Stalk conditioner for a header of an agricultural combine

A header for a combine harvester, the header including a frame mountable to a forward end of the combine harvester, at least one row unit mounted to the frame to receive and process stalks of corn, a stomping shoe mounted to the frame behind the row unit to flatten stalks of corn, and a stalk splitter mounted to frame behind the row unit to split stalks of corn. The face of the stomping shoe is provided with a plurality of structures to guide each stalk of corn along a predefined path on the face while the stalks of corn are flattened. The stalk splitter includes a disk blade biased against the ground for splitting stalks of corn after they are processed by row units of the corn header.

FIELD OF THE INVENTION

The present invention relates generally to a stalk conditioner e.g., stalk splitters and stomping shoes for use with agricultural harvesters.

BACKGROUND OF THE INVENTION

Agricultural harvesters, such as combine harvesters, provide for efficient harvesting of crops such as corn. When configured for corn harvesting an agricultural harvester generally includes a corn header that separates crop material (i.e., ears of corn) from corn stalks. The removed ears of corn are fed into a separator that separates the grains of corn from all other materials other than grain (“MOG”). A typical corn header includes several row units, one for each row being harvested in a single pass over a field. As the corn header moves forward, a corn stalk in each row of corn enters the forwardly extending channel defined by the particular row unit associated with that row. Generally, each row unit includes a stripping plate with a gap (“stripping plate gap”) that is wide enough to receive the corn stalk, but not wide enough for the ear of corn on the stalk to pass through. As the harvester moves forward, the stripping plates exert a backward and upward force on the ear of corn while the row unit stalk rolls pull the corn stalks downwardly. The ears of corn are then collected by a feeder and processed by the combine harvester in a known fashion.

After a field of corn is processed in this manner, the stripped stalks remain behind in the field. Farmers typically leave the stripped stalks in the field between plantings to assist in controlling erosion of ground soil from wind and rain and to provide a natural fertilizer for subsequent crops after decomposition. However, since the stripped stalks remain standing, they sometimes interfere with the planting of subsequent crops. For this reason, farmers typically employ various methods for knocking down or chopping stripped stalks after harvesting a field of corn.

One method involves the use of tillage, whereby a farmer employs tilling equipment to work the stripped stalks into the ground to aid in decomposition of the stalks and clear the field for subsequent planting. A farmer may also employ “no-till” methods of processing the stripped stalks of corn. Unlike tillage, these methods do not process or work the soil, but rather seek to process only the stalks of corn themselves to clear the ground of obstacles that would otherwise prevent a subsequent crop of corn from being sewn. One no-till method involves the use of motorized stalk “cutters” or “choppers” that are dragged across a field after stalks of corn are harvested. Another method involves the use of large scale mowers to cut the stalks down after a harvest. While these methods are effective at clearing stripped stalks of corn before a subsequent planting, they require working the field a second time, which is very time consuming and labor intensive. These methods typically require extensive amounts of power. These disadvantages increase the cost of corn production and, as such, lead to reduced profit margins for farmers.

Accordingly, there is still a need for a stalk conditioner that can accelerate the breakdown of stripped stalks of corn while addresses the drawbacks of conventional methods and without increasing expense.

BRIEF SUMMARY OF THE INVENTION

In accordance with an exemplary embodiment of the present invention, there is provided a header for a combine harvester that includes a frame mountable to a forward end of the combine harvester, at least one row unit mounted to the frame to receive and process crop stalks, a stomping shoe mounted to the frame behind the row unit to flatten stalks, and a stalk splitter mounted to frame behind the row unit to the split stalks.

In accordance with another exemplary embodiment of the present invention, there is provided a stomping shoe having a face with a plurality of structures. The plurality of structures can include, for example, ridges, recesses, fins, welded beads, and/or welded key stock, to guide each stalk along a predefined path on the face, such as a longitudinal centerline of the face. In an exemplary embodiment, the structures include two opposed rows of chevron-shaped ridges arranged on opposite sides of the longitudinal centerline of the face. These structures may be formed into the face of the shoe directly, or alternatively, be formed on a plastic cover fitted over the shoe.

In accordance with yet another exemplary embodiment of the present invention there is provided a stalk splitter having a support structure mounted to the frame of the header and a vertically oriented disk blade rotationally coupled to the support structure. In an exemplary embodiment, the disk blade is biased along a predefined direction with respect to the frame. In yet another exemplary embodiment, a biasing mechanism e.g., a compression spring, provides the biasing force to the disk blade.

