U.S. patent application number 14/449934 was filed with the patent office on 2016-02-04 for net wrap and twine removal system and methods.
The applicant listed for this patent is POET Research, Inc.. Invention is credited to Joshua W.D. Dockstader, Todd L. Peterson, Steven G. Redford, John N. Smith.
Application Number | 20160031579 14/449934 |
Document ID | / |
Family ID | 55179243 |
Filed Date | 2016-02-04 |
United States Patent
Application |
20160031579 |
Kind Code |
A1 |
Redford; Steven G. ; et
al. |
February 4, 2016 |
NET WRAP AND TWINE REMOVAL SYSTEM AND METHODS
Abstract
A method of removing a wrapping material from the outer surface
of a bale of material including the steps of moving the bale of
material to a cutting station, cutting wrapping material along a
length of the bale, moving a plurality of rollers into contact with
the wrapping material, rotating the rollers relative to the
wrapping material until first and second ends of the wrapping
material are free to move relative to an outer surface of the bale,
placing a first spear of a material wind-up system between the
outer surface of the bale and the wrapping material, rotating the
material wind-up system to wind the wrapping material around first
and second spears, positioning the first and second spears in a
generally horizontal plane, and stripping the wrapping material
from the first and second spears with a fin that extends downwardly
from a carriage of a material removal system and between the first
and second spears of the material wind-up station by sliding the
carriage toward a distal end of the first and second spears.
Inventors: |
Redford; Steven G.;
(Brandon, SD) ; Smith; John N.; (Sioux Falls,
SD) ; Dockstader; Joshua W.D.; (Sioux Falls, SD)
; Peterson; Todd L.; (Sioux Falls, SD) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
POET Research, Inc. |
Sioux Falls |
SD |
US |
|
|
Family ID: |
55179243 |
Appl. No.: |
14/449934 |
Filed: |
August 1, 2014 |
Current U.S.
Class: |
53/492 ;
53/381.2 |
Current CPC
Class: |
B65H 2301/46043
20130101; B65H 2701/177 20130101; B65H 2701/1944 20130101; B65B
69/0025 20130101; B65H 19/105 20130101; B65H 2301/41382
20130101 |
International
Class: |
B65B 69/00 20060101
B65B069/00; B65H 18/08 20060101 B65H018/08 |
Claims
1. A method of removing a wrapping material from the outer surface
of a bale of material, comprising the steps of: moving the bale of
material to a cutting station, wherein an outer surface of the bale
of material is at least partially surrounded by the wrapping
material; cutting the wrapping material along a length of the bale
in a longitudinal direction to form a first end and a second end of
the wrapping material; moving a plurality of rollers into contact
with the wrapping material; rotating the plurality of rollers
relative to the wrapping material until the first and second ends
of the wrapping material are free to move relative to an outer
surface of the bale; placing a first spear of a material wind-up
system between the outer surface of the bale and the wrapping
material, wherein the material wind-up system further comprises a
second spear spaced from the first spear; rotating the material
wind-up system to wind the wrapping material around the first and
second spears; positioning the first and second spears in a
generally horizontal plane; and stripping the wrapping material
from the first and second spears with a fin that extends downwardly
from a carriage of a material removal system and between the first
and second spears of the material wind-up station by sliding the
carriage toward a distal end of the first and second spears.
2. The method of claim 1, wherein the step of stripping the
wrapping material comprises a step of moving the fin from a
retracted position to an extended position prior to sliding the
carriage toward the distal ends of the spears.
3. The method of claim 2, wherein the fin is pivotable between the
retracted position and the extended position.
4. The method of claim 2, wherein the fin is vertically moveable
between the retracted position and the extended position.
5. The method of claim 1, wherein the bale of material is one of a
cylindrical bale and a cubical bale.
6. The method of claim 1, wherein the step of stripping the
wrapping material from a first bale of material is performed
simultaneously with at least one of the steps of moving a second
bale of material to the cutting station, cutting the wrapping
material from the second bale of material, moving the plurality of
rollers, and rotating the plurality of rollers relative to the
wrapping material of the second bale of material.
7. The method of claim 1, wherein the step of stripping wrapping
material from a first bale of material is completed prior to a step
of moving a second bale of material to the cutting station.
