Abstract:
A simplified method of assembling a disk from the ground up by first assembling disk gangs and then connecting the disk gangs together to provide a self-standing front and rear main disk gang pairs. The main frame is assembled over main disk gang pairs after which wheel modules are attached. Disks of different sizes are assembled, utilizing generally identical main frame beams with the same connecting locations, by decreasing the distance between the forward and rear gang pairs and moving the main frame beams outwardly as the desired width of the disk increases.

Description:
BACKGROUND OF THE INVENTION 
     (1) Field of the Invention 
     The present invention relates generally to agricultural implements such as disks, and more specifically, to a method of manufacturing disks of various sizes utilizing common structural members. 
     (2) Related Art 
     Agricultural implements such as disks typically use a plurality of different frames to provide for disk widths ranging from approximately eighteen to thirty-five feet. The multiple frames provide proportionality of width between the center and wing sections on multi-section wing fold disks and have been necessary to provide strength adequate to carry the disk in transport. Because of the gang angle associated with the disks, wider frame sections require longer fore-and-aft frame members so that different weld fixtures have to be used for each frame size. The number of common parts which may be utilized is significantly reduced. As a result, manufacturing time and costs are increased. Attempts to increase commonality of parts can result in changes in the geometric relationships between the gauge wheels and the disk blades, as well as other structural problems, which have hindered the development of a method for manufacturing a reduced cost disk. 
     Previous methods of assembling a disk included assembling a frame, generally in a box or rectangular configuration, and then utilizing a lift to raise the frame so that gang tubes could be slid under the frame. Often the method involved forming attaching holes in the underside of the frame and making the necessary connections while the frame was hoisted on the lift. Such a method required inconvenient and time-consuming work under the frame. 
     BRIEF SUMMARY OF THE INVENTION 
     It is therefore an object of the present invention to provide an improved method for manufacturing an implement such as a disk. It is a further object to provide such a method which reduces the cost to manufacture such a disk. 
     It is a another object of the present invention to provide an improved method for manufacturing a disk or similar implement wherein various sizes of the implement may be manufactured utilizing an increased number of common or substantially similar parts while reducing a number of fixtures necessary to manufacture the disk. It is a further object to provide such a method wherein the geometric relationships between the gang wheels and the disk blades remain generally constant for the different sizes of disks. It is still a further object to provide such a method which reduces the time and cost of manufacturing a disk while maintaining adequate disk frame strength. 
     It is a further object to provide a simplified method for manufacturing a disk or similar implement wherein the implement is assembled from the ground up. It is another object to provide such a method which reduces the time that the disk frame must be hoisted by a lift as well as the time an assembler must spend making connections at the underside of the disk. 
     It is still a further object to provide such a method wherein the disk gangs are assembled and connected together at their centers to from self-standing gang pairs and thereafter the main frame is lowered onto and assembled on the gang pairs. 
     In accordance with the above objects, a method of manufacturing a disk includes the steps of bolting gang tubes together at the center line of the disk with the desired gang angles and thereafter laying first and second main frame beams over the gang tubes. The first and second main frame beams are of generally common configuration, regardless of the desired disk frame size, and include connecting brackets spaced a preselected fore-and-aft distance apart and identically located wheel mounting brackets. By decreasing the distance between the front and rear gang tubes as the desired frame width is increased, the generally common main frame beams can be used while the geometric relationships between the gauge wheels and the disk blades remain constant. For wider frames, wider hitch and connecting link members are combined with the common fore-and-aft members. Since common fore-and-aft members are utilized for all frame sizes, fewer parts are needed and fewer fixtures are needed to assemble the parts resulting in a reduced cost method of manufacturing a disk or similar implement. The arrangement of the main fore-and-aft members over the connected gang tubes with the fore-and-aft members diverging outwardly in the rearward direction provides adequate frame strength for even the largest disk and provides more structural stability than a box frame or other rectangular arrangement which has heretofore been commonly used when manufacturing disks. 
     According to another aspect of the present invention, the gang tubes are connected at their centers to form two pairs of self-standing disk gangs. The main frame beams are then lowered onto the gang tubes and bolted loosely thereto. Transversely extending connecting links projecting inwardly from the beams are aligned and connected. Thereafter all of the joints beginning at the center of the disk and extending outwardly are tightened. Wheel modules are then connected to the main frame. After wing gangs are attached to the gang tubes, wing frames are lowered on top of the wing gangs and bolted thereto, and wheel modules are connected to the wing frames. In this manner, the disk is essentially built from the ground up to reduce the time the disk frame must be lifted by a hoist and to reduce the amount of time workers have to spend under the frame to make the necessary connections. The present method can reduce the amount of time necessary to assemble a disk to approximately half that required by previous methods of assembly. 
