Patent Document

The present invention relates to a system and method for mechanically terminating cover crops. Specifically, the current invention relates to a powered rolling and crimping device designed to roll over and crimp crops. 
     BACKGROUND OF THE INVENTION 
     Cover crops are an important part of most no-till soil conservation systems, but they must to be managed correctly to fully realize their potential benefits. Among other things, these benefits include a reduction in soil erosion and the suppression of weed pressure. 
     At the end of a selected cover crop-growing cycle, the cover crops are terminated so that a selected newly planted crop can emerge and thrive. Termination of the cover crop allows the new selected crops to fully benefit from the soil conditioning properties of the terminated cover crops without competing with the cover crops for water and nutrients. 
     In the past, herbicides were the preferred means of terminating cover crops,  primarily because the herbicide application process is relatively fast and effective. Although herbicide application effectively kills the cover crops, there may be problems associated with unintended over-spray, spray drift, and undesirable chemical run-off. The herbicides also leave the cover crop stalks in tact. The stalks and associated crop residue subsequently interfere with the planting process associated with the new crops, particularly for cover crops (such as rye) that generate a large amount of biomass. Further, the use of herbicides is prohibited for farmers that intend to market their corps as “organically grown”. 
     Rolling and crimping devices have been developed to destroy and mulch the cover crops and thereby address these issues. These devices generally require large conventional tractors to tow the rollers and/or crimpers across the cover crops. However, these large tractors are not practical for small-scale organic framers (particularly vegetable farmers) who could benefit from the use of no-till soil conservation practices. 
     The need exists for a roller/crimper system compatible with smaller scale organic farming operations. The current invention provides a rolling and crimping device that is designed to work with the small, inexpensive walk-behind garden tractors that are popular with small-scale organic farmers. 
     SUMMARY OF THE INVENTION 
     The current invention is directed to a powered rolling and crimpling device. The device comprises a power source that provides power to a lifting assembly. In the preferred embodiment, power is provided by the power takeoff portion of a conventional walk-behind type garden tractor and the lifting assembly comprises a cam assembly. A crimping bar is connected to the lifting assembly so that the cam assembly controls the crimping bar. The powered rolling and crimping device also includes a crop roller that precedes the crimping bar during the crimping and rolling process. 
     In operation, as the rolling and crimping device is propelled across a field of cover crops, the crop roller rolls over the crops and the crimping bar crimps the crops, thereby terminating the cover crops and preparing the field for planting the next cycle of crops. 
     The current invention also includes a method of terminating cover crops. The method includes providing a power source and transferring torque from the power source to a gearbox on a crop rolling and crimping device. The torque is then directed from the gearbox to a plurality of cam mechanisms that are connected to a crimping bar. A crop roller is positioned in front of the crimping bar. The crops are terminated by propelling the crop rolling and crimping device across a field of crops so that the crop roller rolls over the crops and the crimping bar crimps the crops, thereby terminating the crops and preparing the crop field for planting the next cycle of crops. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a top perspective view current invention. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     The powered rolling and crimping device PRC of current invention is generally shown in  FIG. 1 . In the preferred embodiment, the powered roller/crimper PRC is designed to be attached to and pulled by a conventional walk-behind tractor. Typical examples of these types of tractors are manufactured by DR, Troy-Built, and BCS. For the purposes of the current invention, a walk-behind tractor is a tractor that does not accommodate a riding operator so that the operator walks behind the tractor and guides the tractor with a linkage that may include handlebars, hand grips, or the like. 
     In the preferred embodiment, the tractor power takeoff extends rearward from the back of the tractor so that the powered rolling and crimping device PRC engages the power takeoff and is towed behind the tractor in a “tow configuration”.  FIG. 1  shows the PRC device in the tow configuration. However, in alternative embodiments, the tractor power takeoff may extend forward from the front of the tractor so that the current invention also has a front-mounted “push configuration”. In the push configuration the PRC device extends out in front of the tractor so that the tractor pushes the PRC device. The push configuration enables an operator to access corners and tight spots that would otherwise be inaccessible. 
     As generally shown in  FIG. 1 , the powered rolling and crimping device PRC comprises a linkage assembly  10 . The linkage assembly  10  includes a mounting plate  12  and a base connecting member  14  as well as a drive shaft  16  with a flexible coupler  17 . The linkage assembly  10  also includes a dynamic stabilizing device  11  and a vertical stabilizing member  13 . 
     As shown in  FIG. 1 , the mounting plate  12  bolts to a power takeoff housing of a tractor. A drive shaft stabilizer flange  18  bolts to the mounting plate  12 . The drive shaft  16  extends through the mounting plate  12  and stabilizer flange  18 , and meshes with the splines of the tractor power takeoff shaft. The dynamic stabilizer device  11  has a first end that is connected to the tractor and a second end connected to the vertical stabilizing member  13 . A mounting bracket  15  for auxiliary wheels extends rearward from the vertical stabilizer. The auxiliary wheels enable a user to more easily maneuver the PRC device for transportation and storage. In the preferred embodiment, the dynamic stabilizer device  11  is a shock absorber that further stabilizes the PRC device and relieves stress on the tractor power takeoff assembly and drive shaft  16 . 
     The linkage assembly  10  is connected to a roller assembly  20 . The roller assembly  20  comprises the crop roller frame support member  22 , endplates  24 , and a crop roller  26 . The linkage assembly  10  base connecting member  14  extends to the roller assembly  20  crop roller frame support member  22 . In the preferred embodiment, an axle (not shown) extends from each end of the crop roller  26 . End portions of the axle nest in a bearing assembly on the inner side of each of the end plates  24  so that the axle turns in the bearing assemblies. 
