Apparatus and Method for Removing Wrap from Cotton Modules

Abstract

An apparatus and method for removing wrapping material from around a cotton module that results in the unwrapped cotton generally retaining the shape and density of the original cotton module. The apparatus has a bale engaging mechanism which straddles the cotton module on a conveyor surface and a cutting device to cut the wrapping material. The bale engaging mechanism has a moveable support frame, one or more arms on each side of the apparatus that pivot downward and inward from the support frame to position a roller at the lower end of the arms against the cotton module and a frame moving mechanism that moves the support frame, arms and cotton module upward and downward. The wrapping material can be cut as the cotton module is moved into the bale engaging mechanism, after the module is engaged by the rollers or after the module is raised above the conveyor surface.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims priority to U.S. Provisional Application No. 61/259,197 filed Nov. 8, 2009.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

Not Applicable.

REFERENCE TO A SEQUENCE LISTING, A TABLE OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON A COMPACT DISC

Not Applicable.

BACKGROUND OF THE INVENTION

A. Field of the Invention

The field of the present invention relates generally to cotton ginning systems and methods. In particular, the present invention relates to apparatuses and methods for removing plastic wrap or other wrap from cotton modules. Even more particularly, the present invention relates to such apparatuses and methods that efficiently and effectively remove the wrap material while maintaining the shape of the modules for feeding into cotton ginning machines.

B. Background

Cotton harvested from a field consists of the desired cotton fibers and cotton seed and a significant amount of undesirable foreign matter, such as burrs, sticks, stems and green leaf material. After harvesting, the cotton/foreign matter material is taken to a cotton gin for processing into bulk cotton fibers and cotton seed. A large part of a modern cotton ginning plant consists of machines and processes for separating and removing the foreign matter from the cotton fiber, both prior to and following the actual separation of the cotton lint from the seed (the actual ginning). For purposes of background and completeness on cotton ginning, and specifically on the equipment used in cotton ginning plants, the reader is directed to the book “Ginning Cotton—An Entrepreneur's Story” by A. L. Vandergriff, Texas Tech University Press, 1997. This book is incorporated in its entirety herein by the above reference.

A number of modern cotton harvesting machines harvest cotton from the field, form the harvested cotton into large cylindrical cotton modules, typically containing three to four bales of cotton, and wrap these modules with a sheet of plastic wrapping material to minimize water and other damage to the cotton before it enters the gin. The harvesting machine then deposits the wrapped cotton modules onto the field. A tractor/loader gathers the modules, usually in groups of four modules placed in end-to-end relationship, where they are staged for transport to the gin. A module transport truck, typically having modifications to the chain loader bed to prevent tearing the plastic, loads the group of modules and transports them to the cotton gin for processing. The cylindrically-shaped cotton modules are approximately 96 inches long and are approximately 24 inches to 96 inches in diameter. The modules can weigh as much as 6,750 pounds.

At the gin, the module transport truck backs up to a module feeder and off loads the modules onto the bed of the feeder. A typical feeder bed is approximately forty feet long. The module feeder of most gins have several feeder beds positioned in series, typically 2.5 to 3.5 feeder beds, depending on how many modules the gin requires to have staged for efficiency of the gin operation (i.e., the faster the gin, the more staged modules are required). The first step in processing the cotton in the cotton modules is to remove the plastic wrapping. The modern cylindrical cotton modules have three to four bales, which is much less than the conventional cotton modules that have an average of eighteen bales of cotton. One effect of the lesser number of bales is that the time allowed to remove the plastic wrap and prepare the three bale modules for the ginning process is very limited. For instance, in a typical 50 bale an hour gin, the time allowed for preparing the three bale module is, on average, limited to only 3.6 minutes. As a result, the gin requires the wrapping be quickly removed.

