Abstract:
A coulter or disc having a plurality of directional notches therein is used in one rotational direction for one use and an opposite rotational direction for a different use. The notches are selected from many arcuate shapes and sizes. The notches taper from sharp to dull from one end to the other, but in use one can chose to lead with the dull or the sharp end of the notches. A method of making and using such coulters or discs is described and shown.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     Not applicable. 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable. 
     REFERENCE TO MICROFICHE APPENDIX 
     Not applicable. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to tillage tools and, more particularly, to a coulter and disc and a method of making them. 
     2. Background Art 
     Coulters are presently used ahead of no-till implements—such as a planter—to fracture a narrow band of soil to prepare the soil to receive the no-till implement. U.S. Pat. No. 7,497,270 to Bruce, which is incorporated herein by reference in its entirety, shows coulters and one way of how they are used to till the soil. 
     A disc can be like a flat coulter that is deformed to a convex shape on one side and a concave shape on the other side so it will throw soil in one direction as it moves forwardly through the ground. Discs are most often used with a plurality of them side by side in “gangs” as shown in U.S. Pat. No. 6,554,079 to Bruce, which is incorporated herein by reference in its entirety. 
     Because of differences in soil types and differences among the crops being grown, there is a need for coulters and discs that can be easily adjusted in shape at the time of manufacture to conform to the conditions anticipated in the field. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention relates to an apparatus and a method of making it. The disc has a metal disc that is generally circular with an outer periphery. A plurality of notches is disposed in the outer periphery of the disc, each of the plurality of notches tapering from a predetermined thickness on a radial inside to a thinner generally sharpened edge at the radially outermost part thereof. In one embodiment of the invention each notch has a forward end that is sharper than a rearward end so the disc will penetrate the ground easier to gather residue to be crushed and chopped by the duller following end of the notch. The disc can be either a flat coulter or a disc that is convex on one side and concave on the other side. This first embodiment is most suitable for sandy soils growing crops like wheat or oats though other uses are possible. 
     In another embodiment of the invention each notch has a forward end that is duller than a rearward end thereof so that the disc will tend gather the crop in the notch and then cut it with the following sharper end of the notch as the notch moves into the soil and whereby the notch with the leading dull end is more self cleaning as the notch releases from the soil. The disc of the second embodiment can be either a flat coulter or a disc that is convex on one side and concave on the other side. This second embodiment is most suitable for heavy, non-sandy, soil for fields that have corn stalks in it, though other uses are possible. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is a front view of a tool with set-up locations for support pins for manufacturing discs and coulters according one method of manufacture of this invention; 
         FIG. 1A  shows a relationship of a 15° cut clockwise pin support axis for a disc on the right and a 15° cut counterclockwise pin support axis disc on the left in relation to a zero pin support axis; 
         FIG. 1B  shows a relationship of a 30° cut clockwise pin support axis for a disc on the right and a 30° cut counterclockwise pin support axis disc on the left in relation to a zero pin support axis; 
         FIG. 1C  shows a relationship of a 45° cut clockwise pin support axis for a disc on the right and a 45° cut counterclockwise pin support axis disc on the left in relation to a zero pin support axis; 
         FIG. 2  is a view of a tool having a zero axis and 15°, 35° and 45° support pin axis locations; 
         FIG. 3  is a view of a punch and die tool set up to use the process of the present invention to make discs and coulters with directional notches; 
         FIG. 4A  is a partial cross sectional view along line  4 A- 4 A of  FIG. 3  showing a punch in cross section; 
         FIG. 4B  is a partial cross sectional view along line  4 B- 4 B of  FIG. 3  showing a die; 
         FIG. 5  is a perspective view of the punch and die tool set up to manufacture the directional notched discs and coulters of the present invention; 
         FIG. 5A  is a cross-sectional view along line  5 A- 5 A of  FIG. 5 ; 
         FIG. 6  is a top view of the punch and die tool set up to manufacture the directional notched discs and coulters of the present invention showing how a pin holder tool can be moved along the axis of an adjusting bolt and how a support pin can go into any one of several support pin holes in the pin holder tool; 
