Best Self-Propelled Lawn Mower Reviews 2023. Lawn mower twin blades

09.06.2023 Fordrejurus best, lawn, mower, self-propelled

US9480200B1. Multi-blade lawn mower cutting system with overlapping cutting circles. Google Patents

Publication number US9480200B1 US9480200B1 US15/008,173 US201615008173A US9480200B1 US 9480200 B1 US9480200 B1 US 9480200B1 US 201615008173 A US201615008173 A US 201615008173A US 9480200 B1 US9480200 B1 US 9480200B1 Authority US United States Prior art keywords blade mower blades spindles spindle Prior art date 2016-01-27 Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.) Active Application number US15/008,173 Inventor Arthur Gary Patridge Original Assignee Arthur Gary Patridge Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.) 2016-01-27 Filing date 2016-01-27 Publication date 2016-11-01 2016-01-27 Application filed by Arthur Gary Patridge filed Critical Arthur Gary Patridge 2016-01-27 Priority to US15/008,173 priority Critical patent/US9480200B1/en 2016-11-01 Application granted granted Critical 2016-11-01 Publication of US9480200B1 publication Critical patent/US9480200B1/en Status Active legal-status Critical Current 2036-01-27 Anticipated expiration legal-status Critical

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Classifications

A — HUMAN NECESSITIES
A01 — AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
A01D — HARVESTING; MOWING
A01D34/00 — Mowers; Mowing apparatus of harvesters
A01D34/01 — Mowers; Mowing apparatus of harvesters characterised by features relating to the type of cutting apparatus
A01D34/412 — Mowers; Mowing apparatus of harvesters characterised by features relating to the type of cutting apparatus having rotating cutters
A01D34/63 — Mowers; Mowing apparatus of harvesters characterised by features relating to the type of cutting apparatus having rotating cutters having cutters rotating about a vertical axis
A01D34/64 — Mowers; Mowing apparatus of harvesters characterised by features relating to the type of cutting apparatus having rotating cutters having cutters rotating about a vertical axis mounted on a vehicle, e.g. a tractor, or drawn by an animal or a vehicle
A01D34/66 — Mowers; Mowing apparatus of harvesters characterised by features relating to the type of cutting apparatus having rotating cutters having cutters rotating about a vertical axis mounted on a vehicle, e.g. a tractor, or drawn by an animal or a vehicle with two or more cutters
A01D34/664 — Disc cutter bars

A — HUMAN NECESSITIES
A01 — AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
A01D — HARVESTING; MOWING
A01D34/00 — Mowers; Mowing apparatus of harvesters
A01D34/001 — Accessories not otherwise provided for
A01D34/005 — Mulching means

A — HUMAN NECESSITIES
A01 — AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
A01D — HARVESTING; MOWING
A01D34/00 — Mowers; Mowing apparatus of harvesters
A01D34/01 — Mowers; Mowing apparatus of harvesters characterised by features relating to the type of cutting apparatus
A01D34/412 — Mowers; Mowing apparatus of harvesters characterised by features relating to the type of cutting apparatus having rotating cutters
A01D34/63 — Mowers; Mowing apparatus of harvesters characterised by features relating to the type of cutting apparatus having rotating cutters having cutters rotating about a vertical axis
A01D34/64 — Mowers; Mowing apparatus of harvesters characterised by features relating to the type of cutting apparatus having rotating cutters having cutters rotating about a vertical axis mounted on a vehicle, e.g. a tractor, or drawn by an animal or a vehicle
A01D34/66 — Mowers; Mowing apparatus of harvesters characterised by features relating to the type of cutting apparatus having rotating cutters having cutters rotating about a vertical axis mounted on a vehicle, e.g. a tractor, or drawn by an animal or a vehicle with two or more cutters

A — HUMAN NECESSITIES
A01 — AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
A01D — HARVESTING; MOWING
A01D34/00 — Mowers; Mowing apparatus of harvesters
A01D34/01 — Mowers; Mowing apparatus of harvesters characterised by features relating to the type of cutting apparatus
A01D34/412 — Mowers; Mowing apparatus of harvesters characterised by features relating to the type of cutting apparatus having rotating cutters
A01D34/63 — Mowers; Mowing apparatus of harvesters characterised by features relating to the type of cutting apparatus having rotating cutters having cutters rotating about a vertical axis
A01D34/64 — Mowers; Mowing apparatus of harvesters characterised by features relating to the type of cutting apparatus having rotating cutters having cutters rotating about a vertical axis mounted on a vehicle, e.g. a tractor, or drawn by an animal or a vehicle
A01D34/66 — Mowers; Mowing apparatus of harvesters characterised by features relating to the type of cutting apparatus having rotating cutters having cutters rotating about a vertical axis mounted on a vehicle, e.g. a tractor, or drawn by an animal or a vehicle with two or more cutters
A01D34/661 — Mounting means

A — HUMAN NECESSITIES
A01 — AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
A01D — HARVESTING; MOWING
A01D34/00 — Mowers; Mowing apparatus of harvesters
A01D34/01 — Mowers; Mowing apparatus of harvesters characterised by features relating to the type of cutting apparatus
A01D34/412 — Mowers; Mowing apparatus of harvesters characterised by features relating to the type of cutting apparatus having rotating cutters
A01D34/63 — Mowers; Mowing apparatus of harvesters characterised by features relating to the type of cutting apparatus having rotating cutters having cutters rotating about a vertical axis
A01D34/73 — Cutting apparatus

A — HUMAN NECESSITIES
A01 — AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
A01D — HARVESTING; MOWING
A01D2101/00 — Lawn-mowers

Abstract

A multi-blade mower includes at least two spindles spaced apart from each other. In one example implementation, two blades are mounted at different heights on each respective spindle, and the blades at each spindle have different lengths. Horizontal clearance is provided between the lower blades, and the cutting circle of one of the upper blades overhangs the clearance zone between the lower blades, so that any grass missed between the lower blades is cut by the overhanging upper blade.

Description

Power lawn mowers are widely used to maintain and enhance the appearance of turf grass and other vegetation. In one simple arrangement, a generally rectangular blade is rotated in a horizontal plane at the desired cutting height. The blade sweeps out a circle, and sharpened cutting zones on the leading edges of the blade cut the grass at the desired height as the entire mower travels across the lawn. The blade may also include raised “wings” on its trailing edges, to lift the grass as it is cut by the sharpened edges. In a single-blade mower, the blade may typically be about three inches across and 18-24 inches long, so that the mower cuts a swath about 18-24 inches wide. The blade may be turned by a motor such as a gasoline or electric motor, and in some mowers, power from the motor is also be used to propel the mower itself. Often, the blade is attached directly to the vertical shaft of the motor.

While such a narrow swath may be satisfactory for cutting small areas, it is often desirable for a mower to cut a wider swath, to reduce the time required to mow a larger area. Because various difficulties arise when a mower blade exceeds about 24 inches, multi-blade mowers have been developed. In a typical multi-blade mower, multiple blades rotate on spaced-apart spindles, each spindle having a single blade mounted thereon, and are transported in parallel across the lawn. The blades of conventional multi-blade mowers are oriented in the same plane and are commonly offset or timed to provide horizontal overlap between the blade swaths. The blades cut an overall swath that approaches the sum of the lengths of the blades, less the overlap necessary to ensure that no gaps exist in the cut swath. That is, a two-blade mower may cut a swath just under twice the width of a mower having a single blade of the same length as each of the two blades. A multiple-blade mower thus achieves improved cutting productivity, while avoiding the difficulties of longer blades. The blades are typically housed within a single deck that has internal baffling that works to minimize conflicting airflow between adjacent blades and also to direct and expedite the discharge of cut clippings from within the deck.

