Abstract:
A sod harvesting machine comprising a wheeled frame with single or dual cutterheads at the forward end and a sod-receiving wind-up saddle at the rear end. An endless conveyor with a single flight spans the length of the machine and cut sod which is received at the forward end is advanced rearwardly for elevation and transport to the wind-up saddle and discharge at the rear end. The wind-up saddle comprises an expandable frame with pivotally attached supporting arms which commence the wind-up operation in a generally closed “U” configuration, but are controllably adjustably expandable outwardly to open the saddle for continuously accommodating the increase in diameter of the sod roll being helically wound therewithin. When the sod roll reaches its maximum and completed size, the saddle arms are pivoted rearwardly to the horizontal for direct discharge from the harvesting machine onto the ground surface.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present application relates to that certain Provisional Application Serial No. 60/271,288, filed Feb. 23, 2001, entitled “SOD HARVESTING MACHINE”. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates generally to a sod or turf harvesting machine, and more particularly to a harvester which is equipped with an endless conveyor having belt flight configuring means for continuously initiating, rolling, and discharging rolled turf or sod from the harvester structure. In this connection, the apparatus of the present invention includes a harvester device having a wheeled frame with opposed front and rear ends, and with a cutterhead mounted at the forward end, and a sod receiving wind-up saddle at the rear end. The endless conveyor passes between the ends along the length of the device, with the front end portion of the conveyor functioning to pick up cut sod from the cutterhead and the remainder functioning to transport and roll the cut sod, with the rear of the endless conveyor having drive means which functions with the components performing the winding operation. The top flight of the conveyor passing adjacent to said front end for receiving cut sod directly from the cutterhead, with the top flight extending and traveling rearwardly of the cutterhead for elevating, transporting and ultimately winding cut sod within the wind-up saddle. The path of the top flight of the conveyor belt along the rear of the machine is configured so as to actually form adjustable or expandable saddle walls as the sod rolls are being formed directly on and expanding within the configured belt. Flight supporting cylinders and platens against which the belt travels are mounted on an adjustably pivotably movable rear belt support arm, the support arm being controllably and adjustably positioned to define the configuration of the wind-up saddle and its roll confining walls, the walls being movable to adjustably control the operating width or jaw of the wind-up saddle. Additionally, the rear belt supporting arms comprise a mounting frame which is controllably positionable so as to permit the rear support to open to a flat disposition and thus enable the discharge of individual finished rolls of sod from the apparatus. With the conveyor configured in the roll discharge position, the rolls are discharged directly onto the surface. 
     Sod harvesting machines of the invention are provided for cutting and rolling sod for later transport from the sod farm to an appropriate destination where the rolls are to be ultimately deposited to form live turf. The harvesting machine is designed to cut and roll the sod in one continuous operation, and is also provided with means to cover the cut sod with a protective film of plastic or netting in order to protect the roll from the ambient and enhance its stability. 
     In the past, sod harvesting machines with multiple conveyors and wind-up mechanisms have been utilized, with these devices normally being highly complex and cumbersome, and with certain operations requiring intensive hand labor. The present arrangement reduces the necessity for a variety of systems and subsystems normally required, and provides a wind-up mechanism featuring a saddle which facilitates in-line rolling, wrapping, and discharging of rolls onto the adjacent surface for later pick up. The arrangement is designed for use with minimum of manual intervention. The harvesting machine is typically attached to a towing vehicle such as a tractor by means of a three-point hitch and may be operated by either a single operator or a pair of operators. 