One mechanism for removing the plastic wrapping material from the cotton modules is described in U.S. Pat. No. 7,165,928 to Haverdink, et al., which describes a cotton bale handling system wherein the cotton modules are suspended by a fork attachment mounted to the boom structure of a front end loader. The module is moved by the loader relative to a fixed knife, located on one end of a roller conveyor that forms the feeder bed, such that the knife slits the bottom of the plastic wrap in a direction generally parallel to the longitudinal axis of the module. The fork attachment includes a spear member that is inserted at the top of the module between the wrap and the cotton bales to suspend the plastic wrap when the cotton flows out through the slit at the bottom of the plastic wrap onto the conveyor surface of the feeding mechanism that conveys the cotton to the ginning machines. U.S. Pat. No. 7,591,628 to Noonan, et al. describes a grappling device for rotating the cylindrical cotton modules to place the module such that its radio frequency identification (RFID) tag assembly, which is attached to a loose tail section of the wrapping material, is at an upper position of the module prior to forming a slit in the plastic along the bottom of the module. The grapple device is equipped with powered rollers that are driven to rotate the module about its axis to position the module as desired prior to the knife slitting operation that releases the cotton from the wrapper onto the conveyor. The rollers aid in the removal of the wrapping material. U.S. Pat. No. 7,757,353 to Stover describes an apparatus for removing plastic wrapping from a cotton module that comprises a mechanism for lifting the module off of a conveyor, rotating the module to locate an untethered tail of the wrapping and stopping the rotation to allow a slitter to cut the wrapping at a location away from the tail. The slitter cuts the wrapping and a control unit controls the operation of both the mechanism and slitter.

Naturally, a cotton gin prefers to have a low cost, fast, efficient and easy to operate mechanism for removing the plastic wrapping material from the modules. While the aforementioned patents generally describe mechanisms that can remove the plastic wrapping from the cotton modules prior to ginning the cotton, what is needed is an improved apparatus and method for removing the plastic or other wrapping material from the modules. An improved apparatus and method should more quickly and efficiently remove the plastic wrap from the cotton modules. Preferably, any new apparatus and method should be readily adaptable to the various machines and systems currently utilized in cotton gins and be relatively inexpensive to install and easy to operate.

SUMMARY OF THE INVENTION

The apparatus and method for removing wrap from cotton modules of the present invention provides the benefits and solves the problems identified above. That is to say, the present invention discloses an apparatus and method for removing wrap from cotton modules that allows the gin operator to quickly, easily, efficiently and relatively inexpensively remove the wrap from the cotton modules so the cotton may be processed in the gin. In addition, the apparatus of the present invention is relatively inexpensive to build and install and it does not require any highly skilled labor to operate or otherwise accomplish the wrap removal. In its preferred configuration, the apparatus and method of the present invention is adaptable to virtually any type of gin for processing cotton from wrapped cotton modules.

In a primary embodiment of the present invention, the apparatus for removing wrapping material from a cotton module generally comprises a main frame that substantially straddles a feeding mechanism which defines an upwardly facing conveyor surface, a bale engaging mechanism supported by the main frame and a cutting device configured to cut the wrapping material. The preferred bale engaging mechanism has a support frame that is configured to move upwards and downwards relative to the main frame, one or more arms which extend generally downward from the support frame on each of a first side and a second side of the apparatus, one or more lift members located at a lower end of each of the arms, a frame moving mechanism which is operatively connected to the support frame for moving the support frame between a lower position with the cotton module on the conveyor surface and an upper position with the cotton module in spaced apart relation to the conveyor surface and a pivoting mechanism located at an upper end of the arms for pivoting the arms between an engaged position with the lift members against the cotton module and a disengaged position with the lift members in spaced apart relation to the cotton module. The bale engaging mechanism is configured to facilitate removal of the wrapping material from cotton module and placement of the cotton on the conveyor surface while substantially retaining the shape and density of the cotton module. In one embodiment, the cutting device is attached to a handle and the user cuts a lower side of the cotton module to provide one or more hanging portions that hang substantially below the cotton module when the support frame and the arms are in the upper position so a fork-like device can be utilized to engage the hanging portions to facilitate removal of the wrapping material from the cotton module. In another embodiment, the cutting device is positioned in the path of the moving cotton module such that as the cotton module is conveyed along the conveyor surface the cutting device cuts the wrapping material. In yet another embodiment, the cutting device moves along the conveyor surface to cut the wrapping material after the lift members engage the cotton module. The lift members can be rollers which do not rotate, rollers which freely rotate or powered rollers. In a preferred embodiment, the bale engaging mechanism has at least a pair of the arms on each of the first side and the second side of the apparatus with at least a forward arm at the forward end of the bale engaging mechanism and a rearward arm at the rearward end of the bale engaging mechanism on each side of the apparatus.

