AU2016202131B2 - Sod harvester with flap control device - Google Patents

Abstract

OF THE DISCLOSURE A method of arranging sod rolls on a pallet including the steps of using a sod harvester to create a plurality of sod rolls and deposit them onto a platform; rotating all but one of the sod rolls so that an end flap on each of the sod rolls is at the same position; rotating the first sod roll for a duration that is longer than the duration by which the remaining sod rolls are rotated so that an end flap on the first sod roll is in a different position on the first sod roll than the end flaps on the remaining sod rolls; using a sod carrier to pick up the plurality of sod rolls from the platform simultaneously; and depositing the plurality of sod rolls simultaneously onto a pallet such that the end flap on the first sod roll faces outward and is viewable by consumers. 1/24 ... .... ... . .......... o~ao~aiooo

Description

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SOD HARVESTER WITH FLAP CONTROL DEVICE

This application claims priority from US Application No. 14/696,453 filed on 26 April 2015, the contents of which are to be taken as incorporated herein by this reference.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of U.S. Patent Application No.

13/946,956 filed on July 19, 2013, the contents of which are incorporated herein by

reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention.

The present invention relates generally to the field of sod harvesters, and more

specifically, to a sod harvester with a flap control device for consistently and neatly

rolling pieces of sod so that the end of the flap is situated at roughly the same position on

each roll of sod.

2. Description of the Related Art.

Sod harvesters for cutting strips of sod from the ground, rolling them into sod

rolls, and stacking the sod rolls onto pallets have existed for a number of years. Various

sod harvester innovations have been patented, several of which relate to the rolling of sod

pieces, and at least one of which has attempted to solve the same problem as the present

invention. U.S. Patent No. 7,021,584 discloses a sod roller for automatically controlling

the angular position of the end or flap of a roll of sod about the roll. The latter invention

differs structurally from the present invention in a number of respects, including, but not

limited to, the fact that it utilizes three conveyors rather than two, and it also incorporates a sensor for measuring displacement of the transport conveyor. The transport conveyor sensor is not needed in the present invention.

When sod is sold at commercial establishments, it is typically stacked several

rows high on a pallet. The more neatly the stack appears, the more likely it is to be sold.

In addition, neatly stacked rolls are less likely to fall off of the pallet. In both of these

respects, the placement of the end of the flap on the sod roll is important. If the end of

the flap is located at roughly the same position on each of the sod rolls, this creates a

more uniform appearance and adds stability to the overall configuration of the sod rolls.

The present invention is designed to ensure that the end of the flap on a roll of sod is

situated at roughly the same position on each roll of sod that comes off of the sod

harvester.

Other innovations relating to sod rollers include U.S. Patent No. 3,790,096

(Brouwer, 1974) (device for starting a turn in the end of a sod strip); U.S. Patent No.

4,142,691 (Watton, 1979) (apparatus for starting a turn in a strip of sod travelling along a

conveyor); U.S. Patent No. 6,834,729 (Brouwer et al., 2004) (pre-starter for starting a

turn in the end of a sod strip travelling up a conveyor); and U.S. Patent Application No.

2001/0050174 (Van Vuuren) (in one embodiment, incorporating a rolling conveyor

between the receiving and discharge ends of the conveyor head for purposes of rolling cut

grass sods). None of these innovations, however, is concerned with the consistent

positioning of the end of the flap on the sod roll.

A reference herein to a patent document or any other matter identified as prior art,

is not to be taken as an admission that the document or other matter was known or that the information it contains was part of the common general knowledge as at the priority date of any of the claims.

BRIEF SUMMARY

Embodiments of the present invention relate to sod harvester comprising: a start

gate; a first switch that is configured to interact with a first sensor; a second switch that is

configured to interact with a second sensor; an inclined conveyor with a first end and a

second end; and a rollup conveyor positioned above the second end of the inclined

conveyor; wherein the first switch is positioned between the start gate and the second

switch; wherein the second switch is positioned between the first switch and the rollup

conveyor; wherein when the second sensor is activated, the rollup conveyor begins

rotating; wherein when the first sensor is activated, an encoder begins measuring distance

traveled rotationally by the rollup conveyor; and wherein the rollup conveyor stops

rotating when the rollup conveyor has traveled a certain distance rotationally.

