AU2012238316A1 - Turfing Apparatus - Google Patents

Abstract

Abstract: A turf substrate distributor and profiler adapted to be towed behind a towing vehicle, the distributor or 5 profiler comprising an enclosure having a front of the enclosure including ground engaging wheels that pivot relative to the enclosure and means to control the position of the wheels relative to the enclosure whereby the height of a distributor roller or profiler rotor 10 relative to the ground surface is adjustable and the roller is driven to distribute the substrate, or the rotor is driven to cut and eject the substrate. 3759545_1 (GHMatters) P87367.AU. 1 10/10112 0 (0 co 0 0 H''U I IeI I 0le 0 00 ' -c R

Description

AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION Standard Patent Applicant(s): STRATHAYR PTY. LIMITED and PETER JOHN SADLER and LOUISE BERNADETTE GEBAUERS Invention Title: Turfing Apparatus The following statement is a full description of this invention, including the best method for performing it known to me/us: - 2 Turfing Apparatus Introduction This invention relates to machines for use in the 5 preparation of laying of natural turf. More particularly, the invention relates to a method and apparatus for forming the base on which natural turf can be laid. Background of the Invention 10 The applicant has adopted and developed systems whereby turf can be grown and harvested, and the soil from the root zone of the turf can then be removed by washing. Subsequently, this turf can be relocated on a growing medium which is preferably sand. It can, however, be a is sand/soil mixture together with sand/peat moss or even soil alone. In preferred form, the growing medium has a base including drainage. There is also additional of sand which has reinforcing material therein. This sand/reinforced material can be referred to as a matrix. 20 The applicant prefers to use, as a reinforcing material, polypropelene mesh elements such as those sold under the trade mark REFLEX. Other elements including fibre elements could be used. Such elements are sold under the Trade Marks TURFGRIDS, FIBRESAND,FIBRETURF or LOKSAND. 25 The laying and levelling of a substrate that includes plastics reinforcements for use on sporting ovals and race tracks has been an ongoing problem. The mesh elements in the sand/peat moss matrix need to be placed precisely. 30 The nature of the plastics mesh means that it is not possible to use graders because they tend to cause the mesh elements to bunch up on the surface. For the mesh elements to work efficiently it is important that they are 3759545_1 (GHMatters) P87367.AU. 1 10/10112 -3 incorporated evenly and randomly through the sand/peat growing medium. Thus, there is a need for a machine to produce a precise thickness of the matrix incorporating plastic mesh 5 elements to automate the turf laying process. Similarly, in the preparation of natural turf in form of grass growing in a substrate that includes a matrix of sand/peat moss and plastic mesh elements, it is important that the matrix of the substrate is precise and sufficiently thin 10 to allow the turf to be rolled up for transportation. It is these issues that have brought about the present invention. 15 Summary of the Invention In one aspect of the present invention there is provided a turf substrate distributor adapted to be towed behind a towing vehicle, the distributor comprising an enclosure that contains an axially rotatable roller, the 20 periphery of the roller having spaced blades that push the substrate into position, a front of the enclosure including ground engaging wheels that pivot relative to the enclosure and means to control the position of the wheels relative to the enclosure whereby the height of the 25 roller relative to the ground surface is adjustable either manually or through laser control. According to a further aspect of the present invention there is provided a turf profiler adapted to be 30 drawn behind a towing vehicle, the turf profiler comprising an enclosure containing a cutting means and a conveyor, whereby the cutting means enables the turf to be cut and placed onto the conveyor for ejection from the 3759545_ (GHMatters) P87367.AU. 1 1010/12 -4 profiler, the front of the profiler being supported by a ground engaging wheels, the height of the wheels relative to the enclosure being adjustable through a hydraulic ram, the rear of the enclosure supporting a trailing roller 5 that is secured to the enclosure to pivot about a horizontal axis extending longitudinally of the enclosure, and a laser mast mounted on the top of the enclosure whereby the height adjustment of the cutting means can be precisely adjusted. 10 Description of the Drawings Embodiments of the present invention will now be described by way of example only with reference to the accompanying drawings in which: 15 Figure 1 is a rear elevational view of a turf substrate distributor in accordance with a first embodiment, Figure 2 is a side elevational view of the distributor, 20 Figure 3 is a plan view of the distributor with height adjustment wheels removed, Figure 4 is a front elevational view of the distributor, Figure 5 in a plan view of a rotating drum that forms 25 part of the distributor, Figure 6 is a elongational view of the drum, Figure 7 is a front elevational view of a profiler in accordance with a second embodiment of the invention, Figure 8 is a side elevation view of the profiler, 30 Figures 9A and 9B are end and side elevations of a cutting rotor of the profiler, Figure 10 is a rear view of the profiler illustrating the association of the rotor with conveyors, 3759545_1 (GHMatters) P87367.AU.1 