Patent Application
20140224514
The invention relates to a press/packer ring structure mountable on a press consolidator or packer roller for breaking down and consolidating a particulate substrate, such as a press cultivator used for breaking down and consolidating soil for cultivation. The invention further relates to a method of mounting a press/packer ring structure onto a press consolidator, to a method of replacement of a packer ring structure on a press consolidator, and to a press consolidator having a plurality of such packer ring structures mounted thereon.
Press cultivators comprising one or more rollers are conventionally used for crumbling and consolidating ploughed ground prior to sowing with seed. Firming the soil profile after disturbance by plough or disc is beneficial as it makes subsequent trafficking and cultivation easier and more effective. The soil profile will accept water more effectively by improved capillary action and if conditions are dry, moisture is more likely to be retained.
In some circumstances with some soil types sufficient consolidation can be achieved by use of a simple roller alone. The roller is drawn across the ploughed ground surface. The weight of the roller serves to break up soil clods and to consolidate the surface to produce a seed bed. Such rollers may be fitted with radically projecting blades to reduce sticking ensuring bite even in inclement conditions and reducing bulldozing. However they primarily act merely by compressing the soil, which can be of limited effectiveness, and the excessively flattened surface can also be undesirable, for example in relation to drainage.
More typically press cultivators may therefore comprise one or more rows of packer or press rings which consolidate and slice the soil clods remaining from ploughing, enabling break down into a seed bed more easily via subsequent weathering effects.
Packer or press rings may be made of cast or steel rings co-axially mounted to be pulled behind a tractor for example. One or more rows of press rings may be mounted on a common trailer chassis to be pulled behind a tractor for example. Such a chassis may also incorporate structures having other functionality; for example rows of press rings may be mounted in train behind a primary or secondary cultivator or like machine.
Packer or press rings may be mounted on a simple axle. For other applications it may be preferable to provide a packer roller or press consolidator roller having annular ring structures on a generally cylindrical roller barrel which itself makes up a substantial part of the overall diameter of the resultant roller, and the surface of which may also have a consolidation role. International Patent Publication WO2004/047515 describes an example of a press consolidator for consolidation of a particulate substrate such as soil in which a generally cylindrical roller barrel is provided with axially spaced packer ring structures, each packer ring structure being an annular structure extending radially outward from the barrel.
This press consolidator meets a general need to consolidate effectively across the width of the press and across the entire surface of an area to be cultivated without excessively flattening or compacting the surface, and in particular can do so using a single roller.
It does so in that the packer ring/roller barrel combination presents a row of radial blade formations projecting from the cylindrical barrel surface, the overall combination acting as a consolidation surface to fragment clods and consolidate the profile of the soil or other substrate, in particular leaving a corrugated ridge and trough surface profile which is weatherproof, wherein the ridges dry quickly and rain drains away through the troughs.
The press consolidator retains many of the advantages of simple barrel rollers, whilst at the same time surprisingly obtaining many of the apparently contradictory advantages of separate press rings. It gives a very evenly packed structure, consolidating across the full width of the roller. It retains a ridged structure to the consolidated surface with the benefits noted.
In such press consolidators, press rings have been fixed to the barrel by welding, this gives a reliable joint but has its drawbacks. In particular, over a few years the rings wear away and need replacing. This is a major engineering task as all the welds have to be cut off, then the barrel is cleaned up and new rings are welded on, this takes a huge amount of time and energy.
It is an object of this invention to provide a more flexible means and method for mounting press rings to a barrel of such a press consolidator in particular preferably to make the press rings replaceable without the need for weld removal or re-welding.
In accordance with the invention in a first aspect, a press ring structure for mounting upon a barrel of a press consolidator roller comprises a plurality of annular segments mutually mechanically engagable such as to form when so engaged a complete annular press ring structure, and adapted to be mountable on a barrel of a press consolidator roller such as when so mounted to form a press ring thereon.
The invention is distinctly characterised in that a press ring is segmented into a number of annular segments, each of these effecting when assembled a simple mechanical engagement with adjacent segments. This facilitates the use of a simple mechanical mount to mount the press ring in place on the barrel. The assembled whole is adapted to be mountable on a barrel, preferably in that each annular segment is adapted to be mountable on a barrel, such that it can be releasably fixed into place, for example by a suitable lockable and releasable engagement mechanism provided in conjunction with the barrel/press ring assembly, so as to allow mounting and subsequent removal of press ring structures on the barrel.
