The present invention relates to a retractable roof.
Retractable roofs are used in a variety of applications, such as sport stadiums, storage facilities and for protection of crops as they grow. The ability to cover and uncover an area enables the ambient conditions beneath the roof to be adjusted and mitigate adverse effects of the environment, such as excessive heat or rain. This is particularly important in horticultural applications where an unexpected weather event can cause serious damage or loss of a crop.
Conventionally, crop protection has been provided by glasshouses which are large permanent structures. They are therefore expensive to build and maintain.
An alternative type of structure is that exemplified in U.S. Pat. No. 5,265,373 issued to Richard Vollebregt in which crop protection is provided by curtains that can be extended and retracted along support wires to adjust the protection afforded to the crop.
U.S. Pat. No. 5,513,470 to Richard Vollebregt shows a crop protection structure in which gables provide support for a ridged curtain system that emulates a conventional greenhouse structure. The gables support curtains that extend across the peaks and through the valleys. The curtains can be extended or retracted by a driven cable to vary the protection provided. The cables are connected to a drive system that includes a rotating shaft that extends along the gable to provide multiple locations to which cables can be connected to the curtains.
Because of the pitched nature of the roof, the drive shafts incorporate universal couplings and more than one drive shaft may be used along the length of the structure. The substantial nature of the gables provides a durable and versatile structure but the complexity of the drive system is relatively expensive and complicated to install. The cost is justified where intensive horticultural practices are concerned with multiple high value crops per growing season.
In order to reduce the overall cost of installation an alternative support structure is shown in U.S. Pat. No. 9,163,401 to Richard Vollebregt where posts and tensioned cables are utilised to provide the gables and support a gutter that collects the rainwater. This allows the structure to be installed on land that is not level and significantly reduces the cost of materials whilst maintaining the versatility. However, for certain applications, the high cost still cannot be justified.
For example, crops like cherries and grapes need to be grown outside since they need cold temperatures in the winter time and need exposure to the natural outdoors to create firm, sweet fruit. Such crops need protection from rain primarily during the last several weeks just prior to harvest to prevent splitting of fruit and maintain the quality to attain the highest available price. Automatic retractable roof systems such as those discussed above can protect plants from cold, heat, wind, rain, hail and are cost effective on crops like vegetables which need protection from rain 12 months per year. However a retractable roof system like those described above is cost prohibitive for crops that only have one harvest of fruit per year (i.e. cherries, grapes) since the value of the crop per hectare is much lower than crops that have multiple harvests over many months. Moreover, the value of the rain shedding capabilities only starts in year 3 when cherry trees start to produce fruit. In addition, crops like cherries can tolerate having rain fall in between the rows of trees as long as the rain does not fall on the tree or fruit whereas crops like vegetables need a gutter system below the retractable roof to catch the rainfall from the valley since the crops cover most of the area beneath the roof.
Where permanent retractable systems cannot be justified, seasonally installed protective coverings may be utilised. Such coverings are manually installed early in the season and are used to advance flowers and protect from frost, wind, sunburn and rain prior to harvest. The covering must be in tension (taut) to minimize flapping since movement of the covering causes failure due to fatigue. It also takes significant manpower to install and remove.
Whilst the seasonal covering may provide for protection from extreme weather events over the growing season, the covering changes the climate in negative ways compared to a natural environment, resulting in softer fruit that is less sweet and has a shorter shelf life. The openings between the lower edges of the curtains allow for continual air exchange between the areas below and above the covering which prevents protection from cold air temperatures. Openings between the coverings mean that the covering cannot be used to raise temperatures like a greenhouse or trap supplemental heat to accelerate the spring flowering.
Movable rain coverings intended to protect crops during the critical period prior to harvest rather than protection over the whole growing season have been proposed where the coverings are slidably supported on guide wires and can be deployed selectively depending on weather conditions. Some proposals require manual deployment using long sticks or ropes, but this is time consuming and can result in crops not being protected in time before adverse weather arrives, resulting in damage to the covering or fruit.