10110/12 -5 Figure 11 is a plan view of a rear roller of the profiler, Figure 12 is an exploded view of a height adjustment wheel assembly of the profiler, and s Figure 13 is a side elevational view of the support for the wheel assembly. Description of the Preferred Embodiment Figures 1-6 illustrate a turf substrate distributor io called a muncher 10 which comprises a rectangular enclosure 11 having sides 12, 13, a front wall 17. The underside 16 of the enclosure 11 is open and the top of the enclosure is covered by a wire mesh panel 18. A roller 20 is mounted across the interior of the enclosure i5 11 to be axially rotatable. One side 12 supports a sprocket 21 and chain drive 22 driven by a hydraulic motor 25 to cause rotation of the roller 20. The chain and sprocket drive 22 are enclosed in a housing 24 (Fig. 4). Each side 12, 13 of the rear wall of the enclosure 11 has 20 an adjustable wear plate 30 on the underside. The front wall 14 of the enclosure has a central quick hitch 36 for connection to the PTO of a tractor or suitable towing vehicle. 25 Across the top at the front 14 of the enclosure is a torsion bar 38 that is connected via hydraulic rams 37 to wheel assemblies 40, 41 that are pivotally secured at each wall to the front edge 17 of the enclosure 11. Operation of the hydraulic rams 37 cause the wheel assemblies 40, 41 30 to pivot about a horizontal axis thereby adjusting the height of the muncher 10. This height adjustment can be effected manually or automatically through a laser height adjustment system. The laser system has electrical 3759545_1 (GHMatters) P87367.AU.1 10110112 - 6 switches on a control box. When an auto/manual switch is in manual, the machine can be raised or lowered by the operator through a raise/lower switch. When the control box is switched to auto, the machine automatically will 5 adjust itself to the height of the laser or GPS program. The system is an electric over hydraulic system (the electrics operate the hydraulic valve which raises or lowers the wheel assemblies). 10 Each wheel assembly 40, 41 comprises two wheel and tyre assemblies that are mounted to rotate about a common stub axle 42 that supports on either ends hubs 43 that rotate about appropriate bearings, not shown. The hydraulic ram 37 is coupled to a flange 39 that extends 15 perpendicularly from the stub axle 42 to locate in the space between the tyre and wheel assemblies. The opposite end of the ram 37 is pivotally secured to a lug 33 on the forward top of the enclosure 11. The end of the flange 39 opposite the wheel assemblies is pivotally secured to the 20 lower front edge 32 of the enclosure so that the wheel assemblies can pivot about a horizontal axis as shown in Figure 2. Thus, as shown in Figure 2, the rear of the enclosure 11 rests on the ground through the wear plates 30 whilst the front end of the enclosure is supported by 25 the tyre and wheel assemblies 40, 41. The level of ground engagement of the roller is determined by the relative position of the tyre and wheel assemblies 40, 41 to the enclosure 11 which is controlled by the hydraulic rams 37. 30 As shown in the plan view of Figure 3 a plate 51 extends across the centre of the top of the enclosure and has a hole 52 to support a laser mast, not shown. The wear plates 30 of the lower rear of the enclosure include two 3759545_1 (GHMatters) P87367.AU. 1o10/1012 - 7 150 X 10 X 620mm plates which are bolted to the frame of the enclosure to provide the necessary adjustability. Figure 3 also illustrates the quick hitch 36 at the centre of the front of the enclosure facilitating attachment to 5 the PTO of the tractor. The roller 20 is a hollow steel drum with a plurality of pushing blades 45 securely spaced along the length and periphery of the drum. In a preferred embodiment the drum 10 20 is 2040mm long, has a 400 mm diameter with a wall thickness of 10mm. The drum 20 supports twenty six left hand pushing blades 45 and twenty six right hand pushing blades 45. The blades 45 are mounted in pairs in two spiral arrays equally spaced axially and radially around 15 the drum as shown in Figure 5. Each blade 45 comprises a pair of L shaped members 46, 47 secured with the upright arms pivotally secured to a lug 49 projecting from the roller surface and laterally outwardly extending feet 50. The roller speed is adjustable between 100 and 300rpm. 20 The hydraulics are operated through a Danfuss proportional valve. A turf profiler 50 illustrated in Figures 7 to 13 of the accompanying drawings is essentially a modification of 25 an existing profiler or top maker to include a laser control structure that provides a facility for accurate height adjustment. Essentially the modification includes a bolt-on structure that includes an overhead support 60 for a laser mast, not shown and hydraulically adjustable front 30 wheel assemblies 51, 52 that pivot relative to the frame 53 of the machine about a horizontal axis. The rear of the machine 50 includes a trailing roller 55 that is mounted to the rear of the machine to be pivotable about a 3759545_ 1 (GHMatters) P87367.AU.1 10/10/12 -8 horizontal axis running parallel to the length of the machine. The internal componentry of the machine namely a cutting rotor 80 and conveyer belt assemblies 71, 72 is untouched. The cutting rotor 80 and conveyor belt s assemblies 71, 72 allow material to be cut by the rotor 80 and transferred by the conveyer belt assemblies 71, 72 to eject from the side of the profiler 50. The cutting rotor 80 as shown in Figures 9A and 9B comprises a drive shaft 81 that supports nineteen spider plates 82 spaced along 10 the length of the shaft. Each spider