John Deere Round Modules

Figure 16 A John Deere 7760 cotton picker carrying a finished round module while harvest continues and the next module is being formed.

Forming and Staging

The John Deere 7760 forms round modules, using a mechanism similar to that of a round hay baler. The operation of the module forming mechanism is highly automated, requiring minimal operator interaction. The round modules are covered with an engineered polyethylene film that both protects the seed cotton and provides compressive force to maintain the module density. The module-forming control system handles the wrapping of the modules; and, when wrapping is completed, the module is ejected onto the carrier at the rear of the machine, as shown in Figure 16. The primary action of the operator regarding the modules is to decide when to drop the module being carried. Typically, the finished module is carried until it can be dropped on a turn-row. If the yield is very high, or the row lengths are long, it may be necessary to drop the modules in the middle of the field. This action has no impact on the operation of the picker, but stalks may puncture or tear the plastic wrap.

Avoiding Module Rolling

Because of the round shape of the modules, there is a concern about dropping the modules on sloping ground. When the carrier is lowered for unloading, the modules do roll onto the ground. Typically, there is enough flexing of the module shape that the rolling stops very quickly. However, there is a potential for continued rolling if the module were dropped when the picker is headed up a steep slope. In rolling terrain, the operator should drop the modules only when the picker is oriented across the slope to prevent excessive rolling.

Transporting Round Modules

Figure 17 Carrying a round module with a three-point hitch attachment. The module is being staged for transport to the gin.

Figure 18 Staging of round modules for transport in conventional module trucks should be done in sets of four. A gap of four to eight inches should be placed between round modules to prevent damage of the wrap when loading (inset). (Photos by Alan Brashears.)

The round modules can be transported to the gin in conventional module trucks or on semi-trailers. The modules must be picked up where they were dropped in the field, and staged together for pickup, four for a module truck and six for a semi-trailer. The staging can be done using several different implements. The most common system is to use a set of forks with hydraulically controlled spacing mounted on the three-point hitch of a tractor (Figure 17). Other devices include a mast-type mounted implement that holds the module with the axis parallel to the tractor rear axle or a set of forks on a front-end loader. Because the round modules can weigh over 6,000 lbs., a large tractor is required for staging. The following practices are recommended when unloading and preparing modules for transport:

  • Modules should be staged only in well drained areas of bare soil, such as turn-rows. If the soil is wet, wheel slip by the truck can cause the chains to tear the plastic wrap. Avoid placing the module on cotton stalks, as the movement of the modules on the stalks can puncture the plastic wrap. If possible, avoid staging in areas where the truck cannot access the modules if rain occurs.
  • When staging round modules together for transport or for storage at the gin, lift the module 12 inches or more above the ground. A lower position can result in stalks tearing the exposed wrap on the bottom.
  • When placing modules together for transport, a 4- to 8-inch space should be placed between modules (Figure 18). Do not allow module ends to touch, as this will cause water to enter the modules rather than to run off down the ends. The modules should be aligned so that the centerlines are within a +/- five-inch band. If not properly aligned, the wrap may be damaged by the sidewalls of the module truck.
  • Stage round modules for transport end-to-end rather than side to side.
  • Module trucks used to load and transport round modules should be fitted with chains that have rounded cleats that will not puncture the plastic wrap.

Module Wrap Protection and Handling

The plastic wrap typically performs well in preventing moisture from entering the seed cotton. The open ends of the modules will shed rainwater, provided the ends are not touching. Modules too close together will hold water between the ends, resulting in wet cotton with the usual potential for reduced-quality grades. When intact, the wrap will shed water on the circumference of the module.

Punctures and tears in the wrap can occur and will allow degradation of the seed cotton if not repaired. Tears can be covered with a water-resistant tape, such as lint bale repair tape. A common problem is that the adhesive at the end of the wrap gives way after weathering, resulting in loose ends. John Deere recommends reattaching the loose end with 3M 90 spray adhesive or lint bale repair tape. Wrap damage should be repaired before transport, as the loading/unloading actions can make damage more serious. The inside walls of the module truck must be free of burrs or edges that could catch and tear the wrap during loading.


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