Abstract:
An implement for extraction and decimation of plant stalks with a puller section and flail section. The puller section is driven by a motor and uses a pair of track belts with interlocking protrusions to grab plant stalks and pull them up by the root. The puller section discharges the plant stalks into a hooded flail section with flail rotor and flail knives that decimate the plant stalk into small pieces.

Description:
PRIORITY CLAIM 
       [0001]    The present application claims benefit of U.S. Provisional Patent Application No. 61/728,287 filed on Nov. 20, 2012. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates to agricultural implements for attachment to the power take-off of a tractor and, particularly, to an implement for the extraction and decimation of plant stalks including cotton. 
         [0004]    2. Discussion of the Prior Art 
         [0005]    Cotton is picked using a harvester having heads for picking several rows at once, usually four to six rows. After cotton is picked, the stalks are left in the field and require additional processing for removal so that a subsequent crop can be planted. Further, cotton is a perennial plant and can re-grow following harvest, providing the potential for development of hostable fruit (squares and bolls) for boll weevil feeding and reproduction. Under good environmental conditions, cotton plants can generate hostable fruit in three to four weeks. Thus, it is considered important to destroy cotton stalks as soon as the crop has been harvested to aid in reducing costs for the boll weevil eradication. Present practices require several passes by mowers and disc harrows to effectively process these stalks. These several passes cause wear and tear on expensive cotton harvesting machines and require the use of fuel that is costly and harmful to the environment. Thus, what is needed is a method for removal of cotton stalks or similar plant crop stalks more efficiently. 
         [0006]    Conventional rotary mowing can leave long pieces of crop stalks that will interfere with future field operations and hinder decomposition of plant matter. It would be more desirable to process plant stalks and leave only small debris or chips of plant material that will readily rot and become organic soil matter. Despite this long-felt need, nothing on the market today effectively pulls and shreds the stalk of a cotton plant to the root, especially with only one trip through a post-harvest crop field. Previous attempts to solve for this need have failed at least in part. For example, the Amadas puller/chopper (U.S. Pat. No. 5,953,895), pulls and chops crop matter in 12″-18″ long sections using pneumatic tires. The Amadas puller only pulls and holds a stalk momentarily and does not promote further processing of the stalk. Thus, the Amadas puller deposits the crop litter in a concentrated band, unfortunately leaving long stalks on the ground. The concentration of the band of stalks left on the ground causes future difficulty in tillage for planting new crops. The remaining root pullers available in the art, such as shown in U.S. Pat. No. 4,779,684, require the crop to be mowed before the root can be pulled, and then when the root is pulled a 12″-20″ length of usually very thick root end of stalk remains on the ground. No implement currently performs the desirable functions of removing plant stalks and then decimating those stalks into small bits for conversion to mulch. 
         [0007]    In addition to the above deficiencies, both the Amadas chopper and the disc puller (U.S. Pat. No. 4,779,684) cause an undesirable amount of soil disturbance, which especially in a conservation tillage system does not contribute to an acceptable seed bed preparation for following crops. Stalks are often partially buried creating problems with further field work. 
         [0008]    Thus, what is needed is an improved implement for the extraction and decimation of plant stalks such as cotton stalks that overcomes the limitations of the prior art. In particular, a need exists to pull cotton stalks from the root and then decimate these cotton stalks so that future field work can be completed without the obstacle of long and thick cotton stalks damaging equipment or inhibiting proper tillage and field preparation. 
       SUMMARY OF THE INVENTION 
       [0009]    The present implement for extraction and decimation of plant stalks operates to both extract plant stalks such as cotton stalks from the ground and shred these stalks into small pieces. Both above ground growth and below ground stem and root are pulled by two rubber track belts with interlocking protrusions that are powered by a hydraulic motor. The pair of track belts provides a puller unit that grasps the plant stalk, typically at the base of the plant, and holds the stalk as the machine moves forward. Multiple puller units are provided on the implement in accordance with the number of rows desired, usually between 4-8 rows. 
         [0010]    The implement operates in a combination of forward ripping of plant roots and lifting the plant stalks as the plant is conveyed rearward and elevated by the angle of the puller unit. The puller unit is angled higher to the rear of the implement to fully separate the plant from the ground. The track belts evenly convey the crop stalk mass to a flail shredding unit to reduce the plant stalk and root to small mulch type chips that are then distributed evenly across the working width of the machine to the soil surface. In doing away with the normal stalk and root stubble this greatly eliminates future problems associated with a line of sharp sticks that cause plugging of tillage equipment and damage such as premature wear of tires be it on tractors or transport wheels on implements. Also, when root matter is removed from the ground the problem with the plants re-growing is eliminated, which eliminates wintering habitat for soil pest; be it disease, insects or nematodes. 