         FIG. 7  is a top view of the punch and die tool set up to manufacture the directional notched discs and coulters of the present invention showing how a pattern disc is placed on a support pin in a clockwise 30 degree hole and how points A and B are defined; 
         FIG. 8  is a top view of the punch and die tool set up to manufacture the directional notched discs and coulters of the present invention like in  FIG. 7 , but showing how points A and B brought together at the same place during a process of setting the rotational axis of the pin in a correct position for making directional discs and coulters; 
         FIG. 9  is a top view of the punch and die tool set up to manufacture the directional notched discs and coulters of the present invention like in  FIG. 7 , but showing the set up just before a first notch is cut from a disc for a 30 degree clockwise cut; 
         FIG. 10  is a top view of the punch and die tool set up to manufacture the directional notched discs and coulters of the present invention like in  FIG. 7 , but showing the set up just after a first notch is cut from a disc and for a 15 degree clockwise cut disc; 
         FIG. 11  is a top view of the punch and die tool set up to manufacture the directional notched discs and coulters of the present invention like in  FIG. 10 , but showing the set up just after a second notch is cut from the disc; 
         FIG. 12  is a top view of a 15 degree clockwise directional notched disc made using the process shown in  FIGS. 1-11 ; 
         FIG. 13  is cross sectional view at line  13 - 13  of  FIG. 12  after the disc is bent to have a concave convex shape using the process shown in  FIG. 13A ; 
         FIG. 13A  is cross sectional view showing how tooling is used to bend the disc to have a concave/convex shape; 
         FIGS. 14-16  are the same as  FIGS. 10-12  except  FIGS. 14-16  are for a 30 degree clockwise disc instead of a 15 degree clockwise disc as shown in  FIGS. 10-12 ; 
         FIGS. 17-19  are the same as  FIGS. 10-12  except  FIGS. 17-19  are for a 45 degree clockwise disc instead of a 15 degree clockwise disc as shown in  FIGS. 10-12 ; 
         FIG. 20  is an enlarged portion of one part of a finished disc with a 15 degree clockwise cut; 
         FIG. 20A  is a cross sectional view taken along line  20 A- 20 A of  FIG. 20  showing a dull end of a notch; 
         FIG. 20B  is a cross sectional view taken along line  20 B- 20 B of  FIG. 20  showing a sharp end of a notch; 
         FIG. 21  is an enlarged portion of one part of a finished disc with a 30 degree clockwise cut; 
         FIG. 22  is an enlarged portion of one part of a finished disc with a 45 degree clockwise cut; 
         FIGS. 23-29  correspond respectively to  FIGS. 6-12  except that  FIGS. 23-29  show the process of setting up the equipment and making a counterclockwise disc instead of a clockwise disc as shown in  FIGS. 6-12 ; 
         FIGS. 30-32  are the same as  FIGS. 27-29 , except that  FIGS. 30-32  are for a 30 degree counterclockwise disc instead of a 15 degree counterclockwise disc as shown in  FIGS. 27-29 ; 
         FIGS. 33-35  are the same as  FIGS. 27-29 , except that  FIGS. 33-35  are for a 45 degree counterclockwise disc instead of a 15 degree counterclockwise disc as shown in  FIGS. 27-29 ; 
         FIG. 36  is an enlarged portion of one part of a finished disc with a 15 degree counterclockwise cut; 
         FIG. 36A  is a cross sectional view taken along line  36 A- 36 A of  FIG. 36  showing a shape end of a notch; 
         FIG. 36B  is a cross sectional view taken along line  36 B- 36 B of  FIG. 36  showing a dull end of a notch; 
         FIG. 37  is an enlarged portion of one part of a finished disc with a 30 degree counterclockwise cut; 
         FIG. 38  is an enlarged portion of one part of a finished disc with a 45 degree counterclockwise cut; 
         FIG. 39  shows one of many possible uses of a 45 degree clockwise concave/convex disc with the dull end of the notch following the sharp end and the dull end crushes wheat stubble as the rear end of the notch goes into the soil; and 
         FIG. 40  shows one of many other possible uses of a 15 degree counterclockwise concave/convex disc leading with the dull end of notch, the disc being shown in use in a corn field with heavy soil going through corn stocks. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views,  FIGS. 1-19  show a method of making a notched blade. This method includes: 
     (A) providing a support surface along a first plane  10  as shown in  FIG. 3  on a tool holder  9 ; 
     (B) placing a die  11  ( FIGS. 1 ,  3 ,  4   a ,  6 ,  7  and  9 ) on one side of the support surface  10 , the die  11  having an arcuate supporting surface  11   a  on said one side thereof, the arcuate supporting surface  11   a  including an arc with a midpoint center  11   mp;    
     (C) providing a punch  12  ( FIGS. 3 ,  4 A,  4 B and  5 ) having a cutting edge  12   a  complementary to the arcuate supporting surface  11   a  of the die  11 , the punch  12  having a first position ( FIGS. 3 and 5 ) on another side of the support surface  11   a  and being moveable, along an operational punch line  12   opl  that is straight, between the first position ( FIGS. 3 and 5 ) and a second position substantially in contact with the die  11 ;
 
