Abstract:
Apparatus and method for crushing plant residue remaining in a farm field following the crop harvest comprising a main frame moveable in a forward path, a yieldable residue knock-down drape suspended on the frame for knocking the plant residue to the ground and breaking the upstanding plant residue apart from its underground roots as the frame forwardly moves, and a transversely disposed residue crushing roller mounted on the frame rearwardly of the knock-down drape for crushing spaced-apart portions of the knock-down residue into a plurality of smaller crop residue segments.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to a farm implement and more particularly to apparatus and method for breaking above-ground farm crop residue following harvest into a plurality of reduced crop residue segments. 
     2. Description of Prior Art and Objects 
     The harvesting of farm crop, such as corn, with a combine or a corn picker results in the harvested corn stalks remaining upright in the field. The remaining upright stalks cause difficulty in subsequently tilling the soil and interferes with the harvesting of following crops. Sometimes, the farmer will plow the field to turn over and bury the remaining corn stalks. If the stalks are too long, the furrows won&#39;t cover the stalks. 
     When a farmer follows a field of harvested corn with a crop of navy beans, for example, it is important in cold climates to plow in the fall of the year to maximize the nutrients in the soil for the following spring planting. If the corn stalks are allowed to remain in their normal harvested length when the field is plowed, the non-buried portion of the stalks do not totally deteriorate, and therefore the nutrients in the soil are not as numerous as they otherwise would be. Accordingly, it is an object of the present invention to provide new and novel apparatus which will enhance the amount of nutrients in plowed soil. 
     For “minimum-till” farming, chisel plows are used to turn the top soil, however, even more of the stalks remain above ground because “minimum till” furrows aren&#39;t as large as plowed furrows. 
     In so-called “no-till” farming, the farmer does not till the soil and a substantial amount of remaining upstanding stalks pass through the combine which is harvesting the following crop thereby adding to the deterioration of the cutting blade and the combine. Accordingly, it is another object of the present invention to provide new and novel apparatus for leveling farm crop residue to preclude the residue from being harvested with a following crop. 
     The prior art includes so-called “flail choppers” which have rotary blades that are mounted on a tractor drawn frame and driven by a power take off coupled to the tractor. A substantial amount of energy is required to drive the flail choppers and thus a substantial amount of expensive fuel is expended. Accordingly, it is yet another object of the present invention to provide apparatus for breaking farm crop residue into smaller pieces in a more efficient and less expensive manner. 
     It is a further object of the present invention to provide apparatus of the type described which incorporates a self-propelled rotary stalk crusher. 
     U.S. Pat. No. 5,329,574 issued to William P. Fuesz on Jul. 19, 1994, is directed to a machine for chopping crop residue including a relatively complicated system with many moving parts. It has been found advantageous to reorient the upstanding stalks by pushing them forwardly and downwardly and to break the stalks from the underlying ground embedded roots prior to chopping the residue into smaller stalk segments. Accordingly, it is still another object of the present invention to provide a farm crop residue machine which includes a new and novel apparatus mounted on the frame for reorienting the upstanding corn stalks prior to crushing them into pieces. 
     It is a still further object of the present invention to provide new and novel apparatus of the type described for forwardly bending the stalks prior to crushing them into smaller stalk segments. 
     It is another object of the present invention to provide new and novel apparatus for knocking down the upstanding farm crop and breaking it from the underlying roots. 
     It is a further object of the present invention to provide new and novel method and apparatus of the type described including a drape for dragging over and knocking down the upright corn stalks prior to crushing them into smaller stalk segments. 
     U.S. Pat. No. 5,953,895 issued to Oliver K. Hobbs on Sep. 21, 1999, is directed to apparatus for processing plant stalks after harvesting, however, rather than breaking the upstanding stalks from the underground roots, this patented construction pulls the stalks and the attached roots from the ground and thus tills the soil contrary to the typical no-till farming operation. Accordingly, it is another object of the present invention to provide method and apparatus for breaking upstanding plant residue apart from the underlying roots into a plurality of plant residue segments without tilling the soil. 
     It is yet another object of the present invention to provide new and novel method and apparatus for breaking the stalks from the underlying roots prior to crushing them with a new and novel stalk crushing roller. 
     Still another object of the present invention is to provide new and novel apparatus of the type described including a new and novel flexible residue knock-down drape disposed forwardly of, and in spaced relation with, a new and novel residue crushing roller. 
     A further object of the present invention is to provide apparatus of the type described including a new and novel residue crushing roller having a drum mounting a plurality of solid crushing blades circumferentially spaced about the outer surface of the drum. 
