coupled to a carrier that is movable by a linkage system, and wherein dispensing module comprises a frame and having at least one feeder wheel and a plurality of tension wheels mounted to the frame of the dispensing module; and wherein the free end is configured to abut the set wall to maintain a gap between the stationary weld jaw and the movable weld jaw to prevent physical contact between the stationary and movable weld jaws.

2. The baling press assembly of claim 1, wherein the gap is adjustable to increase or decrease.

3. The baling press assembly of claim 1, further comprising a strap path extending through a length of the frame of the strap welder and a guide block having a channel aligned with the strap path when in a guiding position and not aligned with the strap path when in a non-guiding position.

4. The baling press assembly of claim 3, wherein the free end is configured to contact the guide block when the guide block is in the guiding position.

5. The baling press assembly of claim 3, wherein the guide block is prevented from returning to the guiding position when the movable weld jaw is in the welding position.

6. The baling press assembly of claim 3, wherein the free end is configured to push against the guide block before the guide block moves to the non-guiding position and before the movable weld jaw moves to the welding position.

7. The baling press assembly of claim 3, wherein the guide block is configured to push against the probe assembly while the movable weld jaw is in the welding position.

8. The baling press assembly of claim 3, wherein the strap path defines a first direction, and wherein the movable weld jaw is movable along a second direction, orthogonal to the first direction.

9. The baling press assembly of claim 3, further comprising a pair of alignment bars located along the strap path.

10. The baling press assembly of claim 20, wherein the pair of alignment bars comprises a first alignment bar and a second alignment bar, and wherein part of the strap path passes between the first alignment bar and the second alignment bar.

11. A strap welder for use with a bailing press assembly, the strap welder comprising: a frame having a welding module and a dispensing module, and wherein the welding module comprises a stationary weld jaw locate adjacent a set wall, a movable weld jar, and a probe assembly comprising at least one probe having a free end, wherein the probe assembly and the movable weld jaw are mechanically coupled to a carrier that is movable by a linkage system; wherein the dispensing module comprises a frame having at least one feeder wheel and a plurality of tension wheels mounted to the frame; and wherein the free end is configured to abut the set wall to maintain a gap between the stationary weld jaw and the movable weld jaw to prevent physical contact between the stationary and movable weld jaws.

12. The strap welder of claim 11, wherein the gap is adjustable to increase or decrease.

13. The strap welder of claim 11, further comprising a strap path extending through a length of the frame of the strap welder and a guide block having a channel aligned with the strap path when in a guiding position and not aligned with the strap path when in a non-guiding position.

14. The strap welder of claim 11, wherein the movable weld jaw is located on a frame of a weld head kit and the frame of the weld head kit and the movable weld jaw are removable from the frame of the strap welder as a unit.

15. The strap welder of claim 11, wherein the dispensing module Is connected to a frame of a strap dispensing kit, and the frame of the strap dispensing kit and the feeder wheel and plurality of tension wheels are removable from the frame of the strap welder as a unit.

16. The strap welder of claim 11, wherein the frame is attached to a bale strapping device of a bailing press assembly.

17. A weld head kit for se with a strap welder comprising: a frame; a first sub-unit comprising a movable weld jaw attached to a carrier mounted to the frame; and a second sub-unit comprising a crank and a connecting rod driven by a driver, wherein the driver, the crank, and the connecting rod are mounted to the frame; and wherein the frame, the first sub-unit, and the second sub-unit are mountable on a frame of a strap welder as a unit and removable from the frame of the strap welder as a unit.

18. The weld head kit of claim 17, further comprising a linkage system mounted to the frame for moving the movable weld jaw.

19. A strap dispensing kit for use with a strap welder comprising: a frame; a first sub-unit comprising feeder wheel and a plurality of tension wheels mounted to the frame; and wherein the frame and the first sub-unit are mountable on a frame of a strap welder as a unit and removable from the frame of the strap welder as a unit.

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