Abstract:
Plant potting machines and methods have synchronized continuous motion pot track and soil drilling systems. In especially preferred forms, potting machines and methods of forming a planting recess in soil contained within a pot are provided which move a soil-filled pot continuously along a linear segment of a pot track, and move a drill bit continuously in synchronized registry with the soil-filled pot at the same time as the pot moves continuously along the linear segment of the pot track. Most preferably, simultaneous horizontal and vertical motion components are imparted to a soil-drilling drill bit relative to the linear segment of the pot track, for example, by moving the drill bit in an arcuate (preferably circular) orbit above the pot track. Such simultaneous horizontal and vertical motion components cause the drill bit to track linearly in registry with the pot conveyed by the pot track along the linear segment thereof and to be moved vertically into and out of contact with soil contained within the pot to thereby drill the planting recess therein.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates generally to machines and methods which assist in plant potting operations.  
         BACKGROUND AND SUMMARY OF THE INVENTION  
         [0002]    Horticultural growers have a need to periodically place growing plants (e.g., seedlings, shrubs, flowers, and the like) in pots of sufficient size so as to accommodate future growth. Once the potted plants have attained a desired size, therefore, they can be sold to retail nurseries, landscape companies or the like for transplanting to a permanent site.  
           [0003]    Potting machines which assist the horticultural growers in placing their plants into soil-containing pots are well known. In this regard, most potting machines include a soil infeed conveyor which transfers potting soil from a soil supply to a soil lift conveyer which elevates the soil over and into pots travelling along a closed-loop pot track. Recently, potting machines have been disclosed in U.S. Pat. No. 5,641,008 (the entire content of which is expressly incorporated hereinto by reference, and referred to hereinafter as “the &#39;008 patent”) which includes coordinated indexing and soil drilling systems. The indexing system serves to sequentially continually advance the plant pots along the potting path so that each pot on the track is brought into a momentary stationary indexed relationship with a reciprocally moveable drill assembly associated with the soil drilling assembly. During such momentary stationary indexed relationship, therefore, the drilling assembly serves to drill a generally centrally located recess in the soil contained within the pot to facilitate the placement of a plant therein.  
           [0004]    While the potting machines and methods disclosed in the &#39;008 patent are entirely satisfactory for relatively small pot sizes (e.g., 5-gallon pots or less), problems tend to arise when relatively large pot sizes (e.g., between about 10-gallon to about 25-gallon pots) are handled. Specifically, the larger pot sizes necessarily require a greater volume of soil and require a recess that is proportionally larger and deeper as compared to the smaller pot sizes (i.e., since proportionally larger root balls need to be planted in the larger pot sizes). As a result, the continual stopping/starting of the pot track as disclosed in the &#39;008 patent is not entirely satisfactory for larger pot sizes as soil in the pots has a greater tendency to shift due to its greater mass weight thereby collapsing the drilled recess before a plant can be placed therein.  
           [0005]    It would therefore be highly desirable if plant potting machines and methods were provided which are especially adapted to the handling of relatively large pot sizes. It is towards fulfilling such a need that the present invention is directed.  
           [0006]    Broadly, the present invention is directed to plant potting machines and methods having synchronized continuous motion pot track and soil drilling systems. In especially preferred forms, the present invention is embodied in potting machines and methods of forming a planting recess in soil contained within a pot by moving a soil-filled pot continuously along a linear segment of a pot track, and moving a drill bit continuously in synchronized registry with the soil-filled pot as the pot moves continuously along the linear segment of the pot track. More specifically, according to the present invention simultaneous horizontal and vertical motion components are imparted to a soil-drilling drill bit relative to the linear segment of the pot track, for example, by moving the drill bit in an arcuate (preferably circular) orbit above the pot track. Such simultaneous horizontal and vertical motion components cause the drill bit to track linearly in registry with the pot conveyed by the pot track along the linear segment thereof and to be moved vertically into and out of contact with soil contained within the pot to thereby drill the planting recess therein.  