In a preferred embodiment, the first sensor is activated when a trailing edge of a

sod piece moves out from underneath a bottom end of the first switch and a top end of the

first switch is moved into proximity with the first sensor. Preferably, the second sensor is

activated when a piece of sod causes the second switch to change position so that the

second switch is moved into proximity with the second sensor.

In a preferred embodiment, the bottom end of the first switch extends through a

front rollup ladder, and the start gate is attached to the front rollup ladder. Preferably, the

rollup conveyor is situated within a rear rollup frame. In one embodiment, the second

switch is situated on the front rollup ladder. In another embodiment, the second switch is

situated on the rear rollup frame.

In yet another embodiment, the invention further comprises a bumper that is

secured to a rear of the rear rollup frame, the bumper extending beneath the rollup

conveyor along a width of the rollup conveyor and preventing from over-rotating an end

flap on a first sod roll in a plurality of sod rolls that are picked up simultaneously by a

sod carrier and deposited simultaneously onto a pallet, each of the sod rolls in the

plurality of sod rolls having an end flap, the end flap on all but the first sod roll in the

plurality of sod rolls being at a same position, the end flap on the first sod roll being in a

different position, and the end flap on the first sod roll being at a position between nine

o'clock and twelve o'clock when the first sod roll is viewed from a side of the first sod

roll.

In a preferred embodiment, the inclined conveyor and the rollup conveyor move

at a same speed and in a same direction rotationally. The certain distance measured by

the encoder is preferably adjustable by an operator.

One aspect of the invention provides a method of arranging sod rolls on a pallet,

the method comprising: using a sod harvester to create a plurality of sod rolls and deposit

them onto a platform; as each of the sod rolls is deposited onto the platform, rotating all

but one of the sod rolls in the plurality of sod rolls so that an end flap on each of the all

but one of the sod rolls in the plurality of sod rolls is at the same position on the sod roll;

wherein one of the sod rolls in the plurality of sod rolls is the first sod roll in the plurality

of sod rolls to be deposited onto the platform, as the first sod roll is deposited onto the

platform, rotating the first sod roll for a duration that is longer than the duration by which

the all but one of the sod rolls in the plurality of sod rolls are rotated so that an end flap

on the first sod roll is in a different position on the first sod roll than the end flaps on the all but one of the sod rolls in the plurality of sod rolls, the end flap on the first sod roll being at a position between nine o'clock twelve o'clock when the first sod roll is viewed from a side of the first sod roll; using a sod carrier to pick up the plurality of sod rolls from the platform simultaneously; and depositing the plurality of sod rolls simultaneously onto a pallet such that the end flap on the first sod roll faces outward and is viewable by consumers.

In a preferred embodiment, the duration of rotation of the first sod roll is

adjustable by an operator via a control screen in a cab of the sod harvester. In another

preferred embodiment, the method further comprises using a bumper that is situated over

the platform to prevent the end flap on the first sod roll from over-rotating.

Another aspect of the invention provides a sod harvester comprising: (a) a start

gate; (b) a first switch that is configured to interact with a first sensor; (c) a second switch

that is configured to interact with a second sensor; (d) an inclined conveyor with a first

end and a second end; and (e) a rollup conveyor positioned above the second end of the

inclined conveyor; (f) a controller including controller software that is configured to

cause the rollup conveyor to start upon activation of the second sensor, an encoder to

begin counting intervals upon activation of the first sensor, and the rollup conveyor to

stop upon the counting of a certain number of intervals by the encoders, an interval being

a measure of distance traveled rotationally by the rollup conveyor; wherein the first

switch is positioned between the start gate and the second switch; wherein the second

switch is positioned between the first switch and the rollup conveyor; wherein the

inclined conveyor is configured to eject a sod roll onto a platform upon cessation of

rotation by the rollup conveyor; and wherein the rollup conveyor is situated within a rear rollup frame; further comprising a bumper that is secured to a rear of the rear rollup frame, the bumper extending beneath the rollup conveyor along a width of the rollup conveyor and preventing from over-rotating an end flap on a first sod roll in a plurality of sod rolls that are picked up simultaneously by a sod carrier and deposited simultaneously onto a pallet, each of the sod rolls in the plurality of sod rolls having an end flap, the end flap on all but the first sod roll in the plurality of sod rolls being at a same position, the end flap on the first sod roll being in a different position, and the end flap on the first sod roll being at a position between nine o'clock and twelve o'clock when the first sod roll is viewed from a side of the first sod roll.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a perspective view of a sod harvester with the flap control device of

the present invention.