     The wind-up portion of the winding mechanism comprises the rear section of the conveyor belt, with this section being configured in a “U” or “V” to form the initial sod receiving saddle portion of the mechanism. The saddle includes a pair of laterally spaced apart normally upwardly directed or extending rear saddle arms. The arms are positioned to provide a conveyor belt path to create the wind-up saddle and bed. In the wind-up mode, the entire wind-up bed is of an initial generally closed “U”-shape configuration with the base of the saddle being disposed at or adjacent the low-point of the conveyor flight. The base or bed of the saddle has an axis arranged generally transverse to the frame axis. The portion of the conveyor belt driving segment in the saddle zone includes at least one drive member such as a driven cylinder sprocket functioning as the conveyor drive and with a plurality of belt supporting idlers and guide platens also being provided in the saddle zone. Each cylinder and platen is mounted within the wind-up saddle transversely of the saddle arms for guiding and supporting the endless belt and otherwise controllably delineating the travel path of the top flight of the conveyor. The conveyor carries lengths of incoming cut sod into the saddle zone where it is helically wound into rolls and discharged from the rear end onto the ground. 
     The upwardly extending rear saddle arms are pivotally coupled at their lower ends to the frame. Actuating means are coupled to the arms for coordinated selective and adjustable pivotal rotation of the arms relative to the frame. The controlled pivotal rotation provides motion between closed and opened saddle dispositions, this motion controllably enlarging the size of the wind-up bed while cut sod is continuously being received and wound and thereby growing helically. Sod cut-off means are disposed directly ahead of the cutterhead and provided with actuating means for periodically severing the sod so that incoming cut sod is formed in rolls of defined lengths. When a given defined length of incoming cut sod has passed along the conveyor and completed its wind-up operation within the device, the actuating means for the rear saddle arms are further extended rearwardly and dropped flat to provide the conveyor with an open tailgate configuration for controlled discharge and dropping of the finished roll onto the surrounding ground. 
     A layer of netting or film may be applied to the sod as it is being helically wound into a roll, with the netting or film being provided from a supply roll positionably mounted within the saddle assembly. Means are provided for unwinding and guiding the film from the supply roll into contact with the sod being formed into helically wound rolls and for periodically severing the unwound film into appropriate lengths whenever the roll-up operation for a given roll is complete. For most purposes, the netting or film is applied to the outer layers of the helically wound material, it being unnecessary to cover the entire surfaces of the roll with such netting or film. 
     One of the valuable features of the present invention is the utilization of the top flight of the conveyor to function as a transport mechanism, a wind-up saddle defining mechanism, as well as an unloading or roll discharge mechanism. In its roll-up or winding configuration, the conveyor belt makes contact with the sod along a sufficiently large surface area so as to create the friction necessary for the initial start of the wind-up operation about a central cylindrical core which has already been dropped into the saddle zone. Furthermore, as the mass and size of the roll about the core increases, the area of contact between the sod and the belt surface may decrease, but given the force created by the increased weight and friction, the wind-up operation continues to move smoothly. In other words, the top flight of the single conveyor first elevates the sod to a high point or apex, then proceeds in a downward declining path to the saddle where the belt reaches a second point of inflection and commences an upward direction of travel. This second point of inflection is where the sod roll-up operation is initiated. When the winding operation is completed, the roll is dropped from the machine and discharged onto the ground surface. These functions are all performed sequentially and smoothly by the single conveyor mat or flight as the harvester machine continues to move forwardly bringing in more cut sod for the roll-up operation. 
     The adjustably movable support arms which serve to delineate, define and guide the conveyor belt in the wind-up saddle zone are capable of pivotal movement to controllably expand the operating width of the wind-up saddle zone. Thus, as the helical wind-up operation progresses, the diameter of the resultant roll increases until the roll reaches its maximum size as determined by the predetermined cut length. Once this stage of the operation has been reached, the pivotal rotational motion of the upwardly extending saddle arms drops the conveyor belt supporting arms to substantially horizontal but descending position with the conveyor belt continuing to advance and function. When the saddle is moved to the open disposition, the downward slope of the belt together with continued belt motion carries the roll to a roll-out position whereupon it is permitted to roll freely off the arms such as in the fashion of an open downwardly inclined tailgate. 
     There is an optional core-dispenser attached to the system which loads roll cores onto the conveyor whereupon the sod will preferably be initially wrapped around the core during the actual wind-up operation. 