According to one aspect, a multi-blade mower comprises first and second spindles spaced apart from each other by a distance. A first lower blade and a first upper blade are mounted to the first spindle. The first upper blade is mounted higher than the first lower blade, and the first upper blade is longer than the first lower blade and sweeps out a larger circle than the first lower blade sweeps out during rotation. A second lower blade and a second upper blade are mounted to the second spindle. The second lower blade is at the same height as the first lower blade, the second upper blade is mounted higher than the second lower blade, and the second upper blade is shorter than the second lower blade and sweeps out a smaller circle than the second lower blade sweeps out during rotation. The circles swept out by the first and second lower blades do not overlap, and the circles swept out by the first upper blade and the second lower blade do overlap, as viewed from above the mower. In some embodiments, the first and second spindles are not timed in relation to each other. In some embodiments, the first lower blade and the first upper blade are held in fixed relation to each other such that the first lower and first upper blades rotate together on the first spindle, and the second lower blade and the second upper blade are held in fixed relation to each other such that the second lower and second upper blades rotate together on the second spindle. Each of the first and second upper blades may lead its respective lower blade in rotation. In some embodiments, each of the first and second lower blades is flat and comprises at least one cutting zone on a respective leading edge. In some embodiments, each of the first and second upper blades comprises at least one raised fan wing and at least one cutting zone on a respective leading edge. In some embodiments, each of the first and second lower blades is flat and comprises at least one cutting zone on a respective leading edge, and each of the first and second upper blades comprises at least one raised fan wing and comprises at least one cutting zone on a respective leading edge. In some embodiments, the heights of the first and second upper blades are equal, and the circles swept out by the first and second upper blades do not overlap, as viewed from above the mower. The first and second spindles may be held with their rotational axes in fixed parallel relation to each other. The first and second spindles may be positioned on an axis that is perpendicular to a nominal direction of travel of the mower. In some embodiments, the multi-blade mower further comprises a prime mover and a drive mechanism that cooperate to rotate the first and second spindles. The first lower blade and the second lower blade may be of unequal lengths. The first upper blade and the second upper blade may be of unequal lengths.

In some embodiments, the multi-blade mower further comprises a third spindle spaced apart from the first and second spindles; and a third lower blade and a third upper blade mounted to the third spindle, the third upper blade being mounted higher than the third lower blade; wherein the third lower and third upper blades have differing lengths and are positioned such that they interact during rotation with the first lower and first upper blades or with the second lower and second upper blades in the same manner as the interaction of the first lower and first upper blades with the second lower and second upper blades.

According to another aspect, a multi-blade mower comprises first and second spindles spaced apart from each other by a distance. A first blade is mounted to the first spindle at a height, and the first blade comprises at least one cutting zone on a leading edge and the first blade has a first length such that the first blade sweeps out a circle having a first radius when the first blade rotates on the first spindle. The multi-blade mower further comprises a second blade mounted to the second spindle at the same height as the first blade. The second blade comprises at least one cutting zone on a leading edge and the second blade has a second length such that the second blade sweeps out a circle having a second radius when the second blade rotates on the second spindle. The sum of the first and second radii is less than the distance between the first and second spindles. The multi-blade mower further comprises a third blade mounted to the first spindle. The third blade comprises at least one cutting zone on a leading edge and is displaced vertically from the first blade, and extends beyond an end of the first blade such that the third blade sweeps out a circle having a third radius when the third blade rotates on the first spindle. The sum of the second and third radii is larger than the distance between the first and second spindles such that the circle swept out by the third blade overlaps the circle swept out by the second blade as viewed from above the mower. The height of the third blade is sufficiently different from the height of the second blade that the third blade and the second blade do not contact each other regardless of the angular positions of the first and second spindles. In some embodiments, the first and second spindles are not timed in relation to each other. In some embodiments, the third blade is mounted to the first spindle in fixed relation to the first blade such that the first and third blades rotate together on the first spindle. The third blade may extend beyond both ends of the first blade. The first and second spindles may be positioned on an axis that is perpendicular to a nominal direction of travel of the mower. The rotational axes of the first and second spindles may be fixed in parallel relation to each other. In some embodiments, the multi-blade mower further comprises a fourth blade mounted on the second spindle, wherein the fourth blade comprises at least one cutting zone at a leading edge, wherein the fourth blade is displaced vertically from the second blade, wherein the fourth blade has a length shorter than the length of the second blade such that the fourth blade sweeps out a circle having a fourth radius when the fourth blade rotates on the second spindle, and wherein the sum of the third and fourth radii is smaller than the distance between the first and second spindles. In some embodiments, the fourth blade is mounted in fixed relation to the second blade such that the second and fourth blades rotate together on the second spindle. In some embodiments, each of the third and fourth blades comprises at least one raised fan wing, and the third blade leads the first blade in rotation, and the fourth blade leads the second blade in rotation. In some embodiments, the multi-blade mower further comprises a prime mover and a drive system that cooperate to rotate the first and second spindles.

According to another aspect, a dual-height lawn mower blade assembly comprises a lower blade having a first length, two coplanar end portions, and an offset portion between the two end portions, the offset portion being planar, parallel to the planar end portions, and displaced from the planar end portions by a first displacement distance. The assembly further comprises an upper blade having second length, two coplanar end portions, and an offset portion between the two end portions, the offset portion being planar, parallel to the planar end portions, and displaced from the planar end portions by a second displacement distance. The offset portion of the lower blade is disposed against the offset portion of the upper blade and the first offset distance is larger than the second offset distance, such that vertical clearance is provided between the end portions of the lower blade and the end portions of the upper blade. The sides of the offset portion of the upper blade are angled with respect to the longitudinal axis of the upper blade, such that the rotation of the lower blade with respect to the upper blade is constrained by sides of the offset portion of the upper blade. In some embodiments, the upper blade includes raised fan wings at its ends. In some embodiments, the upper and lower blades are of different lengths.

FIG. 3 illustrates a mower blade arrangement in accordance with embodiments of the invention, as viewed along the direction of travel of the mower.

FIG. 6 shows an enlarged view of a blade interaction in a multi-blade mower in accordance with other embodiments.

FIG. 7 illustrates an example way of fixing upper and lower mower blades to each other, in accordance with embodiments of the invention.

In multi-blade mowers, it is desirable to maximize cutting area and to ensure complete cutting of the lawn while avoiding collisions between the multiple blades. To avoid blade collisions, there should be absolute clearance between adjacent blades. The nominal design should provide enough clearance to accommodate manufacturing tolerances in spindle positioning and blade lengths, distortion of the mower deck during use, and other factors, so that clearance always exists between the blades. Unless addressed, this running clearance results in a gap between the blade tips that can allow grass encountered at the point of blade path intersection to “slide through” and remain uncut, resulting in an unacceptable cut quality and appearance.

To avoid leaving grass uncut in this way, many multiple spindle cutting deck designs position the blade spindles farther apart than the blade length, so that the blades cannot reach each other regardless of their rotational positions. The lateral mounting axis of the spindles is then intentionally skewed to create overlapping blade tip circles between adjacent spindles as viewed from the mower’s direction of travel. That is, one blade trails the other in the direction of mower travel, and is inset toward the mower center line in relation to the other blade.

An example of skewed spindles is shown in FIG. 1. Two blades turn on respective spindles, and are at the same height relative to level ground. The two spindles are spaced from each other by a distance D sufficient to leave absolute clearance between the two blades. However, the spindles are placed on an alignment axis that is skewed with respect to the direction of mower travel, so that in the direction transverse to the mower travel, the spindles are spaced by distance X, and the second spindle trails the first by distance Y. Thus, the swaths cut by the two blades overlap as the mower moves.

In another arrangement, some mowers position the spindles closer together than the blade length, and ensure that the blades never collide by synchronizing or “timing” the rotation of adjacent blades in relation to each other. Thus, the cutting circles of the blades overlap, even if the spindles are not skewed in relation to the direction of travel. Typically, the blades are driven using cogged pulleys and toothed belts to avoid slippage of the pulleys with respect to each other on the belt, or a gear box is placed at each spindle and the gear boxes are coupled together in a fixed-ratio relationship.

An example of timed blades is shown in FIG. 2. Again, two blades turn on respective spindles, and are at the same height relative to level ground. However, in FIG. 2. the spindles are placed on an axis that is not skewed with respect to the mower travel direction, but is transverse to it. The spindles are spaced apart by distance X, which is not sufficient to guarantee clearance between the blades. Rather, the blades are timed with respect to each other, using a timing belt and cogged pulleys, so that only one blade tip at a time can exist within the area of the blade circle overlap. Thus, the swaths cut by the two blades overlap, and the system relies on the timing mechanism to ensure that the blades do not collide.

Embodiments of the invention provide swath overlap in a novel way, using at least one additional blade displaced vertically from another of the cutting blades.