In accordance with an exemplary embodiment of the present invention, there is provided a stalk splitter pivotally mounted to the frame of the corn header. This allows the stalk splitter to follow rows of stalks, such as when rows of stalks change direction.

In accordance with yet another exemplary embodiment of the present invention there is provided a header for use with a combine harvester that includes a frame, a least one row unit, and a stomping shoe. The frame is configured to mount to a forward end of the combine harvester. The at least one row unit is mounted to the frame and configured to receive crop stalks. The stomping shoe is mounted to the frame behind the row unit and configured to flatten a stalk after the stalk is received by the row unit. The stomping shoe including a face having a plurality of structures disposed thereon. Each of the plurality of structures is configured to guide the stalk along a predefined path on the face while the stalk is being flattened.

In accordance with another exemplary embodiment of the present invention there is provided a header assembly for use with a combine harvester comprising a frame, at least one row unit and a splitting mechanism. The frame is configured to mount to a forward end of the combine harvester. The at least one row unit is mounted to the frame and configured to receive a stalk. The splitting mechanism is mounted to the frame behind the row unit. The splitting mechanism is configured to slice the stalk along its longitudinal axis after the stalk is processed by the row unit.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to the various aspects of the present invention illustrated in the accompanying drawings. Wherever possible, the same or like reference numbers will be used throughout the drawings to refer to the same or like features. It should be noted that the drawings are in simplified form and are not drawn to precise scale. In reference to the disclosure herein, for purposes of convenience and clarity only, directional terms such as top, bottom, left, right, above, below and diagonal, are used with respect to the accompanying drawings. Such directional terms used in conjunction with the following description of the drawings should not be construed to limit the scope of the present invention in any manner not explicitly set forth.

Certain terminology is used in the following description for convenience only and is not limiting. The words “right,” “left,” “lower” and “upper” designate directions in the drawings to which reference is made. The words “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the identified element and designated parts thereof. Additionally, the term “a,” as used in the specification, means “at least one.” The terminology includes the words above specifically mentioned, derivatives thereof, and words of similar import.

The terms “corn,” “ear,” “stalk,” “leaf,” and “crop material” are used throughout the specification for convenience and it should be understood that these terms are not intended to be limiting. Thus, “corn” refers to that part of a crop which is harvested and separated from discardable portions of the crop material. The header of the present invention is applicable to a variety of crops, including but not limited to wheat, soybeans and small grains. The terms “debris,” “material other than grain,” and the like are used interchangeably.

Furthermore, the described features, advantages and characteristics of the embodiments of the present invention may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize, in light of the description herein, that the present invention can be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments of the present invention.

The header includes a stomping shoe200in accordance with an exemplary embodiment of the present invention. Stomping shoe200is configured to be positioned on the header to flatten stalks of corn after the stalks are processed by an associated row unit. For this purpose, stomping shoe200includes a mounting bracket202configured to couple directly to the frame of the corn header such that, when mounted, stomping shoe200is positioned inline and behind an associated row unit. In particular, the stomping shoe200is configured to be vertically in line with a deck plate gap106formed by a pair of deck plates108A,108B of the row unit (FIG. 1A). Additionally, the stomping shoe200is vertically in line with a gap formed by stalk rolls110A,110B of the row unit.

In an alternative exemplary embodiment in accordance with the present invention, mounting bracket202is configured to couple to an intermediate frame member which, in turn, is configured to couple to the frame104of the corn header. It should be appreciated, however, that various exemplary embodiments of the present invention are not intended to be limited to any specific manner of mounting stomping shoe200to a header, and that the full scope of the invention contemplates various additional manners for mounting.

Stomping shoe200also includes a cross bar204and a stomping ski206rotationally coupled to cross bar204about a pivot axis208. A torsional spring210is provided for biasing stomping ski206angularly about pivot axis208with respect to cross bar204, thereby urging face212of stomping ski206along direction214and into the ground when being used in conjunction with a combine harvester. In other exemplary embodiments, the biasing force is provided by other means, such as, for example, via a compression spring (not shown) positioned to provide an angular compression force between cross bar204and stomping ski206. A limit bar216and associated pins218,220limit the angular travel of stomping ski206with respect to cross bar204, thereby preventing undesirable over-travel of stomping ski along direction214and ensuring proper orientation of stomping ski with respect to the ground when being used.