     These and other objects, features and advantages of the present invention will become apparent to those skilled in the art from the description which follows and from the drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a plan view of halves of two disks of different sizes split at their center lines and showing the decrease in spacing between the front and rear gangs of the larger disk to accommodate fore-and-aft extending main frame beams of generally identical construction. 
     FIG. 2 is a flow chart generally outlining the steps of manufacturing a disk according to the present invention. 
     FIGS. 3a-3e are schematic representations of steps utilized in constructing a disk according to the present invention. 
     FIG. 4 is a perspective view of a portion of a disk constructed in accordance with the teachings of the present invention and showing main frame and wheel module connecting brackets. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to FIG. 1, therein is shown opposite half portions of two disks, the smaller one indicated generally at 10 and a similar but larger one indicated at 10a. Only the smaller disk 10 will be described in detail here, with the corresponding parts on the larger disk 10a having a like designation but with a suffix &#34;a&#34; added thereto. The disk 10 includes front and rear disk gangs 12 and 14, respectively, connected to a main frame 18. Front and rear wing gangs 22 and 24 are pivotally connected to the corresponding gangs 12 and 14. The wing gangs 22 and 24 are connected to wing frames 28, and hydraulic folding cylinders 32 are connected between the main frame 18 and the wing frames 28 for rocking the wings between a lowered field-working position and a raised transport position. Wheel modules 36 are connected to the main frame and are rockable vertically by conventional hydraulic structure (FIG. 4) to raise and lower the disk 10. The pair of wheel modules 36 on the main frame are connected by transversely extending rockshaft structure 38. Wheel modules 42 are connected to the wing frames 28. Hitch structure 46 is connected to the forward end of the main frame 18 for towing the disk 10 in the forward direction (F) over the ground. It is to be understood that the construction of the disks 10 and 10a is such that the half of the disk on one side of the center line, indicated generally at 48 in FIG. 1, is generally the mirror image of the half on the opposite side of the center line. 
     The disk gangs 12 and 14 include conventional axle-mounted disks 50 supported from disk bearing standards 52 which in turn are connected to gang frames or tubes 62 and 64, respectively. Similarly, the wing gangs 22 and 24 include disks 50 connected by standards 52 to gang frames or tubes 72 and 74, respectively. The gang tubes are generally rectangular in cross section and extend parallel to the axis of rotation of the corresponding disks 50. The inner ends of the tubes 62 and 64 are connected by tube brackets 76 and 78, respectively. The main gang tubes 62 and 64 are fixed to the main frame 18 by brackets indicated generally at 82 and 84, respectively. The main frame 18 includes a pair of fore-and-aft extending main frame beams 88 which are joined by forward and aft connecting links 92 and 94 which extend transversely between the beams 88. The beams 88 diverge outwardly in the rearward direction. The brackets 82 and 84 include upper flanged portions, indicated at 98 in FIG. 4, which are welded at preselected locations near the front and the rear of the beams 88. Lower flanged portions 102 are fixed to the corresponding gang frame tubes 62 and 64 to mate with the upper flanged portions 98, and both the flanged portions are apertured to receive connecting bolts 104 therethrough. The connecting links 92 and 94 include link brackets 112 and 114 which, as will be described in detail below, are connected at or near the center line 48 during assembly of the disk 10. 
     The wing frames 28 include flanged brackets 122 and 123 connecting the forward wing gang tube 72 to the forward portion of the frame, and rear flanged brackets 124 and 125 connecting the aft end of the frame 28 to the aft wing frame tube 74. Forward and aft pivot structures 132 and 134 are fixed to the outer ends of the gang frame tubes 62 and 64, respectively, and to the inner ends of the tubes 72 and 74, respectively, so that as the cylinders 32 are retracted the wing gangs 22 and 24 will be pivoted about a generally fore-and-aft extending axis. 
     The wheel modules 36 are connected by downwardly opening, hat-shaped brackets 138 connected near the central portion of the beam 88. The wing frame wheel modules 42 are connected to the wing frames by similar wheel module brackets 142 generally centrally located between the brackets 122 and 124. 