     Different soil conditions will provide different resistance to crushing of the crop residue. Some soil dictates that more force be exerted on the stalk to crush it into smaller stalk segments. Accordingly, it is a still further object of the present invention to provide apparatus of the type described which can crush stalks in a variety of different soils and soil conditions. 
     Another object of the present invention is to provide farm crop residue crushing apparatus of the type described including a hollow drum having a hollow cylinder provided with end wall closures adapted to receive liquid therein to control the weight of the drum and selectively crush different stalks with a variety of forces in a variety of soil conditions. 
     Another object of the present invention is to provide new and novel apparatus of the type described including mechanism for mounting a crop residue crushing roller on the frame for vertical movement relative thereto to allow the crusher roller to adapt to the terrain of varying elevations. 
     Another object of the present invention is to provide apparatus of the type described including apparatus for yieldably maintaining a stalk crushing roller in bearing engagement with the soil so that rotation of the crushing roller will be self-propelled in response to the apparatus moving forwardly. 
     U.S. Pat. No. 6,101,800 issued to Albert F. Juraco, et al on Aug. 15, 2000, is directed to field chopping apparatus mounted on the wheels of a tractor for harvesting laterally spaced-apart rows of male corn plants in a hybrid corn producing field. Accordingly, it is yet another object of the present invention to provide a farm crop residue crushing apparatus of the type described including a knock-down mechanism spanning a plurality of rows of crop residue and a crusher roller mounted on the frame behind the roller and spanning the plurality of rows and having continuous chopping blades thereon spanning the plurality of rows. 
     These and other objects of the present invention will become more readily apparent as the description thereof proceeds: 
     SUMMARY OF THE INVENTION 
     Apparatus for crushing upstanding stalk residue in a plurality of longitudinally extending laterally adjacent rows of stalk residue, which have ground-embedded roots, following harvesting of crop from the stalk residue, the apparatus comprising: a main frame adapted to be supported on the ground for movement in a forward path of travel, knock-down apparatus for knocking down the upstanding stalk residue, and apparatus, rearwardly spaced from the knock-down apparatus, for breaking the knocked down stalk residue into a plurality of smaller stalk segments including a transversely extending ground engaging crusher roller for spanning a plurality of adjacent rows of stalks, and a plurality of transversely disposed, radially outwardly extending crusher blades mounted on the crusher roller and adapted to span the plurality of adjacent rows for downwardly crushing spaced-apart portions of the stalks against the ground until the resistance of the ground causes the stalks in the several adjacent rows to be concurrently broken into smaller pieces by the crusher blades. 
    
    
     DESCRIPTION OF THE DRAWINGS 
     The invention may be more readily understood by reference to the accompanying drawings, in which: 
     FIG. 1 is a sectional side view of apparatus constructed according to the present invention, taken along the section line  1 — 1  of FIG. 2; with the stalk crushing roller illustrated in chain lines in an elevated position to accommodate varying terrain being traversed; 
     FIG. 2 is a reduced, top plan view of the apparatus illustrated in FIG. 1, 
     FIG. 3 is a rear elevational view thereof; 
     FIG. 4 is an enlarged opposite end sectional view at one end of the apparatus, taken along the section line  4 — 4  of FIG. 2, to more particularly illustrate the pivotal sub-frame for mounting the stalk crushing roller; 
     FIG. 5 is a further enlarged top plan fragmentary sectional view, taken along the section line  5 — 5  of FIG. 2 to better illustrate a storage stand for supporting the apparatus when the apparatus is not mounted on a tractor; 
     FIG. 6 is an opposite fragmentary sectional end view, taken along the section line  6 — 6  of FIG. 2; 
     FIG. 7 is a front perspective view of the apparatus, constructed according to the present invention, mounted on a draft vehicle such as a tractor; 
     FIG. 8 is a rear perspective view thereof mounted on a tractor; 
     FIG. 9 is a slightly different rear perspective view thereof; 
     FIG. 10 is a front perspective view of the apparatus constructed according to the present invention, removed from the tractor in a stowed on the storage stand illustrated in FIG. 5; 
     FIG. 11 is an enlarged front elevational view of an opposite end portion of the apparatus; and 
     FIG. 12 is an enlarged top plan sectional view taken along the section line  12 — 12  of FIG.  3 . 
    
    
     DESCRIPTION OF PREFERRED EMBODIMENT 
     Apparatus, generally designated  10 , constructed according to the present invention, is particularly adapted for crushing crop residue, such as corn stalks S, disposed in a plurality of laterally spaced apart rows R, into a plurality of smaller stalk segments S 2  and S 3 . The apparatus  10  includes a frame, generally designated  12  which comprises a transversely disposed, hollow tubular steel cross-beam  14  which is square in cross-section and has a front face  15 . A three point coupling, generally designated  17  is centrally mounted on the front face  15  and includes a first pair of centrally located, laterally spaced-apart, upstanding, laterally outer, upstanding angle irons  16  and a pair of less spaced-apart upstanding central angle irons  18 . The angle irons  16  and  18  are coupled to the cross beam  14  via U-bolts, generally designated  19 . 
