Abstract:
A flail element including a base at the proximal end of the flail element which is connected to a pair of elongated fingers. The base has a bore formed therein which is sized to receive a mounting rod. The bore and the fingers are split to enable a flail to be mounted on the rod by spreading open the fingers and the bore and snapping the flail segment over the rod. Another method of attachment can be achieved by utilizing the shaped base and an appropriate receiving system. The elongated fingers and base form a substantially unitary flail element structure. A plurality of flail elements are mounted to the mounting rod to form a flail. In a defoliating machine a plurality of flails are mounted to a rotating drum.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates generally to a defoliating device, and in particular to a quick connecting flail element for use in defoliating sugar beet crops. 
         [0003]    2. Discussion of the Related Art 
         [0004]    Flails are well known in the agricultural industry, and are used in a variety of different applications. In general, defoliating flails are used for removing leaves and other above-grade foliage and roughage in below grade tubers, such as sugar beets, in preparation of a sugar beet field for harvest. The flails are typically constructed from rubber or polyurethane and are formed in a variety of different shapes and sizes. Some flails include metal studs which are formed into the ends of the flails. 
         [0005]    In various sugar beet harvesters, for example, multiple flails are arrayed about the circumference of a supporting drum. The flails mount to a number of spokes or rods, which laterally extend between the ends of the drum. Each rod contains a number of laterally displaced flails, which pivot as the drum is rotated. When rotated, the flails shred encountered foliage. Different sizes and types of flails may be mounted on the drums. Traditional flails often require spacers which are positioned between the flails. The vertical separation of the flails relative to the tuber being harvested, or in some situations the ground, may be adjusted as necessary to optimize contact with the foliage, without damaging the tuber. While existing flails have enjoyed considerable success, such known flails require at least partial dismantling of the defoliation machine in order to replace damaged or broken flails, with commensurate cost and downtime. 
         [0006]    More specifically, prior art flails are mounted horizontally in a defoliation machine, as a group of three to ten units, on a bolt that passes through two plates welded to a round shaft or drum in the machine. Most commonly, known flails are made from rubber and are typically two inches wide with a ⅝ inch mounted hole through the top. Flails are mounted on brackets in clusters of 4 or 6 brackets. Brackets are typically 12 to 16 inches wide. The brackets hold five to seven flails each, one flail short of filling the bracket. Often replacing damaged or broken flails onto the brackets is both time consuming and difficult. For this reason, it is common to wait until the end of the harvesting season to replace the flails, as doing so at the time of failure will seriously interrupt production. The result of defoliating with a machine that includes damaged or broken flails is improperly cleaned or defoliated beets. Improperly cleaned beets leads to higher transportation costs, because the weight of the foliage is included but yields no end product. 
         [0007]    While prior art flails are most commonly made from rubber, there have been attempts to manufacture them from polyurethane. However, the cost for polyurethane flails is nearly double the cost of rubber flails. 
         [0008]    Flails fitted with steel studs have also been proposed. However, the steel studs have often proven to cause damage to the beets because every beet is impacted instead of only an occasional one. The steel studded products are not used in many areas where sugar beets are stored over the winter because the gouges from the studs cause bleeding, reducing the sugar content. With improvements in sugar beet seeds, resulting in producing much larger sugar beets that stand farther out of the ground then those known previously, knocking the beets out of the ground and damaging them is a more serious problem than it was about two decades ago. 
       SUMMARY OF THE INVENTION 
       [0009]    In accordance with an embodiment of the present invention, a flail element includes a base coupled to a pair of elongated fingers. A narrow gap is formed between facing fingers. The base has a bore formed within a proximal region of the base and the bore is sized to receive a mounting rod. The elongated fingers and base form a substantially unitary flail element structure. 