           [0007]    These and other aspects and advantages will become more apparent after careful consideration is given to the following detailed description of the preferred exemplary embodiments thereof. 
       
    
    
     BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS  
       [0008]    Reference will hereinafter be made to the accompanying drawings, wherein like reference numerals throughout the various FIGURES denote like structural elements, and wherein;  
         [0009]    [0009]FIG. 1 is a perspective view of a particularly preferred exemplary potting machine embodying the present invention;  
         [0010]    [0010]FIG. 2 is a closer perspective depiction of the pot track of the potting machine shown in FIG. 1 as viewed generally from the pot discharge position thereof;  
         [0011]    [0011]FIG. 3 is a detailed elevational view of the soil drilling system in accordance with the present invention;  
         [0012]    [0012]FIG. 4 is a rear perspective view of the soil drilling system depicted in FIG. 3; and  
         [0013]    FIGS.  5 - 8  are detailed elevational view showing a typical operational sequence of the soil drilling system and its continuous synchronous movement relative to a soil-filled pot on the pot track. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0014]    Accompanying FIGS. 1 and 2 show a particularly preferred potting machine  10  embodying the present invention. As can be seen, the potting machine  10  includes generally a pot track system  12 , a soil handling system  14 , and a soil drilling system  16 .  
         [0015]    The pot track system  12  essentially includes separated sprockets  20 ,  22  which are engaged with an endless belt chain  24 . A series of pot holders  26  are connect to, and thus supported by, the belt chain  24 . In this regard, accompanying FIG. 2 shows an exemplary large-capacity pot P positioned in one of the pot holders  26 , it being understood of course that during operation, other pots P would likewise be held in others of the pot holders  26 . A vertically oriented drive shaft  20 - 1  is connected operatively between the sprocket  20  at one end thereof and to a drive motor  20 - 2  at the other end thereof. The motor  20 - 2  serves to rotate continuously the drive shaft  20 - 1  which in turn rotates the sprocket  20 . As such, the belt chain  24  will therefore responsively be moved around the sprockets  20 ,  22  thereby carrying the individual pot holders  26  continuously along the closed-loop path established by the chain  24 .  
         [0016]    The soil handling system  14  is most preferably comprised of a soil feed hopper  30  and its associated soil feed conveyor  32 . The hopper  30  provides an available stand-by source of potting soil PS which is carried to the discharge cute  34  by the conveyor  32  and deposited into an awaiting pot P (see FIG. 2). Excess soil which is not deposited into the pot P falls by gravity onto a lower recycle conveyor  36  (see FIG. 2) which serves to transfer such excess soil from the filling operation (as well as excess soil removed from the pot P by virtue of the soil drilling operation by means of the drilling system  16 ) to a return conveyor  38 . The return conveyor  38  transfers the soil to a lift conveyor  40  to thereby deposit the soil back into the soil feed hopper  30  which it may again be conveyed by the conveyor  32  into another awaiting empty pot P. In such a manner, therefore, soil build-up below the pot track system  12  is prevented while at the same time ensuring that the potting soil PS is conserved and used for its intended purpose.  
         [0017]    In the embodiment of the potting machine  10 , the pot track system  12  is continuously moved in a clockwise direction as viewed from the top of FIG. 1. Thus, after being filled with potting soil PS, the pots P will be conveyed continuously by the pot track system  12  and be presented to the soil drilling system  16 . As is perhaps more clearly depicted in FIGS. 3 and 4, the soil drilling system  16  is positioned above a linear segment of the endless pot tract, and is most preferably comprised of a pair of horizontally spaced-apart support sprockets  40 ,  42  interconnected by means of a continuous drive chain  44 . An adjustable tensioner pulley  46  is provided so as to allow adjustable tensioning of the drive chain  44 . Bearing blocks  40 - 1 ,  40 - 2  operatively associated with the support sprockets  40 ,  42  are supported by a structural beam B 1  forming a component part of the supporting frame F of the potting machine  10 . Similarly, structural beam B 2  serves to support the adjustment bar  44 - 1  to which the tensioner pulley  44  is mounted.  