     Spanning the lower ends of the adjacent ones of angle irons  16  and  18  is a pair of lower draw pins  21  to which a pair of laterally spaced-apart tractor mounted lower draw hitches  20  are detachably coupled. The upper ends  23  of the central pair of angle irons  18  are spanned by a centrally disposed, horizontal, upper draw pin  22  to which the tractor mounted centrally disposed upper draw hitch  24  is detachably coupled. The draw hitches  20  and  24  are frequently referred to as a “three point hitch” mounted on a tractor T, for raising and lowering the frame  12  between a raised, inoperative transport position, illustrated in FIGS. 7,  8  and  9  and a lowered ground engaging operative position illustrated in FIG.  1 . 
     Dependently mounted on the hollow cross beam  14  is crop residue knock-down apparatus, generally designated  29 , including a relatively heavy transversely disposed drape or curtain  31  made from resilient material such as rubber belting. The drape may typically be ½″ thick and is of sufficient length to span several corn stalk rows R. The crop residue knock-down apparatus  29  includes a pair of laterally outer, upstanding, drape mounting angle irons  33  coupled to the front face  15  of the tubular bar  14  via U-bolts  35 A. The upper transversely extending edge portion  37  of the rubber drape  31  is sandwiched between, and suspended from, a pair of horizontal cross bars  39  and the lower ends of the angle irons  16 ,  20  and  33 . (See FIG. 12.) 
     Following the harvesting of the corn, the remaining upstanding stalks S, having ground embedded roots  51 , must be severed from the roots  51  and crushed. The knock-down apparatus  29  is particularly adapted for knocking down upstanding crop residue, such as corn stalks S, to separate the stalks S from the roots  51  and break the stalks S into smaller stalk segments S 2  and S 3 . As the frame  12  moves forwardly, in the direction of the arrow  41 , the lower end  43  of drape  31  will forwardly bend the stalks S, in the direction of the arrow  45 , toward the ground G. The dry and brittle stalks S are typically broken off at  53  from the underlying ground-embedded roots  51  and fall to the ground as illustrated as S 1 . 
     Stalk crushing apparatus, generally designated  54 , is mounted on the frame  12  for breaking the knocked down stalks S 1  into smaller stalk segments S 2  and S 3 . The apparatus  54  is mounted on each laterally outer end  25  of the rear face  27  of the tubular frame bar  14  by a pair of laterally spaced-apart upstanding angle irons  56  and  58  spanned by a shaft  60 . 
     Pivotally mounted on each shaft  60  is a longitudinally extending rocker arm  62 . Spanning the rear ends  64  of the laterally spaced-apart rocker arms  62  is a hollow stalk crushing drum roller, generally designated  66 , for crushing the broken corn stalks S 1  into a plurality of smaller stalk segments S 2  and S 3 . 
     The stalk crushing hollow drum roller  66  includes a hollow steel cylinder  67  having opposite ends  68  closed by end walls  70  which are fixed to a horizontal shaft  72  that is journaled on the rear ends  64  of rocker arms  62  via bearings  74 . The cylinder  67  is of sufficient length to span several laterally spaced apart rows R of corn stalks S. Welded or otherwise suitably fixed to the smooth outer cylindrical surface  76  of hollow cylinder  68  is a plurality of solid steel, stalk crushing blades  78  which lie in planes  80  that intersect at a common junction such that the rotational axis  82  of the drum shaft  72  lies in each of the planes  80 . 
     The terminal blade ends  84  may be sharpened if desired for engaging longitudinally spaced portions  86  of the broken off stalks S 1  and pressing the stalks S 1  into the earth or ground G until the resistance of the soil causes the stalks S 1  to be crushed, broken and/or severed at  83  by the blade edges  84  into a plurality of smaller stalk segments S 2  and S 3 . The smaller segments are more easily turned over when the ground G is subsequently plowed. If the soil is not plowed, as is typical in a no till farming operation, the stalk segments S 2  and S 3  will tend to prevent wind and water erosion of the soil. With the prior art flail choppers, the stalks are committed so finely that they easily blow away and don&#39;t protect the soil against erosion. 