         [0011]    The current implement improves removal of plant stalks by both removing and shredding the stalks from its root up, all in one pass. This size reduction of plant stalk material is greatly superior to the standard practice of rotary mowing, because it cuts all of the plant including the root into to small mulch like pieces. This process provides surface mulch that greatly reduces wind and water caused erosion and ultimately improves soil tilth and biology by providing a slow decaying surface covering of organic matter. Meanwhile, the present implement operates above the soil surface and does not disturb or molest the soil profile. The only soil movement is the narrow band where the root pulls up a minor amount of soil, unless the hardness or type of soil requires conditioning. Where desirable, such as heavier clay based soils, an optional plow may be used to loosen soil around the root of the plant prior to pulling. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  is a perspective view of an implement for extraction and decimation of plant stalks constructed in accordance with a embodiment of the invention having a puller section and a flail section. 
           [0013]      FIG. 2  is a top plan view of a puller section of the implement of  FIG. 1  including an embodiment of the puller units and puller drive assembly. 
           [0014]      FIG. 3  is a top plan view of a puller unit in accordance with the invention. 
           [0015]      FIG. 4  is a front plan view of a puller unit supported on the implement in accordance with an embodiment of the invention. 
           [0016]      FIG. 5  is a side plan view of a puller unit and puller drive assembly in accordance with the invention. 
           [0017]      FIG. 6  is a perspective view of a flail unit of the implement in accordance with an embodiment thereof. 
           [0018]      FIG. 7  is a perspective view of a flail used in the flail unit of  FIG. 6 . 
           [0019]      FIG. 8  is a perspective view of a flail rotor with flails attached in accordance with an embodiment thereof. 
           [0020]      FIG. 9  is a side plan cut-away view of the implement for extraction and decimation of plant stalks illustrating the method of operation in an embodiment thereof. 
           [0021]      FIG. 10  is a perspective view of a flail unit in an alternative embodiment having a curved hood. 
       
    
    
     DETAILED DESCRIPTION 
       [0022]    Referring now to the drawings, an implement  2  for the extraction and decimation of plant stalks is shown in  FIG. 1 . This agricultural implement  2  includes a PTO (power take-off) connecting shaft  100  and connects to a typical farm tractor. The implement has a puller section that extracts plant stalks such as cotton from the ground and has a flail section that decimates the stalks. The implement operates to clear a field of stalks after harvest, leaving only a decimated mulch of debris on the ground. 
         [0023]    The puller section of the implement includes a puller unit  10  for each row having a pair of track belts  12  to extract plant stalks from the ground. As a tractor pulls the implement, plant stalks enter the front of the downward sloping puller units  10 . The puller section includes a puller drive assembly  40  for driving the puller units  10 . After the stalks are extracted by the puller units  10 , the stalks exit the puller section into the flail section for decimation. 
         [0024]    The puller section, having a combination of a puller drive assembly  40  and puller units  10 , is shown in  FIG. 2 . The preferred implement will include multi-row puller units  10  according to the size of the implement desired. Four and six row implements are very popular, and the size of the implement may be expanded from two to four or more rows by adding additional puller units  10  and the necessary puller drive mechanics. In the exemplary embodiment of  FIG. 2 , the implement includes two puller units  10  for descriptive purposes. The puller units  10  connect to a hydraulic drive through the shafts shown, whereby each puller unit  10  includes a gearbox  60 ,  66  and shaft  64  for turning the track belts  12  on the puller units. 
         [0025]    The puller units  10  each include a pair of track belts  12  connected within the pulling unit in parallel interlocking relationship. The track belts  12  are supported on a support structure  26  including a belt drive sprocket  14  on one end and an idler wheel  28  on the opposing end of the support structure. Each belt drive sprocket  14  includes teeth. These teeth engage holes  16  in the respective track belt  12  to drive the track belt in a loop around the belt drive sprocket  14  and the idler wheel  28 . The combination of the teeth on the belt drive sprocket  14  and the holes  16  in the respective track belt  12  forms an operating roller track. 
