Sugarcane Harvester With Internal Storage Reservoir For Billets

A sugarcane harvester includes an intake and cutting assembly for cutting the sugarcane stalks from the sugarcane plants as the sugarcane harvester moves through the sugarcane plants, a chopping section for receiving the sugarcane stalks from the intake and cutting assembly and chopping the sugarcane stalks into billets, a reservoir for holding a quantity of the billets, the reservoir having a volume of at least one cubic meter, and a discharge assembly for moving the billets from the reservoir and discharging them from the sugarcane harvester.

BACKGROUND

Sugarcane harvesters are large, moveable, agricultural machines that harvest and partially process sugarcane. Typical sugarcane harvesters cut sugarcane stalks from sugarcane plants as they move through the plants, strip the leaves from the sugarcane stalks, and cut the sugarcane stalks into billets. Conveyor assemblies mounted on the harvesters then elevate the billets and drop them into wagons or other collection vehicles that travel behind the harvesters.

In operation, a sugarcane harvester continuously moves through a sugarcane field and produces a continuous stream of billets which are discharged to a wagon or other receiving vehicle following the harvester. When one wagon is full and must be replaced by another, empty, wagon, the harvester must stop harvesting until the new wagon is in position and ready to receive billets. This can slow the overall harvest operation, particularly in situations where an empty wagon is not immediately ready to replace a full wagon.

SUMMARY

The present invention solves at least some of the above-described problems and related problems and provides a distinct advance in the art of sugarcane harvesters. More particularly, the invention provides a sugarcane harvester with an internal storage reservoir for storing a quantity of billets before they are discharged from the harvester.

A sugarcane harvester constructed in accordance with an embodiment of the invention broadly comprises an intake and cutting assembly for cutting sugarcane stalks from the sugarcane plants as the sugarcane harvester moves through the sugarcane plants; a chopping section for receiving the sugarcane stalks from the intake and cutting assembly and chopping the sugarcane stalks into billets; a reservoir for holding a quantity of the billets, the reservoir having a volume of at least one cubic meter; and a discharge assembly for moving the billets from the reservoir and discharging them from the sugarcane harvester.

In some embodiments of the invention, the reservoir has a volume of at least two cubic meters; and in some embodiments it is positioned between the chopping section and the discharge assembly such that billets from the chopping section fall into and accumulate in the reservoir until they are removed from the reservoir by the discharge assembly.

In some embodiments, the reservoir includes a reservoir conveyor located at a bottom of the reservoir for moving the billets toward the discharge assembly.

In some embodiments, the harvester includes a discharge assembly comprising an elevator for elevating the billets substantially vertically out of the reservoir; and a discharge conveyor for receiving the billets from the elevator, moving the billets substantially horizontally, and discharging the billets to a wagon or other storage vehicle or mechanism.

DETAILED DESCRIPTION

Turning now to the drawing figures, a sugarcane harvester10constructed in accordance with embodiments of the invention is illustrated. As explained in more detail below, the sugarcane harvester10has an improved extractor assembly that more efficiently, effectively, and quietly separates leaves, stems, and other waste material from sugarcane billets and ejects the waste material back onto sugarcane fields without blowing the waste material into a wagon or other billet collection vehicle.

As best shown inFIGS.1and2, an embodiment of the sugarcane harvester10broadly comprises a movable chassis12; an intake and cutting assembly14; a chopping section16; an internal storage reservoir18; a discharge assembly20; and the above-mentioned extractor assembly. Individual components of the extractor assembly are numbered and described below.

The chassis12has a forward end22and a rearward end24disposed along a longitudinal axis that is essentially parallel to a ground surface over which the harvester travels. The chassis12rides on wheels26, belts, or other ground-engaging traction elements that are driven by conventional engines, transmissions, and associated mechanical and electrical components. An operator's station30may be supported on top the chassis, although the harvester may also include various sensors and controls that provide autonomous operation without direct operator control.

The intake and cutting assembly14is supported on the forward end22of the chassis12for cutting sugarcane stalks from sugarcane plants as the sugarcane harvester moves through the plants. The intake and cutting assembly14may include a topper to cut off the leafy top portions of the sugarcane plants, one or more crop divider scrolls32to divide and separate the sugarcane plants, one or more knockdown rollers to knock down the sugarcane plants, one or more base cutter assemblies34to sever sugarcane stalks from the sugarcane plants, and a feed section36to feed the sugarcane stalks rearwardly to the chopping section16.

The chopping section16is supported between the forward and rearward ends of the chassis12and receives the sugarcane stalks from the intake and cutting assembly14and chops or otherwise cuts the sugarcane stalks into billets. As best shown inFIG.2, the chopping section projects the billets rearwardly such that they are temporarily suspended in air before landing in the storage reservoir18.