plate 82 has four equally spaced peripheral blades 83, 84, 85 and 86. The cutting rotor 80 cuts the surface of the ground causing the material to be pitched onto a horizontal conveyor 71 to in turn be transferred to a conveyor 72 that is 15 inclined at 45* to the horizontal. A hydraulic ram 99 controls the inclination of the second conveyor 72 and allows the material to be picked up and transferred to the side of the profiler 50. The arrangement of the conveyors 71, 72 in association with the cutting rotor 80 are shown 20 in Figure 10. Figure 11 illustrates the trailing roller 55 pivotally supported by sides 56 and 57 of a frame member 58. The frame 58 is bolted to the centre of the rear of 25 the profiler 50 via a hollow sleeve 59 so that the frame of the roller can pivot relative to the sleeve 59 via a horizontal axis extending centrally down the length of the profiler 50. A bolt 61 holds the sleeve 59 to the frame 50 of the roller 55. 30 Figures 12 and 13 show the mounting of one of the wheel assemblies. The front of the profiler has an upstanding leg 100 to which is attached a forwardly 3759545_1 (GIH Matters) P87367.AU.1 101012 -9 projecting flange 93 that can pivot about a horizontal axis. The flange 93 supports a stub axle 94 which supports speed wheel bearing assemblies 95, 96 on which are bolted to the wheels of the tyre and wheel assemblies 5 51, 52. A hydraulic ram 90 is located between a lug 91 on the flange and a pivot point 92 on the leg 80 of the profiler so that operation of the hydraulic ram 90 causes pivotal movement of the tyre and wheel assemblies 50, 51 relative to the profiler 50 to adjust the operating height 10 of the profiler. The hydraulic ram 90 is connected to a controller that receives signals from the laser mast to closely and accurately adjust the operational height of the profiler. The advantage of the profiler is its ability to leave a finished surface at the required grade ready 15 for turfing. It is virtually impossible to get a finished, levelled surface when the plastic mesh elements are in the material by any other method (e.g. grader, bob cat, laser buckets, excavator etc.). 20 The muncher 10 and profiler 50 can be used in combination to prepare the substrate for the laying of turf. In a situation where the substrate incorporates a matrix of sand, peatmoss and plastic mesh elements there is a tendency for the mesh elements to cause the substrate 25 to bunch up, thus providing an uneven surface. The rotating drum 20 on the muncher 10 has the ability to spread the plastic elements evenly under laser control without causing the mesh elements to bunch up or be removed from the sand and peamoss substrate. The usual 30 means of operating these machines is to place the matrix at a slightly greater depth than required using the muncher 10. The profiler 50 is then driven over the 3759545_ 1 (GHMatters) P87367.AU. 1 10/10/12 - 10 slightly thicker layer to reduce it back to the required thickness. The turf can then be laid onto the substrate. The profiler 50 can be adjusted on either side 5 through the hydraulic ram and laser controls through increments of 1 mm. It is understood that manual adjustment is also envisaged. The profiler 50 has ability to accurately remove either old turf layers or a recently laid matrix to provide a very accurate final level and 10 finish to which turf can be immediately applied. The muncher 10 spreads to the matrix the required thickness leaving a flat surface ready for rolling and final trimming using the profiler 50. 15 To lay turf in a sports field or a race track, the following methodology is adopted; 1) A laser grader is used to level the base surface, 2) Drainage lines and pipes are installed in the base, 20 3) A gravel drainage layout is placed over the surface at a required level through use of laser buckets. The laser bucket is a tractor pulled machine which is raised or lowered by laser controlled system. The laser bucket pulls the gravel from the high areas and places it 25 in the low areas until the final grade and height are achieved, 4) Sand is then placed over the gravel layer again layered with laser buckets, 5) The substrate matrix layer including sand, peat 30 moss and plastic mesh is positioned over the base to the depth of 100 to 150 mm, 3759545_1 (GHMatters) P87367.AU. 110110/12 - 11 6) The muncher 10 is then used to level and spread the substrate to a thickness ranging from between 140 and 190mm, 7) The profiler 50 then makes three passes using a 5 laser or GPS system, to progressively reduce the height to the required level so it is then ready to receive the turf product. The muncher 10 and profiler 50 can also be used to io produce a turf product that can be distributed in roll form. The base layer is first levelled with a laser levelling device and then covered by a layer of plastics and special backing. Sand is spread onto the joints to stop movement. A substrate mixture of sand peat moss and 15 plastic mesh elements is then placed on the plastic backing using a wide tyred trailer. The muncher 10 is then used to push and spread the matrix under laser control to a thickness of approximately 75mm. The profiler 50 is then passed over the layer to reduce the 20 layer to 60mm and the laser control. The profiler then makes a second pass reducing the layer to 45 mm again under laser control. Finally the profiler makes a third pass to reduce the thickness to 35 mm. All the excess matrix is returned to the stock to be premixed. 25 In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as 30 "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention. 3759545_1 (GHMatters) P87367.AU.1 10/10/12

