Sugarcane harvester extractor with fixed leaf shredder

An extractor is disclosed for a sugarcane harvester that chops stalks of sugarcane into billets. The extractor comprises a housing, a fan positioned within the housing and comprising fan blades mounted for rotation in a rotational path about an axis of rotation to induce a flow of air to extract leaf material from billets produced by the sugarcane harvester, and a leaf shredder positioned within the housing and comprising shredding knives fixed against rotation about the axis of rotation, the shredding knives offset axially from the fan blades relative to the axis of rotation in proximity to the rotational path of the fan blades such that the fan blades and the shredding knives cooperate to shred leaf material by shearing action as the fan blades rotate past the shredding knives about the axis of rotation.

FIELD OF THE DISCLOSURE

The present disclosure relates to extractors for sugarcane harvesters.

BACKGROUND OF THE DISCLOSURE

Sugarcane harvesters often have a chopper, an elevator, and one or more extractors. The chopper chops sugarcane stalks harvested by the sugarcane harvester into segments called “billets.” The elevator lifts the billets to a higher elevation for discharge into a wagon for transport to a mill. A primary extractor is located between the chopper and the elevator. In sugarcane harvesters that have a secondary extractor, the secondary extractor is mounted to the upper discharge end of the elevator. Each extractor has a fan to induce a flow of air to extract leaf material of the harvested sugarcane plants from the billets so as to clean the billets.

SUMMARY OF THE DISCLOSURE

According to an aspect of the present disclosure, there is disclosed an extractor for a sugarcane harvester that chops stalks of sugarcane into billets. The extractor comprises a housing, a fan, and a leaf shredder. The fan is positioned within the housing and comprising fan blades mounted for rotation in a rotational path about an axis of rotation to induce a flow of air to extract leaf material from billets produced by the sugarcane harvester. The leaf shredder is positioned within the housing and comprising shredding knives fixed against rotation about the axis of rotation, the shredding knives offset axially from the fan blades relative to the axis of rotation in proximity to the rotational path of the fan blades such that the fan blades and the shredding knives cooperate to shred leaf material by shearing action as the fan blades rotate past the shredding knives about the axis of rotation.

The above and other features will become apparent from the following description and accompanying drawings.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring toFIG.1, a sugarcane harvester10is configured to harvest sugarcane. The harvester10includes, for example, a topper12, one or more basecutters14(only one basecutter shown), a feed section16, a chopper18, a primary extractor20, an elevator22, and a secondary extractor24. The topper12cuts leaf material off the top of the sugarcane plants before the plants are severed by the one or more basecutters14, but may not remove all the leaf material from the plants before ingestion into the harvester10. Each of the one or more basecutters14includes a left cutting disk and a right cutting disk. The left and right cutting disks of each of the one or more basecutters14cooperate with one another to sever the stalks of sugarcane plants at a location near the ground. The feed section16receives a mat of severed sugarcane from each of the one or more basecutters14and feeds the one or more mats rearwardly. The chopper18receives the one or more mats from the feed section16and cuts the sugarcane stalks into billets. The primary extractor20is positioned between the chopper18and the elevator22. The primary extractor20extracts leaf material ingested into the harvester10from the billets discharged from the chopper18and removes the leaf material from the harvester10. The elevator22is positioned at the rear of the harvester10to receive the billets and convey them to an elevated position where the billets are discharged from the harvester10into a wagon to be hauled away. The secondary extractor24is mounted to the upper discharge end of the elevator22to further extract from the billets leaf material that may not have been removed by the primary extractor20.

The harvester10includes an operator's station26and traction elements28. A human operator can operate the harvester10from the operator's station26. The traction elements28are positioned on the left and right sides of the harvester10for engaging the ground30and propelling the harvester10along the ground30. Illustratively, there may be two traction elements28, each in the form of a ground-engaging wheel, on each side of the harvester10. In other embodiments, there may be one traction element28, in the form of a track unit, on each side of the harvester10

Referring toFIGS.2-4, the extractor20includes a fan31and a leaf shredder32. The fan31includes fan blades33(e.g., four fan blades) mounted for rotation in a rotational path34about an axis of rotation35to induce a flow of air to extract leaf material from billets produced by the chopper18of the harvester10. The billets are discharged from the chopper18, and are airborne upon discharge from the chopper18, facilitating separation of leaf material from the billets by the flow of air induced by the fan31(billets are discharged from the elevator22at the secondary extractor24, and are airborne when discharged from the elevator22, facilitating separation of leaf material from the billets by a flow of air induced by the fan of the secondary extractor24).