Figure 2 is a perspective view of the flap control device of the present invention

shown with a sod piece on the inclined conveyor.

Figure 3 is the same view shown in Figure 2 except that two of the chains, one

turn buckle, and the start gate spring have been removed for clarity.

Figure 4A is a top view of the flap control device indicating where the section

view of Figure 4B has been taken.

Figure 4B is a side section view of what is shown in Figure 3.

Figure 5 is a detail perspective view of the flap control device of the present

invention shown with a leading edge of a sod piece in contact with the start gate of the

flap control device and beginning to roll.

Figure 6 is a side section view of what is shown in Figure 5.

Figure 7 is a first detail perspective view perspective view of the flap control

device of the present invention shown with the leading (rolled) edge of the sod piece

situated under the tail of the first switch and thefirst sensor in a deactivated position.

Figure 8 is a side section view of what is shown in Figure 7.

Figure 9 is a second detail perspective view of what is shown in Figure 7.

Figure 1OA is a top perspective view of what is shown in Figure 7.

Figure 1OB is the same view shown in Figure 1OA except that two of the chains,

one turn buckle, the start gate spring, and part of the hanging frame have been removed

for clarity.

Figure 11 is a wider perspective view of what is shown in Figure 7.

Figure 12A is a detail perspective view of the flap control device of the present

invention shown with the leading (rolled) edge of the sod piece situated underneath the

second switch and the second sensor in an activated position.

Figure 12B is a perspective section view of what is shown in Figure 12A.

Figure 13 is a side section view of what is shown in Figure 12B.

Figure 14 is a wider perspective view of what is shown in Figure 12A.

Figure 15 is a side section view of the flap control device of the present invention

shown with the trailing edge of the sod piece no longer situated underneath the tail of the

first switch and the first sensor in an activated position.

Figure 16 is a perspective view of the flap control device of the present invention

shown with the sod roll in a fully rolled position but with the flap not yet located in the

preferred position.

Figure 17 is a side section view of what is shown in Figure 16.

Figure 18 is a side view of the flap control device of the present invention

showing two sod rolls on the platform.

Figure 19 is a bottom perspective view of the second switch.

Figure 20 is a side view of the present invention showing the over-rotation of the

end roll in a group of sod rolls.

Figure 21 is a detail view of the rubber bumper on the rear end of the rear rollup

frame.

REFERENCE NUMBERS

1 Sod harvester

2 Sod cutting knife

3 Inclined conveyor

4 Rollup conveyor

5 Tension roller

6 Front rollup ladder

7 Rear rollup frame

8 Sod piece

9 Start gate

10 Pivot rod

11 Chain

11a Spring (on start gate)

1lb Spring (on first switch)

12 First switch

12a Bottom end (of first switch)

12b Top end (of first switch)

13 First sensor

14 Second switch

15 Second sensor

16 Encoder

17 Hydraulic motor

18 Platform

19 Conveyor side rail

20 Main frame

21 Hanger frame

22 Collar (first switch)

23 Turn buckle

24 Bolt

25 Support bracket

26 Plate

27 End collar

28 Collar (second switch)

29 Rubber bumper

DETAILED DESCRIPTION OF INVENTION

Figure 1 is a perspective view of a sod harvester with the flap control device of

embodiments of the present invention. As shown in this figure, the sod harvester 1

comprises a sod cutting knife 2, an inclined conveyor 3, and a rollup conveyor 4. The

rollup conveyor 4 is situated directly on top of the upper part of the inclined conveyor 3.

The conveyor side rail 19 and main frame 20 have been removed from subsequent figures

for clarity.

Figure 2 is a first perspective view of the flap control device of embodiments of

the present invention shown with a sod piece on the inclined conveyor. Figure 3 is the

same view shown in Figure 2 except that two of the chains 11, one turn buckle 23, and

the start gate spring 11a have been removed for clarity. In this figure, the sod piece 8 has

not yet come into contact with the start gate 9 of the flap control device. As shown in this

figure, the flap control device comprises a tension roller 5, a front rollup ladder 6, and a

rear rollup frame 7. The tension roller 5 is configured to ensure that the piece of sod 8 on

the inclined conveyor 3 maintains contact with the inclined conveyor 3. The front rollup

ladder 6 comprises a start gate 9 that pivots on two pivot rods 10 on either end of the start

gate 9.