     To detachably yieldably hold the stalk crushing drum roller  66  into frictional engagement with the ground G in rolling terrain having changes in elevation, such as schematically illustrated at G 1 , coil springs  86  span the upper ends of angle irons  58  and the front ends  88  of rocker arms  62 . The coil springs  86  will allow the rocker arms  62  to swing upwardly, to the position illustrated in chain lines in FIG. 1, in response to changes in elevation (such as illustrated at G 1 ) of the terrain or ground G being traversed. As the apparatus moves forwardly, in the direction of the arrow  41 , the frictional engagement of the drum  68  and stalk crushing blades  78  engaging the ground G will cause the drum  66  to be self-propelled and rotated in the direction of the arrow  90  about the shaft axis  82  without the necessity of any other additional external rotary driving power. This construction will reduce the energy otherwise required to drive the chopper roller if it was coupled to a tractor driven power take off. 
     The stalk crushing drum  68  is water impervious and includes a detachably closure, such as a threaded plug  92 , that can be removed to provide access for a hose to fill the cylinder  68  with water or liquid chloride to any desired level to adjust the weight of the roller. The outer cylindrical roller surface  76  will engage the ground G and will force any stones or rocks  67  lying on the earth&#39;s surface to be forced into the surface, as illustrated at  67 A and thus inhibit the stones or rocks  67  from becoming subsequently inadvertently picked up by a harvester such as a combine. 
     The use of the added weight of the liquid chloride or water will aid in holding the roller  66  down against the soil to adjust for different soil conditions. Sand soil will require less weight to crush the stalks and clay soil would require more weight to accomplish the same purpose. 
     A safety screen, generally designated  94  is mounted on the cross beam  14  via suitable braces  96  and  98 . The safety screen  94  may comprise expanded metal and is centrally located on the frame  12  and the transversely disposed frame bars  39  by frame bars  71  and  73  to preclude any debris from being inadvertently forwardly propelled onto the farmer driving the tractor T. 
     Also mounted on the laterally outer ends of the beam  14  is a pair of frame support stands, generally designated  91 , each having an upper vertically disposed tube  93 , fixed to the front face  15  of beam  14 , and a lower rod  98  telescopically received therein. The lower rod  98  mounts a lower ground-engageable foot  95  on which the apparatus  10  is supported when it is removed from the tractor T. The telescoping tube  93  and rod  98  include a plurality of apertures which can be vertically moved into horizontal alignment and detachably coupled in any selected one of a plurality of vertically spaced positions by locking pins P. The foot  95  can be moved upwardly to a position removed from the ground when the device is coupled to the tractor. 
     The Operation and Method 
     The apparatus, generally designated  10 , is mounted on the tractor T via the three point hitch  20 ,  24  and  17 . The tractor T will move the device  10  into a field in the raised inoperative position illustrated in FIGS. 7-9. The corn stalks S will be the crop residue remaining after any corn thereon has been harvested. The stalks S can extend several feet above the ground G and thus can, if not removed, interfere with the subsequent harvesting of a following crop. 
     In the field the apparatus, generally designated  10 , is lowered to a ground engaging position illustrated in FIG.  1  and pulled behind the tractor T over the ground G. The lower edge  43  of heavy resilient drape  31  will tend to be rearwardly deflected by the stalks S and will rearwardly swing, in the direction of arrow  45 A, to forwardly swing and bend the stalks S in the direction of the arrow  45 . The stalks S, which are typically dry and brittle, will typically be broken off at the level  53 , from the ground embedded roots  51  and the lower end  43  of the knock-down curtain  31  will pass over the knocked-down broken off stalks S 1 . If, for some reason, some of the stalks S do not break off, the knock-down apparatus will still forwardly substantially bow the stalks so that they are at a better angle of attack by the crusher roller than they otherwise would be. 
     As the machine moves forwardly, the transversely extending stalk crushing roller  66  which is self-propelled, and stalk crushing blades  78  will traverse the stalks S to break, crush and cut the stalks S 1  into a plurality of reduced pieces or segments S 2  and S 3  for dispatch to the top surface of the ground to prevent soil erosion or for subsequent plowing underground. 
     As the machine, frame  12 , moves forwardly, the springs  86  will yieldably urge the rocker arms  52  to swing in a direction to urge the stalk crushing drum  66  downwardly against the ground G to insure that the drum  66  is rotatably driven about the drum axis  82 . As the stalk crushing drum  66  passes over ground G 1  of a higher elevation, the rocker arms and stalk crushing drum  66  will swing upwardly to the position illustrated in chain lines in FIG. 1 but will remain in bearing engagement with the ground G 1  to continue to be self-propelled. 
     It is to be understood that the drawings and descriptive matter are in all cases to be interpreted as merely illustrative of the principles of the invention, rather than as limiting the same in any way, since it is contemplated that various changes may be made in various elements to achieve like results without departing from the spirit of the invention or the scope of the appended claims.