U.S. patent application number 11/096242 was filed with the patent office on 2006-05-18 for sod handler.
Invention is credited to Donald Tvetene, Gregg Tvetene, Michael Tvetene.
Application Number | 20060102363 11/096242 |
Document ID | / |
Family ID | 35691426 |
Filed Date | 2006-05-18 |
United States Patent
Application |
20060102363 |
Kind Code |
A1 |
Tvetene; Michael ; et
al. |
May 18, 2006 |
Sod handler
Abstract
A sod handling method and a sod handling apparatus, in one
embodiment the sod handling apparatus uses a pressure differential
to hold a sod slab during sod transfer, other embodiments include a
sod lift member for lifting sod, a sod transport mechanism for
moving sod; a sod carriage for transporting sod, a sod bed
positioning system for stacking sod, a system and method for
checking sod quality as well as an apparatus and method of machine
stacking sod to maintain the integrity of a sod stack.
Inventors: |
Tvetene; Michael; (South
Billings, MT) ; Tvetene; Donald; (Billings, MT)
; Tvetene; Gregg; (Billings, MT) |
Correspondence
Address: |
Carl L. Johnson;Jacobson and Johnson
Suite 285
One West Water Street
St. Paul
MN
55107-2080
US
|
Family ID: |
35691426 |
Appl. No.: |
11/096242 |
Filed: |
March 30, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60628053 |
Nov 15, 2004 |
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|
Current U.S.
Class: |
172/20 |
Current CPC
Class: |
A01G 20/15 20180201 |
Class at
Publication: |
172/020 |
International
Class: |
A01B 45/04 20060101
A01B045/04 |
Claims
1. A method of handling a sod slab in a sod harvester comprising:
placing a suction housing over a sod slab; generating a pressure
differential across the sod slab to support the sod slab proximate
the suction housing; and transporting the sod slab to a different
location while the sod slab is supported by the suction
housing.
2. The method of claim 1 including elevating the sod slab toward an
underside of said suction housing.
3. The method of claim 1 including elevating the sod slab from a
moving conveyor.
4. The method of claim 1 including transporting the sod slab to a
position beneath the suction housing and then bringing the sod slab
and the suction housing proximate each other to thereby generate
the pressure differential across the sod slab.
5. The method of claim 4 including the step of lifting the sod slab
from a sod conveyor to bring the sod slab proximate the suction
housing.
6. The method of claim 5 of including the step of lifting the sod
slab from the sod conveyor without stopping the conveyor.
7. The method of claim 6 including the step of reducing the suction
pressure to release the sod slab from the suction housing.
8. The method of claim 7 including the step of lifting a second sod
slab from the conveyor.
9. The method of claim 8 including the step of placing the second
sod slab proximate the sod slab.
10. A method of handling a sod slab comprising: generating a
pressure differential across a sod slab sufficient to support the
sod slab; and releasing the sod slab by reducing the pressure
differential across the sod slab.
11. The method of claim 10 including the step of transporting the
sod slab from a first location to a second location before
releasing the sod slab.
12. The method of claim 10 including the step of generating the
pressure differential across the sod slab by bringing a source of
suction pressure proximate a top side of the sod slab.
13. The method of claim 11 including the step of lifting and
transporting a further sod slab to a third location proximate said
second location by generating a pressure differential across the
further sod slab.
14. A method of transferring a sod slab from a first location to a
second location comprising: generating a pressure differential
across a sod slab; and moving the sod slab while supporting the sod
slab with the pressure differential across the sod slab.
15. The method of claim 14 including the step of forming the sod
slab into a sod roll before generating the pressure differential
across the sod slab.
16. The method of claim 14 wherein the step of generating the
pressure differential includes drawing air through the sod
slab.
17. The method of claim 15 including the step of generating the
pressure differential across the sod slab while the sod slab is
transferred in a sod harvester.
18. A sod harvester comprising: a sod cutting mechanism; a sod
conveyor; and a suction housing, said suction housing positionable
with respect to a sod slab so as to create a pressure differential
across the sod slab to thereby enable the pressure differential to
support the sod slab proximate the suction housing.
19. The sod harvester of claim 18 including a bump bed for bringing
the suction housing proximate the sod slab.
20. The sod harvester of claim 18 including a conveyor for
positioning the sod slab beneath the suction housing.
21. The sod harvester of claim 18 including at least two suction
housings for transferring sod slabs in said sod harvester.
22. The sod harvester of claim 18 including a track on said sod
harvest for supporting said suction housing to permit movement of
said suction housing from a sod pickup position to a sod drop-off
position.
23. The sod harvester of claim 22 including a drive member for
positioning said suction housing on said track.
24. The sod harvester of claim 18 including a sod pallet for
transporting the sod slab to a work site.
25. The sod harvester of claim 18 including a positioning system
for maintaining a distance from a top of the sod slab to a
reference by lowering a pallet as the sod slab is stacked on the
pallet.
26. The sod harvester of claim 18 including a suction pump located
on said sod harvester.
27. The sod harvester of claim 26 including a flexible hose for
connecting said suction housing to said suction pump to enable
positioning of said suction housing.
28. The sod harvester of claim 18 wherein the sod housing includes
a flat lift plate thereunder having a set of spaced apart apertures
therein.
29. The sod harvester of claim 18 wherein the sod harvester
includes a curved lift plate for lifting a sod slab in a
cylindrical condition.
30. The sod harvester of claim 18 wherein the sod conveyor
comprises a set of rotateable members with a bump bed extending
between the set of rotateable members to enable a sod slab to be
lifted from the sod conveyor without engaging the sod conveyor.
31. The sod transfer system of claim 45 including: a sod harvester
having a sod cutting mechanism.
32. The apparatus of claim 63 including: a sod harvester having a
sod cutting mechanism.
33. A sod harvester comprising: a sod cutting mechanism; a sod
pickup hood; a sod quality sensor located prior to said sod pickup
hood to determine whether a sod slab is in a stackable condition,
said sod quality sensor suppressing sod pickup if the sod slab is
not in a stackable condition.
34. The machine stacking apparatus of claim 88 including: a sod
harvester having a sod cutting mechanism.
35. A sod transfer lift mechanism comprising: a suction source; a
sod lift plate; a housing secured to said sod lift plate, said
housing connected to said suction source so that as ambient air is
drawn through the sod lift plate and into the housing a low
pressure region is produced above a sod slab with the pressure
sufficiently low so as to create a pressure differential across the
sod slab to enable the housing to lift and transport the sod slab
from one location to another solely through the use of the pressure
differential across the sod slab.
36. The sod transfer lift mechanism of claim 35 including a base
for rotatable supporting the housing.
37. The sod transfer lift mechanism of claim 35 wherein the sod
lift plate comprises a flat surface.
38. The sod transfer lift mechanism of claim 35 wherein the sod
lift plate has a plurality of spaced apart fluid inlet ports
therein.
39. The sod transfer lift mechanism of claim 35 wherein the sod
lift plate has a shape substantially equal to the shape of the sod
slab carried thereon.
40. The sod transfer lift mechanism of claim 35 wherein the sod
lift plate has a cylindrical shape for engaging a sod slab in a
rolled condition.
41. The sod transfer lift mechanism of claim 35 wherein the sod
slab has an underside of soil and a top side of blades of
grass.
42. The sod transfer lift mechanism of claim 35 including a
flexible hose connecting the sod lift plate to the suction source
to permit transfer of the sod slab from one position to
another.
43. A sod transporting apparatus comprising: a housing; a suction
pump; a hood in fluid communication with said suction pump; a base
plate having a set of fluid ports therein so that when a sod slab
is positioned beneath said hood an air pressure differential
generated across the sod slab by said suction pump is sufficient to
hold the sod slab as the sod slab is transported.
44. The sod transporting apparatus of claim 43 including a
rotatable mount for said hood to thereby rotationally position said
hood.
45. A sod transfer system comprising: a conveyor; a bump bed, said
bump bed normally positioned below said conveyor; and a lift
mechanism for elevating said bump bed above said conveyor to
thereby lift a sod slab thereon free of said conveyor.
46. The sod transfer system of claim 45 wherein the conveyor
comprises a set of spaced apart conveyor belts and the bump bed is
positioned between the set of spaced apart conveyor belts.
47. The sod transfer system of claim 45 wherein the lift mechanism
includes a slider positioned between a pair of slider blocks to
direct the slider along a lift axis.
48. The sod transfer system of claim 45 wherein the lift mechanism
includes a drive shaft rotatable in a first direction to lift a sod
slab from the conveyer and rotatable in an opposite direction to
lift a further sod slab from the conveyor.
49. The sod transfer system of claim 45 wherein the bump bed
includes a rail with beveled ends.
50. The sod transfer system of claim 45 wherein the conveyor moves
in a first direction and the bump bed moves in a direction
transvere to the first direction to thereby elevate the sod slab
therefrom.