FIG. 3 illustrates a mower blade arrangement in accordance with some embodiments of the invention, as viewed along the direction of travel of the mower. FIG. 4 shows an enlarged view of a portion of FIG. 3. In the example of FIG. 3. a first spindle 301 and a second spindle 302 are spaced apart by a distance D. Spindles 301 and 302 are mounted to a mower deck 303, and turn on bearings.

In this example, four different blades are present, two mounted to each of spindles 301 and 302. A first lower blade 304 and a first upper blade 305 are mounted to and turn on first spindle 301. As can be seen in FIG. 3. first upper blade 305 is longer than first lower blade 304. (The blades on each spindle are shown in FIG. 3 as being aligned parallel with each other for ease of explanation, but this is not necessarily the case in practice. As is explained below in more detail, one blade on each axis may lead the other in rotation.) That is, the ends of first upper blade 305 overhang the ends of first lower blade 304, so that first upper blade 305 sweeps out a larger circle during rotation than does first lower blade 304.

A second lower blade 306 and a second upper blade 307 are mounted to and turn on second spindle 302. Second lower and upper blades 306 and 307 have the opposite length relationship from first lower and upper blades 304 and 305. As shown, second lower blade 306 is longer than second upper blade 307, such that second lower blade 306 sweeps out a larger circle during rotation than does second upper blade. In some embodiments the two longer blades (first upper blade 305 and second lower blade 306) may be equal in length, and the two shorter blades (first lower blade 304 and second upper blade 307) may be equal in length, but this is not a requirement.

Upper blades 305 and 307 are mounted higher than lower blades 304 and 306. For the purposes of this disclosure, blade height is the cutting height of the blade, for example as measured from the ground when the mower is resting on level ground. In the example of FIG. 3. first and second lower blades 304 and 306 are at the same height. As shown, first and second upper blades 305 and 307 are also mounted at the same height, but are mounted at a height higher than the height of the respective lower blades.

The circles swept out by lower blades 304 and 306 do not overlap. The lengths of lower blades 304 and 306 are such that the lower blades do not reach each other, regardless of the angular positions of the two lower blades. That is, there is absolute horizontal clearance between lower blades 304 and 306. Stated another way, each rotating blade sweeps out a circle having a respective radius, and the sum of radii of the circles swept out by lower blades 304 and 306 is smaller than the distance D between the spindles.

Similarly, the circles swept out by upper blades 305 and 307 do not overlap. The lengths of upper blades 305 and 307 are such that the upper blades do not reach each other, regardless of the angular positions of the two upper blades. That is, there is absolute horizontal clearance between upper blades 305 and 307. That is, the sum of radii of the circles swept out by upper blades 305 and 307 is also smaller than the distance D between the spindles.

However, the circles swept out by the two longer blades do overlap, as viewed from above the mower. That is, the circle swept out by first upper blade 305 overlaps with the circle swept out by second lower blade 306 as viewed from above the mower. Stated another way, the sum of the radii of the circles swept out by the two longer blades (first upper blade 305 and second lower blade 306) is greater that the distance D between the spindles. Vertical clearance is provided between the two long blades (first upper blade 305 and second lower blade 306) to avoid collisions between the longer blades. Clearance is provided between all of the blades, regardless of the relative angular positions of the blades in their respective rotations. As a result of the clearance of lower blades 304 and 306 and upper blades 305 and 307, it is unnecessary to orient the spindle axes in a skewed relationship, as shown in FIG. 1. or to time the blades, as described above in connection with FIG. 2. Thus, in some embodiments, the first and second spindles 301 and 302 are not timed with respect to each other. In other embodiments, the spindles may be timed, although the un-timed arrangement may be preferable, as it avoids the additional structure necessary to insure timing of the spindles.

For the purposes of this disclosure, for spindles to be “timed” in relation to each other means that measures are taken to ensure that the spindles maintain their relative angular positions. For example, the spindles may be driven by a toothed belt running on cogged pulleys, or may be driven by synchronized gears that prevent drift of the angular relationship between the spindles. In particular, driving two spindles using a simple V-belt is not considered to time the spindles. Even though two spindles driven with a simple V-belt may run for long periods with little or no change in their angular relationship, it is possible for the angular relationships to drift due to differences in pulley diameters, wear, slippage of the belt on the pulleys, and the like.

In the example of FIG. 3. the two lower blades cut the bulk of the grass to the cutting height of the lower blades. The small amount of grass that may slip through the horizontal gap between the lower blades without being cut by the lower blades is cut by first upper blade 305 at only a slightly higher cutting height, leaving only an inconsequential and unnoticeable slight irregularity in the cut height of the lawn, as is shown in FIG. 4.

The amount of horizontal and vertical clearance provided may be determined by the expected manufacturing tolerances of the blades, mower deck, spindles, and other mower components, and by the expected stresses that may deform the components during mowing. Preferably, the clearances are made large enough to guarantee that no blade collisions occur during normal operation, but small enough that no noticeable variation in cutting height of the lawn is visible. Although the dimensions and configurations of the blades may vary widely, in some optional embodiments, the longer blades may have a length from 12 to 36 inches, e.g., from 15 to 30 inches, or from 18 to 24 inches. In some embodiments, the shorter blades optionally have a length from 0.05 to 3 inches shorter than the longer blades, e.g., from 0.25 to 2 inches or from 0.5 to 1 inches shorter. The horizontal clearance between the lower blades and/or between the upper blades may be from 0.05 to 2 inches, e.g., from 0.10 to 1 inches or from 0.25 to 0.5 inches. In some embodiments, the vertical clearance between the lower and upper blades on a given spindle may be from 0.02 to 1 inches, e.g., from 0.05 to 0.5 inches or from 0.1 to 0.4 inches. For example, in one embodiment in which the longer blades are 17.375 inches long and the lower blades are 15.815 inches long, the nominal horizontal clearance between the lower blades is 0.030 inches, and the nominal vertical clearance between the lower and upper blades is 0.125 inches. Other blade lengths and clearance dimensions may be used as well.

It will be recognized that the placement of the blades on the two spindles is completely arbitrary. While FIG. 3 shows a shorter lower blade on spindle 301 and a longer lower blade on spindle 302, this arrangement could be reversed if desired.

FIG. 5 shows the operation of the blade arrangement of FIG. 3. as viewed from above the mower. An area of overlap exists between the swaths cut by first (long) upper blade 305 and second (long) lower blade 306. The blades may be driven by a prime mover, for example a gasoline or electric motor, through a drive belt, which may be for example a simple V-belt. In the example of FIG. 5. the spindles are placed on an axis that is transverse to the direction of travel of the mower, but this is not a requirement. In other embodiments, the axis on which the spindles are placed may be skewed with respect to the mower travel direction. The transverse axis design may be preferable, as it may allow production of a mower that is shorter in its travel direction than a mower using a skewed spindle mounting axis.

In the example of FIGS. 3-5. the two long blades (first upper blade 305 and second lower blade 306) are equal in length, and the two short blades (first lower blade 304 and second upper blade 307) are equal in length, although this is not a requirement. In other embodiments, different lengths may be used. For example, FIG. 6 is similar to FIG. 4. and shows an enlarged view of the blade interaction in an embodiment in which the two lower blades are equal in length and the upper blades differ in length to provide the overlap between the longer upper blade and the gap between the lower blades. In the embodiment of FIG. 6. the lower blades are symmetrical about the mower center line, so that their point of closest approach is at the centerline. The upper blades still differ in length. As compared with the embodiment of FIG. 4. the embodiment of FIG. 6 may have the advantage that fewer unique blade types are used, as the two lower blades may be identical. Similarly, in other embodiments, the two upper blades may be made identical to each other, and the cutting overlap may be provided by lower blades of differing lengths.

As is also shown in FIG. 5. each set of lower and upper blades are fixed to each other, and rotate together on their respective spindles. The upper blades “lead” the lower blades in rotation, and may pre-cut the grass to one height before the final cut performed by the lower blades. This pre-cutting process may beneficially result in improved grass pulverization, which can facilitate grass deterioration over a shorter period of time. This arrangement, however, is also not required. In other embodiments, the lower blades may lead the upper blades. In still other embodiments, the upper and lower blades need not be fixed to each other, and need not rotate together, and in fact could rotate in opposite directions.

