Abstract:
A windrower machine having a pair of forward rotating augers mounted in parallel with one another in overlapping relationship with one another to work in conjunction with a blade and a backstop to form windrows to disrupt and reduce caked material to particulate in windrows as said machine is moved forwardly through a work area.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    The present invention relates to the field of agriculture and more specifically to apparatus used by poultry farmers to properly sanitize chicken farms in an economically efficient manner by windrowing poultry litter. More particularly, the present invention relates to the field of windrower machines for use in the poultry industry. In even greater particularity the present invention is a windrower machine having a first and second auger in which the flighting overlaps, creating a more efficient windrower apparatus. In even greater particularity, the present invention is a windrowing machine for use with a prime mover. 
         [0002]    Chicken mortality rates in broiler houses are a great concern to the poultry industry. Large numbers of chickens living in close quarters present several challenges to the growers, from high ammonia levels, disease and harmful bacteria outbreaks, and beetle infestations. One method used to control these problems is windrowing the chicken litter in between flocks. Previous methods called for the top layer of the litter, referred to as cake because it is clumped together, to be removed in between catching out the adult birds and bringing in the new juvenile birds. However, recent research has shown that the cake layer does not exclusively contain most of the ammonia and harmful bacteria as previously believed. Leaking water lines, in addition to chicken excrement, can seep through the litter to a bottom layer, the clay pad, where it becomes trapped, forming a hardpan. The hardpan is warm and moist, forming the perfect environment for harmful bacteria and disease. 
         [0003]    The developing method to address the threat of bacteria and disease is to windrow the particulate material. When the wet litter is piled into windrows, heat builds up that kills harmful bacteria and nuisance bugs. The heat also helps to dry the litter, and exposing the floor dries the floor as well. The hardpan and cake are broken into smaller pieces releasing ammonia and destroying bacteria habitat. At the end of the process the litter should be dry, relatively clump free, and ready for new birds. Windrowing has already proven to be successful in raising healthier chickens, but is more labor intensive and time consuming than previous practices. 
         [0004]    Windrowing machines that have been previously developed have limitations. Many of the machines move slowly to prevent strain caused by the load of the build up of poultry litter. Others fail to properly break up the poultry litter in a single pass, requiring more than one pass for each windrow. All of these limitations increase the time and labor needed to properly windrow poultry in broiler houses. Therefore, a more efficient and effective means for windrowing is needed. 
       SUMMARY OF THE PRESENT INVENTION 
       [0005]    These and other objects and advantages of the invention will become apparent from the following detailed description of the preferred embodiment of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]    The windrower machine is depicted in the accompanying drawings which form a portion of this disclosure and wherein: 
           [0007]      FIG. 1  is a perspective view of a windrower machine according to one embodiment of the present invention. 
           [0008]      FIG. 2  is an exploded front-perspective view of the embodiment illustrated in  FIG. 1 ; 
           [0009]      FIG. 3  is an exploded back-perspective view of the embodiment illustrated in  FIG. 1 . 
           [0010]      FIG. 4  is a perspective view of the embodiment illustrated in  FIG. 1  engaged with a prime mover. 
           [0011]      FIG. 5  is a perspective view of a windrower machine according to another embodiment of the present invention. 
           [0012]      FIG. 6  is a perspective view of a windrower machine according to another embodiment of the present invention. 
           [0013]      FIG. 7  is a perspective view of a windrower machine according to another embodiment of the present invention. 
           [0014]      FIG. 8  is a cross-sectional view of a portion of the embodiment illustrated in  FIG. 1 . 
           [0015]      FIG. 9  is a perspective view of a windrower machine according to another embodiment of the present invention. 
           [0016]      FIG. 10  is an exploded perspective view of the embodiment illustrated in  FIG. 9 . 
           [0017]      FIG. 11  is a perspective view of the embodiment illustrated in  FIG. 9  engaged with a skid steer according to one embodiment of the present invention. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0018]    Referring to the  FIGS. 1-11  for a clearer understanding of the invention, embodiments of the invention provide a windrower machine with two rotating shafts carrying radial extensions intermeshed to sufficiently break up poultry litter, including the hardpan and cake layers, while forming windrows of sufficient size and shape to generate temperatures within the poultry litter capable of killing harmful bacteria and nuisance bugs. While the embodiments of the windrower machines discussed are for use in the poultry industry, the windrow machines are in no way limited to such use. The windrow machines may be used for formation of windrows of other organic particulates such as compost, wood shavings, rice and peanut hulls, and other small particulates. 