Note that although turn buckles 23 are shown in the accompanying figures, the

present invention is not limited to the use of turn buckles 23 to support the front rollup

ladder 6. Any method of supporting the front rollup ladder 6 may be used. Note also that

although two pivot rods 10 are shown, the start gate 9 may pivot on a single pivot rod 10

that extends from one end of the start gate 9 to the other. In addition, the present

invention is not limited to the use of chains 11 to suspend the front rollup ladder 6 or the

rear rollup frame 7, nor is it limited to any particular number of chains 11.

When a piece of sod 8 moves upward on the inclined conveyor 3, it first passes

underneath the tension roller 5. Next, the leading edge of the piece of sod 8 comes into

contact with the start gate 9, which causes the piece of sod 8 to being rolling up. A

spring 11a is used to adjust the tension on the start gate 9. Note that both the front rollup ladder 6 and the rear rollup frame 7 are preferably suspended by chains 11 so that they can move upward to accommodate the growing sod roll as it passes underneath them.

The rollup conveyor 4 is attached to and situated within the rear rollup frame 7 so that it

moves upward with the entire rear rollup frame 7.

A first switch 12 is attached (welded) to a collar 22 that pivots about a bolt (see

Figure 9). A spring 1lb attached to the first switch 12 and to the hanger frame 21 biases

the first switch downward. The bottom end 12a of the first switch 12 extends through the

front rollup ladder 6 so that it is in a position to come into contact with a piece of sod 8 as

it moves up the inclined conveyor 3. The top end 12b of the first switch 12 is configured

to interact with a first sensor 13. A second switch 14 is attached to two end collars 27

that pivot about a bolt 24 (see Figure OB and 12B); the second switch 14 is configured

to interact with a second sensor 15. The function of the first and second sensors 13, 15 is

discussed below. Although the first and second sensors 13, 15 are depicted as proximity

sensors in the drawings, any suitable type of sensor (for example, an optical sensor) may

be used.

The inclined conveyor 3 and rollup conveyor 4 are preferably powered by

hydraulic motors 17. During operation of the sod harvester 1, the inclined conveyor 3 is

in continuous movement, whereas the rollup conveyor 4 starts and stops based on the

activation or deactivation of the first and second sensors 13, 15, as explained more fully

below. When the rollup conveyor 4 is on, it rotates at the same speed and in the same

direction as the inclined conveyor 3 (that is, counterclockwise from the perspective of the

viewer in Figure 4B).

Figure 4A is a top view of the flap control device indicating where the section

view of Figure 4B has been taken. Figure 4B is a side section view of what is shown in

Figure 3. Figure 4B shows the relation of the first and second switches 12, 14 to the

inclined conveyor 3.

Figure 5 is a perspective view of the flap control device of embodiments of the

present invention shown with a leading edge of a sod piece in contact with the start gate

of the flap control device and beginning to roll. Figure 6 is a side section view of what is

shown in Figure 5; the section is taken as indicated in Figure 4A. As shown in these two

figures, the sod piece 8 starts to form a roll when the leading edge of the sod piece 8

comes into contact with the start gate 9. The start gate 9 pivots upward on the pivot rods

to allow the leading (and beginning to roll) edge of the sod piece 8 to pass through it.

Once the sod roll starts to form, the sod piece 8 continues rolling as it moves upward on

the inclined conveyor 3. The front rollup ladder 6 maintains pressure on the forming sod

roll so that it stays on the inclined conveyor 3.

Figure 7 is a perspective view of the flap control device of embodiments of the

present invention shown with the leading (rolled) edge of the sod piece situated under the

tail of the first switch and the first sensor in a deactivated position. The turn buckle 23

and start gate spring 11a have been removed from this figure for clarity. Figure 8 is a

side section view of what is shown in Figure 7; the section is taken as indicated in Figure

4A. As shown in these two figures, the piece of sod 8 continues to roll (with the roll

getting larger) as it makes its way up the inclined conveyor 3 and underneath the front

rollup ladder 6. As this happens, the bottom end 12a of the first switch 12 rises, and the

top end 12b of the first switch moves away from the first sensor 13.