Rain coverings have also been proposed that are moved with a drive system powered by a rope or cable at the peak that is powered by motor and gearbox or portable drill. The major advantage of a powered system is that the coverings can be closed quickly when rain or hail is approaching to prevent damage to the fruit however the roofs on each set of peaks are operated individually which takes more time and reduces that chance that the covers are deployed or retracted in time.
To be able to move the covering when it is only powered at the peak, the covering must be loose so that there is minimal friction between the plastic hooks that connect the covering to the supporting wires or cables. However, lose fabric will flap in the wind causing fatigue to the covering over time and therefore a shorter life.
To move a covering, an economical way is to have a drive cable at the peak and drag the rain cover panel closed. This causes the lower edge to drag behind which then necessitates that the covering needs to be flexible so that it can easily pleat. This is accomplished by not installing any additional reinforcing or stiffening at the grommet location.
In such an arrangement, the peak of the covering is powered but the lower edge is not powered causing the covering at the valley to lag behind the peak position. This causes sections of the roof to not be completely closed allowing rain to enter and damage the fruit or for heat to escape. In order to ensure a proper closing and retracting of the rain cover it is necessary to power the covering both at the upper and lower edges of the covering. To do that, a drive shaft would need to have universal joints to allow it to follow the profile of the roof so that one motor can power multiple coverings. This adds to the cost and complexity for installation and maintenance especially when covering fields with rolling grades.
One covering system marketed by Valenti under the trade name Wayki (https://valentepali.com/en/orchard/orchard-coverings/antirain/multishield/wayki) uses a drive cable at the peak to move panels of the rain cover sequentially. A hook engages the rain cover panel at the peak as it passes a support and releases it as it gets to the next support. This system has the advantage of being a simple system however it still requires the lower edges to slide freely along the wire and because it releases the panel as it moves along, it does not ensure the covering remains in a fixed position. A strong wind can blow a closed cover open or an open cover closed.
It is an object of the present invention to provide a retractable roof in which the above disadvantages may be obviated or mitigated.
According to one aspect of the invention there is provided a retractable roof structure having a pair of longitudinally spaced supports, guide wires extending between said supports and positioned to support a covering in a required profile, said covering comprising a plurality of sections arranged in seriatim along the guide wires with each section slidably supported on the guide wires so as to be moveable between an open position in which the area beneath the covering is exposed and a closed position in which the area beneath the covering is covered, a drive member extending between the supports and operably connected to one end of each of the sections at a first location to move the one end along the guide wires, and a first tensile member extending between said first location and a second location on another of said sections spaced from said first location and operably connected to said drive member to move said second location conjointly with said first location, whereby movement of the first location of one section is transferred through the tensile member to the second location of the other section to cause a corresponding movement.
Preferably each of said locations is adjacent a respective one of the guide wires.
As a further preference, a second tensile member extends from the first location on the other section to a second location on the one end of the one section.
Still further, the required profile is a ridged profile having an elevated peak extending outwardly and downwardly to a pair of eaves and the guide wires are located at the peak and at the eaves to constrain the covering to the required profile.
Embodiments of the invention will now be described with reference to the accompanying drawings in which:
Referring firstly to
The roof structure 10 comprises support structures 11 positioned at regular intervals along the row R to define a number of bays B for each row R. A spacing of the supports 11 of four metres is typical but different spacing may be used depending on the particular site and application.
Each of the support structures 11 includes three laterally spaced posts 12. Lateral wires 14 are spaced apart vertically and extend horizontally between the posts 12 of each support structure 11. One of the lateral wires 14 is positioned at the top of the posts 12 and the other lateral wire 14 is spaced approximately one third of the height of the post below the upper lateral wire, depending on the crop being protected. Where multiple rows R are to be protected the wires 14 may extend across the whole of the growing area. The height of the upper wire 14 will depend on the crop C but a height of 3.5 metres is typical.
