Abstract:
A corn MOG separator for an agricultural combine having a chopper for chopping MOG, the corn MOG separator being located after the chopper in the MOG flow stream and having a separating chamber for receiving the MOG and separating the lighter from the heavier components, the chamber having a mechanical decelerator for mechanically decelerating the corn MOG.

Description:
RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Application No. 61/244,667, which was filed on 22 Sep. 2009 and is incorporated herein by reference for all that it teaches. 
    
    
     FIELD OF THE INVENTION 
     The invention relates to agricultural harvesters. More particularly it relates to cleaning elements for agricultural harvesters. Even more particularly it relates to attachments for agricultural harvesters for cleaning corn cobs. 
     BACKGROUND OF THE INVENTION 
     Agricultural combines are configured to travel through an agricultural field, cutting the crop plants loose from the field, and gathering them. They also strip the crop portion (e.g. the grain) from the rest of the crop plant and discard the unwanted portion (also known as “material other than grain” or “MOG”). 
     Corn is harvested using an agricultural combine with a corn harvesting head or “corn head” attached on the front end thereof. The ears of corn are separated from the plant stalk itself, and are carried backwards into a threshing separating and cleaning system within the agricultural combine. In the combine the kernels of corn are separated from the corn cobs and are stored in a grain tank located in an upper portion of the agricultural combine. 
     The corn cobs and corn husks are then transmitted to a chopper disposed at the lower rear portion of the agricultural combine where they are chopped into small pieces, approximately 2 to 6 cm long, and are ejected from outlet of the chopper at the rear of the combine and spread over the ground. 
     In recent years, scientists have developed uses for corn cobs for such things as firing boilers or creating ethanol, plastics and other materials. It is desirable therefore to collect the corn cob pieces. It is not generally desirable to collect the husks. The technical problem, therefore, is providing some means for separating the corn cobs from the corn husks. Is also desirable to further direct the corn cob pieces to a storage location and to spread the husks over the ground. 
     US patent publication number 2009/0113867 describes a system for separating post-chopper MOG into lighter and heavier portions using an air blast. In this arrangement, the combine chopper empties into a conduit, which empties into a first blower  14 . The first blower  14  accelerates the MOG (which is already traveling very fast as it exits the chopper) and sends it up a chute  16  which empties into a wagon as the agricultural combine travels through the field. A second blower  22  is provided to provide a cross flow of air across and through the flow path of MOG established by the chopper and the first blower. This cross flow of air is of sufficient speed to blow the lighter material (i.e. the corn husks) out of the MOG flow path and permit the heavier portion of the MOG (i.e. the chopped corn cobs) to continue onward through chute  16  into a collection vehicle  52 . The lighter material ejected from the MOG flow is then spread over the ground, rather than collected in the vehicle  52   
     US patent publication number 2008/0248843 describes a system of dividing post-chopper MOG into two flow streams of variable proportions. The system includes a selectively steerable conduit  125  located between the combine chopper  118  and the blower  126  (described in US 2009/0113867) to separate a portion of the MOG that leaves the chopper and continues on to the blower. In this arrangement, the steerable conduit  125  has a flow dividing edge that is generally horizontal and moves up and down to mechanically direct the flow of material either into the blower  126  or downward toward the ground, depending upon the position to which it has moved. 
     In US 2009/0113867, the function of the air is to separate the flow of MOG based on its size, wind resistance, and density. When experiencing the air blast from the second blower  22 , the denser materials, such as corn cobs, will continue through the conduit and into the vehicle  52 . The lighter materials, such as corn husks, will be blown out of the conduit and directed over the ground. 
     In US 2008/0248843, the function of the conduit is to divide the flow of MOG into two streams. It does not separate the MOG flow into lighter or heavier portions. 
     Both of these arrangements suffer from a similar problem. Whether steered by a secondary air blast, or steered by movable conduit, the lighter material (i.e. the corn husks) is traveling so fast between the chopper and the blower that the blast of air is insufficient to steer it out of the vehicle entirely. Instead, the lighter material accumulates on the edge of the conduit that splits the flow, causing the corn husks to “hairpin” on the edge of the conduit and eventually plug the conduit. 
     Experimentation indicates that the problem is a function of the speed of the MOG flow traveling from the chopper through the first blower, and then up the chute and into the accompanying vehicle. At the high rates of speed the material travels from the chopper to the blower, there is a limited amount of time during which a cross flow air stream can separate the cobs from the husks. Given the limited amount of time for separation, the cross flow air separation arrangement of US 2009/113,867 A1, requires a substantial supply of high-speed air, and thus a powerful fan. 