8. A system for unwrapping and removing wrapping material from a
bale of material, the system comprising: a cutting station
comprising a cutting mechanism for cutting a length of wrapping
material that is at least partially surrounding an outer surface of
the bale of material; a material pulling station for freeing cut
edges of the wrapping material from the outer surface of the bale
of material; a material wind-up station comprising at least two
spears extending from a base plate, wherein the spears are
vertically positionable so that at least one of the spears is
vertically located between the wrapping material and the outer
surface of the bale of material, and wherein the at least two
spears are rotatable to wind the wrapping material around an outer
surface of the spears; a material stripping station comprising a
longitudinal slot extending along at least a portion of a length of
an elongated member, a carriage that is slideable along at least a
portion of the slot, and a fin that is moveable relative to the
carriage; a conveyor for conveying the bale of material from an
entry end of the system to an exit end of the system.
9. The system of claim 8, wherein the fin is retractable and
extendable relative to a bottom surface of the elongated
member.
10. The system of claim 9, wherein the fin comprises an extended
position in which a distal end of the fin is positioned below the
at least two spears when the spears are positioned in a generally
horizontal plane.
11. The system of claim 10, wherein the fin comprises a retracted
position in which the distal end of the fin is positioned above the
at least two spears when the spears are positioned in a generally
horizontal plane.
12. A system for unwrapping and removing wrapping material from at
least one of a cylindrical and a cubical bale of material, the
system comprising: a cutting station comprising a cutting mechanism
for cutting a length of wrapping material that is at least
partially surrounding an outer surface of the bale of material,
wherein the cutting station is adaptable for interchangeably
accepting cylindrical and cubical bales of material; a material
pulling station for freeing cut edges of the wrapping material from
the outer surface of the bale of material; a material wind-up
station comprising at least two spears extending from a base plate,
wherein the spears are vertically positionable so that at least one
of the spears is vertically located between the wrapping material
and the outer surface of the bale of material; a material stripping
station comprising a longitudinal slot extending along at least a
portion of a length of an elongated member, a carriage that is
slideable along at least a portion of the slot, and a fin that is
moveable relative to the carriage; a conveyor for conveying the
bale of material from an entry end of the system to an exit end of
the system.
13. The system of claim 12, wherein the cutting station further
comprises at least one sensor for determining the size and location
of the bale of material.
14. The system of claim 12, wherein the cutting station further
comprises at least one positioning member.
Description
TECHNICAL FIELD
[0001] The present invention relates generally to processing large
bales of material and more particularly relates to removing
wrapping material that is used to contain the materials within the
bale prior to further processing of the bale material.
BACKGROUND
[0002] In recent years, there has been significant interest in the
production of organic chemicals, such as ethanol, from fermentable
sugars that are derived from cellulosic biomass. Useful cellulosic
biomass includes, for example, corncobs, cornstover (e.g., stalks
and leaves), switchgrass, wood chips, and other plant matter.
[0003] In order to facilitate the storage and transportation (e.g.,
to a cellulosic ethanol plant) of cellulosic biomass, the biomass
is harvested from the field and is then formed into bales. Common
bale configurations include "square bales" (e.g., a bale in the
form of a rectangular cube typically measuring about
3'.times.4'.times.8') and "round bales" (e.g., a bale in the form
of a right circular cylinder typically measuring about 6' in
diameter and 5' in length). To provide structural integrity for
storage and handling, the bales are often tied with wrapping
material such as twine, which is more typical for square bales, or
are wrapped with a net wrap or open weave material, which is more
typical for round bales.
[0004] Once the twine or net wrap is at the cellulosic processing
plant, it must be removed from the bale so that the biomass can by
fed into the organic chemical production process. Since a typical
cellulosic processing plant may process a large number of bales per
day, an automated device for the removal of twine and net wrap from
bales is desirable. In addition, since the incoming bales to the
cellulosic processing plant may consist of both square bales and
round bales of varying sizes, it is additionally desirable for a
single device to be configured to remove twine and/or net wrap from
square bales and/or round bales of varying sizes with minimal
manual input.
SUMMARY
[0005] In cellulosic ethanol processes, materials that are used to
tie or wrap individual bales of material (e.g., net wrap and/or
twine) must be removed from each bale prior to processing the bale
materials in order to avoid complications in various process
streams. That is, removing these wrapping materials is necessary to
prevent this material from causing mechanical failures or
disrupting downstream processes in other ways. Equipment and
processes of the present invention are provided to remove the
wrapping materials automatically in order to avoid the cumbersome
and time-consuming labor required to manually remove these wrapping
materials for a commercial scale cellulosic plant.