The method for removing wrapping material from a cotton module to obtain cotton therefrom comprises the steps of: (a) positioning the cotton module on an upwardly facing conveyor surface; (b) moving the cotton module into a bale engaging mechanism that has a support frame with one or more arms extending generally downward on each of a first side and a second side of the apparatus; (c) operating the bale engaging mechanism to pivot the arms generally inward toward the cotton module to place the apparatus in a lower engaged position with a lift member at a lower end of each of the arms disposed against the cotton module; (d) raising the support frame to raise the cotton module so as to place the apparatus in an upper engaged position with the cotton module in spaced apart relation to the conveyor surface; (e) cutting the wrapping material with a cutting device; (f) lowering the support frame to place the cotton at a lower side of the cotton module on the conveyor surface; and (g) operating the bale engaging mechanism to pivot the arms generally outward and the lift members away from the cotton module to place the apparatus in a lower disengaged position with the cotton on the conveyor surface generally retaining the shape and density of the original cotton module. In one embodiment, the cutting step produces one or more hanging portions that hang generally downward from the raised cotton module and the method also includes the step of engaging each of the hanging portions after the cutting step to pull the hanging portions away from the cotton module prior to the lowering step. In an alternative embodiment, the cutting step is performed in conjunction with the moving step. In yet another embodiment, the cutting step is performed after the lift members are placed against the cotton module but prior to the raising step. In a preferred embodiment, the lift members are rollers that are generally disposed against the cotton module at approximately the five-o'clock and seven o'clock positions. The rollers can be fixed, be allowed to freely rotate or be powered to rotate the cotton module therewith.

Accordingly, the primary aspect of the present invention is to provide an improved apparatus and method for removing plastic or wrapping material from cotton modules brought to the gin that has the advantages discussed above and which overcomes the various disadvantages and limitations associated with prior art apparatuses and methods for removing such wrapping from cotton modules.

It is an important aspect of the present invention to provide an apparatus and method that quickly, efficiently, inexpensively and easily removes the wrapping material from cotton modules so the cotton may be processed in the cotton gin.

It is also an important aspect of the present invention is to provide an apparatus and method for removing wrapping material from cotton modules that does not require sophisticated machinery and/or highly skilled labor to operate.

It is also an important aspect of the present invention to provide an apparatus and method for removing wrapping material from a cotton module that results in the cotton module generally retaining its shape and density after having the wrapping material removed therefrom.

It is also an important aspect of the present invention to provide an apparatus and method for removing wrapping material from a cotton module that generally comprises a bale engaging mechanism which engages the wrapped cotton module on a conveying mechanism, raises the wrapped cotton module above a conveyor surface, holds the cotton module in position to allow a cutting device to cut the wrapping material to facilitate separating the wrapping material from the cotton and then lowers the cotton module to the conveyor surface in a manner that generally retains the shape and density of the cotton for further processing in a cotton gin.

Another important aspect of the present invention is to provide an apparatus and method for removing wrapping material from a cotton module that utilizes a hand-held, stationary or powered cutting device to slice through the wrapping material so it may be separated from the cotton.

The above and other aspects and advantages of the present invention are explained in greater detail by reference to the attached figures and the description of the preferred embodiment which follows. As set forth herein, the present invention resides in the novel features of form, construction, mode of operation and combination of the above presently described and understood by the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings which illustrate the preferred embodiments and the best modes presently contemplated for carrying out the present invention:

FIG. 1 is an end view of the apparatus of the present invention shown in its lower disengaged position with a cotton module on the conveyor surface of the feeding mechanism;

FIG. 2 is an end view of the apparatus of FIG. 1 shown in its lower engaged position;

FIG. 3 is an end view of the apparatus of FIG. 1 shown in its upper engaged position with a knife being used to cut the wrap along the lower side of the cotton module;

FIG. 4 is a side view of the second side of the apparatus of FIG. 1 shown in its upper engaged position with the wrap on the lower side of the cotton module cut and hanging down from the sides of the module; and