Where a single row R is to be protected, the wires 14 may be replaced by a rigid arm to define the lateral extent of the roof structure 10. Again, this will depend on the crop C but an overall length of the arm of three metres is typical, 1.5 metres to each side of the post 12 with the arm 3.5 metres above the ground.
The posts 12 are stabilised by tie wires and ground anchors 13 and a stabiliser wire 15 extends between the top of the central posts 12 to transfer loads between support structures 11 of the same row R. The horizontal wires 14 are tensioned by tensioners 17 (
A ridge guide wire 16 extends between the upper ends of the central post 12 and is connected to each of the posts 12 as will be described in greater detail below. Eave guide wires 18 extend between the lower lateral wires 14 and are connected to lateral wires 14 at the lateral extent of the row R, typically 1.5 metres to either side of the central post 12. The guide wires 16, 18 are used to support a covering 20 in the required profile, which in this case is a ridged profile having a peak 22 and eaves 24 as best seen in
The covering 20 is formed in individual sections 26 arranged in seriatim along the row R to provide a leading section 26a at one end of the row R, a trailing section 26b at the opposite end of the row R and intermediate sections 26c between the leading and trailing sections 26a, 26b. Each section 26 is dimensioned to extend between adjacent support structures 11, i.e. across one bay B, and, as shown in
Each of the panels 28 has a leading edge 32 that extends from an upper corner of the panel 28 adjacent the ridge wire 16 to a lower corner of the panel adjacent the eave wire 18. A trailing edge 34 of the panel 26 is secured to a shelf 35 (
As can best be seen in
The upper longitudinal edge 36 is not reinforced with a rope but has grommets 42 to receive the bands 29 and hooks 30 secure the bands 29 to the ridge wire 16. The upper edge 36 is thus more flexible than the lower edge 36 and pleats more easily in the retracted position. In this manner the motive force required to open or close the cover is reduced whilst the wear resistance at the eaves is maintained.
A drive system, collectively indicated by reference numeral 50 and shown in
A drive cable 60 extends from the shaft 54 to a post 12 at the opposite end of the row R, around a pulley 62 secured to the post 12 and back to the shaft 54. The drive cable 60 provides a driving run 64 and a return run 66 which are generally parallel to but spaced from the ridge guide wire 16. The opposite ends of the drive cable 60 are wound in opposite directions about the shaft 54 so that as the shaft 54 rotates, the driving run 64 and return run 66 move in opposite directions but remain a constant length.
As shown in
The leading edge 32 of each panel 28 is connected to the driving run 64 by the bracket 90 shown in
The bracket 90 has a pair of cable clamping blocks 100 mounted on the face of the plate 92 with a V-shaped notch 102 to receive the driving run 64 of the cable 60. The blocks 100 clamp the driving run 64 against the plate 92 to fix the bracket 90 securely to the cable 60.
A tab 104 is bolted to the plate 92 to receive the body of a clip 106. The clip 106 is similar to the hooks 30 having a peripheral body 108 and an open centre 110. One side of the body 108 and can be opened to allow the ridge guide wire 16 to pass into the centre 110 and be encompassed by clip 106. The clip 106 is of known construction, such as that shown in U.S. Pat. No. 5,761,776, and need not be described further. The bracket 90 is thus supported on the ridge wire 16 by the clip 106 for sliding movement along the ridge wire 16 and connected to the driving run 64 of the drive cable 62 for movement with it. A wire loop 112 is mounted to the top of the bracket 90 to maintain the return run 66 in proper spaced relationship to the driving run 64.
Operation of the drive system 50 causes rotation of the shaft 54 and moves the driving run 64 relative to the ridge guide wire 16. The bracket 90 associated with each section 26 of the covering 20 moves along the ridge guide wire 16 and pulls each of the leading edges 32 of the panels 28. Each of the panels 28 will thus deploy from a retracted to an extended condition as shown in
To mitigate this, a pair of tensile members 120 are attached at a first location adjacent to the bracket 90 of each of the sections 26. The tensile members 120 are conveniently a 2.2 mm polyester monofilament wire that is relatively light, smooth and flexible that will not abrade the panels 28. Alternatively, the tensile members may be rope, cables or wires or even rigid rods if preferred.