The leaf shredder32includes shredding knives36fixed against rotation about the axis of rotation35. The shredding knives36are offset slightly axially from the fan blades33relative to the axis of rotation35in proximity to the rotational path34of the fan blades33such that the fan blades33and the shredding knives36cooperate to shred leaf material by shearing action as the fan blades33rotate past the shredding knives36about the axis of rotation35.

The extractor20includes a housing37. The fan31and the leaf shredder32are positioned within the housing37. The fan31is supported by the housing37for rotation relative thereto about the axis of rotation35. The shredding knives36of the leaf shredder32are positioned in fixed relation to the housing37.

The housing37includes a lower portion38and an upper portion39supported on the lower portion38. The lower portion38is fixed to a frame40of the harvester10and includes an inlet41of the housing37through which billets and leaf material enter the extractor20from the chopper18. The upper portion39includes a conduit42, a wear ring51nested at least partially in the conduit42and mounted to the conduit (e.g., welded), a frame43coupled to the conduit42, and a hood44coupled to the frame43. An extractor rotator can rotate the frame43and the hood44relative to the conduit42to redirect discharge of leaf material from a discharge outlet45of the hood44for exit of leaf material from the extractor20and thus the harvester10. In some embodiments, the upper portion39can be raised and lowered relative to the lower portion38, with the conduit42telescoping up and down relative to the lower portion38. In other embodiments, the height of the upper portion39is fixed relative to the lower portion38, although the upper portion with its frame43and hood44supported thereby can rotate relative to the lower portion38. In such a case, the upper portion39may omit the conduit42, and the wear ring51may instead be mounted to the conduit of the lower portion.

The upper portion39includes a support column46. The support column46is positioned within the housing37and is coupled to and depends from a spider47of the frame43of the upper portion39.

The extractor20includes a motor48and a bearing assembly49. The motor48and the bearing assembly49are positioned within and supported by the support column46. A housing of the bearing assembly49is coupled (e.g., bolted) to an end cap of the support column46. The end cap is coupled (e.g., welded) to a sleeve of the support column46. The housing of the motor48is coupled (e.g., bolted) atop the housing of the bearing assembly49.

The motor48includes an output50that rotates about the axis of rotation35. The output50includes a motor shaft52and a shaft extension or coupling54splined to the motor shaft52and extending through the bearing assembly49downwardly out of the support column46.

The shaft extension54is rotatably coupled to the bearing assembly49. A nut is threaded to the shaft extension54near the top thereof and tightened against a hardened spacer ring so as to press the hardened spacer ring against the inner race of a double tapered bearing set of the bearing assembly49. The outer race of the double tapered bearing set is thereby pressed against a shoulder of the housing of the bearing assembly49.

The extractor20includes a hub56coupled to the motor48. The hub56is rotatably driven about the axis of rotation35. The motor48is drivingly coupled to the hub56via the output50to rotate the hub56and the fan31coupled thereto about the axis of rotation35. The hub56receives and is coupled to the output50for rotation of the hub56therewith about the axis of rotation35. The fan blades33are coupled to the hub56for rotation together with the hub56about the axis of rotation35.

The hub56may be constructed and coupled to the shaft extension54in a wide variety of ways. Illustratively, the hub56includes a central support58. The central support58receives and is coupled to the shaft extension54of the output50for rotation of the central support58therewith about the axis of rotation35. A sleeve60of the central support58includes a tapered hole that receives and mates with a tapered portion of the shaft extension54. The sleeve60and the shaft extension54are keyed to one another against rotation therebetween. A nut62is threaded onto the tapered portion of the shaft extension54with a cotter pin64passing through corresponding holes formed in the nut62and an end portion of the shaft extension54, fixing the central support58of the hub56to the shaft extension54for rotation therewith about the axis of rotation35. A support plate66of the hub56is fastened (e.g., with eight bolts) to an annular flange of the central support58. A sleeve68is coupled to the support plate66(e.g., welded) so as to extend upwardly therefrom and surround the support column46.

The fan31is coupled to the hub56to rotate therewith about the axis of rotation35. The fan blades33are coupled to the sleeve68thereabout via a set of attachment points70of the hub56. The fan blades33are coupled respectively to the attachment points70with fasteners71(e.g., bolts). For example, each fan blade33is coupled to the respective attachment point70with four fasteners71.

Each of the attachment points70includes a mounting plate fixedly coupled to the sleeve68(e.g., welded) and a reinforcement plate fixedly coupled to the sleeve68(e.g., welded) and to an underside of the mounting plate of the attachment point70(e.g., welded) to reinforce the mounting plate of the attachment point70. Each fan blade33is coupled to a mounting plate of the respective attachment point70with the fasteners71. The fan blades33may be coupled to the hub56in a wide variety of ways.