FIG. 5 is an end view of the apparatus of FIG. 1 shown in its lower disengaged position with the cut wrap being held away from the cotton with a plurality of fork-like devices and the unwrapped cotton resting on the conveyor surface prior to being conveyed for ginning.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to the figures where like elements have been given like numerical designations to facilitate the reader's understanding of the present invention, the preferred embodiments of the present invention are set forth below. The enclosed text and drawings are merely illustrative of one or more preferred embodiments and, as such, disclose one or more different ways of configuring the present invention. Although specific components, materials, configurations and uses are illustrated, it should be understood that a number of variations to the components and to the configuration of those components described herein and in the accompanying figures can be made without changing the scope and function of the invention set forth herein. For instance, although the figures and description provided herein show certain shapes and configurations for the bale engaging mechanism and the cutting mechanism, those skilled in the art will understand that this is merely for purposes of simplifying this disclosure and that the present invention is not so limited.

In the preferred embodiment of the apparatus and method for removing wrap from cotton modules of the present invention, shown in FIGS. 1 through 5, the wrap removal apparatus is identified generally as 10 and is shown being used to remove the wrapping material 12 from a cotton module 14. As set forth in more detail below, apparatus 10 is configured to quickly, easily and without requiring highly skilled labor remove the wrapping material 12, which is typically a plastic sheet or sheet-like wrap, from the cotton module 14 so the cotton, shown as 16, therein may be placed on the bed or conveyor surface 18 of the feeding mechanism 20 and transported thereby for processing in the cotton gin. In FIGS. 1 through 4, the wrapping material 12 is shown as the outer surface of the cotton 16 that is formed into the generally cylindrical module 14. Although the wrapping material 12 is typically plastic, apparatus 10 of the present invention is suitable for use for a wide variety of materials that may be utilized to wrap the cotton 16 so as to protect it from water and other damage.

After being delivered to the gin by transport vehicle and off-loaded onto the feeding mechanism 20, the wrapped cotton module 14 advances down the conveyor surface 18 to the apparatus 10. The apparatus 10 generally comprises a main frame 22 made up of a plurality of frame members 24 that support a bale engaging mechanism 26 which is configured to selectively move between a lower disengaged position 28 (FIG. 1), a lower engaged position 30 that engages the cotton module 14 (FIG. 2), an upper engaged position 32 that holds the engaged cotton module 14 above the conveyor surface 18 (FIGS. 3 and 4) and back to the lower disengaged position 28 with the cotton 16 from the cotton module 14 resting on conveyor surface 18 (FIG. 5). More specifically, the bale engaging mechanism 26 grabs the cotton module 14, lifts it above the bed of the conveyor surface 18 so that the wrapping material 12 may be cut along a position that is generally parallel to the axis of the cotton module 14 at the center lower side (i.e., the six-o'clock position) of the wrapping material 12. As set forth in more detail below, one of the primary advantages of the apparatus 10 and method of the present invention is that the cotton 16 that is placed onto conveyor surface 18 after the wrapping material 12 is cut and the cotton module 14 is lowered onto the conveyor surface 18 will generally retain its cylindrical shape and density, as shown in FIG. 5. Maintaining the shape and density is important to keep even density feeding into the dispersal cylinders of the module feeder so an even rate of ginning can be achieved and regulated by the operator. An even rate of ginning is necessary to maintain high rates of ginning production. Some prior art apparatuses for removing wrapping material 12 from the cotton module 14 handle the modules in such a way that dense jammed up modules are not presented to the dispersal cylinders.

As shown in FIGS. 1 through 3, the main frame 22 substantially straddles the conveyor surface 18 defined by the feeding mechanism 20 such that the cotton module 14 moves generally through the center of the apparatus 10 on conveyor surface 18. In a preferred embodiment, main frame 22 is made up of a plurality of frame members 24 that are made out of steel or other metal. Preferably, the steel is coated, painted or otherwise protected against rust and other negative effects. Because the cotton modules 14 are typically eight feet long, the main frame 22 of the preferred embodiment is configured to be at least that length and, preferably, slightly longer, such as approximately ten to twelve feet long, so as to support the bale engaging mechanism 26 in a manner that effectively engages the cotton module 14 while it is on or above the conveyor surface 18, as best shown in FIG. 4. As well known by those skilled in the art, main frame 22 can have frame members 24 that are made out of a wide variety of different materials and with the frame members 24 positioned in various different configurations to support the bale engaging mechanism 26 as required for use of the apparatus 10 of the present invention.