     In the preferred embodiment, the crop roller component  26  comprises a smooth cylindrical roller. In alternative embodiments, the cylindrical roller  26  may include straight or angular projections that crimp the crops as the roller  26  is towed behind the tractor. In further alternative embodiments a plurality of crop rollers  26  may be incorporated into a single powered rolling and crimping device PRC. 
     In the preferred embodiment, the base connecting member  14  extends further away from the tractor to a crimping assembly  30 . the crimping assembly  30  primarily comprises a stationary support beam  32  and a movable crimping bar  34 . The crimping assembly  30  stationary support beam  32  is connected to the crop roller frame support member  22  by the base connecting member  14  and a plurality of horizontally extending stabilizers  28 . The stationary support beam  32  is also connected to the vertical stabilizing member  13 . A pair of vertically oriented crimping member control rods  36  extend through the stationary support beam  32  to the crimping bar  34 . A helical compression spring  38  encircles each of the crimping member control rods  36  and maintains the crimping bar  34  in the extended position. 
     The crimping bar  34  is raised and lowered by a crimping bar lifting assembly  40 . In the preferred embodiment, the crimping bar lifting assembly  40  essentially comprises a gearbox  42 , a pair of output power shafts  44 , and at least one cam lobe  48  mounted on each output power shaft  44 . The gearbox  42  is mounted on the aft portion of the base connecting member  14 . The gearbox  42  receives input torque from the driveshaft  16  and distributes the torque to the two output power shafts  44  that extend latterly from the gearbox  42 . The output power shafts  44  are secured and supported by a plurality of shaft support flanges  46 . The shaft support flanges  46  are mounted on the horizontal stabilizers  28  that connect the crop roller base frame member  22  with the stationary support beam  32 . 
     A cam lobe  48  is attached to each output power shaft  44  between two of the respective shaft support flanges  46 . As the output power shafts  44  rotate, the periphery of the cam lobes  48  engages cam followers  50  that extend horizontally from a top portion of each of the crimping bar control rods  36 . As each cam lobe  48  rotates, the associated cam follower  50  travels upwardly along the periphery of the ramp portion of the cam lobe  48 . 
     When the cam followers  50  reach the nose portion of the respective cam lobes  48 , the crimping bar  34  is in the fully raised position and the helical compression springs  38  are fully compressed. As the cam followers  50  pass over the nose portion of associated the cam lobes  48 , the helical compression springs  38  drive the crimping bar  34  downwardly so that the crimping bar  34  crimps the target cover crops. As the output power shafts  44  and associated cam lobes  48  continue to rotate, the cycle repeats itself as the cam followers  50  once again travel upwardly along the ramp portion of each of the respective cam lobes  48 . 
     As discussed supra, the current invention also includes an alternative embodiment (i.e. a push configuration) wherein the PRC device is disposed in front of the walk-behind tractor so that the tractor pushes the PRC device. In the alternative embodiment, the gearbox  42  and linkage assembly  10  are rotated 180 degrees to extend rearward and the vertical stabilizing member  13  is relocated to avoid interference with the linkage assembly  10 . Other aspects of the invention are essentially unaffected by the modification. 
     In operation, the mounting plate  12  is bolted to the tractor power takeoff housing so that the tractor power takeoff engages the drive shaft  16 . The drive shaft  16  provides input power to the gearbox  42 . The gearbox  42  rotates laterally extending power output shafts  44 . Cam lobes  48  mounted on the power output shafts  44  engage corresponding cam followers  50 . The cam followers  50  are attached to crimping bar control rods  36  that essentially raise and release a crimping bar  34 . 
     As the tractor propels the powered rolling and crimping device across a field, targeted cover crops are first flattened by the crop roller  26  and then crimped by the crimping bar  34 . The combination of the rolling and crimping action of the powered roller crimper PRC destroys the cover crop without cutting or uprooting the cover crop stalks. 
     In the preferred embodiment, the number of crimping cycles per unit of time is a direct function of tractor power takeoff rotary speed (for example power takeoff revolutions per minute (rpm)). At a constant power takeoff rpm, if a user increases the ground speed that the device is propelled across a field, the number of crimping cycles per linear foot is decreased. If the user decreases his speed, the number of crimping cycles per linear foot is increased. This arrangement allows a user to vary his horizontal travel speed to apply more crimping cycles to areas of a filed in which cover crop growth has the greatest density. A change in the gearing of a tractor power takeoff transmission (if equipped with a transmission) will increase or decrease the crimping rate by increasing or decreasing the power takeoff rpm. 
     In alternative embodiments, the power takeoff transmission may receive input from the tractor wheels so that the PRC device delivers (for example) a specified number of crimping cycles per linear foot of travel. In further alternative embodiments, the PRC gearbox  42  may be modified so that the gearbox  42  comprises a selectable-speed transmission. In this embodiment, the PRC device crimping revolutions are selectable by a user independent of the tractor power takeoff rpm. 
     For the foregoing reasons, it is clear that the current invention provides an innovative means of destroying a cover crop. The invention may be modified in multiple ways and applied in various technological applications. The current invention may be customized as required by a specific operation or application, and the individual components may be modified and defined, as required, to achieve the desired result. 
     For example, although the preferred embodiment is intended for use with a walk-behind tractor, in alternative embodiments the scale of the components may be increased or decreased. An implement with the design described herein may be used with other types of powered devices including conventional riding-type farm tractors as well as devices that would not conventionally be considered to be “tractors”. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to included within the scope of the following claims.

Technology Category: 1