Round Module Builder

The process of building a round module takes place in three phases:

1. Forming the module.
2. Wrapping the module.
3. Ejecting the module to the handler.

Operational theory, problem symptoms, problems, and possible solutions are covered for each phase of the process as follows.

Forming the Module

Module forming involves an accumulator, a feeder system, and a round module builder (RMB). Cotton from the picking units travels through the ducts and accumulator hood into the accumulator. A double-flighted compactor auger operates periodically while the accumulator is filling in the first pick mode. During unloading, the auger operates continuously in both first and second pick mode. The auger pushes the cotton outward and downward to pack the cotton in the accumulator. The accumulator is equipped with three cotton level sensors at the bottom and one level sensor at the top. Each sensor consists of an emitter and a receiver. The upper sensor emitter, located on the right-hand side of the accumulator projects an infrared beam toward the receiver on the left-hand side. The sensor receiver sends a signal to the baler interface control (BIC) unit when it detects the beam. When the cotton level approaches the top of the accumulator, the beam is broken and the signal to the BIC is lost. The BIC then initiates the forming process.

The round module is formed in the baler using cotton delivered at a consistent rate from the accumulator by the feeder system. Before forming can occur, the various drive components of the system must be started and brought up to a preset operating speed sequentially . Each drive component operates in a closed-loop consisting of a speed control solenoid valve, a drive motor, a speed sensor, and the BIC. The BIC compares the actual speed from the sensor to the preset desired speed and adjusts the speed control solenoid valve as necessary. The forming system is started in the following sequence:

1. The BIC energizes the RMB speed control solenoid valve which starts the RMB belt drive motors.
2. The BIC monitors the signal from the lower RMB speed sensor. When the RMB belts are operating at the desired speed, the BIC energizes the feeder belt speed control solenoid valve which starts the feeder belt drive motor.
3. The BIC monitors the signal from the feeder belt speed sensor. When the feeder belt is running at the desired speed, the BIC energizes the beater roll speed control solenoid which starts the beater roll drive motor.
4. The BIC monitors the beater roll speed sensor signal. When the beater roll is operating at the desired speed, the BIC energizes the metering roll speed control solenoid valve which starts the metering roll drive motor.

Cotton is now fed from the accumulator to the round module builder. When the cotton in the accumulator reaches a low level and one or more of the three lower cotton level sensors is actuated, the drive components are disengaged in the reverse order: metering rolls, beater roll, feeder belt drive roll, and RMB drive rolls. This cycle repeats itself until a module of the preset target size has been built. It normally takes approximately four fill cycles to build a module.

During the module forming process, the rockshaft pressure solenoid controls pressure to the rockshaft cylinders as necessary to maintain module density. The main rockshaft pressure sensor provides feedback to the control unit and to the display unit. Module target size is set using a screen on the armrest display unit. Actual module size is calculated from the output of the rockshaft position potentiometer.

Wrapping the Module

When the module size reaches the preset target size, the wrap process is initiated. The BIC unit activates the round module speed control solenoid to energize the RMB motors and start turning the baler belts. The BIC monitors the signal from the lower RMB speed sensor.

When the BIC confirms that the RMB is operating at proper speed, the wrap floor engage solenoid is activated to apply pressure to the wrap floor cylinders. The cylinders rotate the wrap floor rockshaft and raise the wrap floor. Belts on the wrap floor then raise the wrap material to contact the baler belts.

The wrap clutch is then engaged which turns the wrap feed rollers. The wrap feed rollers turn at a slightly slower speed than the baler belts, which stretches the wrap material to provide a tight wrap on the module. Friction between the wrap floor belts and the baler belts pulls the wrap into the RMB.

Once the wrap material has been fed into the RMB chamber, the wrap floor engage solenoid is de-energized which shifts the valve, reverses the pressure to the cylinders, rotates the wrap floor rockshaft back to its original position, and lowers the wrap floor. Wrap continues to be pulled into the module chamber by friction between the module and baler belts.

During the initial phase of feeding wrap into the module chamber, the RFID reader is actively sensing for the presence of RFID tags on the wrap. If at least one RFID tag is not sensed during this time, a wrap misfeed error message and audible alarm are sent to the armrest display unit (ADU).

The wrap separation sensor emitter projects an infrared beam through the wrap material to the wrap separation sensor receiver. Wrap continues to feed until the infrared beam is broken by the wrap separation label. When the beam is broken, wrap separation is initiated. The wrap brake is engaged which stops rotation of the wrap feed rollers to allow separation of the Z-lock between the wrap portion that is being fed and the next roll portion. This separation exposes adhesive on the tail of the wrap which is pressed against the formed module to secure the wrap tail. The next wrap portion is staged above the wrap floor belts for the next module.