     SUMMARY OF THE INVENTION 
     Therefore, it is a primary object of the present invention to provide an improved sod harvester which incorporates in a single mechanism a sod cutter or cutters, a wind-up mechanism and an unloading means, all operable with minimal manual intervention and as the machine moves forwardly. 
     It is a further object of the present invention to provide an improved sod harvesting mechanism which incorporates a continuously variable width saddle zone for receiving, initiating, rolling, and ultimately discharging rolled freshly cut turf therefrom, the width of the saddle zone being delineated by a conveyor flight which is pivotally moveable to guide and roll the freshly cute turf. 
     It is a further object of the present invention to provide an improved sod harvesting apparatus which incorporates a net or film applicator which supplies netting onto the cut sod during the roll-up operation as deemed helpful for the operation. 
     It is yet a further object of the present invention to provide a continuously adjustably pivotable conveyor for initiating, rolling, and discharging rolled turf, wherein means are provided for chopping or cutting sod into predetermined lengths prior to rolling for delivering finished rolls of turf or sod with a predetermined overall turf area. 
     Other and further objects of the present invention will become apparent to those skilled in the art upon a study of the following specification, appended claims, and accompanying drawings. 
    
    
     IN THE DRAWINGS 
     FIG. 1 is a side elevational view of a preferred embodiment of the present invention, and illustrating a loading mechanism to elevate cut turf being received at the leading portion of the conveyor, and illustrating in phantom the path of an individual winding core as it drops from the core storage rack into the saddle zone of the saddle and roll-up zone of the conveyor; 
     FIG. 2 is a detail side elevational view, partially broken away, and illustrating the detail of the wind-up saddle in the configuration as the sod roll-up operation is initiated, and wherein the netting is being delivered onto the outer surface of the sod being rolled; 
     FIG. 3 is a sectional view, partially broken away, taken along the line and in the direction of the arrows  3 — 3  of FIG. 2; 
     FIG. 4 is a view similar to FIG.  2  and illustrating the configuration of the wind-up portion of the conveyor after the winding operation has progressed, and illustrating the apparatus after a moderate increase in roll girth due to the continuous winding, and also illustrating in phantom the conveyor belt guide or idler roller; 
     FIG. 5 is a view of that portion of the harvester apparatus illustrated in FIG. 4, and illustrating the configuration of the wind-up mechanism as it is dropped to a finished roll discharge disposition; and 
     FIG. 6 is a schematic block diagram illustrating the interaction of various components included in the harvester system illustrated in FIGS. 1-5, and further illustrating the control circuit for actuating operative components in the course of the wind-up and discharge operations. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     With attention now being directed to FIG. 1 of the drawings, the sod harvesting machine generally designated  10  comprises a wheeled frame  11  supported by a pair of laterally disposed pneumatic wheels as at  12 , with the frame having opposed ends including the front end as at  13  and the rear as at  14 . As further shown in FIG. 1, a cutterhead or alternatively one of a pair comprising dual cutterheads  16  is mounted on the front portion of frame  11 , cutterhead  16  including conventional edge cutters and an earth penetrating horizontally disposed blade, all of which is known and conventional in the art. A sod or turf receiving upwardly extending guide ramp  18  may direct the cut sod or turf upwardly, with ramp  18  providing an elevating support for the cut sod or turf  19  for entering onto the endless conveyor mechanism such as shown generally at  20 . Endless conveyor  20  is provided with an endless conveyor belt  21  having a top flight  22  arranged and extending rearwardly along the length of the harvester and supported by idler cylinders or wheels as at  23 — 23 , along with a drive cylinder or sprockets as at  24 . Drive cylinder  24  is typically powered by a hydraulic motor, with such drive systems being known in the art. Belt  21  which comprises steel rods and rubber straps is rendered endless with the lower or return of bottom flight shown at  25 . Frame  11  is provided with a hitch mechanism as at  27 , with hitch  27  normally being a conventional three point hitch. 