Figure 9 is a second detail perspective view of what is shown in Figure 7. This

view shows that the first switch 12 pivots on a collar 22 that rotates about a bolt 24 in a

support bracket 25 that is attached (in this case, bolted) to the underside of the hanger

frame 21. Figure 10A is a top perspective view of what is shown in Figure 7. This

particular view shows more clearly how the bottom end 12a of the first switch 12 extends

through the front rollup ladder 6. Figure 1OB is the same view shown in Figure 10A

except that two of the chains 11, one turn buckle 23, the start gate spring 11a, and part of

the hanging frame 21 have been removed for clarity. Figure 11 is a wider perspective

view of what is shown in Figure 7.

With regard to the first switch, the present invention is not limited to any

particular configuration of the first switch, as long as it is positioned between the start

gate 9 and the second switch 14, as long as the top end 12b of the first switch 12 is

configured to interact with a first sensor 13, and as long as the first switch 12 is

configured so that the bottom end of the first switch 12 extends through the front rollup

ladder 6.

Figure 12A is a detail perspective view of the flap control device of embodiments

of the present invention shown with the leading (rolled) edge of the sod piece situated

underneath the second switch and the second sensor in an activated position. Figure 12B

is a perspective section view of what is shown in Figure 12A; the section is taken as

indicated in Figure 4A. In this position, the piece of sod 8 (now a partially formed sod

roll) has moved upward so that the second switch 14 is forced to rotate upward, thereby

activating the second sensor 15. The trailing edge of the sod piece 8 is still underneath

the front rollup ladder 6, with part of the sod piece 8 situated underneath the bottom end

12a of the first switch 12 (see Figure 13). As long as there is a piece of sod 8 underneath

the bottom end 12a of the first switch 12, the first sensor 13 will be deactivated. Figure

13 is a side section view of what is shown in Figure 12B; the section is taken as indicated

in Figure 4A. Figure 14 is a wider perspective view of what is shown in Figure 12A.

Embodiments of the present invention comprise a controller (not shown) with

embedded software that controls the flap control device. When the second sensor 15 is

activated, this software causes the rollup conveyor 4 to start. Specifically, the controller

software causes the rollup conveyor 4 to start when the second sensor 15 is activated, the

encoder 16 to begin counting when the first sensor 13 is activated, and the rollup

conveyor 4 to stop when the encoder 16 counts a certain number of intervals (an interval

being a measure of distance traveled rotationally by the rollup conveyor 4).

Figure 15 is a side section view of the flap control device of embodiments of the

present invention shown with the trailing edge of the sod piece no longer situated

underneath the tail of the first switch and the first sensor in an activated position. At this

juncture, the trailing edge of the sod piece 8 has moved out from underneath the bottom

end 12a of the first switch 12, thereby causing the top end 12b of the first switch to move

downward so that it is aligned with (in proximity to) the first sensor 13. In this position,

the first sensor 13 is activated.

Activation of the first sensor 13 causes the encoder 16 to begin counting the

rotational distance traveled by the rollup conveyor 4. This particular interval is

preferably adjustable by the operator to ensure that the sod piece 8 continues to roll and

that it is not ejected onto the platform 18 until the trailing edge (or flap) of the sod roll is

in the preferred position. In the position shown in Figure 16, the sod roll has moved past the second switch 14, and the sod roll is situated between the inclined conveyor 3 and the rollup conveyor 4. The sod piece 8 continues to roll as long as it is situated between the inclined conveyor 3 and the rollup conveyor 4 and both conveyors are moving at the same speed. (As noted above, whenever the rollup conveyor 4 is on, it is preferably moving at the same speed as the inclined conveyor 3.)

Figure 16 is a perspective view of the flap control device of embodiments of the

present invention shown with the sod roll in a fully rolled position but with the flap not

yet located in the preferred position. Figure 17 is a side section view of what is shown in

Figure 16. At this stage, the sod piece 8 is continuing to roll and will continue to do so

until the encoder 16 reaches the end of its counting limit (that is, its measurement of the

distance traveled by the rollup conveyor 4). At that point, the controller software causes

the rollup conveyor 4 to stop. When the rollup conveyor 4 stops rotating, the sod roll 8 is

ejected by the inclined conveyor 3 onto the platform 18.