(D) laying out a first straight line  13  ( FIG. 1 ) disposed in a first plane of the support surface, the first straight line  13  ( FIG. 1 ) extending from the center  11   mp  of the arcuate supporting surface  11   a  to a first tool holder zero axis  14   zero  on a tool holder  15 , the operational punch line  12   opl  being disposed at an acute angle with respect to the first plane  10  ( FIG. 3 );
 
(E) laying out a second straight line  16  ( FIG. 1 ) disposed in the first plane  10  ( FIG. 3 ), the second straight line  16  ( FIG. 1 ) being perpendicular to the first straight line  13  ( FIG. 1 );
 
(F) the first tool holder zero axis  14   zero  being perpendicular to the first plane  10  at a place where the first  13  and second  16  lines intersect ( FIG. 1 );
 
(G) determining the size of a production circular disc  17  ( FIG. 5 ) to be notched, the production disc  17  ( FIG. 5 ) being of a predetermined radius and having a center rotational axis;
 
(H) placing a disc, such as pattern disc 30 degrees clockwise  17   pbc  ( FIGS. 6 ,  7  and  8 ) of the size of the production disc  17  ( FIG. 5 ) actually, or conceptually using engineering drawing techniques, on the tool holder  9  ( FIG. 3 ) for reference purposes with the center rotational axis of the circular disc  17   pbc  being coincident with the zero axis  14   zero;  
 
(I) using a third straight line (any one of lines  18   xc ,  18   yc ,  18   zc ,  18   xcc ,  18   ycc  or  18   zcc  shown in  FIG. 1 ) disposed in the first plane  10  ( FIG. 3 ) and extending through the center of the arcuate supporting surface  11   mp  of the disc  17  at a predetermined angle with respect to the first straight line  13  ( FIG. 1 ), the third straight line (any one of lines  18   xc ,  18   yc ,  18   zc ,  18   xcc ,  18   ycc  or  18   zcc  shown in  FIG. 1 ) also intersecting the second straight line  14  ( FIG. 1 ) at a support pin axis  19  ( FIGS. 2 and 3 ), the support pin axis  19  ( FIGS. 2 and 3 ) being perpendicular to the first plane  10  ( FIG. 3 );
 
(J) placing a support pin  19   p  at the support pin axis  19  ( FIGS. 2 and 3 );
 