The storage reservoir18is supported on the chassis12between the chopping section16and the discharge assembly20for storing a quantity of the billets before they are discharged from the harvester. The storage reservoir may be a bin, tank, or any other similar storage device and may be any size and shape, but it's preferably small enough to fit within the side margins of the wheels26. The reservoir is positioned between the chopping section and the discharge assembly such that billets from the chopping section fall into and accumulate in the reservoir until they are removed from the reservoir by the discharge assembly. The storage reservoir18holds sufficient billets to allow the harvester to continue harvesting sugarcane during the process of switching one (full) wagon with another (empty) wagon. The storage reservoir18preferably has a volume of at least one cubic meter and, in some embodiments, preferably has a volume of at least two cubic meters.

The discharge assembly20is positioned at or near the rear of the harvester and receives the sugarcane billets from the storage reservoir18and discharges the billets into a wagon or other storage vehicle that travels alongside the harvester. In one embodiment, the discharge assembly broadly comprises an elevator38and a discharge conveyor40.

The elevator38receives the billets from the storage reservoir18and lifts the billets to an elevated position. In one embodiment, the elevator38lifts the billets vertically about an elevator axis that is substantially perpendicular to the longitudinal axis of the harvester. As best shown inFIGS.2and10, the elevator38projects the billets rearwardly such that the billets are temporarily suspended in air until falling onto the discharge conveyor40.

As best shown inFIGS.2and10, an embodiment of the elevator38includes a lower input42, a raised output44, and an elevating mechanism46that lifts the billets from the input42to the output44. In one embodiment, the elevating mechanism46includes a pair of spaced apart rollers48,50, a continuous belt52trained over the rollers, a number of spaced lifting trays or arms54attached to the belt for supporting and lifting the billets, and a motor or other drive mechanism for driving the belt so as to move the lifting arms and billets upwardly from the input42to the output44and move the emptied lifting arms back down toward the input42. The motor or other drive mechanism moves the conveyor at a speed sufficient to propel the billets onto the discharge conveyor such that they are temporarily suspended in air between the elevator and the conveyor.

The discharge conveyor40receives the billets from the elevator38and discharges the billets to a wagon or other storage vehicle or mechanism following the harvester. As best shown inFIG.3, the conveyor40includes a pair of spaced apart rollers56,58, a continuous conveyor belt60trained over the rollers, and a reversible motor or other drive mechanism for moving the conveyor belt leftward or rightward with respect to the harvester for allowing the discharge of the billets on a left side or a right side of the harvester. In one embodiment, the conveyor40moves the billets horizontally along a conveyor axis that is substantially perpendicular to both the elevator axis and the longitudinal axis of the harvester. This allows the conveyor to move and discharge the billets on either side of the harvester without taking up much space behind the harvester.

The discharge assembly20may also comprises height adjustment mechanism for vertically raising or lowering the conveyor. The height adjustment mechanism may comprise motors, pneumatic cylinders, actuators, or any other electrical, mechanical, electromechanical, or pneumatic components capable of raising and lowering the discharge conveyor36relative to other components on the harvester.

An embodiment of the height adjustment mechanism comprises a pair of moveable shafts62,64that are connected to the conveyor40and that may move within vertically extending rails66,68on opposite sides of the elevator38. The shafts62,64may be moved by motors, pneumatic cylinders, actuators, or any other electrical, mechanical, electromechanical, or pneumatic components.

The height adjustment mechanism may simultaneously raise or lower both ends of the conveyor40so as to maintain the horizontal orientation of the conveyor. For example, the mechanism may move the conveyor40between an uppermost horizontal position depicted inFIGS.1-4and a lowered horizontal position depicted inFIG.5. This permits an operator to adjust the height of the discharge conveyor40to accommodate the discharge of billets into wagons or other storage vehicles of various different heights.

The height adjustment mechanism may also selectively raise or lower the left and right ends of the conveyor40independently of one another. For example, the mechanism may shift the right side shaft64down relative to the left side shaft62as depicted inFIG.6or shift the left side shaft down62relative to the right side shaft64as depicted inFIGS.7and8. This permits an operator to adjust an angle of the conveyor40with respect to the ground upon which the harvester is positioned so as to convey the billets downwardly to a wagon on either side of the harvester.

The discharge assembly20also comprises lateral adjustment mechanism for laterally adjusting positions of the conveyor. The lateral adjustment mechanism may be part of the height adjustment mechanism or may include separate motors, pneumatic cylinders, actuators, or any other electrical, mechanical, electromechanical, or pneumatic components capable of shifting the discharge conveyor40right or left.