51. The sod transfer system of claim 45 wherein the conveyor
includes three spaced apart conveyor belts and the bump bed
includes a first set of rails positioned between an adjacent two of
the three conveyer belts and a second set of rails positioned
between a further adjacent two of the three conveyor belts.
52. The method of sod transfer comprising carrying a sod slab in a
first direction and while the sod slab is being carried in the
first direction terminating the carrying by elevating the sod in a
second direction transverse to the first direction by lifting the
sod slab from an underside of the sod slab.
53. The method of sod transfer of claim 52 where the sod slab is
moved from a first direction to a second direction while the sod
slab is being moved in the first direction.
54. The method of sod transfer of claim 52 including imparting
sufficient momentum to the underside of the sod slab to throw the
sod slab upward from the bump bed.
55. The method of sod transfer of claim 52 including the step of
retracting the bump bed to enable a further slab of sod to carried
into a lift position proximate the bump bed.
56. The method of stacking sod for transport comprising the steps
of: placing a first layer of sod slabs in a side-to-side position
on a pallet to form a first layer of sod slabs; and placing a
second layer of sod slabs in a side-to-side position on top of the
first layer of sod slabs with the second layer of sod slabs
laterally offset from the first layer of sod slabs to thereby
inhibit shifting the first layer of sod slab with respect to second
layer of sod slabs.
57. The method of machine stacking sod of claim 56 including the
step of continuing to laterally offset a further layer of sod with
the further layer of sod slabs laterally offset in a direction
opposite from the first layer of sod slabs.
58. The method of machine stacking sod of claim 56 including the
step of continuing to laterally offset an additional layer of sod
by laterally offsetting the additional layer of sod in a direction
normal to the first layer of sod slabs.
59. The method of machine stacking sod of claim 56 wherein the
placing a first layer of sod comprises lifting a sod slab with a
suction housing and dropping the sod slab by releasing a suction
pressure on the sod slab.
60. The method of machine stacking sod of claim 56 including
laterally displaying the suction housing in a first direction and
then laterally displacing the suction housing a second direction
before releasing suction pressure on the sod slab.
61. The method of machine stacking sod of claim 56 including the
step of laterally displaying the suction housing before placing a
third layer of sod slabs.
62. The method of claim 56 wherein the method of sod stacking
comprising machine stacking of the sod slabs.
63. An apparatus for maintaining a sod drop distance in a sod
harvester comprising; a bed for supporting a stack of sod; a
positionable member for raising and lowering the bed; a sensor
positioned above said bed said sensor determine the distance to a
top of said bed; and a processor for sending a signal to displace
the bed to thereby maintain the sod drop distance.
64. The apparatus for maintaining the sod drop distance of claim 63
wherein the bed includes a pallet and the sensor comprises an
acoustical sensor.
65. The apparatus for maintaining the sod drop distance of claim 63
including a hydraulic cylinder for raising or lowering the bed in
response to a signal from the processor.
66. The apparatus for maintaining the sod drop distance of claim 63
wherein the positionable member includes a hydraulic cylinder
having an extendible ram with a pulley thereon for engaging a
flexible member having a first end connected to a frame and a
second end attached to the positionable member.
67. The apparatus for maintaining the sod drop distance of claim 63
wherein the sod bed cantilevers outward to receive a sod pallet
thereon.
68. The method of maintaining a top of a sod bed with a suitable
sod drop range comprising; measuring a distance from a top of the
sod slab to a reference; and displacing the sod bed in response to
the measured distance to maintain the top of the sod bed within the
suitable sod drop range.
69. The method of claim 68 including the step of measuring the
distance from the top of the sod slab with a sonic transducer.
70. The method of claim 68 including the step of lowering the sod
bed by extending or contracting an extendible ram on an hydraulic
cylinder.
71. The method of claim 68 including the step of maintaining the
sod bed in a horizontal condition to permit sod slabs to be dropped
thereon.
72. The method of claim 68 including lowering a pallet on sod bed
to the ground to allow the frictional forces between the sod pallet
and the ground to pull the pallet free of the a pallet lift
arm.
73. A method of claim 68 including the stacking of sod slabs in a
sod harvester.
74. A sod transfer mechanism comprising; a track; a carriage
displaceable along said track; a sod holding apparatus secured to
said carriage a cable, said cable secured to said carriage; a
rotatable cable drum for winding said cable thereon to thereby
displace said carriage secured to said cable to thereby permit a
transport of a sod slab supported by said sod holding apparatus
from a first location to a second location.
75. The sod transfer mechanism of claim 74 wherein the sod holding
apparatus includes a suction housing.
76. The sod transfer mechanism of claim 74 wherein the track
comprises a set of parallel rails and said sod holding apparatus
comprises a carriage having a set of wheels for rolling supporting
said sod holding apparatus thereon.
77. The sod transfer mechanism of claim 74 including a displacement
mechanism for laterally shifting said track.
78. A method of transferring sod from a first location to a second
location comprising; securing a sod slab to a carriage; moving the
carriage with the sod slab to a different location along a track;
stopping the carriage; and releasing the sod slab from the
carriage.
79. The method of claim 78 wherein the sod slab is secured to an
underside of the carriage by a pressure differential across the sod
slab.
80. The method of transferring sod of claim 78 wherein the carriage
is moved from the first location to the second location by winding
a cable around a cable drum.
81. The method of transferring sod of claim 78 wherein the carriage
is maintained on the track by a set of rollers.
82. The method of transferring sod of claim 78 wherein the track is
shifted laterally prior to releasing the sod slab from the
carriage.
83. The method of maintaining sod stack quality during a cutting
and stacking process in a sod harvester comprising; cutting a sod
slab; directing the sod slab proximate a sod quality sensor; and
removed the sod slab from a stacking process if the sod slab has a
discontinuous surface.
84. The method of claim 83 wherein the sod quality sensor comprises
an acoustic sensor that measures the distance from a top surface of
the sod slab to the sod quality sensor.
85. The method of claim 83 where the length of time that the sod
slab is proximate a sod quality sensor is compared to the length of
time a sod slab in stackable condition would be proximate the sod
quality sensor and rejecting the sod slab if the length of time of
the sod slab is below the length of time the sod slab in stackable
condition would be proximate the sod quality sensor
86. The method of claim 83 wherein a signal is sent to a sod lift
mechanism to stack the sod slab.
87. The method of claim 85 wherein the step of directing a sod slab
beneath a sod quality sensor comprises carrying the sod slab on a
conveyor and the step of rejecting the sod slab from the stacking
process comprises allowing the sod slab to fall off an end of the
conveyor by suppressing a signal to the sod lift mechanism to stack
the sod slab.
88. A machine stacking apparatus comprising: a sod pickup member
for transporting a sod slab along a first axis, said sod pickup
member controllable to deposit a sod slab at specified locations
along said first axis; and a slide for supporting said sod pickup
member, said slide laterally displaceable with respect to the first
axis to thereby enable the sod pickup member to deposit a further
sod slab along a second axis with the second axis laterally offset
of the first axis.
89. The machine stacking apparatus of claim 88 including at least
two sod pickup members supported by said slide.
90. The machine stacking apparatus of claim 88 including a stop for
preventing said slide from being displaced with respect to a
frame.
91. The machine stacking apparatus of claim 88 wherein the sod
pickup member includes a cable drive.
92. The machine stacking apparatus of claim 88 wherein the sod
pickup member includes a suction hood for holding said slab.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from provisional patent
application titled Sod Transfer Mechanism Ser. No. 60/628,053 filed
Nov. 15, 2004.
FIELD OF THE INVENTION
[0002] This invention relates generally to sod harvesting, and more
specifically, to a sod harvester, a sod transfer mechanism, a sod
lift mechanism, a sod transfer mechanism, a sod bed positioning
system, a sod quality monitor, with the method including a method
of transferring sod using a pressure differential to support a sod
slab and a method of machine stacking sod slabs.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0003] None
REFERENCE TO A MICROFICHE APPENDIX
[0004] None
BACKGROUND OF THE INVENTION
[0005] The use of a sod harvesting machine to cut slabs of sod from
a sod field and then prepare the sod slabs for transport to a work
site is known in the art. Once the sod slab is at the work site the
sod slabs are laid down on top of the soil to enable the grass in
the sod to take root in the soil. The use of sod handling machines
is also known in the art. One way of handling the sod after the sod
slab is cut from the field is to roll the sod slab into a
cylindrical sod roll. One can then transport the sod to the work
site where the sod is unrolled as the sod is laid down at the work
site. Examples of sod handling apparatus are shown in our U.S. Pat.
Nos. 6,783,318; 6,681,864; 6,364,027; and 6,296,063 which I hereby
incorporated by reference.
[0006] Another way of handling a cut sod slab is to leave the sod
slab in a flat or unrolled condition and pile the sod slabs on a
pallet and then transfer the pallet with the sod slabs to a work
site where the sod slabs are removed from a pallet and laid on the
top soil.