         [0019]      FIGS. 1-4  illustrate a windrower machine  10  according to one embodiment of the present invention. The windrower machine  10  as depicted is configured to be connected to and carried by a prime mover, including, but not limited to, tractors, skidders and other agricultural vehicles. The embodiment shown in  FIGS. 1-4  is configured to be attached to a tractor  20  through the windrower machine&#39;s mounting system  100 . However, in other embodiments, the windrower machine may be configured to be self-powered and operated. 
         [0020]    As shown in  FIGS. 1-4 , the mounting system  100  includes a hitch frame  110  for engaging a standard three-point lift of an associated tractor  20 , an arm  140 , and a mounting member  170 . The hitch frame  110  is defined by a pair of vertical members  112  and  114  secured at their upper portions by a pair of horizontal members  116  and  118 . A cylindrical post  120  is secured between the two horizontal members  116  and  118 , which provides a pivot connection for the arm  140 . One of the members  118  may include a pivot mount  122 , which is discussed below. Mounting hinges or clevis&#39;  124  and  126  are mounted at the lower ends of the vertical members  112  and  114  that are configured to be pivotably coupled to the tractor lifts  22  of the tractor  20 , as shown in  FIG. 4 . One of the hinges  124  includes an elongated slot  130  and sliding pin  132  which allows the windrower machine  10  to remain in contact with the ground over uneven surfaces, which will be explained in further detail below. A bracket  134  ensures that the sliding pin  132  remains level as the sliding pin  132  travels within the elongated slot  130 . The frame  110  includes a stand  136  that is pivotably mounted to one of the vertical members  112 , which keeps the windrower machine  10  level when disconnected from the prime mover  20 . 
         [0021]    As discussed above, an arm  140  is connected to the frame  110 . The arm  140  includes a cylindrical sleeve  142  at one end that receives the cylindrical post  120  of the frame  110  to form a pivotable connection between the two. Another cylindrical sleeve  144  found at the opposite end of the arm  140  provides a pivotable connection to the mounting member  170 , discussed further below. The arm  140  also includes a flange  146  that provides a mounting surface for an alignment system  150 . The alignment system  150  includes at least one hydraulic cylinder or linear actuator  152  and an adjustable bracket  160 . The hydraulic cylinder  152  includes a piston  154  at one end that is pivotably connected to the pivot mount  122  of the frame  110 . The other end of the hydraulic cylinder  152  is pivotably connected to the flange  146  on the arm  140 . The hydraulic cylinder  152  includes hydraulic hoses  156 ,  158  configured to be connected to a conventional source of hydraulic pressure provided by the tractor  20 . The hydraulic cylinder  152  can be actuated to vary the alignment of arm  140  to frame  110 . Where only one cylinder  152  is to be used an adjustable bracket  160  is configured to be pivotably mounted to both the flange  146  of the arm  140  and the mounting member  170  to establish selectable alignment of mounting member  170  to the arm  140 . The adjustable bracket  160  includes removable pins  162  and  164  that can be inserted within several apertures found o along the length of the bracket  160  to be mounted to the arm  140  and mounting member  170  respectively in various positions. 
         [0022]    The mounting member  170  includes a cylindrical member  172  at its upper end  174  that is received by one of the cylindrical sleeves  144  of the arm  140  to form a pivoting connection between the two. A horizontal flange  180  associated with the upper end  174  includes an aperture that receives one of the removable pins  164  to pivotably secure the adjustable bracket  160  to the mounting member  170 . The upper end  174  of the mounting member  170  also includes a vertical flange  182 , which is discussed below. The mounting member&#39;s middle  175  and lower  177  sections include a pair of brackets  176  and  178  that couple the mounting member  170  to the main body  300  of the windrower machine  10 . The mounting member  170  can be fixed to the backside of the main body  300  through various fastening means. The alignment system  150 , by being connected to both the frame  110 , the arm  140 , and the mounting member  170 , allows the user to control the pitch or angle of the main body  300  as it is drawn by the prime mover  20 . 