(K) placing a pattern circular disc  17   pbc  ( FIG. 7 ) on the support surface  10  so that the center rotational axis of the pattern circular disc  17   pbc  is the same as the support pin axis  19  and so that the pattern circular disc  17   pbc  is rotatable about the support pin axis  19 , the support pin  19   p  and support pin axis  19  being at least temporarily fixed with respect to the tool holder  9  and spaced a predetermined distance from the die  11 , the pattern circular disc  17   pbc  having at least one notch  17   n  of a configuration and size desired to be formed in a production circular disc;
 
(L) selecting one edge of the at least one notch  17   n  of the pattern circular disc  17   pbc  to be point A ( FIG. 7 );
 
(M) selecting a point on the arcuate support surface to be point B ( FIG. 7 );
 
(N) moving the pattern disc point A to point B in the arcuate support surface  10  by moving the support pin  19   p  and rotating the pattern disc  17   pbc  ( FIG. 7  to  FIG. 8 );
 
(O) removing the pattern disc  17   pbc  from the support pin  19   p;  
 
(P) placing the production circular disc  17  ( FIG. 9 ) to be notched on the support surface  10  so that the center rotational axis of the production circular disc  17  ( FIG. 9 ) is the same as the support pin axis  19  and so that the production circular disc  17  is rotatable about the support pin axis  19 , the support pin  19   p  and the support pin axis  19  being at least temporarily fixed with respect to the tool holder  9  at such time;
 
(Q) while keeping the production circular disc  17  ( FIG. 9 ) to be notched stationary, moving the cutting surface  12   a  of the punch  12  between a first and a second position of the punch  12 , through a first portion of the production circular disc  17  to be notched that is at that time located between the punch  12  and the die  11 , thereby cutting off said first portion of the production circular disc to be notched from the remainder of the production circular disc  17  ( FIG. 10 ) to form a notch  17   nca;  
 
(R) (i) moving the punch  12  to the first position thereof ( FIGS. 3 and 5 ), (ii) rotating (from  FIG. 10  to  FIG. 11 ) the production circular disc  17  to be notched about the support pin axis  19  by a predetermined amount and again (iii) moving the punch  12  with respect to the die  11  from the first ( FIGS. 3 and 5 ) to the second position thereof to cut off a second portion ( FIG. 11 ) of the production circular disc to be notched to form another notch  17   nca  in the production circular disc  17  to be notched; and
 
(S) repeating step (R) until the production circular disc  17   f  ( FIG. 12 ) has evenly spaced notches  17   nca  disposed around the periphery thereof.
 