FIG. 7 illustrates one example way of fixing the upper and lower blades to each other, in accordance with some embodiments of the invention. While FIG. 7 illustrates the blade connection using the second lower and upper blades, a similar technique may be used for other blade sets. In this technique, lower blade 306 includes coplanar end portions 706 and an offset portion 701 between end portions 706. Offset portion 701 is planar and parallel to the planar end portions. Upper blade 307 includes two planar end portions 707 and an offset portion 702 between the end portions 707. Offset portion 701 is preferably deeper than offset portion 702, so that the ends of upper blade 307 are held above lower blade 306, providing the vertical clearance between them. The sides 708 of offset portion 702 of upper blade 307 are at an angle to the longitudinal axis of upper blade 307 such that when the blades are assembled onto the spindle, offset portion 701 is disposed against offset portion 702, locking the blades from relative rotation.

Preferably, each lower blade such as blade 306 has at least one cutting zone 703 at a leading edge of blade 306. Two cutting zones 703 are shown in FIG. 7. on different leading edges, but more or fewer cutting zones may be present. Each cutting zone may be sharpened, for example by grinding, to form a cutting edge. Similarly, upper blade 307 may include one or more cutting zones 704.

In some embodiments, the upper blades such as upper blade 307 may include raised fan wings 705, to lift the grass for cutting and to facilitate discharge of cut grass clippings from the mower. The lower blades, such as lower blades 304 and 306 may lack any raised fan wings. For the purposes of this disclosure, a blade lacking raised fan wings is referred to as flat, even in the presence of raised mounting features such as offset portions 701 or 702.

In the embodiments described thus far, only two sets of blades are present, on two respective spindles. However, in other embodiments, three or more spindles may be present, for example a third spindle having a third lower blade and a third upper blade. The third lower and upper blades may interact with first upper and lower blades 304 and 305, or with second upper and lower blades 306 and 307, such that the mower has an even wider cutting width than the embodiment of FIG. 3. for example. The specific arrangement of the blade sets is arbitrary. For example, the center spindle may have its lower blade longer than its upper blade, with the outer spindles having longer upper and shorter lower blades. Or the center spindle may have its lower blade shorter than its upper blade, with the outer spindles having shorter upper and longer lower blades. In any event, the blades on the third spindle interact with either the blades on the first spindle or the second spindle, in a manner like the interaction of the blades on the first and second spindles. than three spindles and blade sets may be provided, alternating in the placement of their respective longer and shorter blades.

Also in the embodiments described thus far, the two spindles are held with their rotational axes in a fixed parallel relation to each other, so that the lower blades turn in the same plane. The multi-blade mower is thus substantially rigid, and acts as a large flat cutter. In other embodiments, however, the spindles may be movable with respect to each other, to allow the mower deck to flex to conform to uneven ground. For example, a hinge may be provided having its axis horizontal, substantially parallel to the direction of mower travel, and intersecting the center line shown in FIG. 3 at about the average height of the blades, or at another suitable location. The vertical and horizontal clearances provided between the blades are preferably selected to accommodate the expected flexure of the mower deck without incurring blade collisions. The flexure of the deck may be mechanically limited in the interest of avoiding blade interference as well. A flexing deck may be especially advantageous when three or more spindles and blade sets are present, as the additional mower width increases the likelihood of encountering uneven ground in any particular swath.

It is also not necessary that all of the blade sets in a mower embodying the invention be of similar sizes. For example, in a multi-blade mower having three spindles and three blade sets, the middle blade set may sweep out a larger circle than either of the outer blade sets, or vice versa. For example, the middle blade set could include blades about 24 inches long (with the upper and lower blades being of somewhat different lengths), while the outer blade sets may be only about 18 inches in length. Any suitable combination of blade lengths may be used, and no two blade sets need be the same size.

In still other embodiments, other blade arrangements may be used. For example, referring to FIG. 3. second upper blade 307 may be omitted entirely. In another example, upper blades 305 and 307 may not be single elongated pieces. Instead, in some embodiments, the raised fan wings and additional cutting zones provided by the upper blades may be provided by short blade segments mounted to the respective lower blades by welds, rivets, bolts, or other techniques.

In one embodiment, the upper and lower blades may be removed from the mower and reinstalled in a reversed configuration in order to prolong the life of the blades and/or provide for even wear. Of course, if the blade positions are reversed in this manner it will likely be necessary to do the same with all spindles in order to ensure that that there is no blade contact between the blades on different spindles during normal usage. If the upper and lower blades are attached to one another, the configuration may still be reversible, but it may be necessary to provide cutting zones on both the leading and trailing edge of the blades, since the trailing edge will become the leading edge after the integrated blade assembly has been reversed (assuming the same direction of blade rotation). In addition, in the latter embodiment, it may be necessary for any integrated raised fan wings to be provided in a separate optionally non-cutting blade higher than the other blades or to provide the ability to remove and reinstall any fan wings to ensure they are in the proper orientation for normal usage.

It will be understood that the principles of the invention may be embodied in walk-behind mowers, self-propelled walk-behind mowers, riding mowers, standing mowers, pulled mowers, or other kinds of multi-blade mowers. A blade arrangement embodying the invention, such as those discussed above, is preferably enclosed in a mower deck, which may include baffling and other features to control air flow near the blades and to exhaust grass clippings.

FIG. 8 shows a schematic overhead view of a riding mower 800 according to some embodiments of the invention. Mower 800 includes a deck 801 housing blades 304, 305, 306, and 307 as discussed above. The deck includes an exhaust chute 802, and is carried by four wheels 803.

The invention has now been described in detail for the purposes of clarity and understanding. However, those skilled in the art will appreciate that certain changes and modifications may be practiced within the scope of the appended claims. It is to be understood that any workable combination of the features and capabilities disclosed above in the various embodiments is also considered to be disclosed.

Claims ( 25 )

a first lower blade and a first upper blade mounted to the first spindle, wherein the first upper blade is mounted higher than the first lower blade, and wherein the first upper blade is longer than the first lower blade and sweeps out a larger circle than the first lower blade sweeps out during rotation;

a second lower blade and a second upper blade mounted to the second spindle, wherein the second lower blade is at the same height as the first lower blade, wherein the second upper blade is mounted higher than the second lower blade, and wherein the second upper blade is shorter than the second lower blade and sweeps out a smaller circle than the second lower blade sweeps out during rotation; and

wherein the circles swept out by the first and second lower blades do not overlap, and the circles swept out by the first upper blade and the second lower blade do overlap, as viewed from above the mower.

The multi-blade mower of claim 1. wherein the first and second spindles are not timed in relation to each other.

the first lower blade and the first upper blade are held in fixed relation to each other such that the first lower and first upper blades rotate together on the first spindle; and

the second lower blade and the second upper blade are held in fixed relation to each other such that the second lower and second upper blades rotate together on the second spindle.

The multi-blade mower of claim 3. wherein each of the first and second upper blades leads its respective lower blade in rotation.

The multi-blade mower of claim 1. wherein each of the first and second lower blades is flat and comprises at least one cutting zone on a respective leading edge.

each of the first and second lower blades is flat and comprises at least one cutting zone on a respective leading edge; and

each of the first and second upper blades comprises at least one raised fan wing and comprises at least one cutting zone on a respective leading edge.

The multi-blade mower of claim 1. wherein the heights of the first and second upper blades are equal, and the circles swept out by the first and second upper blades do not overlap, as viewed from above the mower.

The multi-blade mower of claim 1. wherein the first and second spindles are held with their rotational axes in fixed parallel relation to each other.

The multi-blade mower of claim 1. wherein the first and second spindles are positioned on an axis that is perpendicular to a nominal direction of travel of the mower.

The multi-blade mower of claim 1. further comprising a prime mover and a drive mechanism that cooperate to rotate the first and second spindles.

The multi-blade mower of claim 1. wherein the first lower blade and the second lower blade are of unequal lengths.