The bale engaging mechanism 26 comprises a moveable support frame 36 that slidably engages an upper portion of the main frame 22 to allow the bale engaging mechanism 26 to move up and down relative to the conveying surface 18 of the feeding mechanism 20, one or more arms 38 on each of the first side 40 and second side 42 of the apparatus 10 that are pivotally attached at an upper end 44 thereof to the support frame 36, an elongated lift member 46, such as the rollers shown in the figures, a bar or like members, on each side 40/42 at the lower end 48 of each arm 38 and a frame moving means 50 for moving the support frame 36 up and down on main frame 22, as shown in FIGS. 1 through 5. The moveable support frame 36 preferably comprises a plurality of overhead frame members 52 that support the arms 38 in a position generally above the conveyor surface 18 and to the side of the cotton module 14, as best shown in FIG. 1. The arms 38 on each side 40/42 of apparatus 10 extend downwardly from the moveable support frame 36 and are configured to position the lift members (rollers) 46 so they will engage the cotton module 14 toward the lower side thereof, as best shown in FIGS. 2 through 5. In a preferred embodiment, the lift members 46 engage the cotton module at or near the five-o'clock and seven-o'clock positions of the cylindrical cotton module 14, as best shown in FIGS. 2 and 3, and are approximately the same length as the cotton module 14, which is typically eight feet (96 inches). The rollers or other lift members 46 can be fixed (i.e., non-rotating bars), or configured for free rotating (preferred) or powered rotating. In the preferred embodiment of apparatus 10, the arms 38 comprise a plurality of arm sections that are each beneficially angled such that when the arms 38 pivot at the upper ends 44 thereof, relative to the support frame 36, the pivoting action alone will place the rollers or other lift members 46 at the desired positions along cotton module 14. In the embodiment shown in the figures, the arms 38 comprise three such arm sections.

Interconnecting the upper end 44 of the arms 38 and the support frame 36 is a pivoting mechanism 54 that is configured to pivot the arms 38 inward and outward relative to the cotton module 14 so as to move the apparatus 10 between the disengaged position 28 and the engaged positions 30/32, as explained in more detail below. In the preferred embodiment of apparatus 10 of the present invention, the pivoting mechanism 54 and arms 38 are cooperatively configured so the arms 38 themselves do not have to pivot at the intersection of the various arm segments. Instead, the pivoting of the arms 38 at the pivoting mechanism 54 is sufficient to move the rollers 46 toward or away from the cotton module 14. The pivoting mechanism 54 is configured to lock each set of the arms 38 at the disengaged position 28 and engaged positions 30/32. Such pivoting mechanisms 54, which can comprise a variety of different configurations, are well known by those skilled in the art.

In the preferred embodiment, the apparatus 10 has a pair of arms 38 on each side 40/42 of the apparatus 10 positioned generally at or near a forward end 56 of bale engaging mechanism 26 and generally at or near a rearward end 58 of bale engaging mechanism 26, as best shown in FIG. 4. The pair or arms 38 comprises the forward arm 38a and the rearward arm 38b, shown in FIG. 4 for the second side 42 of apparatus 10. The first side 40 is configured in a similar manner with a forward arm 38c and a rearward arm (not shown). The lower end 48 of each arm 38 is rotatably attached to their respective roller or other lift member 46. Although a pair of arms 38 are shown on each side 40/42 of the apparatus 10, those skilled in the art will readily appreciate that the apparatus 10 can be configured with only one arm 38 on each side 40/42 or more than two arms 38 on each side 40/42. Preferably, each of the arms 38 would attach to and move the lift members 46.

In the preferred embodiment, the frame moving means 50 for moving moveable support frame 36, and therefore the entire bale engaging mechanism 26, up and down on main frame 22 comprises a hydraulic piston/ram mechanism that interconnects the main frame 22 and the moveable support frame 36, as shown in FIGS. 1 through 5. In the preferred embodiment, such a mechanism is utilized on each of the first 40 and second 42 sides of apparatus 10 at the forward and rearward ends of the apparatus 10. Each component of the frame moving means 50 are operatively interconnected so as to evenly move support frame 36 up and down between the lower positions 28/30 and the upper position 32. Preferably, at the location where the support frame 36 connects to the portion of main frame 22 at which the support frame 36 is slidably engaged, these two components are configured to allow the support frame 36 to smoothly move up and down.

