Sod Roll Layer Compactor for Compact Stacking

Solution Overview

Problem

Traditional sod harvesting equipment fails to compact sod rolls effectively, leading to inefficient use of shipping space and a high risk of rolls coming unrolled during transport.

Innovation Solution

A sod harvester with a sod cutter assembly, rolling assembly, pick-and-place apparatus, layer compactor, and side compactor that forms tightly packed stacks of sod rolls by pushing layers and rows against backstops, using extendible pusher bars attached to cylinders to ensure each layer is aligned and compressed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If traditional sod harvesting equipment is used to stack sod rolls, then the stacking process is simple, but the sod stacks are not compact and extend beyond the pallet envelope, increasing shipping space requirements

Engineering Contradiction:

Improveshipping spaceVSAvoidstacking mechanism complexity

Core Design Contradiction:

Volume of moving objectVSDevice complexity

Solution Approach 1:

The compactor applies preliminary compression force to the sod rolls during the stacking process itself, rather than requiring compacted rolls to be manufactured separately. The compactor pushes against the rolls as they are being placed on the pallet, pre-compressing them into a compact configuration that fits within the pallet envelope before shipping.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The compactor acts as an intermediary device between the stacking mechanism and the sod rolls. It receives the rolls from the stacker and applies compression force to them, serving as a mediating element that transforms the simple stacking action into a compacted stack configuration without requiring complex integrated machinery.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If sod rolls are stacked loosely to simplify handling, then the stacking process is easier, but the rolls tend to come unrolled during transport

Engineering Contradiction:

Improveroll stability during transportVSAvoidcompacting mechanism complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The compactor applies preliminary compression force to the sod rolls during the stacking process itself, rather than requiring compacted rolls to be manufactured separately. The compactor pushes against the rolls as they are being placed on the pallet, pre-compressing them into a compact configuration that fits within the pallet envelope before shipping.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The compactor applies a preliminary compressive force that counteracts the potential unrolling tendency of the sod rolls during transport. By pre-compressing the rolls into a stable, compact configuration with proper weighting and positioning, the compactor creates a counter-force that prevents the rolls from unrolling during handling and transportation.

Inventive Principle:

Principle #9Preliminary anti-action

3Productivity

If sod rolls are tightly packed to minimize shipping space, then shipping efficiency improves, but the complexity of achieving proper alignment and compaction increases

Engineering Contradiction:

Improveshipping efficiencyVSAvoidalignment and compaction mechanism complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The compacting function is segmented from the stacking function into a separate compactor device. This allows the stacker to focus on placing rolls in alternating rows and columns while the compactor independently handles the compression and alignment. The segmentation enables specialized optimization of each function without requiring a single complex integrated system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The compactor acts as an intermediary device between the stacking mechanism and the sod rolls. It receives the rolls from the stacker and applies compression force to them, serving as a mediating element that transforms the simple stacking action into a compacted stack configuration without requiring complex integrated machinery.

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution enables compact sod stacks that minimize shipping space and prevent rolls from unrolling, allowing for more efficient and secure transport of sod.

Implementation Method 1

a layer compactor that is in a retracted position while the pick head deposits the arrays of sod rolls and that pushes against a layer of sod rolls while the pick head moves to pick up an array of sod rolls

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Data Source

PatentUS9596798B2Sod roll layer compactor

Publication Date: 2017.03.21 TREBRO HLDG

AI summary

A sod harvester comprising a sod cutter assembly that shaves slabs of sod material from a field and cm them into lengths; a sod rolling assembly that rolls the sod slabs as they are conveyed to a sod roll array forming station; a pick-and-place apparatus comprising a pick head that picks up arrays of sod rolls and places them in layers onto a first location: a layer compactor that is in a retracted position while the pick head deposits the arrays of sod rolls and that pushes against a layer of sod rolls while the pick head moves to pick up an array of sod rolls; and a side compactor that pushes against the sod rolls In a direction orthogonal to that of the layer compactor.