     Although not required, a preferred step is sharpening the exterior periphery  17   s  of the disc  17  before any of the notches are cut therefrom. Optionally the method can include bending the coulter disc  17   f  so that the disc is concave on one side and convex on the other side thereof as shown in  FIGS. 13 and 13A  when bending part  23  is pushed towards bending part  24  (or vice versa) with disc  17   f  being between bending parts  23  and  24 . The bending is typically done while the disc  17   f  is hot, but could be done when it is cold. 
     Also, optionally the method can include using a locking device  21  ( FIG. 11 ) in a notch which has been already been cut to hold the disc from rotating while another notch is being cut. See  FIG. 11  for example which shows how locking device  21  has a part  21   a  at the bottom of a handle  21   b , locking device  21  pivoting about a pin through one of holes  22   a ,  22   b  or  22   c  in tool holder  9 , depending upon the angle of the clockwise cut chosen. 
       FIGS. 5 and 5A  show sequentially how a bolt  20  is threadably engaged with pin holder  15  so that as bolt  20  is rotated in one direction the pin holder  15  moves up and when the bolt  20  is rotated in an opposite direction the pin holder  15  moves down with respect to the housing  9  and die  11 . A locknut bolt  20   a  is used to prevent movement of the bolt  20  with respect to the pin holder  15  when pin holder  15  is in the position desired for use.  FIG. 5A  is a cross sectional view along line  5 A- 5 A of  FIG. 5  and shows how a dovetail joint, including projection  9   a  and depression  15   a , holds pin holder  15  in place while it is moved up or down with respect to tool holder  9 . 
       FIGS. 14 ,  15  and  16  show sequentially how a 30 degree clockwise coulter disc  117   f  is made with notches  117   ncb  like the explanation above referring to  FIGS. 10-13  for a 15 degree clockwise disc  17   f  clockwise disc. 
       FIGS. 17 ,  18  and  19  show sequentially how a 45 degree clockwise coulter disc  217   f  is made with notches  217   nc  like the explanation above referring to  FIGS. 10-13  for a 15 degree clockwise disc  17   f  clockwise disc with notches  17   nca.    
       FIGS. 20 ,  21  and  22  show discs  17   fac ,  117   fbc  and  217   fdc  with corresponding notches  17   nac ,  117   nbc  and  217   ndc . As shown in  FIGS. 20 ,  21  and  22  the dull end of each respective notch  17   nac ,  117   nbc  and  217   ndc  is on the left and the sharp end is on the right. 
       FIG. 20A  is a cross section taken along line  20 A- 20 A of  FIG. 20  and shows that this portion of the notch  17   nac  is dull.  FIG. 20B  is a cross section taken along line  20 B- 20 B of  FIG. 20  and shows that this portion of the notch  17   nac  is sharp. The entire notch  17   nac  tapers gradually from dull to sharp from left to right as shown in  FIG. 20 . This is true of all of the clockwise cut notches shown in the figures of this document when viewed from this same perspective including, but not limited to, notches  117   nbc  and  217   ndc  shown in  FIGS. 21 and 22 . 
       FIGS. 23-26  illustrate how to set up the equipment to make a 30 degree counterclockwise disc with notches  117   nc  in disc  117   pbcc  correspond to the method of  FIGS. 6-9  for making a 15 degree clockwise notches  17   n  in disc  17   f . The process is essentially the same as described for  FIGS. 6-9 . The difference is the size of the notch, the fact that the pin  19   p  is located in the 30 degree hole in tool  15  to the right of the zero hole  14   zero , the members  21 ,  21   a  and handle  21   b  are pinned in hole  222   b  and the disc  17   f  is rotated counterclockwise from  FIG. 30  when the first notch  117   nbcc  is cut to  FIG. 31  when the second notch  117   nbcc  is cut to make disc  117   fbcc  as shown in  FIG. 32 . 
       FIGS. 27 and 28  illustrate making a 15 degree counterclockwise disc  17   facc  with notches  17   nacc  in disc  17   facc . The steps correspond essentially to the method of  FIGS. 6-9  for making a 15 degree clockwise notches  17   nc  in disc  17   f . The process is essentially the same as described for  FIGS. 6-9 , except the differences include the fact that the pin  19   p  is located in the 15 degree hole in tool  15  to the right of the zero hole  14   zero , the members  21 ,  21   a  and handle  21   b  are pinned in hole  222   a  on the right side instead of on the left side and the disc  17   facc  is rotated counterclockwise from  FIG. 27  when the first notch  17   nacc  is cut to  FIG. 28  when the second notch  17   nacc  is cut to make disc  17   facc  as shown in  FIG. 29 . 