The lateral adjustment mechanism is operable to shift the conveyor anywhere between a leftmost position depicted inFIGS.1,3,5, and6and a rightmost position depicted inFIG.4. This permits an operator to adjust the lateral position of the discharge conveyor to discharge billets on either the left or right side of the sugarcane harvester.

The lateral adjustment mechanism and height adjustment mechanism may be operated together to first shift the conveyor rightward or leftward and then raise one end relative to the other. For example, the lateral adjustment may shift the conveyor leftward, and the height adjustment mechanism may then lower the right end of the conveyor relative to the left end so that the left end of the conveyor extends upwardly and the right end downwardly as depicted inFIG.6.

The height adjustment mechanism and the lateral adjustment mechanism may also be cooperatively operated to shift the discharge conveyor between various use positions depicted inFIGS.1-7and a transport/storage position depicted inFIG.8. In some use positions, the conveyor40may extend substantially horizontally with respect to the longitudinal axis of the harvester with its ends extending from the left and right sides of the harvester as depicted inFIGS.1-5. In other use positions, the conveyor40may extend at an angle with one of its ends extending beyond the sides of the rear wheels of the harvester as depicted inFIGS.6and7. When in the transport/storage position, the conveyor is angled with respect to the longitudinal axis of the harvester and positioned so that both its ends are within the sides of the rear wheels of the harvester as depicted inFIG.8so as to occupy less space on either side of harvester.

The extractor assembly removes leaves, stems, and other waste material from the billets before the billets are discharged from the harvester so that less of the waste material is delivered to a mill. In accordance with important aspects of the invention, the extractor assembly includes several fans or blowers strategically sized and positioned on the harvester to more efficiently and effectively separate the waste material from the billets without blowing the waste material into the wagon or other billet collection vehicle following the harvester.

An embodiment of the extractor assembly comprises a fan70or blower positioned between the intake and cutting assembly14and the chopping section16. The fan is positioned above the feed section36of the intake and cutting assembly14and directs pressurized air downwardly on the sugarcane stalks as they are being fed to the chopping section16. This separates and removes loose leaves, stems, and other waste material from the sugarcane stalks before the waste material enters and potentially clogs the blades in the chopping section and directs the waste material below the harvester into the sugarcane field.

An embodiment of the discharge assembly also includes a fan72or blower positioned between the chopping section16and the storage reservoir18. The fan72directs pressurized air upwardly into the billets as they are thrown from the chopping section16and suspended in air before landing in the reservoir18. In one embodiment, the air is directed substantially perpendicular to a direction of travel of the suspended billets as the billets are approximately midway between the chopping section and the storage reservoir. The air then directs the waste material rearwardly through vents74in the rear of the harvester. Because the pressurized air is directed at the billets as they are suspended in air rather than against them while they are supported on a conveyor or other solid surface, the air more thoroughly and efficiently separates and removes loose leaves, stems, and other waste material from the billets. This permits use of a smaller, more energy efficient fan. In one embodiment, the fan is rated 100 Watts or smaller.

An embodiment of the discharge assembly also includes ductwork76that captures exhaust air from an engine cooling fan and directs the pressurized air into the stream of waste material separated from the billets with the fan72. This helps direct the waste material rearwardly through the vents74in the rear of the harvester.

An embodiment of the discharge assembly also includes a fan78or blower positioned near the outlet44of the elevator38. The fan78directs pressurized air upwardly into the billets as they are projected from the elevator38onto the conveyor40. The air then directs the waste material rearwardly through vents80and away from the conveyor and any wagons or other collection vehicles collecting billets from the conveyor. As best shown inFIG.10, pressurized air from the fan78is directed at the billets as they are suspended in air between the elevator and the conveyor, so the air more thoroughly and efficiently separates and removes loose leaves, stems, and other waste material from the billets. This permits use of a smaller, more energy efficient fan. In one embodiment, the fan is rated 100 Watts or smaller. In one embodiment, the air is directed substantially perpendicular to a direction of travel of the suspended billets as they are approximately midway between the output of the elevator and the conveyor.

As shown inFIG.11, the harvester may also comprise a control system100for automatically controlling certain functions of the harvester including movement of the conveyor40and operation of the fans70,72, and78. The control system100may comprise sensors102, cameras104, and/or other electronic devices for sensing obstacles near the harvester such as tree limbs, fence posts, etc. and processing elements106for receiving data and/or signals from the sensors102and cameras14and automatically operating the height adjustment mechanism and/or the lateral adjustment mechanism in response to the received data and/or signals to prevent the discharge conveyor40from striking the obstacles. For example, the control system may sense a tree limb on the right side of the harvester and automatically shift the discharge conveyor40leftward as depicted inFIG.3or5.