[0006] In one embodiment, the equipment and processes of the
invention include using a blade or other sharp cutting member to
cut the net wrap, twine, or other material at a location along the
length of the bottom of the bale. Such a blade may include a
rotating saw or other stationary or rotating cutting device, for
example. Such a cutting device can sever the net wrap in a
direction that is generally parallel to a longitudinal axis of a
round or cylindrical bale, and/or in a direction that is generally
parallel to one of the sides of a rectangular bale. The cutting
device can either be stationary, with the bale being conveyed past
the cutting device during the cutting operation, or the bale can be
stationary, with the cutting device traveling along the length of
the bale during the cutting operation.
[0007] After the wrapping material is cut, multiple rollers can be
moved upwardly relative to the deck on which the bale is sitting to
engage with the bale at locations that are spaced from the location
at which the wrapping material was cut. The multiple rollers can
then rotate, such as in opposite directions, in order to pull the
wrapping material away from the cut line to move the free ends from
under the bale. At this point, the wrapping material will not be
constrained by the weight of the bale and is therefore relatively
free to move relative to the bale. After this process is complete,
a removal device, which may consist of a spear system or a spear
and clamp system, can secure the wrapping material and remove it
from the outer surface of the bale. The spear system is then
rotated on a turret to wind up the wrapping material, and then a
material removal system removes the material from the clamp and
drops it on a conveyor belt or other location for disposal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The present invention will be further explained with
reference to the appended Figures, wherein like structure is
referred to by like numerals throughout the several views, and
wherein;
[0009] FIG. 1 is a perspective view of a material unwrapping and
removal system of the invention, which can be used for removal of
wrapping material from the outer surface of a bale of material;
[0010] FIG. 2 is a front view of the system of FIG. 1;
[0011] FIG. 3 is an enlarged perspective view of a top portion of a
material stripping station of the system of FIG. 1;
[0012] FIG. 4 is a bottom perspective view of a portion of the
system of FIG. 1, including a material wind-up system and a
material removal system;
[0013] FIG. 5 is a perspective view of an embodiment of a material
removal system of the invention;
[0014] FIG. 6 is a bottom perspective view of an embodiment of a
material removal system of the invention;
[0015] FIG. 7 is a top perspective view of an embodiment of a
material removal system of the invention;
[0016] FIG. 8 is a front view of an embodiment of a material
removal system of the invention;
[0017] FIGS. 9-11 are side views of a material removal system of
the invention with its carriage and fin in three sequential
positions relative to a material wind-up system of the invention;
and
[0018] FIG. 12 is a flow chart of processing steps for removing
material wrapped around a bale, in accordance with an embodiment of
the invention.
DETAILED DESCRIPTION
[0019] The systems and methods of the invention can generally be
used with bales of cellulosic biomass or other material that are
harvested and formed into bales, including bale configurations that
are cylindrical, bale configurations that are rectangular cubes in
shape, and/or bale configurations that have a different shape. To
provide structural integrity for storage and handling, the shaped
bales are initially at least partially surrounded with wrapping
material such as twine or a net wrap or other sheet-like and/or
open weave material. Although twine is typically used for wrapping
square or rectangular bales, while net wrap is typically used for
cylindrical bales, it is possible to use either or both types of
materials for bales of any shape or size. When a net wrap or open
weave material is used to wrap a bale, it typically extends along
all or most of the length of the bale, and surrounds the outer
periphery of the bale. When a twine or other elongated material is
used to wrap a bale, it is typical for the bales to have 4-6
strands or wraps of twine surrounding the outer periphery of the
bale and spaced from each other along the length of the bale,
although it is possible to have more or less twine strands or
wraps. The ends of the bales may or may not be covered or partially
covered with wrapping material. It is noted that the material
removal systems of the invention can be used with other wrapping
materials or combinations of wrapping materials, and can be used
with bales having shapes that are not cylinders or rectangular
cubes.
[0020] Referring now to the Figures, wherein the components are
labeled with like numerals throughout the several Figures, and
initially to FIGS. 1 and 2, a configuration of a material
unwrapping and removal system 10 is illustrated, which includes
various features, some of which are also included in the disclosure
of commonly owned International Publication No. WO 2013/154746, the
entire contents of which are incorporated herein by reference.