         [0023]    A gauge wheel system  200  further supports the main body  300  of the windrower machine. The gauge wheel system includes a pair of casters  202 ,  204 . Each caster  202 ,  204  includes hinges  206 ,  208  that are each pivotably connected to a pair of parallel members  210 ,  211 ,  212 ,  213  at one end. The parallel members  210 ,  211 ,  212 , and  213  are pivotably connected at their respective other ends to mounting brackets  302  (as shown in  FIG. 3 ) coupled to the back side of the main body  300 . A horizontal member  214  is fastened between the lower members  210 ,  212  connected to each hinge  206 ,  208 . The horizontal member  214  includes a connecting means  216 . As shown in  FIG. 3 , the connecting means  216  is a flange extending from a surface of the horizontal member  214 . However, connecting means  216  may include, but is not limited to, internal cylinders, pins, and the like. The connecting means  216  is configured to pivotably connect to a height adjustment mechanism  220 . 
         [0024]    The height adjustment mechanism  220  as depicted in  FIGS. 1-3  includes at least one hydraulic cylinder  222 , and a piston  224  extending from an end  226  of the hydraulic cylinder  222 . The other end  228  of the hydraulic cylinder  222  is equipped with a hinge  230 . The cylinder&#39;s hinge  230  is configured to be pivotably connected to the vertical flange  182  of the mounting member  170 . Further, the piston  224  includes a hinge  232  that is configured to be pivotably connected to the connecting means  216  of the horizontal member  214 . The hydraulic cylinder  224  also includes hydraulic hoses  234 ,  236  configured to engage the corresponding connections of the tractor  20 . A clearance gauge  240  is included in the height adjustment mechanism  220 . As shown in  FIGS. 1-4 , the clearance gauge  240  comprises a pair of vertical members  242 ,  244 , pivotally attached to one pair of parallel members  210 ,  211 . One of the vertical members  244  can include vertically arranged numbers that correspond to the distance between the ground and the bottom of the main body  300  of the windrower machine  10 . The other member  242  includes an indicator flange  246 . When activated by controls found on the tractor, the hydraulic cylinder  222  extends or retracts the piston  224 , lowering or lifting the main body  300  of the windrower machine  10  by lowering or lifting the gauge wheels. The indicator flange  246  displays the distance, or clearance, between the bottom of windrower machine  10  and the ground. 
         [0025]    The main body  300  of the windrower machine  10  includes a long blade  350  removably coupled to the bottom of a backstop  352 . The blade  350  is configured to break through hardened particulate material, such as the cake and hardpan typically found inside chicken houses. After dulling, the blade  350  can be removed from the backstop  352  and flipped over and reattached to expose the other sharpened side of the blade, or replaced with a new sharpened blade. The blade  350  can be placed in numerous positions and directions by the user through the combination of the other elements discussed above. For example, the blade can be titled forward or backward, increasing or decreasing the angle between the blade  350  and the ground, by the user lowering or raising the tractor lifts  22  attached to the three-point frame  110 . The pitch of the blade  350  can be changed by adjusting and/or engaging the alignment system  150 , as well as the position of the blade  350  in relation to the tractor. Further, the clearance between the blade  350  and the ground can be adjusted by engaging the height adjustment mechanism  220 . These adjustments allow the operator to have complete control in positioning the blade  350  of the windrower  10  that is best suited for their needs. 
         [0026]    As the windrower  10  moves forward, the blade  350  directs the particulate material to a vertical portion  354  of the backstop  352 . The backstop  352 , as the name indicates, prevents the particulate material from exiting the rear of the windrower machine  10 , and forces the particulate material to exit at one side due to the alignment of the body  300  relative to the tractor  20 . The curvature of the vertical portion  354  urges the particulate material to flow up the backstop  352  and back over itself once it reaches the top as the windrower machine  10  moves forward, easing the load put on the windrower machine  10 . As illustrated in  FIGS. 1-3  and  8 , the vertical portion  354  of the backstop  352  is curved, or bent, at approximately 20° every 3 to 4 inches. However, the vertical portion  354  can be curved at a greater or lesser ratio in other embodiments. In some embodiments, the vertical portion  354  may have no curve. An overhang portion  356  extending from the top of the vertical portion  354  prevents any particulate material form exiting over the backstop  352 . End caps  360 ,  362  are affixed to and form the sides of the backstop  352  and further assist in directing the particulate material in exiting the windrower machine  10 , with one end cap  360  completely enclosing one side. The other end cap  362  provides a specific exit point  364  for the particulate material from the windrower machine  10 . Skid plates  366 ,  368  may be associated with each end cap  360 ,  362 . 