The control system may also sense when billets are being collected and where they are in the harvester and operate the appropriate fans70,72, and78. For example, the sensors may determine that the harvester is currently not harvesting additional sugarcane but is discharging previously harvested billets, and the processing elements therefore turn off fans70and72but turn on fan78. In another example, the sensors may sense that the harvester is harvesting new sugarcane but is not discharging billets from the harvester, and the processing elements may therefore turn on fans70,72and turn off fan78.

The processing elements106may be programmed with logic or a number of routines, subroutines, applications, or instructions for performing the instructions described herein. The control system100may also comprise communication elements108for sending data representative of positions of the discharge conveyor40and operating states of the fans70,72, and78to remote control devices and for receiving instructions from the remote devices to remotely adjust the positions of the discharge conveyor40or operations of the fans. The control system100may also automatically shift the conveyor40to its transport/storage position and turn off all the fans whenever the harvester is not harvesting sugarcane and shift the conveyor40to one of its use positions and turn on some of the fans whenever the harvester is harvesting sugarcane. The control system100may also sense the position and/or size of a wagon or other storage vehicle following the harvester and automatically shift the conveyor40to the appropriate use position. For example, the control system may sense a wagon on its left side and automatically shift the discharge conveyor40to the use position depicted inFIG.3. As another example, the control system may sense a relatively short wagon on its left side and automatically shift the discharge conveyor40to the use position depicted inFIG.5.

A sugarcane harvester200constructed according to another embodiment of the invention is illustrated inFIG.12. The sugarcane harvester200is identical to the harvester10, described above, except that the harvester200includes a reservoir conveyor202in the internal storage reservoir18for moving the billets toward the discharge assembly20. The reservoir conveyor202includes a belt204entrained on a plurality of rollers206, wherein each of the rollers206extends along a width of the belt204and perpendicular to a direction of movement of the belt204. At least one of the rollers206drives the belt204so that an upper surface of the belt204in contact with the billets moves in a rearward direction (toward the discharge assembly20), carrying or urging the billets toward the discharge assembly20.

Although the invention has been described with reference to the preferred embodiment illustrated in the attached drawing figures, it is noted that equivalents may be employed and substitutions made herein without departing from the scope of the invention as recited in the claims.

Having thus described the preferred embodiment of the invention, what is claimed as new and desired to be protected by Letters Patent includes the following:

ADDITIONAL CONSIDERATIONS

In various embodiments, computer hardware, such as a processing element, may be implemented as special purpose or as general purpose. For example, the processing element may comprise dedicated circuitry or logic that is permanently configured, such as an application-specific integrated circuit (ASIC), or indefinitely configured, such as an FPGA, to perform certain operations. The processing element may also comprise programmable logic or circuitry (e.g., as encompassed within a general-purpose processor or other programmable processor) that is temporarily configured by software to perform certain operations. It will be appreciated that the decision to implement the processing element as special purpose, in dedicated and permanently configured circuitry, or as general purpose (e.g., configured by software) may be driven by cost and time considerations.

Accordingly, the term “processing element” or equivalents should be understood to encompass a tangible entity, be that an entity that is physically constructed, permanently configured (e.g., hardwired), or temporarily configured (e.g., programmed) to operate in a certain manner or to perform certain operations described herein. Considering embodiments in which the processing element is temporarily configured (e.g., programmed), each of the processing elements need not be configured or instantiated at any one instance in time. For example, where the processing element comprises a general-purpose processor configured using software, the general-purpose processor may be configured as respective different processing elements at different times. Software may accordingly configure the processing element to constitute a hardware configuration at one instance of time and to constitute a different hardware configuration at a different instance of time.

The various operations of example methods described herein, such as the methods of automatically positioning the conveyor assembly36, may be performed, at least partially, by one or more processing elements that are temporarily configured (e.g., by software) or permanently configured to perform the relevant operations. Whether temporarily or permanently configured, such processing elements may constitute processing element-implemented modules that operate to perform one or more operations or functions. The modules referred to herein may, in some example embodiments, comprise processing element-implemented modules.

Similarly, the methods or routines described herein may be at least partially processing element-implemented. For example, at least some of the operations of a method may be performed by one or more processing elements or processing element-implemented hardware modules. The performance of certain of the operations may be distributed among the one or more processing elements, not only residing within a single machine, but deployed across a number of machines. In some example embodiments, the processing elements may be located in a single location (e.g., within a home environment, an office environment or as a server farm), while in other embodiments the processing elements may be distributed across a number of locations.