     The cutterhead  16  is provided with a depth control mechanism as at  28 , with depth control  28  being utilized to control the elevation of lateral disc cutters  16 A as well as the depth of the horizontally disposed sod cutter blade (not shown). Such depth control mechanisms are known in the art. 
     Cutterhead mechanism  16  further includes a chop blade as at  30 , with blade  30  being driven intermittently along a reciprocatory up-and-down path, with chop blade  30  penetrating the soil and turf to a distance sufficient to enable the individual rolls to be effectively cut-to-length. 
     The Conveyor Operation 
     As indicated, conveyor  20  is equipped with an endless belt  21  having a top flight  22  passing adjacent the front end  13  of the apparatus, and designed to receive cut sod directly from the cutterhead, specifically from ramp  18 . Top flight  22  extends along the length of frame  11  with the forward portion of the top flight traveling along a path both elevating and transporting the cut sod toward the rearwardly disposed wind-up saddle. Belt  21  reaches an apex point as at  32  whereupon the direction of travel is converted to downwardly extending direction, such as is illustrated at  33 . The purpose of the downwardly extending portion of flight  22  is for moving the cut sod or turf into the wind-up saddle zone so that winding will automatically commence. Belt  21  being comprised of steel rods and rubber straps provides sufficient contact friction with the sod for the wining operation to proceed. 
     The path of top flight  22 , as belt  21  continues along declining path  33  is controlled by guide roller  35 . In this connection, guide roller  35  defines the path of top flight  22  as it enters or defines the wind-up saddle, with idler  36  being utilized to further define the saddle. As indicated in FIG. 1, the wind-up saddle zone shown generally at  37  is further shown with a core  39  disposed therewithin. From the base point  39 B of saddle  37 , belt  21  is guided upwardly around the periphery of guide roller  35 , and being further guided by belt guide or platen  38 , and thereafter continuing to the point where belt  21  wraps about drive roller  24 . 
     With attention now being directed to FIG. 2 of the drawings, cut sod or turf  19  is shown as it enters wind-up saddle  37 , and initiates its wrap about the core  39 . The friction between the surfaces of the cut turf or sod  19  and top flight  22  of belt  21  is sufficient to propel or advance the leading edge portion  40  of sod  19  about the circumference of core  39 , with the arrangement providing for the sod to push under the floating core for substantially 180° of wrap against the upper surface of sod  19 . Thus, the initiation of the winding about core  39  is routinely and automatically obtained. 
     It is further indicated in FIG. 2, a supply roll  43  of netting, screening, or plastic resinous film (normally polyethylene) is provided, with supply roll  43  being illustrated as mounted upon the extreme upper end of saddle. Net roll  44  delivers a quantity of film or netting (film) through the bite zone of net rolls  44 , with a plastic netting or film continuing along a path as shown at  45  until it makes contact with the outer surface of the partially completed roll. At the point of contact, the netting is being advanced at the same rate of speed as the sod, therefore permitting the netting to become a part of the wrapping operation, and indeed in contact with the earthen or soil surface of the sod. 
     While it is normally practical to utilize netting in the wind-up operation, it is not necessary for netting to be employed throughout the entire operation, but it is preferably present as the wind-up operation approaches completion. In FIG. 2, the netting is illustrated as being initiated early on, however the netting would normally be applied only toward the end of the wind-up operation and while several revolutions of the wind-up operation remain to be completed. In order to cut the netting into a length for each sod roll, the cutting operation is achieved by permitting a sufficient number of wraps of netting to be wound about the sod, and with the locking net rolls  44  in place, the netting will simply become broken away at a point adjacent the net roll. The next net application operation can be started by initiating action of net rolls  44  and permitting the netting to follow along a drop path as at  45  into contact with the roll. 
     The Saddle Operation 
     With attention also being directed to FIG. 3 of the drawings, it will be noted that guide rollers  35 — 35  provide the configuration for wind-up saddle  37 , and thus provide a resting zone for core  39 . The wind-up axis for core  39  is shown at  49 . As further indicated in FIG. 3, the grass-surface of turf or sod  19  is illustrated at  50 , with the soil-back surface being shown at  51 . Support for guide rollers  35 — 35  is provided by laterally disposed frame members  11 A and  11 B. 