     What is needed is a way to reduce the speed of the MOG, and while the speed is reduced, to separate the MOG into its lighter and heavier components using gravity as well as a secondary airflow. 
     It is an object of this invention to provide such a system. 
     SUMMARY OF THE INVENTION 
     In the description below, the terms “forward”, “front”, “ahead” “rear”, “rearward”, “behind” or other similar terms are defined in terms of the direction of travel of the agricultural combine in its straight line travel through an agricultural field during harvesting operations. 
     The terms “lateral”, “transverse”, “side-to-side” or other similar terms indicate a relative direction or orientation that is generally horizontal and perpendicular to the front-to-rear direction described in the previous paragraph. 
     In accordance with a first aspect of the Invention, a corn and MOG separator includes a housing having a decelerating and separating chamber for decelerating and separating corn MOG into a cob portion and a husk portion, the chamber having a first inlet configured to receive a flow of corn MOG including cobs and husks from an agricultural combine chopper, a second inlet configured to receive a flow of environmental air from outside the combine, a first outlet for transmitting non-cob MOG from the chamber, and a second outlet for transmitting cob MOG from the chamber. 
     In accordance with a second aspect of the invention, a corn MOG separator for an agricultural combine having a chopper for chopping MOG is provided, the separator comprising a housing defining a separating chamber for separating the cobs from the husks, the housing having a MOG inlet disposed to receive a stream of chopped corn cobs and corn husks from the chopper and to convey them into the separating chamber, the housing further having an air inlet configured to introduce a stream of separating air into the separating chamber and into corn MOG in said separating chamber and an air outlet disposed to remove air with entrained husks from the separating chamber; a fan configured to draw separating air into the air inlet, through the corn MOG and out the air outlet with entrained husks; and a mechanical decelerator disposed in the separating chamber and configured to decelerate the corn MOG in the chamber sufficient to let the stream of air and gravity, working in the opposite direction as the air flow, to separate the husks from the cobs. The fan may be disposed to suck the separating air upward through the corn MOG. The corn MOG separator may further comprise a mechanical conveyor disposed at the bottom of the chamber to convey cobs out of the separating chamber. The mechanical conveyor may be an auger disposed at the bottom of the separating chamber. The corn MOG separator may further comprise a MOG distributor configured to spread MOG over the ground, and an operator adjustable conduit disposed between the chopper and the MOG inlet and configured to separate the stream of MOG from the chopper into a first portion of corn plus husks directed into the MOG inlet and a second portion of corn plus husks into the MOG distributor. The MOG inlet may be disposed along a front side of the separating chamber and the mechanical decelerator may be disposed at the rear side of the separating chamber. The mechanical decelerator may be suspended inside a rear wall of the separating chamber and may comprise a sheet of rubber, plastic, metal or lengths of chain. The mechanical decelerator may extend across substantially the entire width of the separating chamber. The mechanical decelerator may be suspended from a rod member. The mechanical conveyor may be an auger disposed at the bottom of the separating chamber. The auger may extend transversely with respect to the combine across substantially the entire width of the separating chamber. The width of the separating chamber may be substantially the same as the width of an outlet of the chopper. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side view of an agricultural harvester with a corn MOG separator attached thereto. 
         FIG. 2  is a fragmentary left side detail view of the agricultural harvester of  FIG. 1  with the plastic side covers of the combine removed to show the mounting arrangement of the corn MOG separator to the chassis of the agricultural combine. 
         FIG. 3  is a perspective view of the  FIG. 2  arrangement. 
         FIG. 4  is a left side view of the corn MOG separator of  FIG. 3  showing the internal construction of the separating chamber by removing the left side end wall  300 . 
         FIG. 5  is a right side view of the corn MOG separator. 
         FIG. 6  is a rear view of the corn MOG separator. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     In the description below, like numbers refer to like elements in the various embodiments of the invention. 
       FIG. 1  is a side view of an agricultural harvester in accordance with the present invention. In the arrangement shown in  FIG. 1 , an agricultural combine  100  has a chassis  102  supported by wheels  104  to carry the combine over the ground. 