As shown inFIG. 2B, the face212of stomping ski206includes a plurality of structures222A-H configured to guide stalks of corn along a predefined path on the face as the stalks are flattened by the stomping ski. The structures can be e.g., ridges222′ (FIG. 2C), recesses222″ (FIG. 2D), fins222′″ (FIG. 2E), welded beads222″″ (FIG. 2F), welded key stock222′″″ (FIG. 2G) and the like, or combinations thereof. Structures222A-H may be formed on or attached to the face212of the stomping ski directly.

Alternatively, in accordance with an exemplary embodiment of the present invention the structures can be structures222A′-H′ formed or disposed on a plastic cover224′ (FIG. 2H) fitted onto stomping ski212′ of stomping shoe200′. That is, the stomping shoe may include a plastic cover, on which a plurality of structures are disposed.

Structures222A-H ensure that stalks of corn are flattened to the ground in a consistent and defined orientation, which assists subsequent operations such as stalk cutting and/or splitting. In sum, the stomping shoe includes a face for flattening crop stalks, and the face includes a plurality of structures configured to guide each stalk along a predefined path on the face. The predefined path extends along a longitudinal centerline226of the face.

In the exemplary embodiments in accordance with the present invention shown inFIGS. 2A and 2B, structures222A-H are configured as two opposed rows of chevron-shaped ridge structures arranged on opposite sides of the longitudinal centerline226of face212. The chevron-shaped ridge structures form a path or corridor (as illustrated by arrow A) that guides stalks of corn along longitudinal centerline of the face while the stalks are flattened.

FIG. 2Iillustrates another exemplary embodiment in accordance with the present invention of the stomping ski206′ having a recessed path228′ that extends along a central longitudinal centerline of the stomping ski206′. Preferably, the recessed path228′ includes a larger proximal end230A′ thereby forming a funnel-like mouth opening for initially receiving stalks therein. Stalks thereafter are oriented and aligned to travel along the recessed path ultimately exiting about it distal end230′. In other words, the stomping shoe includes an elongated concavity extending along a central longitudinal centerline of the stomping shoe for guiding the stalk along a predefined path defined by the elongated concavity. In other exemplary embodiments in accordance with the present invention, structures or recessed path may be positioned on the stomping ski to guide stalks of corn along other predefined paths on face, for example, along curved and/or off-center paths.

Referring back toFIGS. 2A and 2B, cross bar204is configured to releasably attach to mounting bracket202, for example, to facilitate expeditious replacement and/or maintenance of the stomping ski. For this purpose, cross bar204is provided with a locking pin220and an engaging bar232for engaging receptacle234of mounting bracket202. To detach stomping ski115for replacement or maintenance, locking pin220is removed, thereby allowing engaging bar232to be displaced from engaging receptacle234of the mounting bracket.

It should be appreciated, however, that various exemplary embodiments in accordance with the present invention are not intended to be limited to any specific manner of coupling cross bar204or stomping ski212to mounting bracket202, and that the full scope of the invention contemplates various additional manners for coupling.

Referring now toFIG. 3, there is illustrated a stomping shoe assembly300in accordance with an exemplary embodiment of the present invention. Stomping shoe assembly300includes a plurality of stomping shoes, e.g., three stomping shoes200A,200B, and200C coupled to intermediate frame member302via respective mounting brackets202A,202B, and202C. Intermediate frame member302is configured to couple to the frame104of a header via mounting points304A and304B such that each of stomping shoes200A,200B, and200C is positioned inline and behind an associated row unit for flattening stalks of corn after the stalks are processed by the row units. In an alternative exemplary embodiment in accordance with the present invention, stomping shoes200A,200B, and200C are coupled directly to the frame of a corn header without need for intermediate frame member302.

As shown inFIG. 3, stomping shoe assembly300is intended to be used with a corn header having three row units. However, it should be appreciated that stomping shoe assembly300may be sized and configured to include any number of stomping shoes to match corn headers having a commensurate number of row units. For example, stomping shoe assembly300may be sized and configured to include eight stomping shoes to accommodate corn headers with eight row units. Alternatively, multiple stomping shoe assemblies300may be mounted to a corn header in modular fashion to accommodate a certain number of row units. For example, two modular stomping shoe assemblies, each with three stomping shoes may be mounted to a corn header having six row units.