When wrap separation occurs, the wrap counter is decremented. The RFID signature is also compared to the wrap counter value. If there is a discrepancy, the wrap counter is corrected with the RFID indication.

Ejecting Module to Handler

When the module wrap cycle is nearly completed, the BIC control unit lowers the handler to a mid-point catch position to receive the module when it is ejected from the RMB chamber. A text message is sent to the ADU to alert the operator that the wrap sequence has been completed and the module is ready to be ejected.

The module ejection process is automatic but must be initiated by the operator. The highest point on the machine when the RMB gate is in the raised position is nearly 7.6 m (25 ft.) above the ground. When operating the machine on a slope or uneven ground, or near overhead electrical lines, the operator can choose not to initiate the process until the machine is in a more suitable location.

The operator can initiate the module ejection cycle at any time by pressing the top of the auto mode button on the multifunction control handle. Once initiated, the following occurs:

1. Rockshaft raises to remove tension from RMB belts.
2. RMB gate opens and module rolls onto handler.
3. Front bale-on-handler (BOH) sensor beam is broken and module position signal is sent to BIC, ADU, and corner post status display.
4. Handler lowers to provide clearance between module and gate. Module rolls into carry position on handler.
5. Rear BOH sensor beam is broken and module position signal is sent to BIC, ADU, and corner post status display.
6. Gate closes and rockshaft lowers to apply tension to RMB belts.
7. Hooks on gate engage in gate latch towers and activate magnetic gate latch switches. Switches close gate latch circuit and provide indication to operator that eject cycle is complete.

Unfolding the Module Builder

The auto unfold function is used to unfold the round module builder components when preparing the machine for road transport. The engine must be running at slow idle speed and machine must be engaged in the transport mode using the mode management screens on the armrest display unit before unfolding can occur. When button D on the power module tether control is pressed and held, the following sequence occurs at the direction of the baler interface control (BIC) unit.

1. Handler is commanded to lower to a preset position clear of gate. Handler position sensor monitors position of handler and sends an analog signal to BIC.
2. When BIC confirms that handler is clear of gate, the gate is commanded to raise to a preset position clear of handler cradle. Gate position sensor monitors position of gate and sends an analog signal to BIC.
3. When BIC confirms that gate is in proper position, handler is commanded to raise to fully raised position. Handler position sensor monitors position of handler and sends signal to BIC.
4. When handler is fully raised, gate is commanded to lower into handler cradle. Steel flags on gate pins move in front of magnetic gate-in-cradle switches. Switches close circuit to indicate to BIC that gate is in cradle.
5. With gate in cradle, RMB latch unlock valve is powered to unlock front half of baler. Operator must manually release secondary lock to complete this step. When latch is fully retracted, latch-open switches are closed.
6. The handler is now commanded to lower to transport position. As handler lowers, gate and front baler frame pivot toward rear of machine and lower also. While handler and baler are lowering, accumulator extension is commanded to lower to transport position. Switches on left-hand and right-hand side monitor position of accumulator extension. When accumulator extension is in transport position, left-hand switch opens and right-hand switch closes.

Folding the Module Builder

The auto fold function is used to fold the round module builder components into the harvest configuration from the road transport configuration. The engine must be running at slow idle speed and machine must be engaged in transport mode before folding can occur. When button C on the power module tether control is pressed and held, the following sequence occurs at the direction of the baler interface control (BIC) unit.

1. Accumulator extension raise valve is powered. The BIC monitors the status of accumulator extension position switches to determine when extension is fully raised (left-hand switch is closed and right-hand switch is open).
2. When BIC confirms that accumulator extension is fully raised, handler is commanded to raise to full height. As handler raises, gate and front baler frame pivot toward front of machine into harvest position. Handler position sensor monitors position of handler and sends an analog signal to BIC.
3. When BIC confirms that handler is fully raised, RMB latch close valve is powered to lock down front half of baler. When latch moves to locked position, secondary mechanical lock closes by spring action. Steel flags on secondary latch move in front of magnetic RMB latch switches. The switches close the gate latch circuit and indicate to the BIC that the front half of baler is locked in position.
4. Gate is now commanded to raise up and out of handler cradle. Gate position sensor monitors position of gate and sends an analog signal to BIC.
5. When BIC confirms that gate is out of cradle, handler is commanded to lower to a position clear of gate. Handler position sensor continues to inform BIC of handler position.
6. When handler reaches preset position, gate is commanded to lower to fully closed position. When gate closes, hooks on gate are positioned in front of magnetic gate latch switches. Switches close gate latch circuit to indicate to BIC that gate is fully closed.
7. Handler is commanded to move to fully raised position.