The multi-blade mower of claim 1. wherein the first upper blade and the second upper blade are of unequal lengths.

a third lower blade and a third upper blade mounted to the third spindle, the third upper blade being mounted higher than the third lower blade;

wherein the third lower and third upper blades have differing lengths and are positioned such that they interact during rotation with the first lower and first upper blades or with the second lower and second upper blades in the same manner as the interaction of the first lower and first upper blades with the second lower and second upper blades.

a first blade mounted to the first spindle at a height, the first blade comprising at least one cutting zone on a leading edge and the first blade having a first length such that the first blade sweeps out a circle having a first radius when the first blade rotates on the first spindle;

a second blade mounted to the second spindle at the same height as the first blade, the second blade comprising at least one cutting zone on a leading edge and the second blade having a second length such that the second blade sweeps out a circle having a second radius when the second blade rotates on the second spindle, wherein the sum of the first and second radii is less than the distance between the first and second spindles;

a third blade mounted to the first spindle, the third blade comprising at least one cutting zone on a leading edge and being displaced vertically from the first blade and extending beyond an end of the first blade such that the third blade sweeps out a circle having a third radius when the third blade rotates on the first spindle, wherein the sum of the second and third radii is larger than the distance between the first and second spindles such that the circle swept out by the third blade overlaps the circle swept out by the second blade as viewed from above the mower, the height of the third blade being sufficiently different from the height of the second blade that the third blade and the second blade do not contact each other regardless of the angular positions of the first and second spindles; and

a fourth blade mounted on the second spindle, wherein the fourth blade comprises at least one cutting zone at a leading edge, wherein the fourth blade is displaced vertically from the second blade, wherein the fourth blade has a length shorter than the length of the second blade such that the fourth blade sweeps out a circle having a fourth radius when the fourth blade rotates on the second spindle, and wherein the sum of the third and fourth radii is smaller than the distance between the first and second spindles.

The multi-blade mower of claim 15. wherein the first and second spindles are not timed in relation to each other.

The multi-blade mower of claim 15. wherein the third blade is mounted to the first spindle in fixed relation to the first blade such that the first and third blades rotate together on the first spindle.

The multi-blade mower of claim 15. wherein the third blade extends beyond both ends of the first blade.

The multi-blade mower of claim 15. wherein the first and second spindles are positioned on an axis that is perpendicular to a nominal direction of travel of the mower.

The multi-blade mower of claim 15. wherein the rotational axes of the first and second spindles are fixed in parallel relation to each other.

The multi-blade mower of claim 15. wherein the fourth blade is mounted in fixed relation to the second blade such that the second and fourth blades rotate together on the second spindle.

The multi-blade mower of claim 21. wherein each of the third and fourth blades comprises at least one raised fan wing, and wherein the third blade leads the first blade in rotation, and the fourth blade leads the second blade in rotation.

The multi-blade mower of claim 15. further comprising a prime mover and a drive system that cooperate to rotate the first and second spindles.

the first lower blade comprises two coplanar end portions and an offset portion between the two end portions, the offset portion being planar, parallel to the planar end portions, and displaced from the planar end portions by a first displacement distance;

the first upper blade comprises two coplanar end portions and an offset portion between the two end portions, the offset portion being planar, parallel to the planar end portions, and displaced from the planar end portions by a second displacement distance; and

the offset portion of the lower blade is disposed against the offset portion of the upper blade and the first displacement distance is larger than the second displacement distance, such that vertical clearance is provided between the end portions of the lower blade and the end portions of the upper blade.

The multi-blade mower of claim 24. wherein the sides of the offset portion of the upper blade are angled with respect to the longitudinal axis of the upper blade, such that the rotation of the lower blade with respect to the upper blade is constrained by sides of the offset portion of the upper blade.

US15/008,173 2016-01-27 2016-01-27 Multi-blade lawn mower cutting system with overlapping cutting circles Active US9480200B1 ( en )

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Best Self-Propelled Lawn Mower Reviews 2023

Deciding on the best self-propelled lawn mower isn’t as easy as it used to be. Do you need commercial or residential quality? Do you want to use gas or batteries for power? How much grass do you need to cut? Are you a mulcher or a bagger?

Having tested dozens of the best walk-behind lawn mowers from entry-level residential to the top professional models, we got our Pro team together to choose our top mowers in a range of scenarios.

One of the big things changing in the market is Honda’s announcement that the brand is exiting the lawn mower market. While you can still buy Honda mowers until they run out of stock, 2023 marks the end of production. We still highly recommend them, but due to the news and iffy availability, we’re not considering Honda as part of our choices this year.

Want to see more, including ride-on and robotic recommendations? Read out Best Lawn Mower Reviews main article!

Best Self-Propelled Gas Lawn Mower

Commercial: Exmark Commercial X-Series Self-Propelled Lawn Mower

As we bid adieu to Honda this year, the HRC series still gets two thumbs up from us while you can get them. From there, we turn to Exnark and its Commercial X line that complements its Lazer Z zero-turn mowers well. Some professionals will certainly turn to the higher-capacity 30-inch model, but we expect the 21-inch model will find its way onto more trailers.

Exmark wisely uses a Honda 163cc GXV engine with a legendary reputation for reliability. It’s fed by a generous 1-gallon fuel tank and turns the blade at tip speeds up to 18,500 fpm. There’s also an option for a Kawasaki FJ180V engine if you’d like to step up to a 179cc engine.

The deck is 1/4-inch aluminum construction that keeps the weight down (112 pounds) while maintaining high durability. The deck is adjustable from 4.5 inches on the high side all the way down to 1 inch while the drive runs at speeds up to 4.2 MPH.

Residential: Toro Super Recycler Series 21-Inch Self-Propelled Lawn Mower

Toro runs deep in the residential lawn mower sector and our favorite among them is the Super Recycler series. Getting the best of all the technology Toro has to offer, our top recommendation (model 21565) includes the Personal Pace drive system and the Smart Stow design that allows you to vertically store the mower even though it’s a gas model.

It uses a 163cc Briggs Stratton engine that produces 7.25 ft-lbs of torque and just under 17,000 fpm blade tip speed.

Toro touts a commercial-grade construction on this model and includes a lighter aluminum deck rather than steel. In addition to that, you get outstanding cut quality, especially on the mulching side (you better with the name Super Recycler!). Wrapping it up, the Personal Pace drive system adjusts to your walking pace so there are no levers or dials to adjust.

Best Self-Propelled Electric Lawn Mower

Just a few years ago, if you wanted to find the best battery-powered lawn mower, you could only find residential models. Now, there’s an emerging class of professional-grade options and we have picks for both Pros and homeowners.

Professional: Milwaukee M18 Fuel 21-Inch Self-Propelled Lawn Mower

There aren’t many true commercial self-propelled lawn mowers with lithium-ion power sources. Milwaukee launched their effort in 2022 with a monstrous 10 ft-lbs of torque that tops what you typically see from a 200cc gas engine. It’s more than just muscle, though. Its blade and deck combine to handle mulching and bagging better than most.

As you roll into fall, the mower’s high-lift mode keeps the blades at 3300 RPM to help pull those lightweight leaves and clean up your lawn. Other features include 180° LED lighting, LED battery indicators facing you, variable speed thumb bar (in addition to the speed wheel), a durable build, and much more.

Price: 1099.00 with two 12.0Ah batteries and dual-port Rapid charger

Residential: EGO Select Cut XP 21-Inch Lawn Mower with Speed IQ

The evolution of EGO’s flagship mower is interesting. It started with the dual-battery Peak Power model that raised the bar of what lithium-ion is capable of. Then, we saw the first stacked-blade SelectCut options that improved cut quality and effectiveness in tall grass. The two technologies combined in the SelectCut XP. Now EGO adds Speed IQ to the mix.

Speed IQ is a self-propelled drive system that automatically adjusts to your pace. However, it’s not a spring-loaded set of handles like Toro uses on its Personal Pace models. Instead, there’s a sensor doing some serious engineering magic… and it works like a charm from our brief time with it at Equip Expo 2022 (formerly GIE).

Price: 599.00 bare, 999.00 with a 12.0Ah battery and Turbo charger

Best Large Walk-Behind Lawn Mower

Commercial: Greenworks Commercial 30-Inch Self-Propelled Lawn Mower

Can a battery-powered commercial mower really displace gas models? Greenworks Commercial has an 82V 30-inch model that got our attention at the Equip Expo in late 2022, and it’s hard to ignore as a legitimate option. It has the power to replace a 200cc gas engine with blade speeds up to 16,000 FPM. On a full charge, it can cover up to 2 acres.