     A harvesting head  106  is mounted on the front end of the combine to gather corn plants  108  growing in the agricultural field and strip the ears of corn from the plant stalks. The plant stalks  109 , now stripped of their ears of corn, are left on the ground. The ears of corn are carried through the harvesting head  106  and rearward through a feederhouse  112  which supports the harvesting head on the combine. Once the ears pass through the feederhouse they go into a threshing system  114  which includes a rotor  116  disposed inside a concave  118 . The rotor rotates within the concave thereby threshing and separating corn kernels from the corn cobs and corn husks. The corn kernels fall downward into an oscillating cleaning shoe  119  which passes them through a sieve  120  and chaffer  122 , whereupon they are collected and conveyed upward into a grain tank  121 . Corn MOG residue including corn cobs and corn husks pass rearward through the rotor and concave arrangement and are deposited in a chopper  124 . 
     Chopper  124  includes a chopper rotor  126  with pendulous knives  128  affixed thereto that rotates at high speed. The pendulous knives  128  are interleaved with a row of stationary knives  130  which extend inward into the rotor housing  132 . The interaction of the pendulous knives  128  and the stationary knives  130  chops the corn cobs and corn husks into short pieces. Chopper rotor  126  generates an airflow that carries the entrained chopped corn MOG rearward through a chopper outlet  134 . 
     In traditional combines, the chopped MOG is then distributed over the ground by steering vanes or by rotating spreaders. In the present arrangement, however, a corn MOG separator  136  is mounted to the rear of the combine in a position to receive the chopped corn MOG from chopper outlet  134 . 
     Referring now to  FIG. 2 , corn MOG separator  136  is bolted to and supported on rear portion  200  of the combine chassis  102 . For convenience of discussion, rear portion  200  of the chassis is shown with the side panels of the combine  100  removed. A cut off portion of rear panel  202  is attached to the combine chassis  102 . The pulley arrangement and jack shaft for driving the corn cob auger have also been removed. 
     A conduit  204  (preferably steerable) is disposed between the chopper outlet  134  and corn MOG separator  136 . Conduit  204  communicates the chopped MOG expelled from chopper outlet  134  to the inlet  206  of the corn MOG separator. Chopper outlet  134  has a lateral width of between 1-2 m and a height of 10-20 cm, thereby defining a vertically narrow and laterally elongate aperture through which the chopped corn MOG passes. 
     The conduit is repositionable by the operator from a first operating position  205  (shown in solid lines) in which all corn MOG is communicated to the corn MOG separator  136 , to at least a second position  207  (shown in dashed lines) in which a some or all of the corn MOG is communicated to a mechanical distributor  208 . Mechanical distributor  208  is fixed to the bottom of corn MOG separator  136  to direct the flow of corn MOG received from chopper outlet  134  over the ground. 
     In one arrangement, shown here, mechanical spreader  208  includes two counter-rotating rotary impellers  210  with paddles that are driven in rotation by two hydraulic motors  212 . Hydraulic motors  212  rotate rotary impellers  210  about substantially vertical axes  214  to spread the corn MOG in a wide and generally horizontal swath across the ground behind the agricultural combine  100 . Alternatively, mechanical distributor  208  may include (either in place of or in addition to rotary impellers  210 ) other non-motorized devices such as one or more stationary vanes that steer the corn MOG outward in both directions over the ground in generally the same manner as the rotary impellers  210 . 
     A separator fan  216  is fixed to the upper portion of a corn MOG separator housing  218  to create a flow of air upward through the corn MOG that flows from the inlet  206  of corn MOG separator  136  into a central chamber in housing  218 . Separator fan  216  moves air upward through an air inlet  220  disposed adjacent to the bottom of corn MOG separator housing  218 . Separator fan  216  draws air for separating the corn MOG from the ambient environment outside the agricultural combine  100  into inlet  220 , upward through an internal chamber in housing  218 , into separator fan  216  itself, and then expels the air out of the corn MOG separator through outlet  222  of separator fan  216 . Separator fan  216  includes two motors  224 ,  225  disposed adjacent to each other in a transverse relationship that drive impellers  226 ,  227  in rotation about generally vertical axes  228 ,  230  (see  FIG. 3 ). 
     Referring now to  FIG. 3 , motors  224 ,  225  of separator fan  216  are disposed adjacent to one another in a side-by-side relation such that their axes of rotation  228 ,  230 , respectively, are generally parallel and laterally spaced apart from one another. 
     Corn MOG separator  136  housing  218  is generally in the form of a hollow box comprised of vertical and fore-and-aft extending planar end walls  300 ,  302  to which generally vertically and laterally extending rear walls  304  and front walls (not shown) are fixed. The spacing between the left and right end walls  300 ,  302  is preferably substantially the same as the width (e.g. 1-2 m) of opening  301  defined by chopper outlet  134 . In this manner, corn MOG can be directed generally rearward as a fast-flowing planar stream into the separator housing  218  without disrupting the flow of corn MOG in a lateral direction (i.e. steering part of the flow to one side of the combine or the other). This lateral steering can cause unnecessary lateral mixing, turbulence, and therefore the undesirable injection of corn cobs into separator fan  216 . 