The segments may be thus brought together and assembled about the surface of the barrel, into a fixed and mounted configuration where they form a rigid structure mechanically engaged to one another to form a complete annular whole.
Such an arrangement provides for the attachment and removal of individual press rings on a barrel, and in particular provides for a mechanical arrangement which can facilitate this without the need for a welding joint. A welding joint may no longer be necessary and is preferably dispensed with entirely. This provides a potentially more flexible method of mounting the press rings onto a barrel of a press consolidator, in particular one which is suitable to make the press rings replaceable without the need for weld removal and re-welding.
Suitable press ring structures which are formed by the plurality of annular segments of the invention when duly assembled will be familiar to those skilled in the art, and their precise configuration is not pertinent to the invention. A typical annular press ring structure comprises at least a radially projecting press ring formation which extends outwardly from and for example generally perpendicular to the surface of a barrel on which it is mounted, so as to create a furrow in a surface to be consolidated. Typically, as will be familiar, a press consolidator roller barrel will comprise a plurality of axially spaced press rings along at least a substantial part of its surface. Typically, a series of such press rings will be identical and evenly spaced for example. Such arrangements of press consolidator roller will be familiar to those skilled in the art.
In a simplest case the radially projecting press ring formation may comprise a radial blade formation, preferably annularly extending around the entire extent of the ring, and for example comprising an annular disc, projecting perpendicularly beyond the barrel surface when mounted in situ. Such a formation defines generally parallel outwardly presented surfaces for the press ring structure projecting perpendicularly beyond the barrel.
Such an annular disc or other radial blade formation is preferably provided with a circumferentially varying edge profile, for example being notched or serrated, to facilitate rotation even in the most inclement of conditions.
In a typical convenient varying edge profile, an annular disc or other radial blade formation extends beyond a barrel when mounted to a mean radial distance, but the edge profile is notched or serrated, for example according to a sequentially repeating pattern around the annular formation, by a varying amount either side of the mean radial distance. Typically, the annular disc formation will be notched or serrated by a varying amount either side of the mean radial distance that at its greatest extent is less than the total projecting distance between the barrel and the mean radial distance.
Additionally or alternatively to such a notch or serration, the radially projecting press ring formation may comprise one or more drive lug projections comprising portions of the annular disc or other radial blade formation which extend substantially beyond the mean radial distance of the radial blade formation, and for example for at least the same distance again as the total projecting distance between the barrel and the mean radial distance.
A press ring formation may be provided with one or more such drive lugs. For example, one, some or all of the annular segments may comprise one or more such drive lugs.
The purpose of such a drive lug is to create an extra drive to keep the assembled press consolidator roller turning in all soil types and conditions. Different numbers can be fitted for different conditions. In a possible embodiment, at least some annular segments may be interchangeably provided in two alternative forms, with and without such a drive lug, which may allow the conformation of the assembled press consolidator to be changed for different conditions.
Additionally or alternatively the radially projecting press ring formation may comprise a wedge formation tapering from a wider base at the barrel to a narrower distal portion to present a generally v-shaped projecting portion when mounted in situ, preferably annularly extending around the entire extent of the ring. Such a formation defines outwardly presented surfaces for the press ring structure that are generally v-shaped and tapered as it projects perpendicularly beyond the barrel.
The wedge formation is preferably defined by at least a pair of symmetrical opposed shoulder portions protruding radially from the roller barrel when in situ. Conveniently the outward surfaces are either planar or convex.
In a preferred embodiment the radially projecting press ring formation combines both structures, for example having a wedge formation proximal to the barrel and a disc formation extending outwardly beyond it.
In a particularly preferred embodiment, the radially projecting press ring formation preferably comprises three parts, these being a central ring protruding radially to the greatest extent and a pair of shoulder portions extending therefrom from opposing sides of the ring to the roller barrel surface when mounted in situ. Preferably the shoulders are of convex design.
The central ring preferably protrudes radially beyond the greatest radial extent of the shoulder portions, is preferably generally a circular annular disc, is preferably oriented generally perpendicular to the axis of the roller barrel when mounted in situ.
In accordance with the invention, an annular press ring is split into a number of annular segments, each of which is mechanically engagable with its neighbours so that the segments are assemblable into a complete annular press ring.
Preferably, a press ring comprises between three and six annular segments.
Conveniently, each press ring segment making up a press ring is identical.