There are drive system features worth considering as well. Independent hub wheel motors engage what Greenworks calls the Easy Turn System (ETS), making the mower easier to maneuver. Another big deal is that there is a powered reverse function—something that’s incredibly helpful with the weight of mowers in this class. The controls are all up next to your hands and there’s even a display to help you keep track of your battery levels.

Price: 1999.99 bare, 2999.99 with three 8Ah batteries and a dual-port charger

Residential: Toro TimeMaster 30-inch Personal Pace Mower

With 10 ft-lbs of torque delivered from its Briggs Stratton 223cc engine, the 30-inch Toro TimeMaster is our pick as the best large walk-behind lawn mower. Not only does it deliver big power to turn its time-saving 30-inch blade, but it also features Toro’s Personal Pace self-propelled drive and Spin-Stop that lets you stop the blade without shutting off the mower.

It all adds up to big-time savings on larger lawns. Grab model 21200 if you want an electric start or the 21199 if you don’t mind a recoil start and want to save 100.

Price: 1599.00 (21199), 1499.99 (20200)

Best Self-Propelled Lawn Mower for the Money

Toro’s 21-inch Recycler (21352) offers an excellent value for budget-minded homeowners. It’s a Made in the USA rear-wheel drive system powered by a Briggs Stratton 140cc engine. It comes ready to mulch, bag, or side discharge and you don’t have to worry about changing the oil. Just check the levels and add more when it’s necessary.

Best Self-Propelled Lawn Mower Brand

No one in the self-propelled lawn mower market dominates like Honda. Their engines enjoy a reputation for quality and durability every other manufacturer is shooting for, and their mowers are simply outstanding.

They typically run at a premium, though. Both Honda mowers and Honda-powered mowers are more expensive than similar designs from other brands. The big kick in the pants is Honda leaving the market, though.

That opens the door for Toro. There are a lot of Toro models we recommend for good reason and hit a wide range from budget-friendly homeowner mowers to commercial zero turns. It’s one of the best-selling brands of walk-behind mowers.

Getting hard sales figures is tough to come by, and it’s always possible we missed the mark. However, we see more Honda and Toro walk-behind mowers on commercial trailers and residential lawns than any other brand.

Best Self-Propelled Lawn Mower for Bagging

You don’t have to ditch your current self-propelled lawn mower and buy a whole new one to improve your bagging efficiency. In most cases, adding a high-lift blade to your current mower will make a significant difference. With the exception of electric mowers, you don’t need to worry too much about matching the brand making the blade, but you do need to match the arbor style and the length. The package should tell you which brands it is compatible with.

If you’re still in the market for a new mower, higher RPMs make for better airflow and bagging. Check mowers with a 160cc or higher engine and compare the top blade speeds. You can always swap blades, but you can’t change the speed.

Pro Tip: If you have a 2-point or 4-point deck height adjustment, set the front wheels of your mower one notch higher than the rear to improve bagging.

Best Self-Propelled Mulching Lawn Mower

Similar to a high-lift blade for bagging, you can improve your mulching efficiency with a mulching-specific blade. These usually have additional cutting edges that cut the clippings more times before they drop back into the grass. Keeping the blade sharp ensures you get the best mulching results every time you mow.

If you’re in the market for a new mower, look for a 160cc or higher engine to give you the torque you need to keep your blade speed high in thicker grass. Remember, you can always add a mulching blade, but you can’t make up for an underpowered engine.

Pro Tip: You get the best mulching results if you’re only taking an inch or two off the top of your grass, so make sure you stay on top of lawn maintenance during the peak cutting season.

Best Self-Propelled Lawn Mower – Priorities

Best Rear-Wheel Drive Self-Propelled Lawn Mower for Hills: YBravo Gen II 25-inch Commercial Mower

After running into issues with other commercial walk-behind mowers, we turned to YBravo 25-inch commercial mower to take care of a 3-acre soggy field that our ZTs only bogged down in. Its Kawasaki 180cc engine kept the blade turning where others simply stalled.

When it’s time to move out of the radio station swamp and you’re going for a more professional look, its cut quality is excellent as well. Available in a 21-inch and the 25-inch model we tested, Ybravo is worth serious consideration.

If you have a Bad Boy dealer closer to you, check out the same model sold under the Bad Boy brand name.

Price: 1299.00 (25-inch model)

Best All-Wheel Drive Self-Propelled Lawn Mower: Toro 22-inch Personal Pace All-Wheel Drive Mower 21472

AWD mowers are what you turn to for work on slopes and uneven terrain where it’s possible to have a wheel or two lose traction. For the best all-wheel drive self-propelled lawn mower, we like the Toro 21472 Personal Pace model.

Its 22-inch deck is on the larger size of standard mowers and the Personal Pace system is easy to work with once you get used to it. If you switch between mulching and bagging, the mower’s lever system is super simple.

Packing plenty of power with its 163cc Briggs Stratton engine, it’s not so much that it destroys the competition. It’s that its performance is excellent and the innovations are genuinely helpful while keeping its price in check.

Self-Propelled Lawn Mower Recommendations

Not every mower earns an award, but there are several other models we recommend that didn’t find a place earlier in the article. Check these options out if one of the others doesn’t fit your needs.

Best Lawn Mower Buying Guide – What We Look For

Gas vs Battery

Gas power still wins the day when you’re highest priorities are keeping your purchase price down and your power level high. With advancements in battery and motor technology, the OPE world is shifting towards battery power, though. It’s cleaner and quieter to run and requires less maintenance.

However, you have to look at premium models to get true gas power, and runtime can be a limiting factor. It’s also less likely you have a service center nearby that can get you back up and running quickly if there’s a problem.

If your lawn is a 1/4-acre or less, there are a lot of battery-powered options available. Once you get beyond that size, you need to consider how many batteries you’ll need and legitimate options really start to thin out once you hit 1/2 an acre. With larger lawns, newer battery-powered zero turn mowers are a legitimate option.

Take a deeper look at the comparison between gas and battery power in this article.

Commercial vs Residential

This might be better titled “professional vs homeowner” considering there are both commercial and residential professional crews. Regardless, commercial mowers are built with better components and commercial engines, creating a machine that is built to last for years of high-hour daily use.

If you’re a homeowner mowing once a week or so, a good residential mower can still last for 5 or 10 years (or more) if you take care of it. It just uses components and engine designs better fit for occasional use.

Engine Size and Cutting Power

If you stay on top of your mowing and cut quality isn’t a high priority, an engine as small as 140cc is likely fine.

Move up to the 160cc–180cc class for better performance when the grass is thicker and taller, or when you want to make sure you get excellent mulching, bagging, and/or clean cuts. The greater power improves lift and is less likely to bog down in thick patches.

When you’re looking at deck sizes beyond 22 inches, you should start looking for engines in the 180cc–200cc range (or higher) to ensure it can keep the RPMs high while it’s cutting such a large swath.

Cut Quality

We look for three major components of cut quality: evenness, mulching size, and bagging efficiency.

Evenness is pretty straightforward. When we’re testing, we look for grass blades that weren’t cut and indications that there wasn’t enough lift to clip all of the blades at the same level.

When mulching, smaller clippings are better since they drop down closer to the base of the remaining grass. We also look to see if a mower is prone to leaving trails and clumps.

For bagging, it’s all about how much grass is collected, if the chute tends to clog while we’re cutting, and how much grass is deposited back to the ground.

Noise Level

One of the major benefits of battery-powered mowers is the lower noise levels compared to gas, but that doesn’t mean gas mowers have to be obnoxious. We expect higher levels than battery-powered models and that is typically the case.

When we test noise levels, we measure from our operator’s ear to get an idea of what the person using the mower should expect. Even though some mowers are quieter than others, we still recommend hearing protection when you’re using a gas model.

Fuel Efficiency

How efficient gas mowers use fuel has a very direct effect on your wallet, especially when you’re mowing every day as a Pro.

Fuel efficiency testing is more than just a runtime calculation. The cutting swath of a mower comes into play, especially on those 25 and 30-inch models. With larger lawns, it’s possible to get more cutting done per gallon of gas with an engine that uses more gas per hour.