         [0018]    A horizontally disposed upper support platform  48  is mounted rigidly (e.g., by welding) in a cantilevered manner to corresponding eccentric locations on the respective faces of each support sprocket  40 ,  42 . A horizontally disposed lower support platform  50  is vertically spaced in a dependent manner below the upper platform  48  and is connected to the latter by adjustable support posts  52 . A motor  54  is operatively connected to the support posts  50  by means of an adjustment chain (not shown) so as to permit the lower platform  50  to be raised and lowered relative to the upper platform  48  and hence relative to the pots P in the pot track system  12 . By adjusting the vertical spacing between the platforms  48 ,  50 , the depth of the recess drilled into the soil-filled pots P may be selected.  
         [0019]    The lower support platform  50  supports a drill motor  56  connected to one end of the drive shaft  58  associated with the drill bit  60 . When the drill bit  60  is brought into contact with the soil contained within an await soil-filled pot P (as will be described in greater detail below), the rotation of the drill bit  60  by the drill motor  56  will thereby responsively cause the screw flights  60 - 1  thereof to physically lift soil from the pot P and thereby form the desired recess into which a plant may be placed.  
         [0020]    An annular compaction ring  62  surrounds the drill bit  60  and is supported by the lower support plate  50 . The compaction ring  62  is mounted for reciprocal travel between towards and away from the support platform  50  by means of spring-biased support rods  64  slideably received with vertical support cylinders  66 . The support cylinders  66  include spring members (not shown) which bias the compaction ring  62  into its lowermost position and against upward vertical displacement toward the support plate  50 . Apertures  68  are formed in the upper platform  48  so as to receive the upper ends of each support rod  64  and thereby accommodate their uppermost displacement. During operation of the soil-drilling system  16 , the compaction ring  62  thus serves to physically compact the soil contained within the pot P and to physically hold the soil around the recess being drilled by the dill bit  60  to thereby ensure that a well defined recess in the soil is formed.  
         [0021]    The sprocket  40  is rotatably driven by means of a chain and sprocket drive system. Specifically, as shown in FIG. 4, the sprocket shaft  40 - 2  of sprocket  40  is connected to a driven sprocket  70 , while a drive sprocket  72  is coupled operatively to drive motor  74 . An endless drive chain  76  spans the sprockets  70 ,  72  and thereby transfers the rotational drive from the sprocket  72  to the sprocket  70  and hence to the support sprocket  40 . Thus, by operating the drive motor  74 , the support sprockets  40 ,  42  will each be simultaneously rotated at the same rotational speed by virtue of the interconnection provided by chain  46 .  
         [0022]    In order to balance the stress forces exerted on the support sprockets  40 ,  42  by virtue of the weight and cantilevered eccentric mounting of the upper support platform  48  and the structures supported thereby, a counterweight  78  is provided and connected to the rotation shaft  42 - 2  of the support sprocket  42 .  
         [0023]    Downstream of the drilling system  16 , a worker can place a plant into the recess that had been just drilled into the potting soil contained within the pot P. Thereafter, the pot P with the newly re-planted plant therein will then continuously be conveyed to the discharge position and will be urged out of its pot holder  26  by the discharge plate  80  onto a discharge conveyor  82  (see FIGS. 1 and 2). The discharge conveyor  82  may thus transport the finished potted plant to another location (e.g., a collection trailer or growing site on the nursery grounds). A worker may then manually place an empty pot into the vacated pot holder  26  to allow the cycle to repeat itself.  
         [0024]    Accompanying FIGS.  5 - 8  show an operational sequence of the drilling system  16  in accordance with the present invention. In this regard, accompanying FIG. 5 depicts the drilling system  16  in an initial, or starting, position in its operational sequence in that the cantilevered connections between the upper support platform  48  and the support sprockets  40 ,  42  are located essentially at top center thereof relative to their respective rotation axes.  