System 10 generally includes a number of stations, including a
cutting station 12, a material pulling station 14, a material
wind-up station 16, and a material stripping station 18. Individual
bales, each of which includes a layer of wrapping material at least
partially surrounding its outer surface, can move sequentially
through these stations to remove the wrapping material, as will be
described in detail below. In general, however, the system 10
includes a flat conveyor system 20 that extends along the length of
the system 10 that is used to move each bale from one end of the
system to the other. A number of different conveyor systems can be
used, wherein one exemplary system includes a series of belts
and/or chains that are positioned to be generally adjacent to each
other across the width of the system 10 and each of its stations.
The conveyor 20 may include a series of drive chains or roller
chains that are driven by an electric motor or gearbox, for
example.
[0021] The process of removing wrapping material begins by placing
a wrapped bale onto the conveyor system 20. The conveyor system 20
can be positioned so that it starts at the cutting station 12 to
allow for a bale to be loaded directly into the cutting station 12
(e.g., by a forklift operator) or may start in a location prior to
the cutting station 12 such that a bale is conveyed into the
cutting station 12 from a loading dock or other area. In either
case, the cutting station 12 optionally includes positioning
members 30 spaced from each other on opposite sides of the cutting
station width. These members 30 include rails 32 that extend from
support members 34. The rails 32 can be angled outwardly away from
the center of the cutting station 12 at their proximal ends so that
they can act as guide rails that keep a bale centered as it enters
the cutting station 12. The positioning members 30 are generally
positioned at a location that is above the conveyor system 20 and
below the top surface of the bales that are being processed so that
they can provide the desired centering function. As shown, the
positioning members 30 can optionally be adjustable toward and away
from the center of the cutting station by moving them laterally
along the support members 34. Any number of mechanisms can be used
to adjust and secure the positioning members 30 in their desired
location, including manual adjustment and securing devices, or
automated devices that are controlled by feedback received from
sensors, for example.
[0022] The cutting station 12 can be provided with one or more
devices and/or mechanisms for cutting the material that is wrapping
the bale without causing substantial damage to the bale material
itself. That is, the blade or other device is positioned relative
to the cutting device so that it will reliably and repeatedly sever
wrapping material while minimally penetrating the bale material
adjacent to the cut area. In an embodiment of the cutting station
12, a rotating saw blade 40 is positioned on a support frame,
wherein the saw blade is a circular disc with multiple teeth around
its circumference, such as a metal saw blade or a disc made of an
abrasive or other material that is sufficiently sharp that it can
cut relatively easily through the wrapping material. In another
embodiment, the saw mount is attached to the bottom of the conveyor
to support the saw, such as by a direct attachment to the bottom
surface of one or more extending members of a conveyor guard or
other conveyor structure. With such an arrangement, no separate
support stands or structures are required to operatively support
the saw blade or other cutting device.
[0023] In operation, the bale enters the cutting station 12, and
then it passes over a cutting mechanism that can include one of the
configurations discussed above, for example. The cutting station 12
may further include a blade guard that covers a portion of the
exposed blade, and/or may include an auxiliary guard positioned to
prevent or minimize material generated by the cutting operations
from building up on the saw and/or its associated shaft.
[0024] The speed at which any saw blade of the cutting station 12
rotates may be controlled by a conventional motor and control
system that provides a required rotation speed to correspond with
the particular material that is being cut. Further, the speed at
which the bale is moving along the conveyor can be coordinated with
the speed of rotation of the saw blade in order to optimize the
cutting performance of the saw blade.
[0025] One or more sensors can be used to determine and monitor the
size and location of the bale as it moves into the cutting station
12. In any of the mounting systems described herein, the saw blade
extends upwardly through an opening in the deck of the conveyor
system 20 and is positioned vertically so that it can cut through
any wrapping materials of the bale, but is not positioned so high
that it causes excessive damage to the bale itself. In a variation
of this process that is within the scope of this invention, the
bale can instead be moved into a location within the cutting
station prior to any cutting being performed, and the bale can
remain stationary while a cutting mechanism is moved along the bale
length to cut the wrapping material. In either case, once the
wrapping material has been cut, the bale is ready to be moved to
the next station of the system 10.