Deck Size

21 or 22 inches is pretty standard for most mowers. Jumping up to a 25-inch or 30-inch mower may seem tempting, but it’s not for everyone.

If your lawn is a 1/4-acre or less, the time you gain with a larger deck might not mean a whole lot of time savings. Where you really gain some time is on lawns that are a 1/2-acre or more.

Keep in mind, larger deck-size mowers are heavier. When you have to mow wet or soggy areas, the weight can work against you.

Steel vs Plastic (Poly) Deck

The vast majority of gas mowers have steel decks while battery-powered models have a much higher percentage of plastic poly decks.

Those poly plastic decks are tougher than they look, but they probably won’t hold up as well as steel in the long run. It’s still highly unlikely that you’ll wear through one before it’s time to replace the mower, though.

However, there’s a whole lot more design flexibility that comes with poly decks, and engineers can do some amazing things to help with airflow that directly affects cut quality along with bagging and mulching efficiency.

Deck Height

Here in Florida, we have a lot of St. Augustine grass that we cut at 3 1/2 inches, so we prefer a mower that has at least a 4-inch maximum deck height.

Depending on what species of grass you have, you might be able to get away with a lower height, but 4 inches is a good all-around benchmark.

On the low end, most of us aren’t cutting golf course greens (you’d use a reel mower for that, anyway), so the minimum deck height usually isn’t an issue.

However, if you use a blade that dethatches or scalps for maintenance or re-seeding, you might want to make sure the deck height gets low enough—typically 1 1/2 inches or less.

Height Adjustment

Single-point height adjustments are the easiest since you can raise or lower the deck with just one lever. It’s common on battery-powered lawn mowers, but not so much on their heavier gas counterparts.

Part of that is because the single-point mechanisms tend to introduce additional flex into the system and the weight of a gas mower puts more strain on the mechanism. So while we generally prefer single-point, we understand why gas mowers may opt away from them.

Pro Tip: Set the front wheels one notch higher than the rear wheels to improve bagging efficiency on 4-point or 2-point adjustable mowers.

Adjustment Levels

If you’re really OCD, more height adjustments mean more precise cutting. Realistically, most of us are going to find a good height on any mower as long as it hits the maximum and minimum heights we mow at.

Setting the Speed

The type of speed adjustment your self-propelled lawn mower has can make or break your experience. There are pull levers, thumb push levers, full push bars (Toro’s Personal Pace), and iterations on those.

Try it at the dealer before you buy it. If you hate working the mechanism for a couple of minutes, imagine what it’s going to feel like after 30 minutes or an hour.

Front-Wheel Drive, Rear-Wheel Drive, or All-Wheel Drive?

Front-wheel drive lawn mowers are typically the least expensive and work well for even terrain. They also help you turn the easiest since you lift up the drive wheels as you make your turns.

Rear-wheel drive mowers add some cost but create better traction on hills and slopes. They’re particularly good at pushing the mower’s weight uphill where front-wheel drives start to lose traction as they try to pull the weight.

All-wheel drive mowers are the most expensive and generally do the best job on hills, slopes, and uneven terrain. On particularly bumpy areas where it’s likely one or more wheels will lose traction, it’s the best bet.

Wheel Size

Larger wheels tend to handle bumps and uneven terrain better than smaller wheels according to manufacturers. However, it’s a claim that Consumer Reports says isn’t really the case.

Electric Start

If you’ve used a gas engine, there’s a good chance you’ve worn out your arm pulling the cord to start it. There’s no doubt that having an electric start on your mower can take away a lot of the frustration.

It won’t make up for poor maintenance, though. A well-maintained mower starts easily on the first or second pull. That begs the question as to whether the electric start is worth an extra hundred dollars.

It’s totally up to you, but if it’s in the budget, we want it.

Mulch, Bag, or Side/Rear Discharge?

Most quality mowers are 3-in-1, meaning you can bag, mulch, or side/rear discharge. Less expensive models often only provide options for bagging and mulching. Which one you choose depends on what type of grass you have, how fast it grows, and your personal preference.

In central Florida where St. Augustine, Zoysia, and Bahia dominate our landscapes, the summer heat and rains make our grass grow incredibly fast. Most of us mulch out of necessity since we almost need a dumpster for the volume of clippings we create.

Handle Positions

Most lawn mowers have 3 handle positions you can set. For tall guys like me or average-height guys like Clint, it helps you find a more comfortable grip. Some mowers opt for 2, or sometimes just 1 handle position.

Value

Value is more than just price. We take a broad look at the performance and features compared to the price to determine the value of each mower.

Why You Can Trust Pro Tool Reviews

Ever check out a “review” site and you can’t tell if they actually tested the tools or if they’re just “recommending” the Amazon top sellers?

That’s not us. We only recommend what we’d actually use, even if we don’t earn a commission from it. It’s all about giving you a legitimate recommendation and our honest opinion of each product.

We’ve been in business since 2008 covering tools, writing reviews, and reporting on industry news in the construction, automotive, and lawn care industries. Our Pro reviewers work in the trades and have the skills and experience to know whether tools can perform well in the field.

Each year, we bring in and review more than 250 individual products. Our team will put our hands on hundreds of additional tools at media events and trade shows throughout the year.

We consult with innovators in the technology and design of tools to gain a broader grasp of where these products fit and how they work.

We work with more than two dozen professional contractors around the United States who review products for us on real job sites and consult with us on testing methods, categories, and weighting.

We’ll provide more than 500 pieces of new content this year absolutely free for our readers—including objective evaluations of individual tools and products.

The end result is information you can trust because of the editorial, scientific, and real-world professional experience we collectively utilize each and every time we pick up and test a tool.

GreenWorks G-MAX 20” 40V Cordless Twin Force Mower: Product Review

Every year there are more battery-powered mowers on the market, and they’ve gone from being a curiosity to a mainstream option in the lawn care space. Mowers in general have come a long way since I started my first business (Whitehaven Lawn Mowing) at age 12 (it put me through college and I mowed a LOT of lawns!). So it I was looking forward to testing the latest cordless lawn mower designs.

Setting Up The Mower

The GreenWorks G-MAX mower arrived in a box with all of the parts well packaged so there was no shifting or damage during transport.

Included in the box are the following:

Twin Force Mower
Rear discharge bag
Mulching plug
Owners manual
1 4Ah 40V battery
1 2Ah 40V battery
Battery charger

The mower was ready to go out of the box – all I had to do was adjust the handle bar from the storage/transport position to the mowing position by loosening a lever, moving the handle into position, and then flipping the lever back to the closed position. The handle can be just as easily folded back to make it more compact for storage.

The mower is neatly and securely packaged and needs no assembly.

When the mower arrives, the mulching plug is already installed in the slot at the rear of the mower. If you don’t want to mulch your grass, you’ll need to remove this plug before using the mower – just pull it out and store it somewhere safe.

The instruction manual is clear and detailed.

About Lithium-Ion Batteries

Do not have a “memory” and can be charged at any time.
Once the charging light turns green (on the battery charger) remove the battery from the charger.
Unplug charger when not in use.
Fully charge batteries when placing them in storage.
Batteries will eventually need to be replaced.

See our full QA on Li-ion batteries here.

About the Li-Ion Batteries

Inside the box was a battery charger and two 40V lithium-ion batteries. The two batteries are different; one is a 2 Ah and the other a 4 Ah. Don’t worry, it’s not a packing mistake and it doesn’t matter which slot each battery goes into on the mower. (Note: The 19” model (25312) comes with two 4 Ah batteries)

The batteries and charger used in the G-MAX mower are compatible with any other tools that use the GreenWorks G-MAX 40V Li-Ion System.

Eventually, the batteries will need to be replaced (this is the case with all Li-ion batteries). Greenworks gives no recommendation about when you should do this, but Li-ion batteries typically last about 3 years.

Charging the Batteries

Before using the mower, be sure the batteries are fully charged. I found that they charged from fully depleted (0%) to fully charged (100%) in about 1 to 1.5 hours, depending on the Ah. Charge time was less when there was still some charge left on the batteries.

Keep the battery on the charger until the green indicator light on the right turns on.

Each battery has a status light on one end showing how much charge it has left. Depress the green button to the right of the status light bar to get it to light up.

