Abstract:
A plurality of elongate mounting brackets mounted in cantilever relation on a frame of a header at sidewardly spaced locations across at least a portion of a width of the header, respectively, support a sensor rod for rotation about its axis. Each of the brackets has a free end including a bearing having a bore therethrough which receives the sensor rod, at least some of the bearings being self-aligning bearings. The self-aligning capability enables accommodating irregularities in the mounting locations for the brackets, and also bends, flexure and other deformities of the header frame and sensor rod, for achieving free rotatability of the sensor rod. This mounting arrangement also facilitates installation by one person, from the bottom side of the header, both initially and in the field. Additionally, the brackets can include features for aligning the bores of the bearings, to facilitate the installation and free rotation of the sensor rod when installed.

Description:
[0001]    This application claims the benefit of U.S. Provisional Application No. 60/926,873, filed Apr. 30, 2007. 
     
    
     TECHNICAL FIELD 
       [0002]    This invention relates generally to a sensor apparatus for a header height control for an agricultural harvester, and more particularly, to an improved sensor apparatus including a mounting arrangement for a rotatable sensor rod extending across at least a portion of the header that facilitates installation and free rotation of the rod, for improved sensor operation, including when a sensor rod is bent or deformed, for instance, as a result of contact with rocks or other foreign objects on a field, or the rod and/or the header is flexed. 
       BACKGROUND ART 
       [0003]    U.S. Provisional Application No. 60/926,873, filed Apr. 30, 2007, is incorporated herein in its entirety by reference. 
         [0004]    Header height controls which utilize a sensor having an elongate sensor rod which extends along all or a substantial portion of the sideward width or extent of a header, are well known. Typical sensors have sensor arms on the rod at spaced locations therealong, which contact or rest on ground following elements and cause rotation of the rod, to effect a change of state of the sensor. It is crucial for accurate ground sensing, for the sensor rod to have the capability to freely rotate for following the movements of the ground following elements, for translating such movements into sensor inputs. 
         [0005]    As an example of a problem that can be encountered, if the sensor rod does not freely rotate, e.g., the rod is bent, it can be forced by a ground following element into a more upward rotational position, and then remain in that position, even after the ground following element has moved downward responsive to a ground contour change. This can cause the height control to raise the header to its highest position, such that the crops will be cut at a level higher than is desired. To overcome this problem in the field, the operator may be required to override or disable the height control. And, correction of the problem will result in downtime, expense and additional problems. 
         [0006]    In this latter regard, some known sensor rods require two persons to install (one on the floor side of the header, and one on the bottom side, which can be problematic when installing in the field. Alignment of the components for installation can also be difficult. 
         [0007]    Thus, what is sought is sensor apparatus for a height control system of a header for an agricultural harvester, which overcomes one or more of the problems set forth above. 
       SUMMARY OF THE INVENTION 
       [0008]    What is disclosed is sensor apparatus for a height control system of a header for an agricultural harvester, which overcomes one or more of the problems set forth above. 
         [0009]    According to a preferred aspect of the invention, the height control sensor utilizes a plurality of elongate mounting brackets mounted in cantilever relation on a frame of a header at sidewardly spaced locations across at least a portion of a width of the header, respectively. Each of the brackets has a free end spaced from the frame, the free end of each of the brackets includes a bearing thereon having a member including a bore therethrough. At least some of the bearings are self-aligning bearings wherein the member including the bore is supported for pivotal movement about a center of the bore, the centers of the bores being held in alignment along a sidewardly extending axis by the brackets. A sensor rod extends through the aligned bores so as to be supported by the brackets along the sidewardly extending axis for substantially free rotation about the axis. The sensor rod includes a plurality of sensor arms extending laterally therefrom at sidewardly spaced locations therealong. Each sensor arm is disposed for contacting an element of the header configured so as to be movable upwardly and downwardly with contours of a surface over which the header is moved. As a result, the sensor rod will be free to be rotated about the axis by the upward and downward movements of the uppermost element or elements. A sensor is connected to the sensor rod and operable for sensing the rotations of the rod. 