[0007] Whether the sod slabs are rolled or left in a flat condition
the sod slabs need to be transferred from one location to another
location without destroying the integrity of the sod slabs.
[0008] One of the difficulties with handling sod slabs in an
unrolled condition is that it is sometimes more difficult to
transfer an unrolled or flat sod slab as opposed to a compact sod
roll since the integrity of sod slab is affected by numerous
factors including the type and amount of grass roots in the soil,
the adherence of soil particles to each other and the adherence of
the soil particles to the grass roots in the sod slab. In general
care must be taken to ensure that integrity of the unrolled sod
slab remains intact during the transport so that the sod slab can
be laid down at the work site.
[0009] One method for lifting unrolled sod slabs uses a set of
clamps that grasp the blades of grasses to transfer the sod slab in
an unrolled condition. Such a device is shown in U.S. Patent
application Publication U.S. 2005/0000704. In some cases it may be
preferable to roll a sod slab into a cylindrical sod roll as the
roll geometry increases the integrity of the sod for handling as
well as allowing hooks or the like for piercing the sod roll to
enable one to lift the sod roll. However, if the hooks are not
properly applied to a roll of sod the sod roll can unwind or the
sod can tear making it difficult to handle. Thus both methods of
handling sod slabs either in a rolled condition or an unrolled
condition are known in the art.
[0010] In contrast to the prior art devices and methods of moving
sod the present invention includes a sod lift mechanism that
enables one to lift and transport a sod slab from the sod field to
the work site whether the sod slab is in a flat condition or in a
rolled condition while maintaining the integrity of the sod slab.
The various embodiments of the sod handling apparatus described
herein include an apparatus for holding sod with a pressure
differential across the sod slab, a sod transport mechanism; a sod
carriage, a sod bed positioning system, a bump bed for lifting sod
from a conveyor as well as use of such sod handling apparatus in
sod machines such as sod harvesters. In addition the inventions
include novel methods with one method including a method of machine
stacking sod to maintain the integrity of a sod stack. The
embodiments for transferring sod are shown and described with
respect to a sod harvester although each of the various embodiments
of the sod handling apparatus shown and described can be used in
equipment other than sod harvesters.
SUMMARY OF THE INVENTION
[0011] Briefly, the invention includes a sod handling method and a
sod handling apparatus. In one embodiment the sod handling
apparatus uses a pressure differential to hold a sod slab during
sod transfer, other embodiments include a sod lift member for
lifting sod, a sod transport mechanism for moving sod; a sod
carriage for transporting sod, a sod bed positioning system for
stacking sod, a system and method for checking sod quality as well
as an apparatus and method of machine stacking sod to maintain the
integrity of a sod stack with each of the sod handling apparatus
useable in a sod harvester.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a side view of a sod harvester for cutting and
stacking sod slabs for delivery to a work site;
[0013] FIG. 1A is a top view of the sod transport mechanism of the
sod harvester of FIG. 1;
[0014] FIG. 2 is a partial side view of the sod harvester of FIG. 1
showing a sod slab being elevated to a suction housing for
transport of the sod slab to a pallet;
[0015] FIG. 3 is a partial side view of the sod harvester of FIG. 1
showing a further sod slab being elevated to a suction housing for
transport of the sod slab to a pallet;
[0016] FIG. 4 is a top view of the sod slab transport mechanism of
FIG. 2;
[0017] FIG. 4A is a perspective view of a sod carriage;
[0018] FIG. 4B is a partial cutaway view of the suction hood
showing a butterfly shutoff valve in the open condition;
[0019] FIG. 4C is a partial cutaway view of the suction hood
showing a butterfly shutoff valve in the closed condition;
[0020] FIG. 4D is an isolated view of the cable drive mechanism
including the cable drum for displacing the sod carriage;
[0021] FIG. 5 is a rear view of the sod slab transport mechanism of
FIG. 2;
[0022] FIG. 5A is an isolated top view of the carriage displacement
mechanism;
[0023] FIG. 5B is a side view of the carriage displacement
mechanism sliding supported by the sod harvester frame;
[0024] FIG. 5C is a partial front view of the carriage displacement
mechanism in a first position;
[0025] FIG. 5D is the partial front view of the carriage
displacement mechanism of FIG. 5C in a second position;
[0026] FIG. 5E is a partial sectional view showing the sliding
relation ship between the carriage displacement mechanism and the
frame;
[0027] FIG. 6 is a rear view of the sod slab transport mechanism in
the sod lifting condition;
[0028] FIG. 6A is a partial side view of the bump bed in the
retracted condition;
[0029] FIG. 6B shows the bump bed of FIG. 6A in the sod lifting
condition;
[0030] FIG. 6c shows the bump bed of FIG. 6A in the retracted
condition;
[0031] FIG. 7 is a rear view of the sod slab transport mechanism
depositing a sod slab onto a pallet;
[0032] FIG. 8 is a rear view of the sod slab transport mechanism
depositing a second sod slab onto a different position on a
pallet;
[0033] FIG. 9 is a rear view of the sod slab transport mechanism
depositing a third sod slab onto a further position on a
pallet;
[0034] FIG. 10 is a rear view of the sod slab transport mechanism
with the pallet moving downward in response to the slabs of sod on
the pallet to enable a further layer of sod slabs to be stacked on
top of the sod slabs on the pallet;
[0035] FIG. 10A is an isolated partial view of the sod bed
positioning system for maintaining a drop distance;
[0036] FIG. 11 is a side view of a pressure lift device comprising
a suction housing positioned over a sod slab;
[0037] FIG. 12 is a side view of the pressure lift device of FIG.
11 holding a sod slab on the underside of the suction housing;
[0038] FIG. 13 is a bottom view of the lift plate shown a plurality
of holes or fluid ports therein for flow of air therethrough;
[0039] FIG. 14 is a top view of a system for transferring sod with
a pivotable pressure lift;
[0040] FIG. 15 is a side view of an alternate embodiment of a
suction housing having a curved lift plate about to engage a sod
slab in a roll form;
[0041] FIG. 16 is a side view of the suction housing of FIG. 15 in
lifting engagement with the sod slab in a roll form;
[0042] FIG. 17 is a top view of a top layer of sod in an offset
relationship to a base layer of sod;
[0043] FIG. 18 is a top view of a further layer of sod in an offset
relationship to the base layer of sod of FIG. 17;
[0044] FIG. 19 is a top view of a further layer of sod in an offset
relationship to the base layer of sod of FIG. 17;
[0045] FIG. 20 is a top view of a further layer of sod in an offset
relationship to the base layer of sod of FIG. 17;
[0046] FIG. 21 is a side view of a layer of sod slabs in an offset
condition; and
[0047] FIG. 22 is an end view of the layer of sod slabs in FIG. 21
in an offset condition.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0048] FIG. 1 is a side view of a sod harvester 10 including an
agricultural tractor 11. In general, the sod harvester 10 cuts sod
slabs, removes sod slabs from a conveyor, transfers and stacks the
sod slabs on a pallet while simultaneously monitoring sod slab
quality and the sod receiving position of the pallet.
[0049] The sod harvester 10 includes a power source such as an
agricultural tractor 11 which is used to power a sod cutting
mechanism 12 and an elevator 13 for elevating the cut sod slabs
from the sod cutting mechanism 12 to a sod transfer mechanism 14.
Sod cutting mechanism 12 and the sod elevator 13 for elevating
slabs of sod in a sod harvester which is either self propelled or
pulled by an agricultural tractor are known in the art and are not
described herein.
[0050] After the sod harvester cuts the sod slabs from the sod
field the sod slabs are delivered to a conveyor 20 in the sod
transfer mechanism 14 where a sod quality monitoring system
including a sensor 19 determines if a sod slab is of proper sod
quality. If the sod slab is of proper sod quality the sod transfer
mechanism 14 transfers the sod slab to a pallet. The pallet, when
loaded with sod, can be transferred to a truck by a fork lift and
the pallet of sod can then be transferred to a work site.
[0051] FIG. 1 shows a side view of the sod transport mechanism 14
for transferring sod slabs within the sod harvester 10. The sod
transport mechanism 14 includes a conveyor 20 for transporting sod
slabs to a position proximate a sod lift mechanism 37 and 38.
Conveyor 20 is shown supporting a sod slab 15c and a sod slab 15d
and in a condition to receive a sod slab 15b and a sod slab 15a
which are on sod elevator 13.
[0052] A wheel 14d, which can be hydraulic raised or lowered,
supports the rear of sod transport mechanism 14 with the front of
the sod transfer mechanism 14 supported on the agricultural tractor
11. If desired, the sod transfer mechanism 14 could be cantileverly
mounted or integrally mounted on an agricultural tractor or the
like as well as used in other sod handling operations independent
of sod harvester 10. A pallet storage and feed mechanism 18 as well
as an air suction pump 50 can be included on sod transfer mechanism
14 when the sod transfer mechanism 14 is used as part of a sod
harvester.