         [0025]    It will of course be understood that, during the sequence of operation to be described below, the sprockets  40 ,  42  are driven simultaneously by means of motor  74  and its associated chain drive system so as to rotate continuously about their respective rotation axes in a counterclockwise direction as viewed in FIGS.  5 - 8 . Thus, the upper support platform  48  and the structures supported thereby, including the drill bit  60 , will likewise be rotated continuously in a counterclockwise direction so as to trace a circular path whose radius or curvature is coincident with the radium of the support sprockets  40 ,  42 . At the same time, the individual pot holders  26  will be driven continuously by the pot track system  12  by means of motor  20 - 2 , drive shaft  20 - 1  and sprocket  20  so that the pot holders  26  will be presented sequentially to the soil drilling system  16 . Speed synchronization between the continuous motion drilling system  16  and pot track system  12  may be achieved by a suitable programmable controller (not shown) operatively connected to the various drive motors.  
         [0026]    The relative positioning of the pot holders  26  and the continuous operational speeds of the pot track system  12  and soil drilling system  16  will thus be synchronized such that the drill bit  60  and the top of soil-filled pot P will be substantially vertically aligned with one another as shown in FIG. 6. At this stage in the continuous cycle, the compaction ring will have come into contact with the upper rim of the pot P and the drill bit  60  will have penetrated somewhat into the soil contained therein. Continuous synchronous rotational of the movement of the sprockets  40 ,  42  will thus translate into movement of the drill bit  60  having simultaneous horizontal and vertical motion components. The horizontal motion component of the drill bit  60  will thus allow it to follow the pot P within the pot holder  26  as it moves continuously along a linear segment of the pot track. At the same time, the vertical motion component of the drill bit  60  allows the drill bit  60  to be forcible lowered into the soil within the pot P to the desired maximum depth. Such a state (i.e., a state where the drill bit  60  has simultaneously tracked the pot P along the linear pot track segment and has been vertically forced to its maximum depth within the soil contained within the pot) is shown in FIG. 7.  
         [0027]    Continued rotation of the sprockets  40 ,  42  will thereafter cause the drill bit  60  to be raised relative to the pot P thereby leaving a recess of desired depth in the potting soil contained therein. Ultimately, further continued rotation of the sprockets  40 ,  42  will cause the drill bit  60  to be vertically spaced above the pot P so that it again assumes the starting position shown in FIG. 5. The thus drilled pot can then proceed downstream of the drilling system while the next sequential pot P is presented to the drilling system, whereby the cycle repeats itself.  
         [0028]    A variety of modifications and equivalents are envisioned and could be implemented by those skilled in this art without undue experimentation. For example, although the potting machine  10  has been described above as being especially well suited for use with relatively large-sized pots (and for that purpose includes a single, relatively large-sized drill bit  60 ), smaller sized pots could likewise be handled making the potting machine  10  universally suitable for a wide range of pot sizes. Thus, the single, relatively large-sized drill bit depicted in the accompanying drawings, could be replaced with a pair of smaller-sized drill bits and their associated motors. These relatively smaller-sized drill bits could then be synchronously registered with smaller sized pot holders holding relatively smaller pots. That is, each of the large sized pot holders  26  shown in the accompanying drawings could be replaced with a pair of smaller sized pot holders which would then be synchronously registered with the pair of drill bits associated with the soil drilling system  16 .  
         [0029]    Furthermore, the chain and sprocket drive system used to rotate simultaneously the support sprockets  40 ,  42  could be replaced with virtually any suitable equivalent drive system. For example, each of the sprockets could be driven independently by its own separate variable speed drive motor. In addition, the support sprockets  40 ,  42  could be replaced with suitable gearboxes and computer-controllable drive motors to effect the desired continuous orbital movement of the drill bit (i.e., so as to achieve the desired simultaneous horizontal and vertical motion components in a manner described previously). In such a case, non-circular orbital movements (e.g., elliptical or oval orbital movements) of the drill bit above the pot track could possibly be achieved, in addition to the circular orbital movements described above.  
         [0030]    Thus, while the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.