     Outlet  222  of separator fan  216  preferably includes an outlet for each of the motor-driven impellers. These are shown in  FIG. 3  as outlet  306  and outlet  308 , which are mirror images of each other, in which outlet  306  directs the flow of material from the impeller driven by motor  224  in a rearward direction and to the left side of agricultural combine  100 , and outlet  308  directs the flow of material from the impeller driven by motor  225  in a rearward direction and to the right side of agricultural combine  100 . Outlets  306 , 308  are defined by openings in generally cylindrical and horizontal housings  310 ,  312 , that enclose impellers  226 ,  227 , respectively. 
       FIG. 4  illustrates a cutaway of corn MOG separator housing  218 , indicating the internal construction of the housing and the flow of corn MOG during processing. The inner surfaces of housing  218  define a separating chamber  406 , including the inlets and outlets for air and MOG. The corncob auger, its pulley, the jack shaft and its pulley have been superimposed on the lower portion of the Figure. 
     A first planar sheet  400  forms the bottom surface of inlet  206 . It is removably fixed to and extends between end walls  300 ,  302 . Planar sheet  400  extends from inlet  206  in a generally curved fashion until it abuts a top portion of corn cob auger  402 . Planar sheet  400  extends in a curve around the front side of corn cob auger  402  to partially define a channel in which corn cob auger  402  rotates. 
     Corn cob auger  402  is a spiral auger having a generally horizontal and laterally extending axis of rotation  404  that is disposed above the floor of separating chamber  406 . Corn cob auger  402  is driven by a pulley  408  that is mounted to the left end of the shaft of auger  402  extending outside end wall  300 . Pulley  408  is driven by belt  410 . Belt  410  is driven by pulley  412  which is mounted on the left end of a jack shaft  414 . 
     Jack shaft  414  extends across the width of corn MOG separator  136  from end wall  300  to end wall  302  just underneath planar sheet  400  and outside the flow path of corn MOG. Jack shaft  414  is supported on end walls  300 ,  302  of housing  218  for rotation by a gearbox (See  FIG. 5 ) that is disposed just outside the right end wall  302 . 
     An air permeable panel  416  defines a portion of the floor and the rear wall  304  of separating chamber  406  and also functions as air inlet  220 . It extends between end walls  300  and  302  to which it is fixed. Air permeable panel  416  serves to retain corn cobs within separating chamber  406 , and to provide a low-air resistance inlet for ambient air that is drawn into separating chamber  406  by separating fan  216 . Air permeable panel  416  is preferably a planar sheet of material, such as metal, that is provided with a plurality of apertures extending therethrough to permit the passage of air while denying the passage of chopped corn cobs. It may be a mesh or screen, such as a metal mesh or screen. It may comprise a plurality of interlocking rods, or of interconnected ribs and rods, such as a typical construction of a concave for a rotor in an agricultural combine. It may also comprise expanded metal or pierced metal. 
     The size of the apertures in panel  416 , however they are defined, are preferably configured to pass a spherical object no larger than 4 cm in diameter. More preferably they are configured to pass a spherical object no larger than 3 cm in diameter. Even more preferably they are configured to pass a spherical object no larger than 2.5 cm in diameter. 
     To provide strength sufficient to contain the cobs, yet also provide minimal air resistance to the flow of air for separating the cobs and husks, the ratio of the total membrane aperture area versus the overall surface area of the membrane should be 0.5 or greater, preferably 0.7 or greater, and more preferably 0.8 or greater. 
     Rear wall  304  extends laterally between the two end walls  300 ,  302  and extends vertically from the top of air permeable panel  416  to just underneath separating fan  216 . 
     A mechanical decelerator  418  is disposed across substantially the entire lateral width of the separating chamber  406  just inside the rear wall  304 . Mechanical decelerator  418  is spaced just far enough ahead of rear wall  304  that it can absorb the kinetic energy of the corn cobs when it is hit and permit them to fall generally downward toward corn cob auger  402  where they will rest until they are gathered by corn cob auger  402 . If the kinetic energy of the corn cobs is not absorbed, the cobs will bounce off the rear wall and return toward the inlet colliding with other cobs, causing significant turbulence, and even directing corn cobs upward into the inlet of separating fan  216  where they could jam the fan or be mistakenly ejected from the corn MOG separator  136  and thrown onto the ground. 