Claims (14)

1.A turf substrate distributor adapted to be towed behind a towing vehicle, the distributor comprising 5 an enclosure that contains an axially rotatable roller, the periphery of the roller having spaced blades that push the substrate into position, a front of the enclosure including ground engaging wheels that pivot relative to the enclosure and means to 10 control the position of the wheels relative to the enclosure whereby the height of the roller relative to the ground surface is adjustable and the roller is driven to distribute the substrate. is

2. The distributor according to claim 1 wherein the roller has two spiral arrays of spaced blades located around its periphery.

3. The distributor according to claim 2 wherein each 20 blade is L-shaped and pivotally secured to the periphery of the roller.

4. The distributor according to any one of the preceding claims wherein a hydraulic ram controls the position 25 of the ground engaging wheels relative to the enclosure.

5. The distributor according to any one of the preceding claims wherein the height of the roller relative to 30 the ground surface can be controlled manually or through laser control.

6. The distributor according to claim 5 wherein a laser mast is mounted on the top of the enclosure to 35 receive GPS signals.

7. A turf profiler adapted to be drawn behind a towing vehicle, the turf profiler comprising an enclosure 3759545_1 (GHMatters) P87367.AU.1 10/10/12 - 13 containing cutting means and a conveyor, whereby the cutting means enables the turf to be cut and placed onto the conveyor for ejection from the profiler, the front of the profiler being supported by ground 5 engaging wheels, the height of the wheels relative to the enclosure being adjustable through a hydraulic ram, the rear of the enclosure supporting a trailing roller that is secured to the enclosure to pivot about a horizontal axis extending longitudinal of the 1o enclosure, and a laser mast mounted on the top of the enclosure whereby the height adjustment of the cutting means can be precisely adjusted.

8. The turf profiler according to claim 7 wherein the is cutting means is a bladed rotor driven to rotate about a vertical axis.

9. The turf profiler according to either claim 7 or 8 wherein a first substantially horizontal conveyor 20 transfers material to a second conveyor inclined at an angle to the horizontal, the second conveyor transferring cut material laterally of the profiler.

10. The turf profiler according to claim 9 wherein a 25 hydraulic ram controls the inclination of the second conveyor.

11. A method of laying turf comprising the steps of a.preparing the substrate, 30 b.using a turf substrate distributor according to any one of claims 1 to 6 to level and spread the substrate to an elevated level c.using a turf profiler according to any one of claims 7 to 10 to progressively reduce the 35 height of the substrate to a desired level, and d.laying turf onto the substrate.

12. The method according to claim 11 wherein the turf 3759545_ 1 (GHMatters) P87367.AU.1 10o1012 - 14 profiler makes a plurality of passes whilst receiving signals from a laser or GPS system to progressively reduce the height of the substrate to the desired level. 5

13. A turf substrate distributor substantially as herein described with reference to and as illustrated in Figures 1 to 6. 10

14. A turf profiler substantially as herein described with reference to and as illustrated in Figures 7 to 11. 3759545_1 (GHMatters) P87367.AU.1 1010/12