The press ring segments making up a given press ring are provided with mutually co-operable mechanical engagement formations such that in an assembled state each end face of each annular segment abuts with an adjacent end face of an adjacent annular segment in mechanically engaged manner. For example, complementary first and second engagement formations are provided in association with and for example in or on the adjacent end faces of each pair of abutting annular segments. For example, complementary projections and recesses may be provide on or in such adjacent end faces.
In a convenient embodiment, the first and second end faces of each annular segment of a press ring are respectively provided with identical first and second engagement formations, such that in a complete assembled press ring a first engagement formation of a first face of each segment is mutually engaged with a second engagement formation of an adjacent second face of a neighbouring segment successively around the ring.
In a particularly convenient arrangement, mutually co-operable and engagable projections and recesses are provided such that a projection on a first face of a first press ring slots in a releasably retained manner into a complementary recess in an adjacent second face of a second press ring segment.
Although it is a requirement of the invention that the assembled press ring structure must be rigidly formed and rigidly retained on the barrel when fixed in situ, and preferably lockably retained thereon, it is not a requirement of the invention that any such locking mechanism is necessarily provided between the annular segments themselves so long as they lock suitably in place in situ on the barrel.
Each press ring, when assembled, and in the preferred case each press ring segment, is thus adapted to be mountable on a barrel, for example by releasable mechanical fixing formations associated with the press ring and/or barrel and or discretely provided, so as to be releasably lockable thereon for use.
In a possible convenient arrangement, each press ring, and in the preferred case each press ring segment, has at least one through aperture configured to seat on a projection on the barrel in use and/or to receive a through fixing member to attach the press ring to the barrel in use.
In a more complete aspect of the invention, an assemblable and dissassemblable press consolidator roller comprises a plurality of press ring structures each comprising a plurality of annular segments in accordance with the first aspect of the invention; a barrel; and mechanical fixing formations to releasably fix assembled press rings to the barrel.
The mechanical fixing formations may be provided as separate structures co-operating with the press rings and the barrel to attach the former to the latter and/or may be integrally formed with ring segments and/or may be integrally formed with the barrel.
The mechanical fixing formations preferably comprise a means to lock each annular press ring releasably in situ on the barrel surface in such a manner that it is rigidly mechanically engaged thereto for use.
Suitable mechanical fixing formations may include one or more of the following:
Fixing formations in accordance with this aspect of the invention may include locking structures, for example being threaded, and for example comprising combinations of nuts/bolts and like threaded connectors which may be in suitable combination integrally formed with and/or separate from the barrel or ring segments.
It is the key to the invention that regardless of the precise mechanism chosen for such fixing formations, they fix the assembled annular press rings in situ on the barrel in mechanically rigid manner for use, but in a manner which is releasable to allow the subsequent removal of the press ring structures. The provision of such mechanical fixings may obviate the need for any welded joint, and thus simplify removal, for repair and replacement for example. Typically, after a few years when the press ring structures have suffered excessive wear, the fixing formations may be released allowing the rings to be removed and replaced with ease.
In a typical arrangement, as will be familiar, a row of press ring structures is provided axially arrayed along the roller. Preferably, all of the press rings in a row are arranged to extend outwardly in parallel planes, and in particular in planes perpendicular to the axis of the roller.
Preferably, press rings are generally evenly spaced axially along the roller when so arrayed. Preferably, each press ring in a row has a similar size and profile. For example the press ring structures are identical and evenly spaced when so arrayed.
The barrel is adapted to receive a plurality of mounted press ring structures so axially arrayed along at least a substantial part of its length for example by being adapted by provision of or to co-operate with suitable fixing formations as above described.
The press ring structures are conveniently spaced along the roller to project in such manner as to leave gaps therebetween, such that in use both the press ring structures and the circumferential surface of the barrel together make up the consolidation surface. This ensures consolidation across the whole width of the roller, whilst at the same time ensuring that a ridged structure is maintained.
In this way, the press rings create furrows in generally conventional manner. However, since the soil at the ridges contacts the barrel surface it also gets consolidated. This gives a mirror finish to the entire packed surface which offers more resistance to wind erosion and capping. The barrel acts as a positive depth control effective in a range of substrate conditions, since the ridged portions can only sink to the level of the roller surface. Excessively deep ridges are prevented. Thus the apparently contradictory benefits of the barrel systems and ring systems can be combined, and many of the disadvantages of ring systems overcome, in admirably simple manner.