[0026] The conveyor system 20 is then reactivated to move the bale
toward the material pulling station 14. Again, one or more
proximity sensors, such as sensor 36 illustrated in FIG. 2 can be
used to sense the position of the bale so that it can be stopped in
a desired location within the material pulling station before the
conveyor 20 is stopped. When the bale is in its desired location,
rollers that were previously retracted below the material path of
the bale can be raised upwardly from beneath the conveyor 20 so
that they extend through openings in the conveyor until they
contact the bottom surface of the bale. This can be accomplished
via hydraulic cylinders, for example. These rollers are preferably
long enough that they can contact most or all of the length of the
bale that is being processed. The rollers can then be activated so
that they rotate in opposite directions from each other to
essentially "pull" the wrapping material away from the line along
which it was cut in the cutting station 12. That is, the rollers
pull the wrapping material(s) (e.g., net wrap and/or twine) from
under the bale, while the weight of the bale is at least partially
supported by the rollers.
[0027] The rollers can have a variety of different configurations,
but in one exemplary embodiment, the rollers are 8 inches in
diameter and are approximately 7 feet long. In order to provide a
desired level of friction between the wrapping material and the
rollers, the outer surface of the rollers can include a rubberized
material or other material against which the wrapping material does
not slip. After the material pulling operation is complete, the
rollers can retract below the surface of the conveyor so that they
do not interfere with continued movement of the bale from the
station 14. At this point, the cut ends of the wrapping material
will generally be loose so that the wrapping material drapes or
hangs freely over the top of the bale, and the bale is therefore
ready to be moved via the conveyor to the next station of the
system 10. It is noted that if the wrapping material is twine, the
rolling operation to free the ends of the twine from under the
roller may optionally be used, as desired, while the rolling
operation would more typically be used for net wrap or other
wrapping materials that have more surface area than twine.
[0028] The area immediately adjacent to and beneath the rollers of
station 14 may include one or more angled plates that are used for
collecting material that comes loose from the bales during the
process of conveying the bale and loosening the wrapping material
from its outer surface. The angled plates can direct the loose
material downwardly and onto an optional waste conveyor that can
convey the material away from the rollers and into a collection
area so that the loose material can be processed along with the
other materials provided by the bale.
[0029] After the wrapping material ends are free from under the
bale, the conveyor system 20 is then reactivated to move the bale
into the material wind-up or material removal station 16, which is
the station at which the wrapping material is removed from the
bale. Again, one or more proximity sensors can be used to sense the
position of the bale so that it can be stopped in a desired
location within the material removal station 16. Additional
proximity sensors (e.g., laser sensors) can be used in this station
and/or in one or more of the previous stations to accurately
determine the location of the top surface of the bale, which
information is transmitted to a controller that can adjust the
locations of various components within the station 16.
[0030] Station 16 includes a material wind-up system 60 that has at
least two spears 62, 64 that extend longitudinally from a base
plate 66. The material wind-up system 60 is vertically moveable to
position one of the spears 62, 64 at least slightly below the
wrapping material in a vertical direction (i.e., between inner
surface of the wrapping material and the outer surface of the bale
itself). In an embodiment of the invention, the material wind-up
system 60, or at least a portion thereof, is vertically
positionable via a cylinder 68 (e.g. a hydraulic cylinder) that is
located within a lift tower 80, such as is also illustrated in FIG.
3, for example, to position it in a desired location relative to
the bale. In this way, as the bale is being moved into the material
wind-up station 16, one of the spears 62, 64 will be inserted
between the wrapping material and the bale along the length of the
bale.
[0031] Lift tower 80 includes a stationary frame member 82 that is
configured as an inverted U-shaped structure that extends upwardly
from the lower support structure of the material stripping station
18. The frame member 82 can include multiple support pieces that
are connected throughout its structure to provide a desired amount
of stability. Tower 80 further includes a moveable frame member 84
that is vertically positionable relative to the stationary frame
member 82. Frame member 84 includes two side structures 86, 88
spaced from each other and a support structure 90 extending between
them. The side structures 86, 88 each include two vertical rails
87, 89, respectively, which are configured for engagement with
rollers, as is described below. The cylinder 68 extends downwardly
from the support structure 90 and can be positioned generally at
the center of gravity of the lift tower 80, for example. Cylinder
68 includes a shaft that is used to raise and lower the moveable
frame member 84 and control the height of the corresponding
material wind-up system 60.
[0032] Lift tower 80 further includes a roller frame 100 that
surrounds both the stationary frame member 82 and the moveable
frame member 84. Roller frame 100 is mounted so that it is
stationary relative to the lower support structure of the material
stripping station 18. Roller frame 100 includes side members 102.