       FIGS. 30 and 31  illustrate making a 30 degree counterclockwise disc  117   fbcc  with notches  117   nbcc  in disc  117   fbcc . The steps correspond essentially to the method of  FIGS. 6-9  for making a 15 degree clockwise notches  17   nc  in disc  17   f . The process is essentially the same as described for  FIGS. 6-9 , except the differences include the fact that the pin  19   p  is located in the 30 degree hole in tool  15  to the right of the zero hole  14   zero , the members  21 ,  21   a  and handle  21   b  are pinned in hole  222   b  on the right side instead of on the left side and the disc  17   fbcc  is rotated counterclockwise from  FIG. 30  when the first notch  117   nbcc  is cut to  FIG. 31  when the second notch  117   nbcc  is cut to make disc  117   fbcc  as shown in  FIG. 32 . 
       FIGS. 33-35  for making a 45 degree counterclockwise disc  217   fdcc  with notches  217   ndcc  in disc  217   fdcc  correspond to  FIGS. 6-9  for making a 15 degree clockwise notches  17   nc  in disc  17   f . The process is essentially the same as described for  FIGS. 6-9 , except the differences include the fact that the pin  19   p  is located in the 45 degree hole in tool  15  to the right of the zero hole  14   zero , the members  21 ,  21   a  and handle  21   b  are pinned in hole  222   c  on the right side instead of on the left side and the disc  217   fdcc  is rotated counterclockwise from  FIG. 33  when the first notch  217   ndcc  is cut to  FIG. 34  when the second notch  217   ndcc  is cut to make disc  217   fdcc  as shown in  FIG. 35 . 
       FIGS. 36 ,  37  and  38  respectively show discs  17   facc ,  117   fbcc  and  217   fdcc  with corresponding notches  17   nacc ,  117   nbcc  and  217   ndcc . As shown in  FIGS. 36 ,  37  and  38  the dull end of each respective notch  17   nacc ,  117   nbcc  and  217   ndcc  is on the left and the sharp end is on the right. 
       FIG. 36A  is a cross section taken along line  36 A- 36 A of  FIG. 36  and shows that this portion of the notch  17   nacc  is dull.  FIG. 36B  is a cross section taken along line  36 B- 36 B of  FIG. 36  and shows that this portion of the notch  17   nacc  is sharp. The entire notch  17   ncc  tapers gradually from dull to sharp from right to left as shown in  FIG. 36 . This is true of all of the counterclockwise cut notches shown in the figures of this document when viewed from this same perspective including, but not limited to, notches  117   nbcc  and  217   ndcc  shown in  FIGS. 37 and 38 . 
       FIG. 39  shows one of many possible uses of the present invention showing a 45 degree clockwise disc  217   fdc  made according to  FIGS. 17-19  and  22  leading with the sharp end of the notch  217   nc . In sandy soil where wheat is often grown, like places in Kansas, the disc  217   f  ( FIG. 19 ) or  217   fdc  ( FIG. 39 ), which can either be flat like a coulter or concave/convex like other tillage discs (FIG.  13 / 13 A), is shown being pulled to the left as shown in  FIG. 39  through the sandy soil SS. As this is done, the notch  217   nc  slowly gathers or captures wheat stubble WS in the notch  217   nc . Leading with the sharp end of  217   nc  permits the disc  217   f  to go into the soil SS but the smaller notches prevent the disc  217   f  from going too deep into the soil SS. The dull end of the notch  217   nc  follows the sharp end and the dull end crushes the wheat stubble WS as the rear end of the notch  217   nc  goes into the soil SS. The smaller notch  217   nc  moves less soil SS as is passes through the ground. It is to be understood that one can vary the size of the notch and vary whether the dull or sharp edge of the notch is leading or following depending upon the anticipated conditions. This allows the user to control what the disc will do under the conditions present in the soil. For example a smaller notch (like a 45 degree notch) penetrates the soil less and does less aggressive tillage than a larger notch (like a 15 degree notch). Penetrating too deep during tillage in loose sandy soil will cause erosion, so the notch has to be smaller to prevent that in sandy soil. 
       FIG. 40  shows one of many other possible uses of a 15 degree counterclockwise disc  17   facc  made according to  FIGS. 27-29  and  36  leading with the dull end of notch  17   nacc . The disc  17   facc  is shown in a corn field with heavy soil HS going through corn stocks CS. This disc  17   facc  will do more aggressive tillage, i.e. it will go deeper into the soil and cause more displacement of the soil. A dull end of notch  17   nacc  leads the sharp end in this case. The dull end of the notch  17   nacc  releases the corn stalk residue more as it goes out of the soil HS than if the sharp end is leading. Residue R drops out better with the leading dull end of notch  17   nacc  and the sharp end of the notch  17   nacc  more easily cuts the large corn stalks CS as the notch  17   nacc  goes into the soil HS. 
     Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.