For optimum effectiveness, the spacing between adjacent press ring structures should be of the same general order of magnitude as the width of press ring structures at their widest point, with a clear space of for example 0.5 to 3 press-ring structure widths being left between each adjacent press ring structure. Preferably, press ring structures are provided along the entire length of the barrel or a substantial part thereof.
An example of such a press consolidator for consolidation of a particulate substrate such as soil is described in WO2004/047515. The present invention is particularly applicable to, though not limited in application to, press consolidator rollers of the type described therein, which may be considered incorporated herein by reference.
The preferred diameter of the cylindrical barrel structure and detailed dimensions of the press ring projections might be varied for different intended substrate conditions. However, it is a virtue of the present invention that a single basic design will be widely applicable to a range of conditions. Preferably, the barrel will be up to 1000 mm in diameter and for example between 400 and 700 mm in diameter, therefore giving optimum performance in a range of substrate conditions, and in particular providing a large rolling circumference to prevent bulldozing in light sandy soil conditions.
As an alternative to simply altering the size of the barrel, means may be provided to alter the downward pressure it exerts for different conditions. In particular, means may be provided to increase the weight of the barrel where a more aggressive rolling action is required. Conveniently, the barrel is at least partly hollow, providing a reservoir therewithin for the addition and removal of ballast weight to effect this, most simply by filling with a liquid such as water.
In this way, in heavy soil conditions the press consolidator can have its weight increased by filling the barrel with water giving a much more aggressive crushing rolling action as necessary.
This aspect of the invention encompasses the above mentioned segmented annual press ring structures and/or barrel and/or integral or separate fixing formations in any combination for example as a kit of parts. This aspect of the invention additionally comprises a press consolidator roller assembled from such a combination of annular segments and barrel and integral or separate fixing formations.
In a further aspect the invention additionally comprises a barrel configured for use with mountable segmented press ring structures in accordance with the first aspect of the invention, in particular in that the outer surface of the barrel is specifically adapted to locate and/or mount press rings in accordance with the first aspect of the invention upon it. For example the barrel is provided with projections, recesses, fixing projections or apertures to receive fixing means that are complementary to those provided on or provided with the press ring segments in accordance with the first aspect of the invention.
In a further aspect of the invention, a press consolidation system comprises a chassis having mountable thereon at least one press consolidator assembly (i. e. at least one roller comprising a cylindrical barrel and mounted projecting press ring structures) as above described. A plurality of press consolidators as above described may be serially mounted in train upon such a chassis so as to act sequentially on the soil or other substrate when drawn thereacross. Other cultivation units having other functionality may be serially mounted in train on the chassis with the one or more press consolidator roller assemblies to provide other sequential functionalities as the whole chassis assembly is drawn across a substrate. For example, primary or secondary cultivators or the like may be provided.
Each press consolidator assembly is preferably mounted on a pair of bearings on the chassis, enabling the entire roller to revolve freely.
The press consolidator system is drawn across the substrate in use. This might be effected in that the chassis may comprise an integral vehicle provided with drive means to enable it to be driven across a surface to be consolidated and/or in that the chassis may comprise part of a trailer structure to enable it to be towed there across. In particular, the chassis comprises a trailer structure, with means provided to engage a forward part thereof with the towing apparatus of a suitable towing vehicle, such as a tractor or the like. Road wheels may be provided on such a trailer deployable from a road engaging position whereat the press consolidator and any other assemblies upon the chassis are lifted above the surface for road use, and a stowed configuration whereat the wheels are out of the way allowing the press consolidator and any other assemblies upon the chassis are in position to engage the surface of the substrate to be consolidated.
The press consolidator assembly can be fitted and retrofitted into a wide range of primary/secondary cultivation machines, this will allow for pressing and firming to a higher quality with a lower power requirement than any current land press.
Although the invention is discussed in the context of cultivation, it can be applied wherever substrate levelling with conditioning is required. Other uses for the press consolidator assembly may easily be envisaged. For example the consolidation may be used in construction, for road building or road levelling or in any similar form of ground levelling or the like.
In accordance with the invention is a further aspect, a method of assembly of a press consolidator roller comprises the steps of:
The method of this aspect of the invention is thus a method of fitment of segmented press ring structures in accordance with the first aspect of the invention and/or a method of assembly of a roller system in accordance with the second aspect of the invention, and preferred features will be understood by analogy.