104 that are spaced from each other in the same direction that the
side structures 86, 88 of the frame member 84 are spaced from each
other. Each of the side members 102, 104 extends in a generally
horizontal direction and includes rollers 106 adjacent to each of
their ends. Rollers 106 are mounted in the inner area of the roller
frame 100 for engagement with the vertical rails 87, 89 of the
vertical rails 86, 88. During movement of the moveable frame member
84 relative to the stationary frame member 82, each of the rollers
106 will ride vertically along one of the vertical rails 87, 89,
and are therefore made of materials that will cooperate with the
material from which the rails are made. Bearings can hold the
rollers 106 against the rails 87, 89 and the bearing shafts can be
adjusted to tension the rollers against the rails 87, 89 to
compensate for wear, if desired. The use of a single cylinder 68
can help to compensate for any alignment issues that otherwise may
occur when raising and lowering the moveable frame member 84,
although it is understood that more than one cylinder can be used
for this purpose.
[0033] Once the bale has been moved into the station 16 by a
sufficient distance that one of the spears 62, 64 is fully engaged
along at least a portion of its length with the wrapping material,
the conveyor system 20 can again be stopped so that the bale is
stationary. At this point, the other of the two spears 62, 64
(i.e., the spear that is not positioned under the wrapping
material) can optionally be moved to clamp or grasp the wrapping
material between the two spears, although it is also contemplated
that the spears 62, 64 do not move relative to each other. Whether
or not a clamping motion is activated, the material wind-up system
60 can then be moved upwardly at least slightly relative to the
outer surface of the bale until a desired amount of tension is
placed on the wrapping material. The spears 62, 64 can then be
rotated or spun via their support plate 66 until all or most of the
wrapping material is wrapped around the spears 62, 64. Once the
wrapping material is wrapped around the spears in this way, the
bale can be moved toward the end of the system 10 by reactivating
the conveyor until the unwrapped bale reaches the end of the
conveyor is available for use in another manufacturing process.
[0034] At this point, the wrapping material will be entirely
removed from the bale and wrapped around the spears 62, 64, and the
material wind-up system 60 can be rotated from a position to where
the spears 62, 64 are extending generally in the direction of
travel of the bales via the conveyor to a position that is at an
angle from this direction of travel. For example, as is illustrated
in FIG. 4, spears 62, 64 can be positioned at approximately 90
degrees from the longitudinal axis of the bale so that they extend
outwardly from the area immediately adjacent to the material
removal station 16, which is illustrated generally as the material
stripping station 18. If one or both of the spears 62, 64 have been
moved relative to each other to provide a clamping motion, such a
clamping motion can be reversed at this point, if desired, to
provide for at least a slight relief of the clamping force on the
wrapping material. As is also illustrated in FIG. 4, a material
removal system 70 is provided for removal of the material that is
wrapped on the spears 62, 64 in order to prepare the spears for
removing wrapping material from a subsequent bale.
[0035] Referring additionally to FIGS. 5-8, the material removal
system 70 includes an elongated beam 72 with a longitudinal slot 74
extending along at least a portion of its length. A slideable
carriage 76 is positioned in the slot 74 and is moveable along the
length of the slot 74 in both directions via a gearing system or
other mechanism. A fin or push rod 80 is extendable and retractable
relative to the slideable carriage 76, as desired, in response to
input from an operator and/or an automated command generated by a
control system and/or another type of input. The gearing system may
include at least two sprockets that are connected by a chain (not
shown) and may be controlled by hydraulic components, for
example.
[0036] In one embodiment, the fin 80 retracts by rotation about a
pivot point, although it is understood that the fin 80 can instead
be vertically retractable into the slot 74 by sliding it upward
using a different mechanism that provides for extension and
retraction of the fin 80. In its extended position, the fin 80 is
positionable between the spears 62, 64 for removal of the wrapping
material from the spears. Thus, in order for the material removal
system 70 to provide such a function, the spears 62, 64 will be
positioned so that they are both generally parallel to each other
in a horizontal plane and so that fin 80 can extend downwardly
between them.