         [0010]    As a non-limiting example, the sensor can be connected to the sensor rod utilizing a suitable linkage. As another example, the sensor can be mounted adjacent to an end of the header, and connected to other elements of the header height control in the customary manner, as well known in the art. 
         [0011]    According to another preferred aspect of the invention, the elements of the header movable upwardly and downwardly with surface contours, comprise skid plates which ride along the ground. The sensor rod and mounting apparatus are preferably disposed above the skid plates, or particularly, above support arms in connection therewith, and below a floor of the header. As noted above, it is contemplated that accidental bending or other deformation of the sensor rod can occur, as a result of contact with rocks, logs and other hard objects that may be present on the ground over which the header passes. An important advantage of the self-aligning bearings of the invention, is that the pivotable bearing members thereof which carry the sensor rod, can individually self-adjust, e.g., pivot and rotate, to align with any bent portions of the sensor rod, so as to still allow free rotation of the rod about the axis. This is also true for flexure and other deformations of the sensor rod. 
         [0012]    According to one preferred embodiment of the invention, the mounting brackets are individually adjustable in length, e.g., utilizing spacers, for aligning the bearings of the individual brackets with the bearings of others of the brackets. The mounting brackets can also be adjustably positionable rotationally about a longitudinal axis thereof, to facilitate aligning the bearings. As a result, the installation can accommodate misalignments of the locations on the frame where the brackets are mounted resulting from damage, manufacturing tolerance, and flexure, and also bends or other deformations and flexure of the sensor rod, to allow free rotation of the rod when installed. 
         [0013]    According to another preferred embodiment of the invention, the mounting brackets are connected to the frame of the header in a manner to automatically align the bearings. This can utilize, for instance, a self-aligning carriage bolt or the like. In this way, the variances in the frame and sensor rod are accommodated by the bearings, to allow the sought after free rotation of the sensor rod. 
         [0014]    According to still another preferred embodiment of the invention, each of the mounting brackets includes a free end including a concavity for receiving the pivotable member of the bearing, so as to allow the free pivotal movement thereof, without binding and the like, or otherwise impeding the free rotation of the sensor rod. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]      FIG. 1  is a fragmentary perspective view of a representative header including a header height control sensor apparatus according to the present invention; 
           [0016]      FIG. 2  is a simplified a bottom view of the header of  FIG. 1 ; 
           [0017]      FIG. 3  is a fragmentary perspective exploded view, illustrating elements of the sensor apparatus of the invention, including a representative mounting bracket of the apparatus; 
           [0018]      FIG. 4  is a side view illustrating an alternative mounting bracket of the invention; and 
           [0019]      FIG. 5  is a bottom view of the bracket of  FIG. 4 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0020]    Referring now to the drawings, in  FIGS. 1 and 2 , a header height control sensor apparatus  10  constructed and operable according to the teachings of the present invention, is shown incorporated on a header  12  for an agricultural harvester (not shown). 
         [0021]    Header  12  is of generally conventional construction, including an elongate frame  14  supporting cutting apparatus  16  along a front edge thereof, which cutting apparatus  16  in this embodiment comprises a conventionally constructed sickle reciprocatingly operable in the well-known manner for severing crops from a field as header  12  is moved forwardly thereover. Header  12  includes a floor  18  (underside shown in  FIG. 2 ) extending rearwardly from cutting apparatus  16 , and onto which the crops will be conveyed by a reel  20 , also in the well-known manner. The crops will then be conveyed toward the center of the header by additional conveyor apparatus, e.g., auger or draper belt (not shown), for induction into a feeder  22  which will convey the crops into a harvester on which the header is mounted. 