         [0010]    The quick connect flail of this invention has been configured to easily install on current rods in defoliation machines and makes replacing failed flail elements economically viable. The flails of this invention brush the tops off the sugar beet instead of scalping and shredding the foliage. The invention attaches to the cluster bracket of the defoliation apparatus with a split design so it slides over the rod instead of needing to disassemble the entire rod to replace one flail. The quick connect flail element is of a reversible construction. A flail comprised of one or more flail elements of the invention can be produced to he as long as any defoliating apparatus may require covering the entire width of the machine, or to be as short as to cover only a portion of the beet itself. As an example, the possible ranges are from as short as ½ inch to as long as 20 feet. The flail of this invention can be constructed from any elastomer or tough plastic. Specific examples, would be rubber, nylon elastomers, thermoplastics, other elastomers, and preferably, polyurethane. The flail can optionally include metal studs, or other hardened materials. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
         [0011]    The above and other aspects, features, and advantages of the present invention will become more apparent upon consideration of the following description of preferred embodiments, taken in conjunction with the accompanying drawing figures, wherein: 
           [0012]      FIG. 1  is a front view of a flail element in accordance with an embodiment of the present invention; 
           [0013]      FIG. 2  is an edge or side view of the flail of  FIG. 1 ; 
           [0014]      FIG. 3  is a front-view of a flail comprised of a plurality of the  FIG. 1  flail elements which are shown coupled to a mounting rod and associated brackets; 
           [0015]      FIG. 4  is a side view of a rotor having a flail cluster formed with four separate flails; 
           [0016]    FIG. S is a perspective view of a defoliating apparatus implementing flails in accordance with an embodiment of the present invention; 
           [0017]      FIG. 6  is a partially broken away top view of the defoliating apparatus of  FIG. 5 ; and 
           [0018]      FIG. 7  is an alternative embodiment of a flail element in accordance with the invention. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0019]    In the following detailed description, reference is made to the accompanying drawing figures which form a part hereof, and which show by way of illustration specific embodiments of the invention. It is to be understood by those of ordinary skill in this technological field that other embodiments may be utilized and structural, as well as procedural, changes may be made without departing from the scope of the present invention. As a matter of convenience, various components of a flail will be described using exemplary materials, sizes, shapes, and dimensions. However, the present invention is not limited to the stated examples and other configurations are possible and within the teachings of the present disclosure. 
         [0020]    By way of example only, various embodiments will be described in conjunction with a flail for defoliating sugar beets. However, it is to be understood that the present disclosure applies equally to other types of applications such as removing leaves and other above-grade foliage and roughage, prior to harvesting below grade tubers. 
         [0021]      FIGS. 1 and 2  are front and side views, respectively, of flail element  11  in accordance with an embodiment of the present invention. Base  12  includes bore  13 , which is sized to pivotally receive mounting rod  14  ( FIG. 3 ). A pair of facing elongated fingers  15 ,  16  are shown connected to the base at the proximal region of the flail element. At the distal end of flail element  11  are heads  17  and  18 , each of which is large compared with the cross section of the majority of the length of the fingers. The flail element thus has a substantially unitary structure. 
         [0022]    Each finger  15 ,  16  of flail element I  1  is thin compared with respective head  17 ,  18 . Ribs  21 ,  22  are formed along the sides of fingers  15 ,  16  to reinforce and stiffen the fingers. 
         [0023]    Bore  13  of base  12  is split at gap  23  so that slot or space  24  between fingers  15 ,  16  provides a continuous opening from slot  24  into bore  13 . The base is made of somewhat rigid, but sufficiently flexible material so that gap  23  may be opened sufficiently to fit over mounting rod  14 . This enables base  12  to be pivotally secured to mounting rod  14  as seen in  FIG. 3 . The mounting rod may be secured to brackets  25  and  26 , which in turn are secured to a drum (not shown in this figure). The spacing between the mounting brackets is typically structured and positioned so that the flail elements are positioned with their bases closely adjacent or touching so that there is little or no lateral movement of them relative to the mounting rod, while at the same time permitting the flail elements to rotate a desired amount about the mounting rod. 