         [0026]    Each of the track belts  12  includes a plurality of spaced track protrusions  24  along the outer surface of the track. These track protrusions  24  on each track belt  12  are arranged in opposing relationship for the parallel track belts  12  such that the track protrusions overlap each other by resting within the gaps between the opposing tracks protrusions to form the interlocking relationship of the pair track belts  12  in a puller unit  10 . The interlocking track protrusions  24  improve the grip of puller unit  10  on the crop material and convey the crop material along the track by gripping and moving the crop mass rearward and upward toward the flail unit in accordance with the mechanical angle and arrangement of the track belts  12 . The typical rubber track belt  12  that is provided in the invention will be about  7  inches in width and provide for gripping a substantial portion of the plant stalk for extraction thereof. 
         [0027]    In addition to the gripping proficiency of the track belts  12 , the upward elevation angle of the puller unit  10  as shown in  FIG. 1  and  FIG. 5  improves separation of the roots of crop mass or plant stalks from the ground. The angle may be fixed according to a preferred mode or may be adjustable. If adjustable, the angle of attack on the tracks will vary depending on the crop from 10 to 45 degree upward from entry to exit. The implement could be used in different ways for different crops. For instance, with the puller units  10  arranged at a lower and less steep angle of attack, the implement would be able to pull more deeply rooted crops such as cotton with a more gradual pulling action, providing more dragging than lifting. Whereas on a less deeply rooted crop such as vegetables planted on plastic mulch, a very steep angle in the puller unit  10  would promote pulling the plant more vertically and reduce the tearing of the plastic. 
         [0028]    In an alternative embodiment with adjustable puller units  10 , the angle of the puller units may be adjusted through hydraulic pumps connected to the support structure  26  to pivot and raise or lower the puller units. Thereby, the optimum height and angle of the puller unit  10  can be determined for a particular crop of plant stalks for optimum decimation. Of course, a fix angle may be provided that is optimized for most crop scenarios to reduce the complexity and cost of the implement. In addition, the length of the puller unit  10  may vary. The typical length of a desirable puller unit  10  will be approximately  36  inches from the entry end of the track belts  12  to the exit end where the crop mass is engaged by the flail unit, providing a 3 foot grip length for extraction and removal of plant stalks. 
         [0029]    The combination of the belt drive sprocket  14  and idler wheel  28  maintains each track belt  12  in sufficient tension for rotation of the track belt around the support structure  26 . The idler wheel  28  moves rearward on a slide track  30  to remove any excess slack between the idler wheel and the track belt  12 . A tension adjustment bolt  32  moves the idler wheel  28  to tighten and adjust the tension. Once the proper desired tension is achieved, then retention bolts  36  are tightened to retain the position of the idler wheel  28  within the plates  34  forming the portion of the support structure  26  that supports the idler wheel. In a preferred embodiment, the idler wheel  28  provides a smooth rolling surface on the back of the support structure for the track belt  12 , as opposed to the toothed belt drive sprocket  14  that operates to engage the track belt with force. 
         [0030]    The belt drive sprocket  14  for each track belt  12  is supported on the support structure  26  by a pair of support bearings  22   a,    22   b  providing top support bearing  22   a  and bottom support bearing  22   b.  A belt drive sprocket  14  shaft extends from each belt drive sprocket as shown in  FIG. 3 , and a pulling force is applied to the belt drive sprocket via a universal joint  20  connected to one of the belt drive sprockets on each puller unit  10  as shown in  FIG. 5 . Each respective puller unit  10  has a drive side of the unit in which the track belt&#39;s belt drive sprocket  14  is connected to a universal joint  20  connecting the belt drive sprocket&#39;s shaft to the puller drive assembly  40 . This side of the puller unit  10  connected to the drive assembly performs the mechanical operation of engaging the track belt  12  and driving the puller unit  10 . The remaining track belt  12  on the passive side will move with engagement by the interlocking track protrusions  24 . 
         [0031]    The universal joint  20  connects the belt drive sprocket shaft  18  to the puller drive assembly  40  via a bottom output shaft on a respective gearbox  60 ,  66 . Each puller unit  10  may have a separate gearbox output as shown in the exemplary embodiment of  FIG. 2 . The puller drive assembly  40  includes a hydraulic motor  42  for driving the puller units  10 . As shown in  FIG. 5 , the hydraulic motor  42  includes a motor shaft  44  with a motor sprocket  46  and connects to a front counter shaft  50  through a drive chain  48  and a front counter shaft sprocket  52 . A drive chain tensioner  54  is shown for governing the tension in the drive chain. 