         [0027]    Significantly, the windrower machine  10  also employs a pair of driven shafts  400 ,  402  with radial extensions  401 ,  403  that assist in displacing particulate material from the main body  300  into windrows more efficiently. The shafts are  400 ,  402  are rotatably mounted in a substantially parallel relationship with each other between the end caps  360 ,  362  in front of the vertical portion  354  of the backstop  352  and above the blade  350 , with one shaft  400  aligned vertically over the other shaft  402 . As shown, the upper shaft  400  is aligned directly above the lower shaft  402 . However, in other embodiments of the present invention, the upper shaft may be vertically aligned above the lower shaft at an offset. 
         [0028]    As shown in  FIGS. 1-4 , the shafts  400 ,  402  with the radial extensions include fighting  401 ,  403  that runs in the same direction, helically wrapping the shaft, defining a pair of augers. The current embodiment of the present invention uses standard augers, which have a diameter of  14  inches and flighting that completes a full rotation around the axle of the auger every  14  inches. However, augers of varying diameter and fighting rotations may be used. In addition, the apparatus is not limited to augers. For example, as illustrated in  FIG. 5 , a windrower machine may use a shaft  1400  with paddles  1401  in combination with an auger  1402  with flighting  1403 . Further, the windrower may use shafts  2400 ,  2402  that utilize a combination of flighting  2404 ,  2406  and paddles  2408 ,  2410 , as shown in  FIG. 6  or use shafts  3400 ,  3402  that utilize paddles  3401 ,  3403  extending radially from the shafts as shown in  FIG. 7 . Embodiments of the present invention may utilize a variety of rotatable elements with radial extensions, which include, but are not limited to, spikes, blades, and other similar extensions. Therefore, it is understood that the term auger is interchangeable with shaft, and the term flighting is interchangeable with rotational extensions in further discussions below. 
         [0029]    When rotating, the augers  400 ,  402 , with the assistance of their flighting  401 ,  403 , laterally move the particulate material in front of the backstop  352  out the exit  364  of the end cap  362  to form the windrows. As shown in  FIG. 8 , the augers  400 ,  402  are configured to rotate in the same angular direction  420 ,  422  as the gauge wheels of the windrower machine  10  as the machine moves forward, thus the top of each auger  400 ,  402  moves away from the backstop  352 , as shown in  FIG. 8 . By rotating in this angular direction, the augers  400 ,  402  urge the particulate material up the vertical portion  354  of the backstop  352 , rather than throwing the particulate material forward as in other windrower machines. Taller windrows result as the particulate material exits the windrower machine at a greater height. Additionally, the augers  400 ,  402  are mounted such that the flighting  401  of one auger  400  overlaps or enters into the space  430  between the flighting  403  of the other auger  402 . For example, using standard augers, the centers of the augers  400 ,  402  are mounted with  12  inches of one another, which leaves an overlap of  2  inches between their respective fighting  401 ,  403 , as shown in  FIG. 8 . In the overlap area  430 , the flighting  401  along the bottom of the top auger  400  moves in an opposite direction than the flighting  403  along the top of the bottom auger  402 , which creates a shearing affect on the particulate material, breaking the clumped portions of the cake and hardpan clumped portions into smaller pieces. Additionally, the overlapping region  430  also helps the bottom auger  400  feed the particulate material to the upper auger  402 , utilizing the entire height of the backstop  352 , which reduces the load on the windrower machine  10  as well as increasing the height of the windrows produced. 
         [0030]    The augers  400 ,  402  are mechanically driven at one end cap  360 . As shown in  FIG. 3 , the augers  400 ,  402  are driven by a sprocket assembly  500  with each auger  400 ,  402  coupled to an auger gear  502 ,  504  associated on the opposite side of the end cap  360 . The auger gears  502 ,  504  may be driven by a chain assembly  506  that engages with a driving gear  508 . The driving gear  508  can be driven by a variety of means, as discussed below. As shown in  FIG. 3 , the chain assembly  506  may include two separate chains  506   a,    506   b  which engage with a 2-1 gear  502 . However, a single chain may be used in other embodiments of the invention. In addition, idle gears  510 ,  512  may assist the sprocket assembly  500  by preventing slack within the chain assembly  506 . In the preferred embodiment of the present invention, the sprocket assembly  500  is sealed within a sprocket housing  520 . The sprocket housing is preferably sealed on all sides to contain lubricating agents within the housing  520  to prevent fouling or burning out any of its components. A wall scraper  540  may be associated with the closed end cap  360  to prevent the windrower machine  10  from striking fully any walls or other protruding surfaces and to direct litter away from the wall towards the augers. 