In use, the wrapped cotton module 14 is moved into position at apparatus 10 on the conveyor surface 18 of the feeding mechanism 20, as shown in FIG. 1, with the apparatus 10 in its lower disengaged position 28. Once the wrapped cotton module 14 is in position, the operator engages the bale engaging mechanism 26 of apparatus 10, by operating the controls associated therewith, to pivot the arms 38 downward and place the rollers 46 against the cotton module 14, placing the apparatus in its lower engaged position 30, as shown in FIG. 2. In the preferred embodiment, the rollers 46 engage the cotton module 14 at or about the five-o'clock and seven o'clock positions (as shown in the figure). The operator then engages the controls to cause the frame moving means 50 to raise the support frame 36, causing the bale engaging mechanism 36 to raise the cotton module 14 above (e.g., 48 inches or so) the conveyor surface 18 of feeding mechanism 20 to place the apparatus 10 in its upper engaged position 32, as shown in FIG. 3. Because the rollers 46 extend the full or nearly the full length of the cotton module 14 and are on opposite sides thereof, they will be able to support the cotton module 14 above the conveyor surface 18 in its cylindrical shape and with the desired density.

The operator or his/her helper will then cut through the lower side 60 of the wrapping material 12 around cotton module 14 with a knife or knife-like cutting device 62, as shown in FIG. 3. The cut will extend the entire length of the cotton module 14 and be generally parallel to the axis of the cotton module 14. In one embodiment, the cutting device 62 comprises a knife-like blade attached to a handle or handle-like extension 64 so the person cutting the lower side 60 can more easily reach under the cotton module 14 to cut the wrapping material 12. The wrapping material 12 at the lower side 60 that is below the lift members 46 will hang downward after the wrapping material 12 is cut. The hanging portions of wrapping material 12 are designated as 66 for the first side 40 and as 68 for the second side 42, as best shown in FIG. 3. As the cutting device 62 moves along the cotton module 14, for instance from the forward end 56 to the rearward end 58 as shown in FIG. 3, the cotton 60 of the cotton module 14 will remain in place, due to the compactness thereof and the positions of lift members 46, and the hanging portions 66/68 will drop down. The operator's helpers will then utilize a fork or fork-like device 70 to engage each of the hanging portions 66/68 and the upper side 72 of the wrapping material 12, as shown in FIG. 5. The position of the lift members (rollers) 46 against the sides of the cut cotton module 14 will help maintain the shape and density of the cotton 16. The operator then utilizes the controls to cause the frame moving means 50 to lower bale engaging mechanism 26, with the cut cotton module 14 held in place by the lift members 46, downward to place the lower side 60 of the cotton module 14 on the conveyor surface 18, as shown in FIG. 5. Then the operator utilizes the controls of the apparatus 10 to move the arms 38 outward, which also moves the lift members 46 away from the cotton module 14, placing the apparatus 10 in its lower disengaged position 28, as shown in FIG. 5. The operation of apparatus 10 will result in the cotton 16 on the conveyor surface 18 generally retaining the desired cylindrical shape and desired density so that the feeding mechanism 20 can efficiently move the cotton 16 into the ginning machinery. As described above, this is important to maintain the efficient operation of the cotton gin.

A variety of modifications can be made to the apparatus 10 and method of the present invention. One such modification is that the cutting device 62 can be fixed relative to the conveyor surface 18 at or ahead (i.e., upstream) of where the cotton module 14 enters the apparatus 10 of the present such that as the cotton module 14 is conveyed it passes over the cutting device 62 and the cutting device 62 cuts the wrapping material 12 at the lower side 60 of the cotton module 14 at or near the six-o'clock position. Alternatively, the cutting device 62 can be positioned such that it cuts the wrapping material 12 around the cotton module 14 at or near the position of one of the lift members 46 (i.e., such as at or near the five-o'clock or seven-o'clock position). In this configuration, only one side of the cut wrapping material will fall downward and it will be longer. The other side will be held in its pre-cut position by the associated lift member 46 near the cut. The longer length hanging wrapping material will be easier to reach, require only one person on one side 40/42 of apparatus 10 and reduce the likelihood that any plastic will get into the cotton 16.