Figure 18 is a side view of the flap control device of embodiments of the present

invention showing two sod rolls on the platform. Note that the present invention ensures

that each sod roll will be placed onto the platform 18 with the end of the roll (or flap) in

the same position each time, even if the sod piece 8 does not start rolling as soon as the

leading edge of the sod piece 8 hits the start gate 9. If the sod piece 8 does not begin to

roll until the leading edge of the sod piece 8 has passed the start gate 9, then the sod roll

will be smaller around by the time it hits the second switch 14 than it would have been

had the sod piece 8 begun to roll at the start gate 9. In this situation, however, the sod

roll will continue to turn longer (in between the inclined conveyor 3 and the rollup

conveyor 4) because it will take longer for the trailing edge of the sod piece 8 to clear the bottom end 12a of the first switch 12, thereby triggering the encoder 16 to count and the rollup conveyor 4 to stop after a certain interval. In other words, the present invention ensures that every sod roll is the same size before the encoder 16 begins to count because the trailing edge of the sod piece 8 must clear the bottom end 12a of the first switch 12 before the rollup conveyor 4 stops and the sod roll is ejected onto the platform 18.

Figure 19 is a bottom perspective view of the second switch. As explained above,

the second switch 14 is attached to two end collars 27 that rotate (or pivot) about a bolt

24. The bolt 24 extends through a collar 28 that is fixed to a plate 26. The plate 26 in

turn is attached (welded) to the rear rollup frame 7. Note that the present invention is not

limited to any particular configuration of the second switch 14, as long as it is positioned

between the first switch 12 and the rollup conveyor 4, and as long as it is configured to

interact with the second sensor 15. For example, the second switch may be attached to

either the rear rollup frame 7, as shown in the drawings, or it may be attached to the front

rollup ladder 6.

Embodiments of the invention described above, that is, with a second switch that

starts the rollup conveyor upon being triggered by the sod roll, are an improvement over

prior art (for example, the invention described in U.S. Patent No. 7,021,584 ) because it

provides a greater degree of accuracy in terms of starting the rollup conveyor.

In the embodiment discussed above, the end of the roll (or flap) on each piece of

sod that is deposited onto the platform 18 is in the same position; however, in an alternate

embodiment, the software that controls the flap control device is programmed so that the

first sod roll (also called the "end" roll) in a group offive sod rolls is rotated slightly

longer than the other four sod rolls so that the flap is situated in a 10:00 position when the end roll is deposited onto the platform 18 (see Fig. 20). In other words, for every fifth sod roll 8, the controller software causes the rollup conveyor 4 to start when the second sensor 15 is activated (as described above), the encoder 16 to begin counting when the first sensor 13 is activated (as described above), and the rollup conveyor 4 to stop when the encoder 16 counts a certain number of intervals (the number of intervals being larger for the end sod roll than for the other four sod rolls in the same group). The duration of rotation of the end roll is preferably adjustable by the operator via a control screen in the cab of the harvester.

In Figure 20, six sod rolls are shown on the platform 18; five of these sod rolls

will be picked up by the sod carrier (not shown) and deposited onto a pallet (not shown).

Thus, the sixth sod roll (that is, the one closest to the inclined conveyor 3) will be the end

roll in the next group of sod rolls. As used herein, the term "end roll" or means the roll of

sod that is the first in a group of sod rolls that are sequentially deposited onto the

platform 18 and picked up simultaneously by the sod carrier. When the group of sod

rolls is deposited onto the pallet, the array of sod rolls appears neater and more attractive

if the flaps on the end rolls (which face the outside of the pallet) are all in the 10:00

position. Note that the flaps on the next three sod rolls in the group do not need to be at a

:00 position because they are interior sod rolls (that is, they do not face the outside of

the pallet when the sod rolls are arranged on the pallet), and the flaps on these rolls are

held in place by virtue of the fact that the flap abuts up against an adjacent sod roll.

Although the fifth or last sod roll in the group is an exterior sod roll (that is, it does have

a side that is exposed to the outside of the pallet), the flap on this sod roll faces inward rather than outward on the pallet and is held in place by abutting up against the adjacent sod roll; therefore, there is no need to over-rotate this particular sod roll either.

Note that in the embodiment shown in Figure 20, five sod rolls 8 constitute a

group that is then lifted off of the platform 18 by the sod carrier and deposited onto a

pallet. The present invention is not limited to any particular number of sod rolls being

picked up at once; rather, the invention constitutes rotating the first or "end" roll in a

group of sod rolls (all of which are picked up at the same time by the sod carrier) more

than the other sod rolls in the group so that the flap on the end roll is positioned

differently than the flap on the other sod rolls in the same group. In a preferred

embodiment, the flaps on the five non-end sod rolls are in the 7:00 position, and the flap

on the end roll is in a 10:00 position.