     With attention also being directed to FIG. 3 of the drawings, it will be noted that guide rollers  35 — 35  provide the configuration for wind-up saddle  37 , and thus provide a resting zone for core  38 . The wind-up axis for core  38  is shown at  49 . As further indicated in FIG. 3, the grass-surface of turf or sod  19  is illustrated at  50 , with the soil-back surface being shown at  51 . Support for guide rollers  35 — 35  is provided by laterally disposed frame members  11 A and  11 B. 
     As indicated hereinabove, and with added attention being directed to FIGS. 4 and 5 of the drawings, lift cylinder  55  is shown with clevis  56  anchoring or supporting cylinder  55  along upright frame post  11 C. A pair of cylinders  55  may be employed if desired, with each such cylinder being mounted on opposite sides of the harvester. Operation of dual cylinders will, of course, be undertaken by conventional hydraulic circuitry. The hydraulic ram shown in FIG. 5 extending from cylinder  55  is coupled through clevis  59  to rear support arm  47 . Linkage as at  60  provides the coupling. The positioning of ram  58  will, accordingly, adjust the angular position of rear support arm  47  to define the path of upper flight  22  of belt  21 . In the disposition shown at FIG. 5, upper flight  22  is arranged along a descending path as it enters the saddle, thereby permitting conveyor belt  22  and its supports to function as a tailgate to drop a completed roll as illustrated generally at  60  (FIG.  5 ). In other words, sod or turf  19  has been helically wound about core  39  to form a completed roll  60 . To assist in the discharge or dumping operation, idler rolls as shown at  61 — 61  are provided for this purpose. The phantom lines of FIG. 5 illustrate a bed-path for supporting completed roll  60  as it is discharged from the apparatus. 
     As the winding operation is advanced from the disposition illustrated in FIG. 2, the width of the “U” -shaped saddle is increased, with FIG. 4 illustrating the disposition as the roll nears completion, and as the “U” saddle has been widened to accommodate the ongoing growth of the roll. The progression of turf  19  as it is being rolled requires that the link to the saddle be progressively expanded so as to accommodate the rolls which are being formed directly on the top of the conveyor belt  21 . Thus, as the roll increases in size, supporting cylinders and platens as illustrated at  36  and  38  assist in maintaining the integrity of the wind-up saddle and the expanding roll as it progressively increases its diameter. As the size of the roll gradually increases, it can be seen that the area of contact between the belt and the roll is constantly changing, however the weight of the roll has been found sufficient to continue and maintain the wind-up operation. As indicated hereinbelow, the operation of cylinder  55  and its ram is controlled so as to substantially constantly advance the width of the “U” configuration of the wind-up saddle so as to accommodate the increasing diameter of the turf roll. The width of the “U” configuration is advanced either continuously or alternatively it may be advanced in steps. When a stepping function is utilized, it is possible to undertake the motion in approximately three separate steps or more. Also, as indicated hereinabove, the portion of conveyor belt  21  which passes along the rear surface of the “U” is ultimately permitted to open to a flat and downwardly incline disposition so as to create an on-demand discharge gate for finished rolls of sod. 
     With attention now being again directed to FIG. 1 of the drawings, it will be observed that a supply of individual cores is stored on the machine within core storage rack  65 . Core storage rack is supported on frame  11  primarily by upright posts as shown at  11 C, thus creating a cradle network for the supply of cores. Means such as an intermittently operated gate are provided for the dropping of an individual core from the supply as shown at  39 A wherein the individual core, under the influence of gravity, follows the drop path indicated in phantom in FIG.  1 . The gate may either be automatic or operated by hand. 