[0053] A reference to FIG. 1 (side view) and FIG. 1A (top view)
shows the sod conveyor 20 comprises a set of three spaced apart
rotating chains or flexible belts 20a, 20b and 20c that are driven
from the power source such as the PTO of agricultural tractor 11.
Conveyor 20 receives the sod slabs from the elevator 13 and a sod
lift mechanism 37 including a bump bed 35 and a sod lift mechanism
37 including a bump bed 36 located below the top surface of the
conveyor 20 elevates sod slabs from the conveyer 20 to a sod slab
support member where the sod slab support member includes a suction
housing 30 to support the sod slab thereunder through generation of
a pressure differential across the sod slab. In the embodiment
shown a second sod slab support member comprising a second suction
housing 31 can be used to support a further sod slab.
[0054] A carriage 28 in conjunction with the suction housing 30
transfers the sod slab from conveyor 20 to a sod bed such as a sod
pallet. The sod slabs, which are deposited on the sod bed can be
maintained at a proper sod drop distance by a sod positioning
system 21, shown in isolated view in FIG. 10a, to ensure that the
sod slabs can be stacked properly. A second carriage 28a, which is
identical to the carriage 28 can transfer a sod slab from conveyor
20 to the sod pallet at the same time that sod carriage 28 is
transferring a sod slab from conveyor 20 to the sod pallet. As
carriage 28 and carriage 28a are identical carriage 28 is not
described herein. A carriage shift system 29, FIG. 5A, provides for
lateral displacement of the sod carriage 28 and sod carriage 28a to
enable one to position sod slabs in two transverse different
directions.
[0055] Thus, the sod harvester 10 includes a sod transfer mechanism
14 with the sod transfer mechanism 14 (shown in FIG. 1) including a
sod quality monitor 19, a sod conveyor 20, a sod lift mechanism 37,
38, including bump beds 35, 36 (shown in isolated view in FIG. 6A
to FIG. 6C), sod slab support members or pick up heads including
suction housings 30 and 31 (shown in isolated view in FIG. 11-FIG.
13), a carriage mechanism including a cable driven sod carriage 28,
28a (shown in isolated view in FIG. 4A), a carriage shift system 29
(shown in isolated view in FIG. 5A-FIG. 5E) and a sod positioning
system 21 (shown in isolated view in FIG. 10A)
[0056] In the embodiment shown in FIG. 1 a first sod slab 15c in a
flat or unrolled condition is supported by conveyor 20 with sod
slab 15c located beneath suction housing 31 and a second sod slab
15d also in the unrolled condition, which is also supported by
conveyor 20, located beneath suction housing 30. Counter clock wise
rotation of conveyer 20 brings the sod slabs 15d and 15c to a lift
position beneath suction housing 30 and suction housing 31.
[0057] As the sod slabs 15d and 15c are carried by conveyor 20 they
pass under a sod quality monitor or sensor 19, which is mounted to
frame 14a. Sod quality sensor 19 is located above conveyor 20 and
prior to the sod pickup hood or suction housing 31 and determines
whether a sod slab is in a stackable condition by determining the
distance from the sensor to the top of the sod slab on conveyor 20
by emitting an acoustical signal indicated by dashed line 19a. If
the sod slab is of proper sod stacking quality the top of the sod
slab will have a continuous surface, i.e. the sod slab will be of
proper length and not contain any tears or gaps. However, if the
sod slab has a discontinuous surface or if the sod slab is to short
or to long the sod slab is not of proper quality for stacking.
Thus, if the distance from the sensor 19 to the sod slab remains
substantially constant over a given length of sod the sod slab can
be considered of proper quality for stacking. A processor, not
shown, can measure and compare the expected relative displacement
of the conveyor 20 and the expected length of a signal from sensor
19, which would indicate a continuous sod surface. If the signals
are within determined ranges the sod slab is allowed to pass
through the sod transfer mechanism 14. In an alternative
embodiment, the sod processor can measure the length of time that a
sod slab carried by conveyor 20 is proximate the sod quality sensor
19 and compared the measured time to the length of time a sod slab
in a stackable condition would be proximate the sod quality sensor
19. If the times are within determined ranges the sod slab is
allowed to pass through the sod transfer mechanism 14. Thus,
processor comparisons can be done on either a time mode or a
displacement mode and can also be done on-the-go.
[0058] In a time mode with a sod slab below stacking quality, the
processor sends a rejection signal rejecting the sod slab if the
length of time of a continuous surface from sensor 19 exceeds or is
less than the length of time from a sod slab with a continuous
surface i.e. the time a sod slab in stackable condition would be
proximate the sod sensor 19. In the displacement mode with a sod
slab below stacking quality, the processor sends a rejection signal
rejecting the sod slab based on expected displacement of the
conveyor while the sod monitor 19 determines the distance from the
sod slab to the sod monitor 19 is within the determined range.
[0059] In either case, the sod quality sensor 19, generates a fault
signal through a processor (not shown) that interrupts the sod
transfer process. The interruption can be done by suppressing a
signal to sod lift mechanism 37 and 38 thereby preventing sod
pickup from conveyor 20 if the sod slab thereon is not in a
stackable condition. Consequently, if the sod slab is not of proper
sod quality the step of rejecting the sod slab from the stacking
process of harvester 10 comprises allowing the conveyor 20 to
continue to rotate and allow the sod slab, which is lacking in
stacking quality, to fall off the end of the conveyor 20. One can
thus automatically perform the process of sod slab quality
monitoring and sod slab rejection without having to interrupt the
operation of the conveyer 20 or have an operator interrupt the
operation of the sod transfer process.
[0060] FIG. 1 and FIG. 4 show the sod carriers or sod slab support
members comprising a first suction housing 30 and a second suction
housing 31 located in a lift position above the individual sod
slabs 15d and 15c on conveyor 20. The suction housing 30 is carried
by a first carriage 28 having a set of wheels 41 and 41a on one
side which are connected to wheels 42 and 42a by a cross member 45
and a cross member 46 that supports suction housing 30 thereon. The
wheels 41 and 41a and wheels 42 and 42a roll on a track comprised
of a first cylindrical rail 40a and a second cylindrical rail 40b.
In order to maintain the wheels and the tracks in engagement under
rough field harvesting conditions the wheels are provided with a U
shaped circumferential groove so that the wheels can be maintained
on the tracks as the wheels move back and forth on the track rails
40a and 40b carrying the suction housing 30 from a lift position
shown in FIG. 4 to the various sod drop positions shown in FIG. 7,
FIG. 8 and FIG. 9. Although a U-shape groove is used other shape
tracks and rails can be used to maintain the wheels on the
rails.
[0061] To further hold the carriage 28 on rail 40a a lower set of
stops or wheels 41a' and 41' cooperate with the upper wheels 41a
and 41 (see FIG. 4A). Similarly, an identical set of stops or
wheels (not shown) located on the opposite side of carriage 28 hold
the opposite side of carriage 28 on rail 40b.
[0062] FIG. 1A shows that located in a parallel condition to track
rails 40a and 40b are identical track rails 40d and 40c which
support a second sod carriage 28a and a second suction housing 31.
As carriage 28 and suction housing 31 are identical to carriage 28
and suction housing 30 they are not described herein. If desired,
the sod transfer mechanism 14 could use other methods of sod
transfer besides tracks and wheels. For example, a pivotal or
rotatable arm with a suction hood that picks and places sod slabs
as illustrated in FIG. 14 could be used to move a sod slab from one
location to another.
[0063] Thus sod carriage 28 and the cable drive mechanism 48 as
well as the sod carriage 28a and its cable drive mechanism provide
for sod transfer from the sod conveyor 20 to selected drop off
position above pallet 70 as illustrated in FIG. 7, FIG. 8 and FIG.
9 through a cable drive system 48 that includes, a cable, a cable
drum, a pulley, a processor controlled hydraulic motor that rotates
and stops the cable drum at proper positions.
[0064] The sod carriage 28, which is shown in isolated detail in
FIG. 4A, fixedly connects to cable 75 through a first cable clamp
75a and a second cable clamp 75b. The fixed connections ensures
that if the cable 75 is pulled one way or the other by rotating the
cable drum in one direction the sod carriage 25 must also move. A
conventional cable drum having a hydraulic motor, which is
controlled by a processor (not shown) controls the postion of sod
carriage 28 along track rails 40a and 40b.
[0065] FIG. 4D shows an isolated top view of a portion of the cable
drive system 48 including cable drive member 72a having a rotatable
cable drum 7 with a cable 75 wound therearound. A hydraulic motor
72c controlled through leads 72 rotates in one direction to move
carriage 28 in a first direction and in the opposite direct to move
carriage 28 in the opposite direction.