         [0024]    The distal portions of the fingers are formed so that there is increased mass at heads  17 ,  18  than would be in equivalent lengths of the fingers between the base and the heads. This weight distribution provides for maximum impact force and enhances centrifugal recovery, or bounce back, after the flail impacts the beet foliage, for example. Because fingers  15 ,  16  are relatively thin and made of flexible material, reinforcing ribs  21 ,  22  are provided to somewhat stiffen the fingers. 
         [0025]    Another functional element of flail element  11  is cleaning projection  19 . This cleaning aspect comes into play when flail elements  11  are engaged on rod  14  and the thus formed flail  32  is mounted to a drum by means of brackets  25 ,  26 . This will be explained below. 
         [0026]    In a typical implementation, a number of flails, each having a plurality of flail elements ( FIG. 1 ), may be secured to an outer portion of drum  31 , such as that illustrated in  FIG. 4 . A preferred embodiment is shown in  FIG. 3 , where flail  32  is formed of a plurality of flail elements, in this case twelve elements  11 , each rotatably and removable mounted to rod  14  which is mounted to brackets  25 ,  26 . 
         [0027]    Base  12  and fingers  15 ,  16  of each flail element  11  may be formed from any suitable material which provides flexing combined with suitable stiffness to accomplish the desired defoliation or topping, for example, of row crops. By way of non-limiting example, these flail elements may be formed from rubber, plastic, elastomers, nylon elastomers, thermoplastics, polyurethane, and the like. The overall length of flail element  11 , as defined by the distance from the center of bore  13  and extending to the distal end or tip of fingers  15 ,  16 , may be about 8-24 inches, with 12 inches being typical. The overall width of base  12  of segment  11  is preferably about two inches, but other widths could be employed. A flail  32  may be very narrow, having only a single flail element, or it may be very wide for a very large defoliating machine, as wide as 20 feet. 
         [0028]    As can be seen more clearly in  FIG. 2 , the thickness of fingers  15 ,  16  is substantially uniform through most of its length, tapering at 33 to the thickness of heads  17 ,  18 . Although no particular thickness is required or critical, the fingers may have a thickness of about 0.25 inch to about 2.0 inches. From  FIG. 1  it can be seen that the fingers have widths which decrease toward their linear center, and increase to heads  17 ,  18 . However, the tapering of the fingers is not a requirement and non-tapered fingers may also be used. Referring to  FIG. 1 , the width of base  12  is about two inches, as stated above, and the width of heads  17 ,  18  are about 1¾ inches. 
         [0029]    This means that there is minimal space between adjacent distal ends or heads  17 ,  18  of flail elements, as seen in  FIG. 3 . This results in more complete defoliation as compared with known prior art defoliation machines because there is minimal space along the width of a flail that is not occupied by the head of a flail element. Further, the increased mass of the flail element head results in cleaner, more complete defoliation. 
         [0030]    Linear beads  34 ,  35  on the operative length of respective heads  17 ,  18  have two functions. In the first place, they provide wear surfaces. Because they project outwardly from the foliation-engaging surfaces of heads  17 ,  18 , each flail element has an enhanced functional life. Further, beads  34 ,  35  add yet additional mass to the distal ends of the flail elements, further adding to the impact of the flail heads with the foliage. These beads may also be formed in a grid pattern, or they may be circular, angular, horizontal, or any combination thereof. 
         [0031]    Because each flail element in this embodiment is two sided, its life is further increased because it is reversible on rod  14 . Since drum  31  normally rotates in only one direction, only one of facing flail element heads makes contact with the foliage. When this leading flail element head is worn or is damaged, a flail element can be easily removed from rod  14 , reversed, and reinstalled in seconds. 