     With attention now being directed to FIG. 6 of the drawings, the description of the control mechanism will be described hereinafter. The control mechanism  70 , shown schematically in FIG. 6, comprises a ground speed and distance speed  71 , along with a series of individual control systems. Control systems include net roll control  72 , conveyor speed control  73 , rear support arm tailgate positioning control  74 , core feeder control  75 , cutterhead operation and depth control  76 , and chop blade control  77 . Each of the controls functions in combination with the mechanism illustrated in FIGS. 1-5, the operation of which is as follows: 
     Ground wheel  12  is equipped with a conventional rotary counter, preferably magnetic, (not shown) which delivers a signal to input  80  provides an indication or measure of ground speed and also inputs to distance meter  71 . Thus, the data obtained from ground wheel include both ground speed of the harvester as well as distance. The distance indicator is utilized to control the action of reciprocatory chop drive as at  81 , for intermittently actuating chop  30  thereby defining the length of sod or turf present in each individual sod roll, such as roll  60 . In addition to the chop drive, an audible signal is preferably obtained in advance of each chop operation. In the event hand control of the chop is desirable, hand control  82  is provided. 
     Conveyor speed control, as indicated at  73 , is utilized to activate and control conveyor drive through drive control  83 . Thus, when desired, conveyor speed can be precisely coordinated with ground speed, although such control is not always essential. If hand control of conveyor speed and motion is desired, handle  84  is provided. For many applications, conveyor speed may be pre-set to a normal cutting speed, with control  83  being configured in such a way that it operates primarily under hand control. 
     As the wind-up operation is commenced, a core feeder is actuated through control  75 , with the core feeder normally being a manual operation through a hand control lever positioned in proximity to an operator, with such a control being accomplished through a simple manual hand-actuated linkage as at manual lever  86 . 
     With attention now being directed to FIGS. 4 and 5, the disposition of support arm  47  will define the configuration of the wind-up saddle through lift cylinder  55 . Tailgate position control is further utilized to position rear support arm  47  for the discharge disposition as illustrated in FIG.  5 . Hand operation of the tailgate position control is undertaken by control lever  89 . 
     Net roll control  72  along with net roll drive  92  is utilized to initiate rotational motion of net rolls  44 , as well as the locking of rolls  44  to permit automatic tear-off of netting from net roll supply  43 . This operation may also be undertaken automatically through conveyor speed control, or alternatively through distance control. In either event, hand control is also possible through hand lever  90 . 
     As indicated hereinabove, cutterhead operation and depth control is also a desirable feature, with the cutterhead operation and depth control being shown at  76  and  91 . Normally cutterhead operation and depth control is a function undertaken by the operator, with the cutterhead being lowered its operative disposition, and permitted to remain at that level during the working cycle. For transport positioning, the cutterhead is elevated to a travel position where it is safely out of contact with the road or other supporting surface. 
     Operation—Wind-up Mode 
     The forward segment of conveyor belt  21  travels along a gradually ascending upwardly directed path from the sod receiving end or the wind-up end, until reaching a high point where there is a first inflection point such as at apex  32 . At apex  32 , the rearward segment of the conveyor travels along a gradually descending path until a second point of inflection is reached, the second inflection point being the wind-up saddle zone where the belt path resumes upwardly directed travel. Upwardly directed travel continues with the slope of the path changing in response to the opening of the wind-up zone to accommodate increase in sod roll diameter. 
     Operation—Roll-off Mechanism 
     Upon reaching full size due to completion of winding an entire pre-cut length of sod, the path for the rearward segment of upper flight  22  of conveyor belt  21  is again modified when the conveyor belt support arms including the rearward support arms  47  and accompanying belt assembly is dropped to assume a roll-off or discharge position. Ongoing belt motion or travel together with the downward slope of the belt is sufficient to cause the roll  60  to be discharged directly onto the ground. Thereafter, the arms  47  are again pivoted through the action of cylinder  55  to a substantially upright position whereupon the wind-up operation for the next succeeding cycle is resumed. 
     It will be appreciated that the harvester device illustrated hereinabove is given by way of an example of the preferred embodiment, it being understood that the scope of protection to which this invention is entitled is not intended to be limited to the specific examples given herein.