[0066] In order to position the carriage 28 at the proper position
along the track rails the cable drive system 48 is powered by a
hydraulic motor 72c located on one side of transport mechanism 14
and a free wheeling pulley 72 located on the opposite side of
transport mechanism 14. Cable 75 is attached to carriage 28 by
cable clamps 75a and 75b (FIG. 4) The hydraulic motor 72c allows
carriage 28 to be moved to and fro on the track rails 40b and 40a.
That is, as cable 75 is wound around the top side of cable drum 73
the cable 75 is allowed to unwind from the opposite side of the
cable drum 73 which allows for displacement of carriage 28. Thus,
the carriage displacement can be precisely and quickly controlled
by rotating the cable drum 73 in either direction. When the
carriage 28 needs to be moved in the opposite direction the reverse
occurs, namely, cable 75 rotates in an opposite direction. Thus,
through suitable rotational control of the cable drum one can
quickly position the carriage 28 and consequently the suction
housing 30 carried thereon at the proper position for either sod
slab pick up or sod slab drop off. Through use of a cable drum that
simultaneously winds and unwinds the cable 75 remains in a taut
condition one minimize hysteresis in the positioning of the sod
carriage 28.
[0067] While the preferred embodiment comprises a cable mechanism
with a cable drum to displace carriage 28 other carriage
displacement mechanisms are envisioned such as a motor driven cog
wheel on the carriage with a corresponding cog track for one or
both of the rails. In either event the sod carriage 28 can be
positioned in the proper position along the track rails for sod
slab pickup or drop-off.
[0068] The carriage and rails for moving the suction housing 30 in
the sod transfer mechanism 14 is shown in end view in FIG. 1 and in
top view of FIG. 1A.
[0069] FIG. 4B shows an isolated view carriage 28 carries the
suction housing 30 thereon with the suction pressure generated in
housing 30 and controllable by a butterfly valve 101 located in
suction housing neck 30a. FIG. 4B shows the butterfly valve 110 in
the open condition with air being drawing into suction hood or
suction housing 30. The suction housing neck 30a connects to vacuum
pump 50 though a flexible conduit 51 (see FIG. 1). The flexible
conduit 51 allows one to move the carriage 28 along track rails 40a
and 40b while maintaining the continuous suction power to suction
housing 30.
[0070] FIG. 4C shows the suction housing 30 thereon with the
butterfly valve 110 in the closed condition in neck 30a. In this
condition the lack of suction pressure which is used to maintain a
sod slab on the suction housing 30 causes the sod slab to fall from
hood 3-because of the inherent porous nature of the sod slabs, thus
causing a sod slab held on housing 30 to be dropped onto a sod bed.
While dependent on sod conditions one can maintain a sod slab on
the sod carriage by maintaining suction pressure on the sod slab
proximate the suction housing 30 and can release the sod slab from
the suction housing 30 by closing the butterfly valve 110.
[0071] With the embodiment and method shown the sod slabs 15c and
15d can be elevated in an unrolled condition from conveyor 20 which
brings the sod slabs 15c and 15d to a sod lift position immediately
below the sod suction housings 30 and 31. In this postion a sod
engagement step can take place between the suction housings and the
sod slabs through bump beds in the sod lift mechanisms.
[0072] In the sod engagement step the sod suction housing 30 and
the sod slab 15d are brought into engagement or close proximity
with each other to enable a pressure differential across the sod
slab 15d to generate a force sufficient to support the sod slab 15d
thereunder as the sod suction housing 30 is moved about on track
rails 40a and 40b. Similarly, the sod suction housing 31 and the
sod slab 15c are brought into engagement or close proximity with
each other to enable a pressure differential across the sod slab
15c to generate a force sufficient to support the sod slab 15c
proximate suction housing 31 as the sod suction housing 31 is moved
about on track rails 40c and 40d.
[0073] The suction of suction housing 30 and suction housing 31 is
obtained by a suction from a vacuum pump 50 mounted on the sod
transfer mechanism 14 that draws air through the suction housing or
suction hoods 30 and 31. Pump 50 can have its own independent power
source or can be powered from the agricultural tractor 11. A first
flexible hose 51 extends from pump 50 to suction housing 30 and a
second flexible hose 53 extends from pump 50 to suction housing 31.
The flexible hoses allow the suction housing 30 and 31 to move in
the sod transport mechanism while still maintaining a suction
pressure that supports a sod slab thereunder. The suction housings
30 and 31 are identical to each other and are described in greater
detail in FIG. 11 to FIG. 13.
[0074] FIG. 13 shows a bottom view of lift plate 30a that is
located on the underside of suction hood 30. Lift plate 30a
includes a set of spaced apart holes 30c that are in fluid
communication with a plenum chamber 30b (see FIG. 11). As air is
continually pulled through the holes or fluid ports 30c it creates
a static and dynamic pressure differential across the sod slab 15d
which can hold the sod slab thereon without sacrificing the
integrity of the sod slab.
[0075] FIG. 11 shows a partial cutaway side view of sod slab 15d
positioned on a support surface comprising bump bed 35 which
extends through and above the top support surface of conveyor 20.
Sod slab 15d contains soil on the underside and grass on the top
side. The suction housing 30 includes a sod lift plate 30a having a
plurality of openings therein. Suction housing 30 includes having a
plenum chamber 30b is shown positioned above sod lift plate 30a. A
flexible hose 51 connects to an air suction pump (see FIG. 1). In
the position shown the sod lift plate 30a is spaced a distance D
from the top of sod slab 15d with air being drawn through sod lift
plate 30a. In this condition the sod slab 15d remains on the
support surface 35 as the air flows (as indicated by arrows) over
the sod slab 15d and into the plenum chamber 30b in housing 30.
[0076] FIG. 12 illustrates what occurs when either the suction from
the source is increased or as the sod lift plate 30a is brought
proximate the sod slab 15d. In this embodiment the sod slab 15d is
supported against the sod lift plate 30 solely by the presence of a
pressure differential across the sod slab 15d. That is the pressure
in housing 30 is less than atmospheric pressure with the
differential pressure being sufficient to provide a lifting force
greater than the weight of the sod slab. Although the sod slab
contains soil on the bottom side and grass shoots on the top side
and is porous to air it has been found that the generation of a
lower pressure (i.e. below atmospheric pressure) in the plenum
chamber 30b by connecting the housing 30 to a suction or vacuum
pump is sufficient to engage and support a sod slab 15d during a
sod transfer either through static or dynamic pressure on the sod
slab without the aid of mechanical hooks or lifts. That is, air can
flow through the sod it can generates a fluid frictional force
against the sod slab i.e. drag to generate a lift force and the
static pressure differential across the sod also generates a force
to hold the sod slab on the sod plate 30a. It has been found that
by maintaining a pressure differential across the sod slab either
through static or dynamic flow conditions such as when air is drawn
through the sod slab enables one to lift and transfer a sod slab
without disrupting the integrity of the sod slab. Thus, even though
some soil or grass on the sod slab may be drawn into the plenum
chamber 30b by suction the amount drawn therein is insufficient to
upset the integrity of the sod slab. An incidental benefit is that
if there is loose material on top of the sod slabs, such as grass
clippings or unwanted weed seeds they are removed from the sod slab
during the sod harvesting process by the suction pressure across
the sod slab.
[0077] FIG. 14 shows a top view of an alternate embodiment of a sod
transfer mechanism 80 which can be used in a sod transfer mechanism
to either stack or unstack sod slabs. For example, the sod transfer
mechanism 80 can be used to transfer a first stack of sod slabs 90
to a second set of sod slabs 91 with a rotatable sod slab transfer
mechanism 80 positioned therebetween. The sod slab transfer
mechanism 80 includes a rotatable base 89 with a arm, 81 connected
to suction housing 82. A sod lift plate 83 located having a sod
slab 86 carried thereon by the suction pressure generated in
housing 82. In operation the stack of sod slabs 90 is to be
transferred from the first position to a second position
represented by the stack of sod slabs 91. To do so the sod slab
lift mechanism 80 is rotated until the sod lift plate 83 is over
the stack of sod slabs 90. The application of a suction pressure
picks the sod slab 86 form the stack of sod slabs 90 with the
suction housing 82. Housing 82 is shown in the mid rotational
position to transfer the sod slab 86 to a position over the stack
of sod slabs 91. In this embodiment the sod slab sod 86 is
transferring from one stack 90 to another stack though the use of
the pressure differential generated in the suction housing 82 in
conjunction with the rotation of suction through rotatable base
89.
[0078] While the sod suction housing have been shown and described
in a sod transfer mechanism in a sod harvester the suction housing
can also be used in other sod handling equipment.
[0079] For example, one can unload a pallet of sod and lay the sod
on a work site using the sod transfer mechanism with the suction
housing. In this operation one could mount the movable housing 89
on a device such as a front end loader. The suction housing 82 can
then be placed over a stack of sod slabs and one-by-one transfer
the sod slabs from the sod pallet to the field without a user
having to lift and place the sod slab in position.