The tensile members 120 pass along the outer surface of a respective panel 28 and the opposite end 121 is connected to the leading edge 32 of the adjacent trailing section 26 at a second location. Conveniently, the second location is adjacent to the eave guide wire 18 so the lower corner of each of the panels 28 is connected by a tensile member 120 to the peak of the leading edge of the preceding section 26. As the bracket 90 is moved by the driving run 64, the movement is transferred through each of the tensile members 120 to the lower corner of the following section to pull it along the eave guide wire 18. In this way the friction between the hooks 30 and the eave guide wire at the leading edge is overcome.
To provide for a similar effect when the covering is being moved in the opposite direction, i.e. to the retracted position in the example above, a second pair of tensile members 122 are connected from the bracket 90 of the trailing section to the lower corners of the leading edge 32 of the preceding section 28.
Thus movement of the bracket 90 of one section 26 in either direction by the driving run 64 of cable 62 is transferred through the tensile members 120, 122 to the lower corners at the panels 28 of another section 26 to promote sliding of the panels on the eave wires 18.
The leading edge 32 of the leading section 26a, that is the section closest to the drive shaft 54, cannot be connected to a preceding section. To assist in moving the leading section along the eave guide wires 18, an additional tensile member 124 is connected to each lower corner of the leading edges 32 of section 26a as shown most clearly in
With the drive system 50 operating to move the covering 20 from a retracted condition of
A similar arrangement is provided at the trailing section 26b as shown in
The organisation and direction of movement of the tensile members 120, 122, 124 and 126 is shown in
In some circumstances, depending primarily on the dimensions of the sections 26, it is found that the connection of the tensile member 124 and the tensile member 122 at the leading edge 32 places a significant lateral load on the eave guide wire 18. This may be sufficient to displace the wire 18 and distort the balance of the covering. An alternative arrangement to address this is shown in
It will be seen therefore that the provision of the tensile members from the peak of one section to the eaves of the adjacent section can be used to assist movement of the panels along the eave guide wires and promote a smooth sliding action for the panels. The arrangement is achieved with a single power source and avoids a complex jointed drive shaft.
It will be apparent that different profiles of covering may be utilised. For example, a shed roof may be provided with a single inclined panel in each section. In this arrangement a single tensile member from one location on one of the sections, typically the higher point of the leading edge, to a second location on the adjacent panel, typically the lower point of the leading edge, may be used to maintain proper sliding motion.
The attachment of the tensile members to the peak at one end and the eave at the lower end may also be chosen to suit individual needs. The attachment to the driven run may be at the connection of the section to the run or may be spaced from it along the leading edge provided there is sufficient stiffness in the leading edge to transmit the movement. Similarly, the connection may be made at a location spaced from the leading edge in the direction of the ridge wire.
The attachment to the adjacent panel may also be varied from the location of the eaves cable but it is believed the optimum locations are at the peak and at the eaves where there is adequate structure to withstand the loads imposed.
The points of attachment should be chosen so as to convey the movement of the leading edge by the driven run through the tensile member to another of the panels so as to induce movement of the leading edge along the eave wires 16. The exact location will depend on the nature of the connections of the panels to the guide wires and driving cable, the dimensions of the panels and the durability of the panels.
As described, the driven run is attached to the peak but it might also be attached to the eaves with the tensile members extending to the peak on the adjacent section. This would of course require a drive cable at both eaves and might impair access to the crop.
A further embodiment of a retractable roof structure is shown in
These issues are mitigated in the embodiment shown in
Additional support for the stabiliser wire 15 is provided by intermediate posts 204 with lateral wires 206 extending between the posts 204.