[0037] The fin 80 has a length that is allows it to extend by a
desired distance between the spears 62, 64 when in its extended
position. The fin 80 can have a tapered shape, as shown, or can be
relatively blunt and/or differently shaped. The fin 80 is rigid
enough that it does not deform substantially during the process of
removing wrapping material from the spears. It is noted that the
vertical aspect of the fin 80 will allow gravity to facilitate the
movement of the wrapping material from the material wind-up system
60. It is further noted that a new bale of material can
simultaneously be moving into and/or through the other stations of
the system 10 while the material is being removed from the spears
62, 64 using the material removal system 70.
[0038] FIGS. 9-11 illustrate the material removal system 70 in
three exemplary positions in which it can be located during a
material removal process. In particular, FIG. 9 illustrates the fin
80 in a retracted position in which it is pivoted upwardly so that
its distal tip does not extend substantially below the elongated
beam 72 and/or between the spears 62, 64. When the fin 80 is
retracted to its highest position, a maximum distance is provided
between the fin 80 and the material that is wound around the spears
62, 64 that are positioned below the beam 72. When it is desired to
remove the material from the spears 62, 64, the fin 80 is extended
downwardly, such as until its longitudinal axis is located at an
angle of approximately 90 degrees relative to the bottom surface of
the elongated beam 72, although it can be positioned at a different
angle relative to the elongated beam 72. In any case, the fin 80 is
preferably able to be rotated sufficiently downward that it can
contact all or most of the layers of material that are wound around
the spears 62, 64.
[0039] An exemplary starting position of the fin 80 and its
corresponding carriage 76 is illustrated in FIG. 10, wherein the
fin 80 is positioned at approximately 90 degrees relative to the
bottom of the elongated beam 72. The slideable carriage 76 is then
actuated so that it moves longitudinally within the longitudinal
slot 74 toward a distal end of the elongated beam 72. As the
carriage 76 moves in this direction, its extending fin 80 will
slide between the spears 62, 64 until it contacts the material that
is wound around the spears. As the carriage 76 continues to move
distally along the length of the elongated beam 72, the fin 80 will
push the material toward the distal ends of the spears 62, 64 until
the material is pushed completely from the distal ends of the
spears 62, 64. At this point, the carriage 76 with its downwardly
extending fin 80 will be located relatively close to the distal end
of the longitudinal slot 74, as is shown in FIG. 11, for example.
The carriage 76 with its extending spear 80 can then be moved back
toward the proximal end of the elongated beam 72. The spear 80 can
be retracted upwardly either by pivoting or some other motion, as
described above, in order to prepare the material removal system 70
for the approach of a subsequent bale that has been introduced into
the system 10. That is, after wrapping material is removed from a
bale using the above-described methods and equipment, the various
stations and systems can then return to their original staged
positions.
[0040] FIG. 12 is a flow chart describing one exemplary method of
removing net wrap and/or twine from bales of material, which begins
with a step 200 in which a bale of material enters a material
removal system and ends with a step 218 in which a conveyor carries
material from which net wrap and/or twine has been removed to
another process, such as a cellulosic ethanol process. After the
step 200, steps 202 and 204 can optionally be performed at the same
time, wherein step 202 includes determining the height and type of
bale that has entered the system, and step 204 includes using a
rotary blade to cut through wrapping material on the outside of the
bale. In step 206, rollers can engage with the bale, which can be
done in order to free the loose edges of the wrapping material from
the bale. Next, one or more spears can penetrate the bale under the
net wrap or twine, as is set out in step 208, and then a clamp can
grab the net wrap or twine, as is set out in step 210. The
spear/clamp can then spin to wrap the wrapping material around it,
as in step 212, and then the step 214 can take place, in which the
spear turret rotates. Step 216 can then be performed, in which a
moveable carriage having a retractable and extendable fin can be
used to slide the wrapping material from the spears and then the
bale material can be moved by a conveyor to another process, as in
step 218. All of these steps are not necessarily performed on every
bale of material, and it is contemplated that other processing
steps can be added and/or illustrated processing steps can be
eliminated for some or all of the methods of the invention.
[0041] The present invention has now been described with reference
to several embodiments thereof. The entire disclosure of any patent
or patent application identified herein is hereby incorporated by
reference. The foregoing detailed description and examples have
been given for clarity of understanding only. No unnecessary
limitations are to be understood therefrom. It will be apparent to
those skilled in the art that many changes can be made in the
embodiments described without departing from the scope of the
invention. Thus, the scope of the present invention should not be
limited to the structures described herein, but only by the
structures described by the language of the claims and the
equivalents of those structures.
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