[0080] While our sod handler apparatus have been shown and
described in relation to the lift and transferring a flat sod slab
i.e. in an unrolled condition the present invention can also be
used to transfer sod in other forms. For example, FIG. 15 and FIG.
16 illustrate a sod transfer mechanism 90 for transferring a sod
roll 91 using a suction housing 92. In the embodiment shown the sod
transfer mechanism 90 includes a suction housing 92 with a flexible
conduit 93 that connects to a suction pump or the like. Instead of
having a flat lift plate the suction housing 92 contains a curved
lift plate 94 having a set of air ports therein identical to the
ports 30c in lift plate 30a. In the position shown in FIG. 15 the
suction housing is positioned above sod roll 91 which rests on a
conveyor 95.
[0081] A reference to FIG. 16 shows the suction housing 92 lowered
around the cylindrical sod roll 91 with the lift plate 94
conforming to the shape of the sod roll 91. By application of
suction pressure to housing 92 one can lift the sod roll 91 for
transport. In this procedure it is preferred that the end 91a of
the sod roll 91 be on the top side so as to avoid unraveling of the
sod roll as the sod roll 91 is lifted by the pressure differential
generated across the sod roll 91.
[0082] Referring to FIG. 1, although two sod slabs 15d and 15c are
shown on conveyor 20 the sod engagement process with each of the
sod slabs can be achieved independently for each sod slab. In
addition, to minimize the suction generated, and hence the power
required, in the suction housing 30 and 31 each of the sod slabs
can be elevated into a sod engagement position through bump beds
35, 36 that elevates the sod slab from the moving conveyor 20 to a
condition of engagement or close proximate to the suction housing
30 or 31 where the suction pressure becomes sufficiently great so
as to support the sod slab thereunder thereby bringing the suction
housing into the transport condition. In the transport condition
the suction housing 30 holds a sod slab proximate the suction
housing 30 though a pressure differential across the sod slab or
through a fluid flow through the sod slab or both. That is the sod
slab can be supported without impairing the integrity of the sod
slab and without the aid of mechanical hooks or clamps either by
the pressure differential forces generated by the pressure
differential from the top side to the bottom side of the sod slab
or by the fluid friction i.e. drag as air flows through the sod
slab and into the suction housing.
[0083] To illustrate the process of engagement between the suction
housing 30 and 31 while minimizing power usage reference should be
made to FIG. 1A which shows a top view of the sod bump beds 35 and
36. Bump bed 35 includes a set of four parallel spaced rails 35a,
35b, 35c and 35d for lifting the sod slabs to a sod transport
condition. Located between chains 20a and 20b is a first set of
rails 35a and 35b and located between chains 20b and 20c is a
second set of rails 35c and 35d for engaging the underside of a sod
slab that is carried by conveyor 20. Similarly, bump bed 36
includes a set of four parallel spaced rails 36a, 36b, 36c and 36d
for lifting the sod slabs to a sod transport condition. Located
between chains 20a and 20b is a first set of rails 36a and 36b and
located between chains 20b and 20c is a second set of rails 36c and
36d for engaging the underside of a sod slab that is carried by
conveyor 20. The rails are spaced sufficiently close so as to
distribute a lifting force over the underside of a sod slab
sufficient to lift the sod slab without creating a localized
pressure point that might cause rupture or separation of the sod
slab.
[0084] The bump bed 35 is further revealed in FIG. 5 which shows a
rear view of the sod transport mechanism 14. A lift member 37
supports bump bed 35 with bump bed rails 35a, 35b, 35c and 35d
located on the underside of sod slab 15d. The bump bed rails are
shown in a pre sod lifting condition on the underside of sod slab
15d. Bump bed 35 is vertically displaceable through the lift member
37
[0085] In order to appreciate the operation of the bump beds
reference should be made to FIG. 1A and FIG. 6A to FIG. 6C. FIG. 1A
shows a top view of the conveyor 20, wherein the suction housing 30
for lifting the sod slab has been retracted to provide a clear view
of the relationship of conveyor 20 to bump bed rails 35a, 35b, 35c,
35d of bump bed 35 and bump bed rails 36a, 36b, 36c and 36d of bump
bed 36. Conveyor 20 includes a set of three rotatable chains 20a,
20b and 20c that are rotatingly driven through a drive shaft 20e
which is connected to a suitable power source. Each of the
rotatable chains 20a, 20b and 20c are spaced from each other in a
parallel relationship and are driven at the same speed to transport
a sod slab from the elevator 13. In operation conveyor 20 receives
a sod slab from the elevator 13 and carries the sod slab to a sod
engagement position beneath the suction housing. Each of the three
rotatable chains 20a, 20b and 20c are spaced from each other with a
spacing sufficient close so as to support and carry a sod slab
thereon without destroying the integrity of the sod slab
thereon.
[0086] FIG. 1A shows the rails of the first bump bed 35 and the
rails of second bump bed 36 spaced between the rotatable chains of
conveyor 20. A feature of the bump beds is that they can provide
for on-the-go elevation of a sod slab from the conveyor 20 to a
condition beneath the suction housing since they operate
independently of the conveyor 20. That is, the conveyor 20 can
continue moving while the bump beds extend through the space
between the rotatable chains to lift the sod slab from the conveyor
20 and bring the sod slab to a condition of engagement or close
proximity with the suction housings. The bump beds 35 and 36 can
reduce the power consumption of the suction housing since the sod
slabs can be brought proximate the suction housing to allow suction
pressure in the suction housing to draw the sod slab against the
suction housing. That is, the farther away the suction housing is
from an object the more air needs to be pumped to generate the
pressure differential to lift the sod slab. In addition, the bump
bed 35 can be operated independently of bump bed 36 which allows
one of the sod slabs to be brought into engagement with the suction
housing while another suction housing is dropping a sod slab on a
pallet. As a result, if desired, the power consumption can be
controlled by staggering the operation of the sod lifting and sod
dropping operation.
[0087] A reference to FIG. 6A to FIG. 6C shows the sod lift
mechanism 37 and illustrates the cyclic operation of the bump bed
35 in lifting a sod slab 15d to engagement or close proximity to
suction housing 30 and then returning to a ready condition for
lifting a further sod slab. To illustrate the lifting process only
bump bed rail 35c is shown, however, the lifting operation of bump
bed rails 35a, 35b and 35d work in condition with bump bed rail
35c.
[0088] FIG. 6A shows the bump bed 35 in the non-sod lifting
condition or retracted condition. In this condition the lift
mechanism 37, which is supported on frame member 14, is in the
retracted condition. In the retracted condition the sod slab 15d is
carried by conveyor 20 and the bump bed rail 35c is in a ready
condition beneath the underside of sod slab 15d.
[0089] FIG. 6B shows the bump bed 35 in the lift condition. In the
lift condition the lift mechanism 37 raises bump bed 35 to bring
the bump bed rail 35c into engagement with the underside of sod
slab 15d. Once engagement between the sod slab underside and the
bump bed rail is established the continued upward movement of the
bump bed 35 lifts the sod slab 15d off the conveyor 20. Lifting the
sod slab 15d off the conveyor ceases the lateral displacement of
the sod slab 15d caused by the conveyor without having to stop the
conveyor 20. However, if desired the conveyor 20 could be stopped
to stop the forward motion of the sod slab. As the sod slab 15d is
brought proximate or in engagement with the suction housing 30 the
suction generated within the suction housing 30 supports the sod
slab 15d on the underside of the suction housing 30 whereupon the
bump bed 35 retracts to the ready condition shown in FIG. 6C.
Depending on the composition of the sod slab the sod slab is held
on the suction housing 30 by the pressure differential forces
across the sod slab or the fluid friction forces produced by drag
as air flows through the sod slab or by a combination of the
pressure differential forces and the fluid friction forces. In
either event the sod slab can be lifted and transported by
establishing a pressure differential across the sod slab.
[0090] FIG. 6A to FIG. 6C is an isolated sectional view of a sod
transfer mechanism for moving a sod slab from one location to
another with the sod transfer mechanism including bump bed rail
35c, which is a part of bump bed 35, and a portion of one of the
conveyor belts 20c, which is a part of conveyor 20, in conjunction
with a lift mechanism 37 for elevating and lowering bump bed 35c.
FIG. 6A shows the conveyor belt 20c carrying a sod slab 15d in the
direction indicated by the arrow. The bump bed rail 35c is in the
retracted condition. The drive mechanism for bump bed 35c includes
a power source 106 such as a hydraulic motor that is mounted on
frame 14a with the motor 106 operable from a remote processor
through control leads 106a. Mounted to frame 14 is a drive shaft
105 that connects to a first end of first link 103. The opposite
end of link 103 connects to a second link 104 through a pivot pin
107 that allows link 103 to pivot with respect to link 103. The
opposite end of link 104 connects to slider 102 which is held in
position by slide blocks 101a and 101b which are located in a
parallel spaced condition on opposite sides of slider 102 to
laterally confine slider 102 therebetween. The result is that a
rotary motion of drive shaft 105 imparts linear displacement of
slider 102 along a lift axis parallel to the slider blocks 101a and
101b.