In particular, the method comprises:
In accordance with a further aspect of the invention, a method of repair of a press consolidator roller assembly assembled in accordance with the foregoing aspect of the invention is provided, comprising the steps of:
The invention will now be described by way of example only with reference to the accompanying drawings in which:
a and 4b show a perspective view of two alternative embodiments of annular segment in accordance with the invention;
Referring to
A press ring in the embodiment comprises a radially extending primary central disc 2 and convex shoulder portions 1. The convex shoulder portions 1 together form a wedge shape that tapers from a wider base at the barrel to a narrower structure distal from the barrel. The convex shoulder portions 1 do not extend the full radial width of the disc 2, but are configured such that a projecting portion of the disc 2 remains projecting beyond the top of the shoulders to cut a primary channel within the consolidated soil surface.
In the illustrated embodiment the disc 2 is given a serrated edge. This serrated edge ensures bite in difficult and heavy conditions, assisting consistent rotation. A number of serrated tooth profiles will be appropriate.
Also illustrated is a mounting bearing 9 by which the roller assembly can be mounted upon a chassis for use.
Each annular press ring formation 5 is split into a number of segments (labelled as 5′ when detached) which together make up an assembled whole when assembled in situ on the barrel 3.
In
The embodiment differs in that each press ring structure is provided with a drive lug 21 which extends substantially beyond the otherwise regular serrated edge profile of the annular disc 2. This radially extending drive lug has the effect of increasing the overall diameter of the assembled packer ring, creating extra drive to keep the roller turning in all soil types and conditions.
One or more such lugs may be provided in an assembled packer ring, and where multiple lugs are provided these are conveniently evenly arrayed around the system. For example, in a convenient embodiment, one, some or all of the segments may each be provided with one such drive lug. In the illustrated embodiment, where an annular formation is split into four segments, this means that drive lugs can be fitted as four per annular ring, three per ring, two per ring, one per ring or none at all depending on conditions and preferences. This gives an additional flexibility to the device which further exploits the mountable and demountable nature of the annular segments.
Each of the two alternative embodiments of annular segment is illustrated in greater detail in
In particular, this is achieved in that each segment is open underneath to define a hollow portion, and has a forward projection 23 which engages in the recess defined by the hollow portion of a further segment against which it abuts. The forward projection 23 and the corresponding hollow body of the segment against which it abuts define mutually co-operable and engagable projections and recesses. Multiple segments can thus be assembled onto a barrel. They may then be fixed in place by provision of suitable fixing means inserted through the through apertures 13.
The invention is distinctly characterised by the way in which the roller assembly is assembled, and in particular the way in which the press rings are demountably attached to the barrel. This can be seen in
Each annular press ring formation 5 is split into a number of segments (labelled as 5′ when detached) which together make up an assembled whole when assembled in situ on the barrel 3.
Each of these annular segments 5′ has a forward connecting portion at a forward face which slots into a suitable receiving portion in the back of the next segment. In the case of the example, a forward lug 23 extends beyond the convex shoulder portions at one end of a segment and is received in and located in the recess defined by the inner walls of the next segment. Multiple segments are thus successively linked together in a ring around the barrel ready for fixing.
Each segment locates over and fixes on a dowel 11 welded to the outer surface of barrel 3. Each dowel 11 extends through a through aperture 13 extending in a radial direction (relative to the barrel) through the annular segment. This locates and fixes each annular segment making up a complete ring assembly into position on the surface of the barrel 3.
In the embodiment, the dowel 11 is provided with an internal threaded portion with which the segment is bolted down by means of the bolt 15, so that the overall assembly making up each annular ring is stably and rigidly locked into position, but can be released if desired by unscrewing of the bolt.
After a few years, when the press ring structure is showing unacceptable signs of wear, it is a simple matter to unscrew the bolts allowing the rings to be removed and replaced. There is no need to provide a welded joint between the barrel 3 and the rings 5, and consequently when the rings are to be replaced there is no requirement to remove existing welds and re-weld new rings from scratch.
The arrangement is easy to assemble and lend itself particularly to the ready replacement of individual press ring structures, when this might be required for example through wear and tear.
| Number | Date | Country | Kind |
|---|---|---|---|
| 115327.7 | Sep 2011 | GB | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/GB2012/052182 | 9/6/2012 | WO | 00 | 3/4/2014 |