         [0032]    A typical arrangement as shown includes a slip clutch  58  attached to the front counter shaft  50  that will momentarily disconnect power transmission to the front counter shaft  50  in the event the implement encounters an obstruction such as a root or rock that is pulled into a puller unit  10 . The slip clutch  58  helps to avoid damage to the track belts  12  or gearboxes in the case of an impassable object. Universal joints  56  connect the front counter shaft  50  to each three shaft gearbox  60 ,  66  to transfer power from the slip clutch  58  to each gearbox and respective puller unit  10 . As shown in the embodiment of  FIG. 2 , the front counter shaft  50  connects to the first row puller unit gearbox  60  by a universal joint  56  that is connected to a gearbox connecting shaft  64  extending from the side of the gearbox. The bottom output shaft  68  on the gearbox extends from the bottom of the gearbox and connects to the belt drive sprocket shaft  18  as discussed above. An additional gearbox connecting shaft may extend from the other side of the gearbox and connect to an additional length of the front counter shaft  50  by a universal joint  56 , and then the next second row puller unit gearbox  66  connected to the front counter shaft  50  in similar fashion using another universal joint  56 . This puller unit drive system is repeated with consecutive gearboxes connected along the length of the front counter shaft  50  in accordance with the number of rows and puller units  10 . 
         [0033]    Referring now to  FIGS. 6-10 , the flail shredder assembly includes a flail unit and drive system for flail unit. The flail unit  80  of the implement operates to receive the pulled plant stalks as discussed and shred them as shown in  FIG. 9 . The flail unit  80  may be operated by connection to a tractor&#39;s PTO. The connection of the implement to the tractor PTO includes a drive shaft  100  for driving a flail unit  80  situated behind the puller section of the implement. The drive shaft is connected through a center mounted drive gearbox  106  to a pulley system that includes a drive pulley  102  that pulls a multiple groove drive belt  104  connected to a flail shredder assembly of the flail unit  80 . The drive belt  104  connects via a flail rotor pulley  82  on a flail rotor shaft  84  in the flail unit  80 . A tensioner  108  operates to control tension in the drive belt  104  and ensure proper operation. The flail rotor shaft  84  operates at high speed causing flail knives  86  to cut sections of plant stalk entering the flail unit  80 . Said shaft may rotate at speeds of 2000 rpm or more causing the tips of the flail blades to move at a speed of 160 mph or more. The cutting of stalks at such high speed decimates the stalks into very small pieces. 
         [0034]    The flail knives  86  are “L” shaped and combined in pairs for connection to the flail rotor  90  as shown in  FIG. 8 . The pair of flail knives  86  forms a “Y” shaped flail  88  or an inverted “Y” when hanging downward from a bracket. Each flail  88  is pivotally connected to flail rotor  90  by a bracket extending from the flail rotor as shown in  FIG. 7 . The flail rotor  90  is rotated by the flail rotor shaft  84  to spin at high speed, which causes the pivotally connected flails  88  to whip outward from centrifugal force as the rotor turns. The blades of the flails  88  are extended but pivotally mobile and provide a resilient cutting edge. The flail rotor  90  rotates clockwise such that the flails  88  move from the bottom forward to churn plant stalk further into flail unit  80 . 
         [0035]    A flail hood  92  of the flail shredder assembly covers the flail unit  80  as shown in  FIG. 6  and keeps stalks in the flail unit during the cutting phase from decimation and also protects the flails  88 . The flail hood  92  may be arranged to maximize shredding by adjusting the tolerance between the hood and the flails and also by adjusting or changing the shape and structure of the hood. For example, a flat flail hood  92  may be provided as shown in  FIG. 6  for a simple and economical hood. Alternatively, a curved flail hood  92  as shown in  FIG. 10  with less distance between the flails  88  and bottom surface of the hood may be provided for improved operation or aesthetic appearance. In one particular embodiment the entrance clearance between the flails  88  and the flail hood  92  may be reduced to 1.9 inches and the exit clearance between the flails and the hood may be reduced to 1.1 inches. These tolerances may maximize the effectiveness of the flails  88  within a curved flail hood  92 . The actual tolerances and hood structure may be adjusted further through experimentation and according to the type of plant stalk being decimated.