The covering 20 is divided into sections 26 between each of the support structures 11 but in this embodiment, in view of the connection of the hanger 200 to the ridge wire 16, each section 26 is divided in to two subsections 206. The peak of each subsection 206 is slidably supported on the ridge wire 16 and the eaves are slidably supported on the eave guide wires 18.
Each subsection 206 has a leading edge 208 and a trailing edge 210. The leading edge 208 is free to move between a retracted and deployed position by sliding on hooks along the ridge wire 16 and eave guide wire 18 as discussed above. Movement of the trailing edge 210 is prevented at the peak by abutment with the hanger 200 in midspan or the post 12 at one end of the section 26. Similarly, each of the trailing edges 210 is secured to the eave guide wire 18 by an abutment of the ring 30 with clamp 212 as shown in
As can be seen in
A plate 224 is connected to the return run 66 and carries a cable capstan 226 mounted at one corner. A tensile member which could be wire or cable, referred to as a diverter wire, 124, is connected to the capstan and passes forwardly through pullies 136, 134, 132 (
The diverter wire 124 continues to the distal support structure 11 where it is routed through the pullies 132, 134, 136 and connected to the return run 66 in the distal subsection 206.
A similar diverter wire 124 is routed along the opposite eave and connected to each of the leading edges 208, as indicated in
Where necessary, a second tensioning spring 232 is incorporated into the diverter wire 124 as shown in
The pulley 132 is supported on a lateral wire and therefore subject to changes in orientation as the tension in the diverter wire 124 varies. To alleviate this, the pulley 132 is incorporated into the connection of the eave guide wire 18 as shown in
The body 252 has a sleeve 260 that receives the lateral wire 14. The eave guide wire 18 is wrapped around the spindle 254 and torque applied through the boss 254 to impart a significant tension in the guide wire 18. The locking plate 256 is then pinned to the body 252 to maintain the tension. Alternatively, the body 252 could be clamped onto the lateral wire 14
The body 252 has an ear 262 extending above the guide wire 18 with pulley 132 mounted on the ear. The pulley is aligned with the guide wire and forces in the diverter wire 124 are resisted by the tension in the guide wire and lateral wire 14 to reduce deviation in the pully 132. The pulley 132 can be aligned with the eave guide wire 18 by installing washers between the pulley and the ear.
In operation, to move the cover from a retracted to a deployed position as shown in
The return run 66 of drive cable 60 is moving in the opposite direction and transmits that movement through the pullies 132, 134, 136 to the leading edges 208 of the subsection 206 at the eaves. Because of the direction reversal through the pullies, the eaves are also pulled toward the support 11 so that the peak and eaves move conjointly to the closed position.
To open the covering 20, the shaft 54 is reversed (
Where the roof structure extends over multiple rows of trees as illustrated in
The elastic bands 29 used to connect the panels to the eave guide wire 18 provide a degree of resilience to accommodate wind loads and fluctuating tensions caused by the movement along the wires but also introduce a spacing of the lower edges 36 between adjacent rows. In some circumstances this can lead to an ingress of rainwater as shown in
In the embodiment of
A further embodiment is shown in
A yet further embodiment, similar to that of
As can be seen in
A drive cable 60 extends as an endless loop between the central posts 12 at the opposite ends of the row R with a driven run 64 and a return run 66. The leading edge of each panel 28 is connected to the driven run 64 by a plate 90, as described above with respect to
As described above with respect to the embodiment of
The vertical tube 300 and the foot 302 are connected to upper and lower cables 14 instead of a rigid member since orchards are not always built on flat land and existing orchards do not always have a consistent spacing between tree rows which means that supports 12 may be at a variable spacing. Using cables 14 instead of a rigid member allows for the house to follow rolling grades and for supports 12 to be a variable spacings without any customization.
The tensioner 250 for the eave wire 18 is welded or otherwise secured to the front face of the tube 300 with the pulley 132 mounted on its side face immediately above and the pulley 134 mounted on the front face adjacent the upper wire 14.