Referring now toFIGS. 4A and 4B, there is shown a stalk splitter400in accordance with an exemplary embodiment of the present invention. Stalk splitter400is configured to be positioned on a corn header to split stalks of corn after the stalks are processed by an associated row unit. For this purpose, stalk splitter400includes a mounting bar402configured to couple directly to the frame of the corn header such that, when mounted, stalk splitter400is positioned inline and behind the associated row unit. In an alternative exemplary embodiment, mounting bar402is configured to couple to an intermediate frame member which, in turn, is configured to couple to the frame of the corn header. It should be appreciated, however, that various exemplary embodiments of the present invention are not intended to be limited to any specific manner of mounting stalk splitter400to a header, and that the full scope of the invention contemplates various additional manners for mounting.

Stalk splitter or splitting mechanism400includes a disk blade402rotationally coupled to a holding arm404via pivot406. Disk blade402is operable to roll along the ground behind an associated row unit of a corn header to split stalks of corn after the stalks are processed by the row unit. In other words, the disk blade is operable to slice stalks along their longitudinal axis. Using disk blade402to split stalks e.g., corn stalks, not only aids in decomposition of the stalks, but also protects the tires of the combine harvester by weakening the stalks before they are run over. It should also be appreciated that, by using a rolling disk blade402, no power is required, thereby reducing the expense associated with clearing stripped stalks of corn.

In another exemplary embodiment of the present invention, as shown inFIG. 4C, the disk blade can be powered by a drive mechanism to actively split the stalks of corn. That is, the splitting mechanism400′ can include a drive mechanism408′ to rotate the disk blade. The powered disk blade can be driven by an independent motor408′ operatively attached to the disk blade, or a driven shaft410′, e.g., a shaft operatively connected to a Power Take Off of the combine.

The holding arm404is rotationally coupled to a mounting plate412via pivot406to permit a biasing mechanism414to urge disk blade402against the ground when in use. Biasing disk blade402against the ground allows disk blade to better follow terrain and provides greater cutting force when slicing through the ball root of a stalk of corn or a particularly strong stalk. It also allows disk blade to absorb a portion of the weight of the corn header or feeder and to traverse over difficult obstacles (such as metal, dense wood, and other obstacles resistant to slicing) without breakage.

Biasing mechanism414includes intermediate plates416and418rigidly coupled to holding arm404, flange420rigidly coupled to mounting plate412, and a threaded screw422slidingly positioned through holes (not shown) within flange420and intermediate plate416. Threaded screw422includes a washer424for maintaining the threaded screw in frictional engagement with intermediate plate416and a stopping plate426(kept in place on threaded screw via adjustment nut428) for maintaining a biasing member430, e.g., compression spring, in frictional engagement between stopping plate426and flange420. The foregoing provides for the disk blade to be biased along a predefined direction with respect to the frame. In operation, contact of disk blade402with a stalk of corn, the ground, debris, or other obstacles causes holding arm404to rotate about pivot406along direction432, thereby causing intermediate plate416to retract threaded screw422along a direction perpendicular to flange420. Retraction of threaded screw422causes stopping plate426to compress compression spring428against flange420to produce a biasing force about pivot406toward the ground in a direction opposite to direction432.

Although biasing mechanism414ofFIGS. 4A and 4Bemploys a compression spring430for biasing disk blade402against the ground, it should be appreciated that other means may be employed for biasing disk blade402. For example, biasing mechanism414may include a torsional spring (not shown) positioned about pivot406for providing a torsional biasing force against holding arm404with respect to mounting plate420. Alternatively, in accordance with an exemplary embodiment of the present invention, a separate compression spring (not shown) may be mounted between mounting bar402and holding arm404for producing the biasing force. It should be appreciated, however, that the various exemplary embodiments of the present invention are not intended to be limited to any particular type of biasing mechanism, and that the full scope of the invention contemplates various additional manners for producing a force to bias disk blade402against the ground while in use.

The mounting bar402, holding arm404, and mounting plate412, along with other associated parts collectively form a support structure of the stalk splitter for mounting the stalk splitter to the frame of the header. The disk blade is preferably vertically oriented and coupled to the support structure. However, the disk blade can alternatively be substantially vertically oriented, e.g., angled with respect to the horizontal ground surface. Further, the vertically oriented disk blade402is rotationally coupled to the support structure. The support structure along includes at least one biasing member to bias the disk blade along a predefined direction with respect to the frame, and is pivotably mounted the frame of the header. As such, the support structure is configured to urge the disk blade along a predefined direction with respect to the frame of the header.