         [0022]    Cutting apparatus  16  is preferably constructed so as to have limited flexibility from end to end, for purposes including accommodating and conforming at least generally to varying ground contours at different locations along the width. Cutting apparatus  16  is additionally preferably supported for upward and downward movement beneath floor  18  (as denoted by arrow A in  FIG. 1 ), for further accommodating changing ground contours, by a plurality of support arms  24  disposed beneath floor  18 . Each support arm  24  is pivotally connected at a rear end thereof to frame  14 , by a pivot joint  26 , for enabling the movements A. A forward end of each support arm  24  is connected to a bar  28  that extends the width of header  12  and carries cutting apparatus  16 , and which also supports a row of skid plates  30  extending across the width of the header and configured for contacting the ground or other surface therebeneath. Such contact with raised portions of the ground or other surface beneath the header will effect upward movements of the affected skid plate or skid plates  30  making the contact, that portion of bar  20  in the vicinity thereof, and also the support arm or arms  24  carrying the affected skid plate or plates. And, when the ground contour decreases in height, the affected skid plate or plates  30  will follow the decrease, to pivot arm or arms  24  downwardly. As a result, arms  24  provide a reliable ground sensing capability, e.g., indicators of ground contour changes, and serve as indicators of a need to adjust the height position of header  12 . 
         [0023]    Referring also to  FIG. 3 , header height control sensor apparatus  10  is configured and operable according to the teachings of the present invention, for following and sensing upward and downward movements of support arms  24 , and outputting signals representative thereof to a header height control (not shown) of the harvester. Sensor apparatus  10  includes a sensor  32  on one or both ends thereof, for this purpose. In response, the height control is automatically operable to control a fluid cylinder or cylinders (not shown) in connection with feeder  22 , to raise or lower header  12  as required for maintaining cutting apparatus  16  at a desired level above the ground surface. 
         [0024]    Sensor apparatus  10  includes one or more elongate sensor rods  34  extending sidewardly across the width of header  12  in connection with sensor or sensors  32 , and including a plurality of sensor arms  36  extending laterally from the rod at spaced locations therealong. Sensor rod or rods  34  is/are preferably disposed beneath floor  18  of header  12  and generally above support arms  24  and skid plates  30 , with sensor arms  36  being positioned so as to extend forwardly to contact the respective support arms  24 . Each sensor rod  34  is supported for rotation about an axis  38  extending longitudinally therethrough, such that support arms  24  are allowed to move upwardly and downwardly in following relation to the upward and downward movements of support arms  24 . In this regard, sensor arms  36  are preferably L-shaped members, having free ends which normally rest on respective arms  24 , although it is also contemplated that alternative designs could be used as desired or required for a particular application. 
         [0025]    Here, it should be noted that it is a sought after feature of the present invention, that sensor rod or rods  34  be freely rotatable about axis  38 , particularly, so as to closely follow the movements of the uppermost one or ones of the support arms  24 , and so as not to bind or stop in a raised position, not supported by at least one raised arm  24 . As a result, the rotational position of sensor rod  34  will be determined by the uppermost skid plate or plates  30  and associated support arm or arms  24 . This is achieved according to the invention by supporting sensor rod or rods  34  using a plurality of elongate mounting brackets  40  mounted in cantilever relation on frame  14  of header  12  at sidewardly spaced locations across the width of the header, respectively. Each bracket  40  has a free end  42  spaced from the point of attachment to the frame, which includes a bearing  44  thereon having a member  46  including a bore  48  therethrough, as best illustrated in  FIG. 3 . At least some, and preferably all, of bearings  44  are self-aligning bearings wherein member  46  including bore  48 , is supported for pivotal movement about the center of member  46 , bores  48  when centered being aligned along axis  38 . Sensor rod  34  extends through bores  48  of the bearings so as to be supported by brackets  40  for substantially free rotation about axis  38 . 