Another variation is that the lift members 46 can move only partially away from the cotton 16 when after the bale engaging mechanism 26 returns the cotton module 14 back to the conveyor surface 18 so the lift members 46 can help maintain the desired shape of the cotton 16 as it moves into the ginning equipment. The lead-in to the ginning equipment can comprise a pair of spaced apart side walls that direct the cotton 16 into the ginning equipment in the desired generally cylindrical shape. In another variation, the arms 38 can extend toward the cotton module 14 from carts or cart-like machines on each of the sides 40/42 of the apparatus 10 instead of pivoting from the overhead frame members 52 as shown in the figures. In this embodiment, the carts with the arms 38 extending inward therefrom or just the arms 38 extending from the carts would move inward to dispose the lift members 46 against the cotton module 14 and raise it above the conveyor surface 18 for cutting by cutting device 62, as described above. In another embodiment, the alternatives discussed above could be combined, for instance the cutting device 62 could be fixed and the lift members 46 be mounted on carts that move in from the sides to hold the desired shape of the cotton 16 after the wrapping material 12 is cut. The embodiment with the carts could be particularly useful for those gins that utilize a walking floor type of conveying system that continuously moves to the ginning equipment. Because it is important to keep the at least four of the cotton modules 14 together (which combined are approximately equal to a conventional sized module) in an end-to-end relationship as the cotton 16 goes into the gin, the carts could be utilized to move the cut cotton 16 from the cotton modules 14 along (but above) the walking floor into an abutting position against the cotton 16 from the previously cut cotton module 14.

After the cotton modules 14 are formed, staged and gathered from the field, a module truck delivers the cotton modules 14 to the module yard at the gin where they stay until scheduled for ginning. At that time, a module truck will pick up all four cotton modules 14 and deliver them to the feeding mechanism 20 where they will be unwrapped by the apparatus 10 of the present invention. As set forth above, some of the prior art patents are directed to machines that are attachments to front end loaders. These systems require that the front end loaders go to the module yard at the gin and pick up one cotton module 14, return to the feeder mechanism 20, assist in unwrapping the cotton module 14, place it on the feeder bed or conveyor surface 18, and then return to the module yard for another cotton module 14. These systems, which require retrieval of one cotton module 14 at a time, is a messy operation that results in the cotton modules 14 not retaining their shape and requires the loader operator to not fall behind or the gin will run out of cotton 16. Another problem with these systems is that the driver of the loader does not have time to get off of the loader during the process of moving cotton modules 14 to the gin or the gin will be short on cotton 16.

While there are shown and described herein specific forms of the invention, it will be readily apparent to those skilled in the art that the invention is not so limited, but is susceptible to various modifications and rearrangements in design and materials without departing from the spirit and scope of the invention. In particular, it should be noted that the method of the present invention is subject to modification with regard to any dimensional relationships set forth herein and modifications in assembly, materials, size, shape, and use. For instance, there are numerous components described herein that can be replaced with equivalent functioning components to accomplish the objectives of the present invention.

Claims

1. An apparatus for removing wrapping material from a cotton module to obtain cotton therefrom, said apparatus comprising:

a bale engaging mechanism substantially straddling an upwardly facing conveyor surface, said bale engaging mechanism having a support frame, one or more arms on each of a first side and a second side of said apparatus, one or more lift members at a lower end of each of said arms, a frame moving means operatively connected to said support frame for moving said support frame and said arms between a lower position with the cotton module on said conveyor surface and an upper position with the cotton module in spaced apart relation to said conveyor surface and a pivoting mechanism associated with each of said arms and said support frame for pivoting said arms between an engaged position with said lift members against the cotton module and a disengaged position with said lift members in spaced apart relation to the cotton module; and

a cutting device configured to cut the wrapping material,

wherein said bale engaging mechanism is configured to facilitate removal of the wrapping material from the cotton module and placement of the cotton on said conveyor surface while substantially retaining the shape and density of the cotton module.