The tube 300 maintains the spacing between the pullies 132, 134 as tension is applied to the diverter wire 124. The connection to the wires 14 also maintains the lateral spacing between adjacent eave wires 18. The tension applied through tensioner 250 will cause bowing of the lower wire 14 and the holes 304 allow adjustment of the cross beam on the foot 302 to maintain the tube 300 substantially vertical, thereby maintaining the required geometry of the diverter wire 124.
As can best be seen in
A similar configuration is provided at the distal end of the row R as shown in
In operation, assuming the roof 20 is in an open position, the plate 90 will be positioned adjacent the support structure 11 separating the first and second bays B and the link 312 and its associated plate 90 positioned adjacent the support structure separating the second and third bays B. The drive shaft 54 is rotated to move the driven run and pull the peak toward the leading end structure 11. The link 312 is moved in the same direction by the driven run 64 and causes a corresponding travel of the diverter wire 124. The direction of the diverter wire 124 is reversed by the pulley 310 to move the diverter wire 124 through the pullies 136, 134, 132 and pull the leading edge of the panel 28 at the eave toward the end structure 11.
At distal end, as the driven run 64 pulls the cover to the closed position, the connection of the diverter wire 124 to the driven run 64 moves towards the pulley 316 and the diverter wire 124 is released and passes through the pulleys to allow movement of the panels 28 at the eaves.
Movement of the roof from a closed to open position is the reverse of the above with the retraction of the eaves being initiated by tension in the diverter wire 124 at the distal end with a corresponding release at the leading end.
By adopting the routing of the diverter wire 124 discussed above, it will be noted that there is a relatively short distance between the point of application of the drive force at the peak and the transmission of that motion through the diverter wire to the eaves. By contrast, in the embodiment of
To maximize heat retention without the use of flaps as in
In order to avoid undue friction and wear of the loops 30 as the diverter wire 124 moves along the valley, each of the lower horizontal wires 14 is used to support a cable guide 320 as shown in
It is desirable that the width of the panel 28 is the same for all locations where the spacing of the support posts 12 from peak to peak is the same. To accomplish this, the horizontal distance from the support post 12 to the valley 18 must be consistent in order for the length of the slope to be the same. In
Moreover, in certain situations where multiple crop protection systems are to be arranged side by side it is important that the spacing of the posts 12 is maintained at an industry norm, typically 4000 mm. and 2000 at the outside postline to support ½ of the roof) In that case, the tensioner 17 for the horizontal wires 14 and the eave support wire 18 have to be located inboard of the post 12 so a similar connection can be made on the other side of the post for the adjacent roof system. However, the width of the panel 28 is the same for all panels and to avoid excessive flapping of the panel 28 it is necessary to mount the outside panel differently while still retaining the functionality of the retractable roof 20.
Referring to
A strap 336 extends from the post 12 to the bracket 332 to provide lateral support for the bracket and maintain the position of the eave wire 18.
A support rod 338 projects laterally inwardly from the bracket 332 above the cable clamp 334 and holds the diverter wire 124 above the hook 30 to avoid abrasion in a manner similar to the rod 312 employed in the valley.
In each of the embodiments, it will be seen that a tensile member is used to transfer motion from one location, typically the peak, to another location, typically the eave so that conjoint movement of the locations is attained. The provision of the tensile member to transfer motion from one location to another enables a single linear drive shaft to be utilised for multiple rows without the need for jointed drive shafts or multiple shafts and related bracing complications. The panels forming the roof are maintained under control when open or closed to enhance the protection offered.
Although the invention has been described with reference to certain specific embodiments, various modifications thereof will be apparent to those skilled in the art without departing from the spirit and scope of the invention as outlined in the claims appended hereto. The entire disclosures of all references recited above are incorporated herein by reference.
Number | Date | Country | |
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63396062 | Aug 2022 | US | |
63419656 | Oct 2022 | US | |
63516010 | Jul 2023 | US |