[0091] FIG. 6A shows sod slab 15d on top of conveyer belt 20c with
conveyor belt 20c supported by a conveyor slide rail 14e. In this
condition the top of the bump bed 35c is located beneath the
conveyor belt 20c and the sod 15d can be carried by conveyor belt
20 without interference by bump bed rail 35c. When the sod slab 15d
is in the proper position for pickup a signal is sent to power
source 106 to rotate drive shaft 105. FIG. 6A shows the drive shaft
105 midway through its cycle and FIG. 6C shows the drive shaft at
the end of its cycle.
[0092] FIG. 6B shows that in the middle of the cycle the bump bed
35c lifts the sod slab 15d off the conveyor belt 20c while the
conveyer belt 20c continues to rotate. Once the sod slab is at the
zenith of its position the top pick up mechanism, (which can be
hood 20 FIG. 1) lifts the sod slab 15d and carries the sod slab 15d
to a sod stack.
[0093] FIG. 6C shows the end of the cycle with the link 103 and 104
located at an angle to each other but in a mirror position of that
shown in FIG. 6A. In the position shown in FIG. 6C the bump bed
rail 35c is again located below conveyor belt 20c and does not
interfere with a sod slab 15b which is being carried by conveyer
20c. Thus the bump bed rail 35c provides an on-the-go lifting of
the sod slab from the conveyer 20c. Consequently, one need not stop
the conveyor 20 to lift the sod slab 15d therefrom since the bump
bed 35 with the bump bed rails 35a, 35b, 35c and 35d are positioned
between the conveyor belts 20a, 20b and 20c and can elevate sod
slabs from between the conveyor belts 20a, 20b and 20c (see FIG.
1A) while the conveyor 20 maintains its motion.
[0094] To lift the sod slab 15b from the conveyor the cycle is
repeated with the link mechanism 103 and 107 rotating from the
position shown in FIG. 6C to the position shown in FIG. 6A by a
counterclockwise rotation of the link 103.
[0095] Thus the invention includes a sod transfer system wherein
conveyor 20 has a movable top sod support surface 20c' for carrying
a sod slab 15d, a bump bed 35 which is normally positioned below
the movable top sod support surface 20c' and a lift mechanism 37
for elevating the bump bed 35 and a lift mechanism 38 for elevating
the bump bed 36 above top sod support surface 20c' to thereby lift
a sod slab free of the top support surface 20c' with the lift
mechanisms 37 and 38 if desired, to provide on-the-go elevation a
sod slab from the conveyor to a sod pickup head located above the
bump bed.
[0096] FIG. 7 illustrates the movement or displacement of a sod
slab 15d while using the suction housing 30 to hold the sod slab
15d during sod transfer. In operation, a suction housing carriage
28 carries the sod slab 15d to a position over a pallet 70. When
the desired position above pallet 70 is reached the suction
pressure can be reduced by the butterfly valve (see FIG. 4C) which
allows the sod slab 15d to fall onto pallet 70. Note, that the
carriage 28 moves on track rails with the flexible hose 51
permitting the carriage 28 and the suction housing 30 to move from
the position shown in FIG. 6 to the position shown in FIG. 7 while
still maintaining the suction pressure on the sod slab 15c.
[0097] FIG. 8 illustrates the sod transfer step wherein a sod slab
15c is placed alongside the first sod slab 15d on pallet 70 through
the action of carriage 28 and suction hood 30. That is, the
carriage 28 is positioned so that the sod slab 15c is above pallet
70 and in a position that allows sod slab 15c to fall next to the
sod slab 15d. At this point the butterfly valve (see FIG. 4C) is
closed allowing the sod slab to fall free of suction hood 30.
[0098] FIG. 9 illustrates the sod transfer step with carriage 28
positioned at a third location along the track rail 40a to allow
sod slab 15b to be deposited proximate side sod slab 15c on pallet
70. That is the carriage 28 is positionable so as to carry the sod
slab 15b to a position on pallet 70 where the sod slab 15b can be
dropped into position along side sod slab 15c by releasing the
suction pressure on housing 30. Thus the carriage 28 can be
positioned along track rail 40a using the cable drive system 48 to
position the carriage 28 at various location so that the sod can be
stacked on the pallet 70.
[0099] FIG. 10 shows the sod transfer step with carriage 28 suction
housing 30 returned to a position over the conveyor 20 where a sod
slab 15a on conveyor 20 is about to be lifted from the conveyor.
The process can now be repeated with bump bar 35 lifting the sod
slab 15a to a position wherein the suction generated in suction
housing 30 is sufficient to hold the sod slab 15a thereon during
the transfer of the sod slab 15a from one location to another.
[0100] FIG. 10 also shows that pallet 70 is lowered in response to
placement of sod slabs 15d, 15b and 15c. This allows another row of
sod slabs to be stacked on top of sod slabs 15d, 15b and 15c. Thus
the present invention can in one continuous operation convey a sod
slab to a position to be lifted, engage a sod slab by lifting the
sod slab proximate a suction housing and then transfer the sod slab
attached to the suction housing to a position where the sod slab
can be stacked on a sod pallet. By repeating the process the sod
slabs can be stacked on the pallet in a condition where they are
ready to be transported to the work site using a fork lift and
transport vehicle.
[0101] FIG. 10A shows an isolated partial schematic side view of
the sod bed positioning system 27 that raises and lowers pallet 70
comprising a pallet 70 with a fork lift member 71 having a
horizontal extending arms 71a that support pallet thereon and a
vertical extending arm 71b that slides vertically upward and
downward in guide members 14f and 14g that are attached to frame
14a. A power cylinder such as a hydraulic cylinder 74 is affixed to
frame 14a with hydraulic cylinder 74 having an extendible ram 74a
extending therefrom. Located at the end of ram 74a is a pulley 76
that engages the flexible member 73a, which comprises a link chain.
Link chain 73a has a first end secured to frame 14a and a second
end secures to the top end of arm 71b. A hydraulic hose 79a
connects the power cylinder 74 to a controllable source of
hydraulic fluid 78. Hydraulic fluid source 78 supplies hydraulic
power through hydraulic hose 79a to the hydraulic cylinder 74. A
lead 78a connect the processor 9 to the source of hydraulic fluid
to control the delivery of hydraulic fluid to the hydraulic
cylinder 74 and thereby control the displacement of extendible ram
74a.
[0102] Positioned above the sod slab stack 77 is a sonic transducer
75 that measures the distance (indicated by dashed line) from the
sonic transducer 75, which is affixed to frame 14a, to the top of
the sod stack 77. Sonic transducer 75 connects to processor 9
through lead 75a. Processor 9 is mounted on the sod harvester frame
14a.
[0103] In operation of the sod bed positioning system 27 the sonic
sensor 75 sends a signal (indicated by the dashed line) to the top
of the sod stack 77. The signal is used by the processor 9 to
control the elevation of the sod pallet 70 and thereby control the
sod drop distance D (see FIG. 9) from the bottom of the sod
carriage 30 to the top of the sod slabs on the pallet. As the
layers of sod accumulate on the pallet 70 the sod pallet 70 is
periodically lowered by retracting extendible arm 74a which causes
fork lift like member 71 to move from the solid position to the
position indicated by the dashed lines. Thus, through measurement
of the distance of the top of the sod slab from a fixed reference
on the frame 14a of the sod harvester 10 one can move the sod
pallet 70 progressively downward in response to the increased
height of the sod stack thereby ensuring that the sod slabs, which
are dropped thereon do not have to fall an excessive distance. By
controlling the sod drop distance D of the sod stack from the
bottom of the sod carriage one can control the impacting of the sod
on the sod pallet. That is, by lowering the sod pallet 70 in
response to adding layers of sod to the pallet one can assure that
the sod carriage does not interfere with the layers of sod on the
pallet 70. Similarly, by limiting the drop distance D one can
ensure the sod slabs dropped on the pallet 70 are not dropped from
a height that might cause the impact to effect the integrity of the
stack as well as the quality of the sod slab.
[0104] FIGS. 17-22 illustrate the machine stacking of sod slabs
using the sod transfer mechanism 14. FIG. 17 shows a first layer of
sod slabs that have been deposited by the sod carriages 28 and 28a.
The first row of sod slabs, which are in a side by side condition
are identified by reference numeral 121c, 121b and 121a and the
second row of sod slabs which are in a side by side condition
proximate the first row are sod slabs 121d, 121e and 121f. These
two rows of sod slabs comprise the first layer of sod slabs 121 and
are used herein as a reference layer to describe how subsequent
layers of sod are stacked.