When you’re ready to mow, the batteries are easily installed into the mower – just slip one into each of the slots in the covered battery bays. The batteries have a depressed locking mechanism to keep them in place while in use and then quickly release them for charging and storage.

When not in use, remove the batteries from the mower and store them inside.

Testing the G-MAX Cordless Twin Force Mower

I put the GreenWorks G-Max mower through its paces on two large lawns made up of either fescue or St. Augustinegrass. After several mowings at different heights, I found a lot to like about this mower, plus a few things I’d like to see improved. Below are my observations and recommendations, as well as a video review so you can see it in action.

Long Battery Run Time

One of the big questions everyone has about a battery-powered lawn mower is how long it’ll run before you need to recharge the battery. The convenience factor of not needing to use gas or drag around an extension cord only goes so far if the battery runs out quickly!

So I was pleasantly surprised to find that the run time when using the recommended 4.0Ah and 2.0Ah batteries was about 1 hour and 15 minutes. That’s more than enough time to mow a typical suburban lawn.

An interesting feature on the G-MAX Twin Force mower is the automatic battery switchover. When you start mowing, power is pulled from only one battery. When that’s depleted, power is pulled from the second battery.

Two battery bays on the GreenWorks G-Max Twin Force mower.

This also allows you to run the mower on just one battery at a time. Although I don’t recommend this, it’s possible to put one battery in the mower and keep the other on the charger until the first battery runs out. Of course, you then have to swap out the batteries.

One thing that’s missing is a battery status indicator on the mower handle, as found in some other cordless mower models. As it is, you have to stop the mower, open each battery compartment and depress the indicator button to see how much life is left in each battery.

The only way to tell how much “juice” is left in the batteries is to press the green button on the batteries.

Simple to Start the Mower

The G-MAX Twin Force mower has a nice dual-stage safety feature to prevent accidentally starting it. First press the button on the right handle to activate the batteries, and then hold down the safety bail handle to start the blades.

Start the GreenWorks mower by holding down the start button and then gripping the safety bail against the handle.

Excellent Mulching Mowing

The GreenWorks G-MAX Cordless Twin Force Mower has two separate cutting blades that rotate in different directions (they both rotate inwards, effectively shooting cut grass backwards into the grass catcher on the back of the machine).

The twin blades move in opposite directions to shoot grass out the back of the machine.

This resulted in excellent mulching when the mulching plug was inserted and a very clean cut across the entire 20-inch cutting deck in both the mulching and non-mulching cutting modes. The mulching blade chopped grass on both fescue and St. Augustinegrass lawns into such small pieces that no grass clippings were visible when I’d finished mowing. Even in longer grass, there were no visible clippings and the cut was even across the entire lawn surface.

The large (55L capacity), rear-mounted grass catcher has mesh sides, a hard top and semi-hard bottom. There’s a small flap on top that lifts up when the bag is getting full, indicating that it’s time to empty it.

GreenWorks has built their “Smart CUT technology” into the G-MAX mower. Although I couldn’t test it directly, GreenWorks claims that it adjusts power or runtime based on the thickness of your grass. All I can say is that it worked extremely well on both fine and thick grass of different heights.

Think a cordless mower can’t cut a large lawn? Think again! The GreenWorks managed this lawn with plenty of run time left on the batteries.

Easily Adjustable Cutting Height

Cutting height on the G-MAX mower can be set at 5 positions, ranging from 1 ¾” to 3 3/8”.

The mowing deck height is easy to adjust with the lever on the top of the mower, although I did find that it was a little cumbersome moving the lever upwards (increasing the cutting height) and found that it worked better if I also lifted up on the body of the mower (obviously you shouldn’t do that with the batteries installed as your fingers would be dangerously close to the blades!).

It would be easier and more convenient if GreenWorks included a handle at the center of the mower so you could lift it when needed (for example, when transporting it in the back of a vehicle, raising the cutting height or just moving it into position when mowing).

The cutting height can be adjusted into 5 positions by moving the levers.

Comfortable and Maneuverable

There’s a layer of foam covering the handle grips, dampening any vibration and making it comfortable to push the mower around even when the safety bail is engaged. It doesn’t take much pressure to hold down the safety bail so my hands didn’t get tired from gripping it.

However, the foam covering isn’t very thick and can easily wear or rip. It would be better if it was made of sturdier material for longer life. Of course, you could always use the “universal fix-it solution” – duck tape – wrapped around the handle to protect the foam. But it seems silly to have to go to that extreme on a machine that costs around 400….

Another potential negative is the fact that the handle height isn’t adjustable so it may feel a little short for taller individuals, or too high for shorter people.

The G-MAX mower feels very similar to a traditional gas-powered mower when in use. Still, it’s relatively lightweight (42.5 lbs – one person could lift it without any help) and very maneuverable.

Part of what makes it easy to maneuver is the size of the wheels, with larger 10” wheels in back and 7” wheels up front.

Limited Warranty

The mower itself is warranteed for 4 years (with proof of purchase) against defects in materials, parts or workmanship. This warrantee is valid only for units which have been used for personal use (they haven’t been hired or rented for industrial/commercial use), and that have been maintained in accordance with the instructions in the owners’ manual.

As usual, normal wear and tear, routine maintenance items and normal deterioration of the exterior finish aren’t covered.

The batteries carry a 2-year warrantee against workmanship and materials, as long as they’ve been charged in accordance with the operator’s manuals directions and regulations.

Safety First

An important safety feature on lawn mowers is the hard strip across the underside at the rear of the mower. This is intended to stop a toe or other object from inadvertently getting chopped to pieces by the blades when moving backwards. (Editor’s Note: Mowing backwards is never recommended by lawn mower manufacturers as it increases the risk of stumbling, running over something, or injuring yourself.) However, on the Twin Force mower this strip is a very flexible piece of rubber that does nothing to protect you or the mower. I’d have liked to see a stronger protection device here.

This is an electrical device and should not be used in wet weather or severely wet lawn conditions as you risk getting a nasty electrical shock.

As with all lawn mowers, wear safety glasses, sturdy boots and, although the G-MAX is relatively quiet (at least compared to a gas mower), I recommend hearing protection as well.

Recommendation

Overall, this is a nice replacement for a conventional gas mower. It has plenty of power, excellent mulching capability, a long enough run time to mow most suburban yards, a 20″ cutting deck, and good maneuverability and balance. There are a few small drawbacks that you wouldn’t expect in a mower at this price point, such as the flimsy foam padding on the handles and the lack of a handle-mounted status indicator. I’ve also seen reports of the cable between the start switch and safety bail stretching to the point that the machine becomes inoperable, although this hasn’t happened on the machine I tested (yet).

Sources:

https://patents.google.com/patent/US9480200B1/en
https://www.protoolreviews.com/best-self-propelled-lawn-mower-reviews/
https://gardeningproductsreview.com/greenworks-gmax-40v-cordless-twin-force-mower-review/

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Best Self-Propelled Lawn Mower for the Money

Best Self-Propelled Lawn Mower Brand

Best Self-Propelled Lawn Mower for Bagging

Best Self-Propelled Mulching Lawn Mower

Best Self-Propelled Lawn Mower – Priorities

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Self-Propelled Lawn Mower Recommendations

Best Lawn Mower Buying Guide – What We Look For

Gas vs Battery

Commercial vs Residential

Engine Size and Cutting Power

Cut Quality

Noise Level

Fuel Efficiency

Deck Size

Steel vs Plastic (Poly) Deck

Deck Height

Height Adjustment

Adjustment Levels

Setting the Speed

Front-Wheel Drive, Rear-Wheel Drive, or All-Wheel Drive?

Wheel Size

Electric Start

Mulch, Bag, or Side/Rear Discharge?

Handle Positions

Value

Why You Can Trust Pro Tool Reviews

GreenWorks G-MAX 20” 40V Cordless Twin Force Mower: Product Review

Setting Up The Mower

About Lithium-Ion Batteries

About the Li-Ion Batteries

Charging the Batteries

Testing the G-MAX Cordless Twin Force Mower

Long Battery Run Time

Simple to Start the Mower

Excellent Mulching Mowing

Easily Adjustable Cutting Height

Comfortable and Maneuverable

Limited Warranty

Safety First

Recommendation