2. The apparatus of claim 1 further comprising a main frame having a plurality of frame members, said support frame moveably connected to said main frame.

3. The apparatus of claim 1, wherein said pivoting mechanism is at an upper end of each of said arms.

4. The apparatus of claim 1, wherein said cutting device is configured to cut a lower side of the cotton module and provide a hanging portion substantially below the cotton module when said support frame and said arms are in said upper position.

5. The apparatus of claim 4, wherein a fork-like device is utilized to engage said hanging portion to assist in removal of the wrapping material from the cotton module.

6. The apparatus of claim 1, wherein said cutting device is attached to a handle.

7. The apparatus of claim 1, wherein said bale engaging mechanism has at least a pair of said arms on each of said first side and said second side of said apparatus.

8. The apparatus of claim 7, wherein said arms comprise at least a forward arm at a forward end of said bale engaging mechanism and a rearward arm at a rearward end of said bale engaging mechanism.

9. The apparatus of claim 1, wherein each of said arms extend generally downward from said support frame.

10. An apparatus for removing wrapping material from a cotton module to obtain cotton therefrom, said apparatus comprising:

a main frame comprising a plurality of frame members, said main frame substantially straddling a feeding mechanism defining an upwardly facing conveyor surface;

a bale engaging mechanism supported by said main frame, said bale engaging mechanism having a support frame movably associated with said main frame, one or more arms extending generally downward from said support frame on each of a first side and a second side of said apparatus, one or more lift members at a lower end of each of said arms, a frame moving means operatively connected to said support frame for moving said support frame between a lower position with the cotton module on said conveyor surface and an upper position with the cotton module in spaced apart relation to said conveyor surface and a pivoting mechanism at an upper end of said arms for pivoting said arms between an engaged position with said lift members against the cotton module and a disengaged position with said lift members in spaced apart relation to the cotton module; and

a cutting device configured to cut the wrapping material,

wherein said bale engaging mechanism is configured to facilitate removal of the wrapping material from cotton module and placement of the cotton on said conveyor surface while substantially retaining the shape and density of the cotton module.

11. The apparatus of claim 10, wherein said cutting device is configured to cut a lower side of the cotton module and provide a hanging portion substantially below the cotton module when said support frame and said arms are in said upper position.

12. The apparatus of claim 11, wherein a fork-like device is utilized to engage said hanging portion to assist in removal of the wrapping material from the cotton module.

13. The apparatus of claim 10, wherein said cutting device is attached to a handle.

14. The apparatus of claim 10, wherein said bale engaging mechanism has at least a pair of said arms on each of said first side and said second side of said apparatus.

15. The apparatus of claim 14, wherein said arms comprise at least a forward arm at a forward end of said bale engaging mechanism and a rearward arm at a rearward end of said bale engaging mechanism.

16. A method for removing wrapping material from a cotton module to obtain cotton therefrom, said method comprising the steps of:

a) positioning the cotton module on a conveyor surface;

b) moving the cotton module into a bale engaging mechanism having a support frame with one or more arms extending generally downward on each of a first side and a second side of said apparatus;

c) operating said bale engaging mechanism to pivot said arms generally inward toward the cotton module to place said apparatus in a lower engaged position with a lift member at a lower end of each of said arms disposed against the cotton module;

d) raising the support frame to raise the cotton module to place said apparatus in an upper engaged position with the cotton module in spaced apart relation to said conveyor surface;

e) cutting the wrapping material with a cutting device;

f) lowering the support frame to place the cotton at a lower side of the cotton module on said conveyor surface; and

g) operating said bale engaging mechanism to pivot said arms generally outward and said lift members away from said cotton module to place said apparatus in a lower disengaged position with the cotton on said conveyor surface generally retaining the shape and density of the cotton module.

17. The method of claim 16, wherein said cutting step is performed in conjunction with said moving step.

18. The method of claim 16, wherein said cutting step is performed prior to said raising step.

19. The method of claim 16, wherein said cutting step produces one or more hanging portions hanging generally downward from the cotton module and said method further comprises the step of engaging each of said hanging portions after said cutting step to pull said hanging portions away from the cotton module prior to said lowering step.

20. The method of claim 16, wherein said lift members are disposed against the cotton module at approximately the five-o'clock and seven o'clock positions.