In the embodiment shown in Figures 20 and 21, a rubber bumper 29 has been

secured to the rear of the rear rollup frame 7 and extends beneath the rollup conveyor 4.

Preferably, the rubber bumper 29 extends the entire width of the rollup conveyor 4. The

purpose of this rubber bumper 29 is to prevent the flap on the end roll from opening up

clockwise (that is, from flapping over from the 10:00 position shown in Figure 20 to a

1:00 or greater position) and getting caught up in the rollup conveyor 4. The rubber

bumper 29 is situated so that if the flap on the end roll were to open up (clockwise from

the vantage point of Figure 20), the rubber bumper 29 would knock the flap back into

place (that is, back into its 10:00 position). Although the bumper is rubber in a preferred

embodiment, it could be made of any suitable material.

Where any or all of the terms "comprise", "comprises", "comprised" or

"comprising" are used in this specification (including the claims) they are to be interpreted as specifying the presence of the stated features, integers, steps or components, but not precluding the presence of one or more other features, integers, steps or components.

Although the preferred embodiment of the present invention has been shown and

described, it will be apparent to those skilled in the art that many changes and

modifications may be made without departing from the invention in its broader aspects.

The appended claims are therefore intended to cover all such changes and modifications

as fall within the true spirit and scope of the invention.

Claims (4)

1. A method of arranging sod rolls on a pallet, the method comprising:

(a) using a sod harvester to create a plurality of sod rolls and deposit them

onto a platform;

(b) as each of the sod rolls is deposited onto the platform, rotating all but one

of the sod rolls in the plurality of sod rolls so that an end flap on each of the all but one of

the sod rolls in the plurality of sod rolls is at the same position on the sod roll;

(c) wherein one of the sod rolls in the plurality of sod rolls is the first sod roll

in the plurality of sod rolls to be deposited onto the platform, as the first sod roll is

deposited onto the platform, rotating the first sod roll for a duration that is longer than the

duration by which the all but one of the sod rolls in the plurality of sod rolls are rotated so

that an end flap on the first sod roll is in a different position on thefirst sod roll than the

end flaps on the all but one of the sod rolls in the plurality of sod rolls, the end flap on the

first sod roll being at a position between nine o'clock twelve o'clock when the first sod

roll is viewed from a side of the first sod roll;

(d) using a sod carrier to pick up the plurality of sod rolls from the platform

simultaneously; and

(e) depositing the plurality of sod rolls simultaneously onto a pallet such that

the end flap on the first sod roll faces outward and is viewable by consumers.

2. The method of claim 1, wherein the duration of rotation of the first sod

roll is adjustable by an operator via a control screen in a cab of the sod harvester.

3. The method of claim 1, further comprising using a bumper that is situated

over the platform to prevent the end flap on the first sod roll from over-rotating.

4. A sod harvester comprising:

(a) a start gate;

(b) a first switch that is configured to interact with a first sensor;

(c) a second switch that is configured to interact with a second sensor;

(d) an inclined conveyor with a first end and a second end; and

(e) a rollup conveyor positioned above the second end of the inclined

conveyor;

(f) a controller including controller software that is configured to

cause the rollup conveyor to start upon activation of the second sensor, an encoder to

begin counting intervals upon activation of the first sensor, and the rollup conveyor to

stop upon the counting of a certain number of intervals by the encoders, an interval being

a measure of distance traveled rotationally by the rollup conveyor;

wherein the first switch is positioned between the start gate and the second

switch;

wherein the second switch is positioned between the first switch and the rollup

conveyor;

wherein the inclined conveyor is configured to eject a sod roll onto a platform

upon cessation of rotation by the rollup conveyor; and

wherein the rollup conveyor is situated within a rear rollup frame;

further comprising a bumper that is secured to a rear of the rear rollup frame, the

bumper extending beneath the rollup conveyor along a width of the rollup conveyor and

preventing from over-rotating an end flap on a first sod roll in a plurality of sod rolls that

are picked up simultaneously by a sod carrier and deposited simultaneously onto a pallet, each of the sod rolls in the plurality of sod rolls having an end flap, the end flap on all but the first sod roll in the plurality of sod rolls being at a same position, the end flap on the first sod roll being in a different position, and the end flap on the first sod roll being at a position between nine o'clock and twelve o'clock when the first sod roll is viewed from a side of the first sod roll.