     Assembly of the Disk 
     Referring now to FIGS. 2 and 3, the procedure for assembling a disk will be discussed in detail. As shown generally at 152 in FIG. 2, the front and rear disk gangs 12 and 14 and the front and rear wing gangs 22 and 24 are first assembled by connecting the disk-bearing standards 52 to the disks 50 and to the corresponding gang tubes 62, 64 and 72, 74. Thereafter, as shown at 154, the main disk gangs 12 and 14 are connected together at their innermost ends by bolting the brackets 76 on the forward gangs 12 together and bolting the brackets 78 on the rearward gangs 14 together. As can be seen in FIGS. 1 and 3, the brackets 76 and 78 are fixed to the corresponding gang tubes 62 and 64 such that when the brackets are bolted together, the gangs diverge in the fore-and-aft direction from the center line 48 outwardly to provide the desired gang angles. The connected disk gangs 12 and 14 are self-standing and are placed on the floor or other supporting structure in generally the configuration they will assume in the finally assembled disk 10 (see FIG. 3a) with the gang tubes 62 and 64 located above the disks 50. 
     Each main frame beam 88 with its corresponding brackets 82, 84 and 138, as well as the inwardly directed connecting link portions 92 and 94, are fabricated in a weld fixture. The locations of the brackets 82, 84 and 138 and link portions 92 and 94 are fixed, regardless of the disk size so that the same fixtures may be utilized for any size disk. 
     The individual weldments including the respective main frame beams 88 with brackets and link portions are then lowered onto the self-standing disk gang pairs so that the flanges 98, 102 on the brackets 82 and 84 generally align. As shown at 156, the main frame beams 88 are loosely connected over the main gangs 12 and 14 by inserting the bolts 104 through the aligned apertures in the flanges. Prior to this time the central main frame joints defined by the front and rear link brackets 112 and 114 are disconnected to facilitate the placement of the weldments on the gang pairs and loose alignment of the main frame brackets 82 and 84. Thereafter, as indicated at 158 in FIG. 2, the brackets 112 and 114 are aligned and bolts are inserted through the brackets to rigidly secure the links 92 and 94 and thus the main frame beams 88 together. Preferably, as shown at 162, the joints are tightened from the center out beginning at the link brackets 112 and 114. The apertures in the brackets 82 and 84 are slightly oversized to facilitate assembly and accommodate manufacturing tolerances. After the link brackets 112 and 114 are secured, the bolts in the brackets 82 and 84 are tightened to provide a rigid center disk structure. In the larger disk 10a, the rear link brackets 114a are bolted to the center tube brackets 78a for increased strength. 
     The front hitch structure 46 is then connected to the forward ends of the beams 88 as indicated at 164 and in FIG. 2 and at FIG. 3c . Also, as shown at FIG. 3c, the main frame wheel modules 36 are pivotally connected to the downwardly opening module brackets 138 on each of the beams 88. As can be appreciated from FIG. 1, the same bracket locations are utilized on the beam 88a for the larger disk 10a as on the beam 88 for the smaller disk 10. For the larger disk 10a, the front and rear disk gangs 12a and 14a are moved more closely together at the center line 48 so that the beam 88a may be moved outwardly farther on the gang tubes 62a and 64a. The connecting links 92a and 94a are also lengthened to accommodate the wider spacing between the beams 88a. A larger hitch structure 46a is also utilized. 
     The rockshaft structure 38 is connected between the wheel modules 36 for constraining the modules to operate in unison. Brackets 166 connect the rockshaft structure to the wheel modules 36 and shims are provided for inserting between the brackets 166 to facilitate assembly and accommodate manufacturing tolerances in the main disk assembly. 
     After the main frame portion of the disk 10 is assembled, the wing gangs 22 and 24 are pivotally connected at their inner ends to the outermost ends of the corresponding main frame disk gangs 12 and 14 by the pivot structures 132 and 134, 15 respectively (see 172 of FIG. 2 and FIG. 3d). At this point of the process, the wing frames 28 are not yet attached to the wing gangs 22 and 24 so that each of the gangs can be conveniently moved into position. Once the wing gangs 22 and 24 have been connected to the respective main disk gangs 12 and 14, the wing frames 28 are lowered onto the wing gangs 22 and 24, and the flanges on the brackets 122, 123 and 124, 125 are aligned and secured together rigidly by bolts (see 174 of FIG. 2). Once the wing frames 28 are secured in position on the wing gangs 22 and 24, the wing gang wheel modules 42 are connected to the wing frame brackets 142 (see FIG. 3e and 176 of FIG. 2). Thereafter, miscellaneous hardware is connected to the disk 10 to provide the completed implement 178. The folding cylinders 22 are attached, as well as the hydraulic lift circuit indicated generally at 182 in FIG. 4. Hitch leveling structure and other components are also added to the disk 10. 
     Having described the preferred embodiment, it will be apparent that modifications can be made without departing from the scope of the invention as defined in the accompanying claims.