Referring now toFIG. 5, there is seen a stalk splitter assembly500in accordance with an exemplary embodiment of the present invention. Stalk splitter assembly500includes three stalk splitters400A,400B, and400C coupled to intermediate frame member402via respective mounting pipes504A,504B,504C. Intermediate frame member502is configured to couple to the frame of a corn header via mounting points506A and506B such that each of stalk splitters400A,400B and400C is positioned inline and behind an associated row unit for splitting stalks of corn after the stalks are processed by the row units. In an alternative exemplary embodiment in accordance with the present invention, stalk splitters400A,400B, and400C are coupled directly to the frame of the corn header without need for intermediate frame member502.

Mounting pipes504A,504B,504C receive respective mounting bars402A,402B, and402C in various selectable positions, thereby permitting the vertical heights of stalk splitters400A,400B and400C to be selectively adjusted to accommodate different sized headers. In one alternative exemplary embodiment, mounting pipes504A,504B,504C also permit stalk splitters400A,400B, and400C to pivot about mounting bars402A,402B, and402C to permit the stalk splitters to better follow rows of corn, such as when rows of corn change direction in a field.

In another alternative exemplary embodiment, a looped chain508is coupled to intermediate frame member502and dragged behind the stalk splitters to knock down or otherwise flatten stalks of corn after they are split by stalk splitters400A,400B, and400C. In other words, the looped chain508is mounted to the frame and extends behind the splitting mechanism, and is configured to knock over stalk after the splitting mechanism slices the stalk along its longitudinal axis.

As shown inFIG. 5A, stalk splitter assembly500is intended to be used with a corn header having three row units. However, it should be appreciated that stalk splitter assembly500may be sized and configured to include any number of stalk splitters to match corn headers having a commensurate number of row units. For example, stalk splitter assembly500may be sized and configured to include eight stalk splitters to accommodate corn headers with eight row units. Alternatively, multiple stalk splitter assemblies500may be mounted to a corn header in modular fashion to accommodate a certain number of row units. For example, four modular stalk splitter assemblies, each with two stalk splitters, may be mounted to a corn header having eight row units.

Referring now toFIG. 6, there is shown a stalk splitter and stomping shoe assembly600in accordance with an exemplary embodiment of the present invention. The assembly includes e.g., three stomping shoes200A,200B, and200C coupled to intermediate frame member602via respective mounting brackets202A,202B, and202C, and three stalk splitters400A,400B, and400C coupled to intermediate frame member602via respective mounting pipes604A,604B, and604C. In an alternative exemplary embodiment, stomping shoes200A,200B, and200C and stalk splitters400A,400B, and400C are coupled directly to the frame of the corn header without need for intermediate frame member602.

As shown inFIG. 6A, stalk splitters400A,400B, and400C are positioned inline and behind respective stomping shoes200A,200B, and200C and row units (not shown) to split stalks of corn after they are processed by the row units and flattened by the stomping shoes. In other words, the stalk splitter is mounted to the frame behind the stomping shoe. In another exemplary embodiment, stomping shoes200A,200B, and200C include a plurality of structures on their faces that guide stalks of corn along longitudinal centerlines of the faces while the stalks are flattened. In this manner, stalks of corn remain aligned with stalk splitters400A,400B, and400C for splitting the stalks of corn longitudinally.

FIG. 6Billustrates another exemplary embodiment in accordance with the present invention having a stalk splitter and stomping shoe assembly600′. The assembly600′ includes stomping shoes200A,200B, and200C mounted behind stalk splitters400A,400B, and400C (FIG. 6B) to flatten stalks of corn after they are split.

The stalk splitter and stomping shoe assembly600is intended to be used with a corn header having three row units. However, it should be appreciated that the assembly600may be sized and configured to include any number of stomping shoes and stalk splitters to match corn headers having a commensurate number of row units. Alternatively, multiple assemblies600may be mounted to a corn header in modular fashion to accommodate a certain number of row units.

It will be appreciated by those skilled in the art that changes could be made to the various aspects described above without departing from the broad inventive concept thereof. It is to be understood, therefore, that the subject application is not limited to the particular aspects disclosed, but it is intended to cover modifications within the spirit and scope of the subject application as defined by the appended claims.