         [0031]    The driving gear  508  of the sprocket assembly  500  may be driven by a variety of different means. For example, as shown in  FIGS. 1-4 , the driving gear  508  is configured to be driven by a power take-off of the tractor  20  through the combination of a double cv driveshaft  600  and an 90° gearbox  610 . The double cv driveshaft  600  includes a first end  602  and a second end  604 . The first end  602  of the driveshaft  600  may be configured to engage a PTO of the tractor  20  with the second end  604  configured to engage a socketed-connection rod  612  of the 90° gearbox  610 . The rod  612  is configured to engage and rotate a shaft  614  that extends from the gearbox  610  that is rotationally coupled to the driving gear  508 . Activating the PTO of the tractor  20  rotates the cv driveshaft  600 , which in turn engages the rod  612  of the gearbox  610  to drive the shaft  614  connected to the driving gear  508  that rotates the augers  400 ,  402 . In the preferred embodiment of the present invention, the combination of the PTO driveshaft  600 , gearbox  610  and driving gear  508  rotate the augers  400 ,  402  at approximately  400  rpms. While the augers may rotate through out a wide range of rpms,  400  rpms is preferred as this rate of rotation increases the speed at which the particulate material exits the windrower machine  10  while effectively breaking up the cake and hard pan. 
         [0032]    The windrower machine  10  may also include chopper blades  700 ,  710  associated with the augers  400 ,  402 . The chopper blades  700 ,  710  are coupled to the free ends of the augers  400 ,  402  in a parallel fashion, as shown in  FIG. 1-4 , and are configured to rotate with the augers. The chopper blades may include curved ends  702 ,  704 ,  712 ,  714  that are oriented at alternate angles from one another so that when the chopper blades  700 ,  710  rotate, a curved end  702  of the upper chopper blade  700  passes a curved end  714  of the lower chopper blade  710 . The chopper blades  700 ,  710  and their respective curved ends  702 ,  704 ,  712 ,  714  further facilitate additional shredding and breaking of clumped portions of particulate material. In other embodiments of the present invention, the chopper blades  700 ,  710  may have no curved ends, but sharpened ends to provide the same assistance. The chopper blades  700  may also interact with a grill guard  720  associated with the free end of the upper auger  400 . The grill guard  720  includes fixed extensions  722  spaced apart from one another. The fixed extensions  722  allow the grill guard to act as an auxiliary disrupter, preventing most large clumps of particulate material from exiting the windrower machine  10  before being broken-up to a smaller size by either the chopping blades and/or the augers. If any large clumps of particulate material remain, the combination of the chopping blades  700 ,  710  and the grill guard  720  ensure that the large clumps exit only at the lower auger  402 . By exiting at the lower auger, the large clumps are prevented from resting on the exterior of the windrows. Instead, the large clumps are forced into the interior of the windrow and are exposed to the interior&#39;s higher temperatures. This exposure further dries out the large clumps, and makes them more likely to crumble with the windrow is turned or moved at a later date. 
         [0033]      FIGS. 9-11  show another embodiment of a windrower machine  1010  that is driven by a hydraulic system  800 . The other components of the windrower machine  1010  may function in the same ways as described above. The hydraulic system  800  takes the place of the PTO-driven driveshaft  600  and gearbox  610  assemblies. The hydraulic system  800  includes a hydraulic motor  810 . The hydraulic motor  810  is configured to be driven conventionally by hydraulic pressure supplied by the prime mover or skid steer to which the windrower machine  1010  is coupled. The hydraulic motor  810  is coupled to the driving gear  508  of the sprocket assembly  500 , which in turn rotates the augers as discussed above. The windrower machine  1010  may be mounted to a variety of movers in a variety of positions that were not available previously available due to size and power-source considerations. For example, the hydraulically-powered windrower machine  1010  may be used with a skid steer  900  as shown in  FIG. 9 . The windrower machine is mounted to the lift arms  902 ,  904  of skid steer  900 . The lift arms  902 ,  904  can control the position of the windrower machine, placing the blade at a variety of angles without the need of the hitch frame, turning system, and height adjustment mechanisms discussed in the other embodiments above. The hydraulic system of the selected mover  900  is connected to the hydraulic system  800  of the windrower  1010  to provide power to the augers. 
         [0034]    It is to be understood that the forms of the apparatus shown are preferred embodiments thereof and that various changes and modifications may be made therein without departing from the spirit of the invention or scope as defined in the following claims.