         [0026]    As noted above, accidental bending or other deformation of sensor rod  34  can occur, as a result of such occurrences as contact with rocks, logs and other hard objects that may be present on the ground over which the header passes. Sensor rod  34 , and/or frame  14 , can also flex. To accommodate these conditions, pivotable members  46  of bearings  44  have the capability to individually self-adjust, e.g., pivot and rotate, to align with adjacent bent portions of sensor rod  34 , so as to still allow free rotation of the sensor rod. 
         [0027]    Preferably, mounting brackets  40  are connected to frame  14  in a manner to automatically align bearings  44  along axis  38 . This can be achieved, for instance, by attaching brackets  40  using a single self-aligning carriage bolt  50  or the like, securable with a nut  52 . Brackets  40  and the portion of frame  14  to which the brackets are to be attached, here, a metal angle, can be provided with suitably shaped, e.g., rectangular, holes alignable for receiving bolts  50 . In this way, manufacturing and other variances in the relative positions of frame  14  and sensor rod  34  are accommodated by bearings  44 , to allow the free rotation of sensor rod  34 . Brackets  40  can have an L-shape or other suitable configuration for facilitating the alignment and attachment. 
         [0028]    Also preferably, free end  42  of each bracket  40  preferably includes or forms a concavity  54 , sized and shaped for receiving member  46  of bearing  44  when mounted thereto, for facilitating and accommodating pivotal movements of member  46 , as required for allowing the free rotation of rod  34 . Bearings  44  can be suitably mounted to free ends  42  of brackets  40 , respectively, for instance, utilizing screws  56  and additional nuts  52 . Holes through bearings  44  and free ends  42  can have close tolerances for precise positioning of the bearings, for alignment with axis  38 . 
         [0029]    Referring also to  FIGS. 4 and 5 , an alternative mounting bracket  40 A is illustrated, like parts of bracket  40 A and bracket  40  being identified by like numbers. Mounting bracket  40 A, like bracket  40 , includes a free end  42  carrying a self-aligning bearing  44 , constructed and operable in the above-described manner, for supporting sensor rod  34 . As a nonlimiting example, bearings  44  can comprise commercially available spherical bearings of suitable size and including suitable characteristics, such as heat and corrosion resistance, so as to be suitable for being subjected to a painting process involving oven baking, and exposure to the outdoor environment over a long period of time. As an additional feature, mounting bracket  40 A has a mounting end  58  configured to include a threaded stud or other fastener  60  over which a spacer  62  can be fitted, for setting a distance between bearing  44  and frame  14 , for aligning sensor rod  34  with axis  38 . Fastener  60  can extend through a hole through frame  14 , and can be secured with a mating fastener, such as a nut  52 . Additionally, this enables rotation of bracket  40 A about the center of fastener  60 , as required for achieving the alignment with axis  38 . Here, an advantage is that each bracket  40 A can utilize a different size spacer  62 , as required for achieving the alignment. This can be useful, when the brackets are mounted at locations on frame  14  which are damaged, e.g., bent or otherwise deformed, or are at an outer limit of a manufacturing tolerance. 
         [0030]    The end or ends of sensor rod  34  are preferably connected to sensor or sensors  32 , in the conventional, well-known manner. Here, this utilizes an adjustable linkage  64  ( FIG. 3 ) which will translate rotations of rod  34  to sensor  32  as is well known in the art. 
         [0031]    In light of all the foregoing, it should thus be apparent to those skilled in the art that there has been shown and described a sensor apparatus for a header height control, which achieves one or more of the objectives sought therefor. However, it should also be apparent that, within the principles and scope of the invention, many changes are possible and contemplated, including in the details, materials, and arrangements of parts which have been described and illustrated to explain the nature of the invention. Thus, while the foregoing description and discussion addresses certain preferred embodiments or elements of the invention, it should further be understood that concepts of the invention, as based upon the foregoing description and discussion, may be readily incorporated into or employed in other embodiments and constructions without departing from the scope of the invention. Accordingly, the following claims are intended to protect the invention broadly as well as in the specific form shown, and all changes, modifications, variations, and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention, which is limited only by the claims which follow.