         [0032]    With specific reference to  FIG. 4 , there is shown a side view of a rotor implementing four separate flails which make up flail cluster  30  in accordance with an embodiment of the present invention. Several such rotors are installed in defoliating apparatus  40  ( FIGS. 5 and 6 ). The illustrated portion of flail cluster  30  includes four separate flails  32 , mounted onto drum  31  at various locations about the drum, collectively defining a flail cluster. As an example, during operation, the rotor may rotate in a counter-clockwise direction as viewed in  FIG. 4 , causing the elongated fingers of the individual flail segments to contact beet foliage. 
         [0033]    The rotor illustrated in  FIG. 4  is formed as a single flail cluster containing four individual flails  32 . If desired, flail clusters containing additional or fewer flails (for example, 2-8 flails, or even more) may alternatively be implemented. 
         [0034]    From  FIGS. 3 and 4  it can be perceived that there is some element of free space between mounting rod  14  and the surface of drum  31 . This is necessary to enable flail elements  11  to rotate about rod  14  which is secured to the drum by means of brackets  25 ,  26 . Dirt, mud, foliage, and possibly other detritus tends to collect in this small area between flail  32  and drum  31  and moving projections  19  aid in keeping that material from caking into that area. 
         [0035]      FIGS. 5 and 6  are perspective and top views, respectively, of defoliating apparatus  40  in accordance with an embodiment of the present invention. Defoliator  40  is an example of an otherwise conventional defoliating apparatus, as modified to include the flails disclosed herein. The defoliator includes tongue assembly  41 , drive assembly  42 , leveling assembly  43 , and height adjusting assembly  44  with an associated hydraulic cylinder  45 . The height adjusting assembly may be used to control the vertical relative positioning of wheel  46  and frame  47 , and consequently, the relative positioning of the frame relative to the ground. 
         [0036]    As shown in  FIG. 6 , three rows of flail clusters  30  are rotatably attached to frame  47 . These flail clusters may be rotated in the same or different directions. For example, the flail clusters may be rotated in a single direction, causing the elongated fingers of the flails to move either rearward or forward. An alternative is to rotate the two rows of flail clusters nearest to tongue  41  in one direction (rearward or forward), and to rotate the remaining single row of flail clusters in a direction that is opposite to the direction of the front-two rotors. Still further rotational arrangements may also be used and are within the teachings of the present disclosure. 
         [0037]    In operation, defoliator  40  may be pulled through the field such that the tops of the crops, such as sugar beets, would be removed due to the flails on the rotating flail clusters striking the tops of the plants. Note that the spacing between the flail clusters may be adjusted as necessary. Also, flail clusters  30  are shown in the same positions in each row. The flail clusters could be staggered so that there are no gaps undefoliated after defoliater  40  makes a single pass over the ready-to-harvest crop. 
         [0038]    An alternative flail element embodiment is shown in  FIG. 7 . Flail element  51  has a single finger  52  extending from one side of split base  53 . Finger  52  is formed with head  54  which may be shaped similar to head  17  on finger  15  ( FIGS. 1 and 2 ), or it may have some other enhanced mass configuration. Base  53  may be cylindrical, as shown in  FIG. 7 , or it may be shaped similar to base  12  in  FIGS. 1 and 2 . The base has bore  55  and gap  56 , similar to the  FIG. 1  embodiment. 
         [0039]    Flail element  51  also includes counterweight finger  57 , which finger is shorter than finger  52 , and is formed with head  61  of enlarged mass. As with the  FIG. 1  embodiment there is a slot or space  62  between fingers  51  and  57 . 
         [0040]    The flail element of  FIG. 7  functions in the same way as that of  FIG. 1 , to the extent that it is a quick connecting replacement flail element. It is not operationally reversible but the base gap can be easily opened to engage with, or be removed from, a mounting rod such as rod  14  in  FIG. 3 . 
         [0041]    While the invention has been described in detail wit reference to disclosed embodiments, various modifications within the scope of the invention will be apparent to those of ordinary skill in this technological field. It is to be appreciated that features described with respect to one embodiment typically may be applied to other embodiments. Therefore, the invention properly is to be construed only with reference to the claims.