[0105] FIG. 21 shows a front view of a sod stack 120 with sod layer
121 as the bottom layer and sod layers 122, 123, 124 and 125
located thereon. Similarly, FIG. 22 shows a side view of the sod
stack 120 with sod layer 121 as the bottom layer and sod layers
122, 123, 124 and 125 located thereon.
[0106] FIG. 17 illustrates the sod slab positioning obtained
through the machine stacking of sod slabs. Note, the sod slab layer
121 is laterally offset in two mutually perpendicular directions
from the sod slab layer 122 to increase the integrity of the sod
stack. That is, sod slabs 122a, 122b, 122c, 122c, 122d, 122e and
122f (shown in dashed lines) form the second layer 122 (see FIG. 21
and FIG. 22) with the individual sod slabs of sod slab layer 122
offset from the sod slabs in the first sod slab layer 121. This
causes the junction of sod slabs on the first layer 121 to be
covered by a sod slab on the second layer 122 thus providing a
frictional force between the two layers of sod slabs that holds or
binds the sod slabs in the first layer 121 and the sod slabs second
layer 122 proximate each other.
[0107] A reference to FIG. 18 illustrates the first layer of sod
121 as the reference layer with the layer of sod 122 omitted in
order to illustrate the offset stacking of sod slabs in layer 123
with reference to the position of the sod slabs in first layer 121.
The third layer of sod slabs comprise a row of sod slabs 123a,
123b, 123c and a row of sod slabs 123d, 123e and 123f which make up
the third layer of sod slabs 123. FIG. 21 and FIG. 22 show the
position of the third layer of sod 123 with respect to the sod
layer 122 and sod layer 121.
[0108] FIG. 18, which does not include sod layer 122, illustrates
how sod slab layer 123 is laterally offset from the first layer 121
through displacement along the x axis but not along the y-axis.
This shifting brings the intersections of sod layers 122 and 123
into an offset condition in the x axis as illustrated in FIG.
21.
[0109] FIG. 21 and FIG. 22 show the end view and side view of stack
120 with a fourth sod slab layer 124 located on top of sod slab
layer 123 with the edges of the sod slab layers 124 and 123 in
alignment in FIG. 21 but in misalignment or laterally offset in
FIG. 22.
[0110] A reference to FIG. 19 again illustrates the first layer of
sod 121 as the reference layer with the layer of sod 122 and 123
omitted in order to illustrate the offset stacking of sod slabs of
sod layer 124 with reference to first layer 122. The fourth layer
of sod 124 comprise a row of sod slab 124a, 124b, 124c and a row of
sod slabs 124d, 124e and 124f which make up the fourth layer of sod
slabs 124. The layer of sod slabs 124 have been offset in the y
axis with respect to sod layer 121. FIG. 21 and FIG. 22 show the
position of the fourth layer of sod 124 with respect to the sod
layers 123, 122 and 121.
[0111] A reference to FIG. 20, which again illustrates the first
layer of sod 121 as the reference layer with the layer of sod 122,
123 and 124 omitted in order to illustrate the offset stacking of
sod slabs of fifth sod layer 125 with reference to first layer 121.
The fifth layer of sod comprise a row of sod slab 125a, 125b, 125c
and a row of sod slabs 125d, 125e and 125f which make up the fifth
layer of sod slabs 125. The fifth layer of sod slabs 125 have been
offset in the x axis. FIG. 21 and FIG. 22 show the position of the
fifth layer of sod 125 with respect to the sod layers 124, 123, 122
and 121.
[0112] As can be seen from FIGS. 17-18 after the first layer of sod
slabs is laid on a pallet or the like the second layer of sod slabs
is laterally offset in both the x and y axis. Each successive layer
of sod slabs is laterally offset in either the x axis or the y
axis. The result is a sod stack 120 wherein the sod slabs in
adjacent layers at least partially overlap each other to thereby
create a frictional force that resist shifting of the sod
slabs.
[0113] Thus one embodiment includes the method of machine stacking
sod for transport comprising the steps of placing a first layer of
sod slabs in a side-to-side position on a pallet to form a first
layer of sod; and placing a second layer of sod slabs in a
side-to-side position on top of the first layer of sod slabs with
the second layer of sod slabs laterally offset from the first layer
of sod slabs to thereby inhibit shifting a sod slab with respect to
another sod slab. The process continues by laterally offsetting a
further layer of sod with the further layer of sod slabs laterally
offset in a direction opposite from the first layer of sod slabs
and continuing to laterally offset an additional layer of sod by
laterally offsetting the additional layer of sod in a direction
normal to the first layer of sod slabs.
[0114] While the method shown and described with respect of FIG. 17
to FIG. 20 includes the stacking of sod slabs of similar size and
shape. The machine stacking of sod slabs can also be done when sod
slabs of different size and shape are interspersed with sod slabs
of a conventional size and shape. In this method one could maintain
stack integrity by laying a first layer of sod slabs of a first
size in a side-to-side position on a support surface and then
laying a second layer of sod slabs with at least one of the second
layer of sod slabs having a size larger than the sod slabs in the
first layer of sod on top of the first layer of sod slabs so that
said at least one of the second layer of sod slabs overlaps at
least two of the first layer of sod slabs to thereby inhibit
shifting of the first layer with respect to the second layer.
[0115] While the method of machine stacking has been described in
FIG. 17 to FIG. 22 the carriage shift system 29 for stacking the
sod slabs in laterally offset layers is illustrated in FIGS. 5A,
5B, 5C, 5D and 5E.
[0116] FIG. 5A shows a top view of the carriage 28 with rails 40b
and 40a mounted on a first runner 96 and a second runner 96a which
can be displaced with respect to frame members 14a. FIG. 5E is an
isolated view showing how rail 40a is secured to runner 96 by an
extension 95. The extension 95 prevents axial displacement of rail
40a. The runner 96 can be slid along rail 14. As the attachment of
each of the other rails are identical they are not described
herein.
[0117] FIG. 5B shows an isolated side view of the sod carriage 28
positioned between frame members 14a with the cable drive mechanism
for the carriage omitted for clarity.
[0118] As a result of the sliding engagement of runners 96 with
respect to frame 14a the carriage 28 and rails 40a and 40b can be
laterally offset as a unit as shown by the dashed lines in FIG.
5A.
[0119] FIG. 5C is a partial front view of frame 14a with runner 96
located thereon. Hood 30 and hood 31 are shown and are supported by
runner 96. A rotatable stop 97 is shown in engagement with stop 96a
on runner 96 to prevent lateral displacement of runner 96 on rail
96. That is the pressure cylinder arm is extended which cause arm
97b to pivot stop 97 about 97a to bring the rotatable stop 97 to
the condition shown in FIG. 5C. This prevents lateral shifting of
the carriage 28 and the carriage 28a as well as the support rails
and cable drive mechanism.
[0120] In order to shift the rails laterally, the rotatable stop 97
is pivoted counterclockwise as shown in FIG. 5D. This disengages
stop 96a and stop 97 which allows runner 96 to be shifted from the
first position shown in FIG. 5C to the second position shown in
FIG. 5D. That is the sod carriages 28 and 28a are shifted in the
direction of the arrows by a power cylinder or the like (not
shown). Thus both the suction hoods 30 and 31 are laterally shifted
with respect to a sod being stacked using suction hoods 30 and 31.
As a result when one drops sod slabs from the suction hoods when
the suction hoods are in the second position the sod slabs will
also be shifted from sod slabs that were dropped from the first
position. This feature of the sod shift system proves for lateral
displacement of the sod labs in one direction. To obtain lateral
displacement of the sod slabs along the direction of the rails the
carriage stop or drop off condition is controlled by a processor
(not shown) that determines when the cable drive mechanism 48 is
stopped on the rails. As a result the position of suction hoods can
be altered in two mutually perpendicular axis and thus provide
displacement in both the x and y axis as illustrated by the sod
layers in FIG. 17-FIG. 22.
[0121] Thus the sod transfer mechanism 14 provides lateral shifting
of sod slabs through sod shift mechanism 29 with laterally
shiftable members that includes a track supported by runners 96
which are slidable along frame member 14a, a carriage 28
displaceable along the track with a sod holding apparatus secured
to the carriage 28. A cable 75 secured to the carriage 28 with a
rotatable cable drum 73 for winding the cable thereon to thereby
controllable displace the carriage 28 secured to the cable 75 to
thereby permit a transport of a sod slab supported by sod holding
apparatus from a first location to a second location along the axis
of the tracks.
[0122] The sod shift mechanism 29 provides for lateral displacement
of the entire carriage and tracks so that the sod supported thereon
can be laterality positioned with respect to a first layer of sod
deposited by carriage 28 and the cable drive mechanism provides for
shifting the sod drop off position along a rail axis by controlling
the stop position of the carriage 28 and 28a.
* * * * *