     Mechanical decelerator  418  may be formed of rubber sheet, plastic sheet, wire mesh, chain, a chain wall, a metal sheet, steel, urethane, a pierced metal sheet, and expanded metal sheet or other media that is configured to absorb the impact of corn cobs thrown into separating chamber  406 . 
     The deflection sheet  418  is disposed directly in the path of corn MOG entering separating chamber  406  from inlet  206  on the side opposite inlet  206 . Corn cobs in corn MOG entering separating chamber  406  travel across the chamber and impact deflection sheet  418 . 
     A plurality of mounting points is shown in  FIG. 4  as a series of holes in end walls  300 . An identical row of holes in a mirror image position is formed in end wall  302 . These mounting points support a rod that extends substantially across the entire width of the separating chamber and from which the mechanical decelerating material is suspended. The mechanical decelerator  418  is thereby suspended as a sheet across substantially the entire width of the chamber  406  and can be positioned either closer to or farther from the rear wall of the chamber by selecting a different set of mounting points (e.g. the holes) in the horizontal array. This permits the mechanical accelerator to be variously adjusted to different positions based upon the speed of the chopper rotor, the crop being harvested, and the size of the chopped cob pieces to be decelerated. 
     The corn cobs in separating chamber  406  pass through the stream of air that is pulled into and upward through separating chamber  406  from air inlet  220  to separating fan  216 . This upward airflow through the chamber and through the now (relatively) slowly falling corn cobs serves to more effectively separate the corn cobs from corn husks and other low density residue portions of corn MOG (for example dust, chaff, leaves, and the like). 
     Once the cobs have fallen into the bottom of separating chamber  406  The movement of corn cob auger  402  and the angle of inlet  220  and sheet  400  directs them toward the right end of the separating chamber  406 , where they pass-through an aperture in the bottom of separating chamber  406  into a blower (not shown). The blower accelerates the corn cobs, providing them with enough kinetic energy that they travel up a curved exit chute  420  and into a collection vehicle such as a truck, cart or wagon traveling alongside the agricultural combine  100 . 
     A second planar sheet  422  defines the upper wall of MOG inlet  206 , from conduit  204  to separating chamber  406 . Planar sheet  422  extends from and is fixed to end wall  300  and wall  302  to define (in conjunction with planar sheet  400  and end walls  300 ,  302 ) a generally rectangular conduit having substantially the same width in a transverse direction and the same height as outlet  134  of the chopper. 
     Planar sheet  422  is configured to guide the stream of corn MOG entering the inlet  206  into a generally horizontal flow path as it enters separating chamber  406 . Once the stream of corn MOG is inside separating chamber  406 , it is traveling generally horizontally and also generally perpendicularly to the separating airflow (i.e. the airflow generated by separating fan  216 ) the separating airflow traveling generally vertically upward through separating chamber  406  from air inlet  220  to the inlet of separating fan  216 . 
     The housings  310 ,  312  that enclose impellers  226 ,  227  are fixed to the top of separating chamber  406  and define the top of the separating chamber. The housings  310 ,  312  have downwardly facing central axial openings  424 ,  426 , respectively, that receive air from separating chamber  406  and conduct it into impellers  226 ,  227  near the central axes  228 ,  230 , respectively, of the impellers. 
     Referring now to  FIGS. 5-6 , a delivery conveyor  500  is fixed to the right end of corn MOG separator housing  216 . Corn cob auger  402  draws the corn cobs to the right across the bottom of separating chamber  406  and through an aperture  502  (that is circular, concentric with auger  402 , and has a slightly larger diameter than the diameter of the auger flights) into a lower portion of generally cylindrical housing  504  of delivery conveyor  500 . 
     A hydraulic motor  506  fixed to the outer planar wall  508  of housing  504  and drives an impeller  510  at high speed. Impeller  510  sweeps the corn cobs entering housing  504  through aperture  502 , around the inner surface of housing  504  and out through an exit chute  420 . 
     Motor  506  is coupled to a shaft that extends through housing  504  and into a gearbox  512  that is disposed between delivery conveyor  500  and end wall  302 . Gearbox  512  provides a gear reduction and drives jack shaft  414  at a reduced speed. Jack shaft  414 , as explained above, extends across the width of corn MOG separator housing  218 , through sidewall  300 , and is coupled to pulley  412  to drive auger  402  at an even slower speed. 
     Having described the preferred embodiment, it will become apparent that various modifications can be made without departing from the scope of the invention as defined in the accompanying claims.