The fan blades33are mounted to the hub56to rotate therewith about the axis of rotation35. Such rotation of the fan blades33induces the flow of air through the extractor20. Each of the fan blades33includes a leading edge72relative to a direction of rotation73of the fan31and its fan blades33about the axis of rotation35. The leading edge72includes a cutting edge74to cut leaf material. Illustratively, the cutting edge74extends the full length of the leading edge72to promote the cutting effectiveness of the fan blade33. In other embodiments, the cutting edge74may extend less than the full length of the leading edge72.

The extractor20includes a cover75coupled to the hub56. The cover75includes a dome located on the support plate66via a positioning ring76fixed to the support plate (e.g., welded) and a cap fastened to a bottom portion of the dome. A rod of the cover75is threaded at one end into the nut62, and a nut of the cover75is threaded onto an opposite end of the post to secure the cap against the dome.

Referring toFIGS.4-9, the housing37includes vanes77. The vanes77are positioned just upstream of the fan31and spaced evenly about the axis of rotation35to help guide air and leaf material entrained therein toward the fan blades33. The vanes77are coupled to an inner periphery78of the housing37in fixed relation thereto. The vanes77are mounted (e.g., welded) to the conduit42, although the vanes77may be coupled to the inner periphery78in any suitable manner. The wear ring51is positioned above the vanes77. The vanes77may be positioned just below the wear ring51, with the vanes77positioned on top of the vanes77.

The leaf shredder32is coupled to the housing37. The shredding knives36of the leaf shredder32are supported by the inner periphery78of the housing37so as to be mounted in fixed relation thereto. The shredding knives36are positioned below the rotational path34of the fan blades33to cooperate therewith to shred leaf material by shearing action as the fan blades33rotate past the shredding knives36about the axis of rotation35.

The shredding knives36include a first set of shredding knives36-1and a second set of shredding knives36-2. The first set of shredding knives36-1is mounted to the wear ring51, and the second set of shredding knives36-2is mounted to the vanes77. The shredding knives36-1are positioned in alternating relation with the shredding knives36-2about the axis of rotation35. In other embodiments, the shredding knives36-1and36-2may be arranged in non-alternating relation with one another. It is to be understood that, in some embodiments, the leaf shredder32may include the first set of shredding knives36-1but not the second set of shredding knives36-2, and, in other embodiments, the leaf shredder32may include the second set of shredding knives36-2but not the first set of shredding knives36-1.

Regarding the first set of shredding knives36-1, the shredding knives36-1are spaced evenly about the axis of rotation35. Illustratively, the shredding knives36-1are positioned respectively between the shredding knives36-2. Each shredding knife36-1is centered angularly between a respective pair of angularly adjacent shredding knives36-2relative to the axis of rotation35, to maximize the open space between angularly adjacent shredding knives36-1,36-2so as not to limit air or material flow that might otherwise provide an area where material collects.

The shredding knives36-1are mounted to the wear ring51. Illustratively, the shredding knives36-1are mounted respectively to and project radially inwardly respectively from support ledges80relative to the axis of rotation35. Each support ledge80is mounted to the wear ring51in fixed relation thereto (e.g., welded). Each shredding knife36-1may be fastened to the support ledge80with fasteners82(e.g., two bolts). In other embodiments, the shredding knife36-1may be welded or otherwise mounted to the support ledge80or directly to the wear ring51.

Each shredding knife36-1may be triangle-shaped. In such a case, the shredding knife36-1includes a base84, a upstream side86, and a downstream side88(“upstream” and “downstream” here in relation to the direction of rotation73of the fan31and its fan blades33). In the illustrated embodiment, the base84is mounted to the support ledge80with the fasteners82. The sides86,86extend radially from the base84to a radially innermost tip90of the shredding knife36-1relative to the axis of rotation35. The shredding knife36-1is configured, for example, as a horizontal plate.

The shredding knife36-1includes a cutting edge92to cut leaf material. The cutting edge92is positioned in proximity to the rotational path34of the fan blades33to cooperate with the cutting edges74of the fan blades33to shred leaf material by shearing action as the fan blades33rotate past the shredding knife36-1about the axis of rotation35. The upstream side86includes the cutting edge92, which extends radially between the base84and the tip90relative to the axis of rotation35.

In some embodiments, the shredding knife36-1may be reversible to extend the useful life of the shredding knife36-1. In such a case, the downstream side88of the shredding knife36-1may have a similar cutting edge as the upstream side86but inverted, such that, when the shredding knife36-1is flipped over, the bevel of the cutting edge also faces downwardly. To reverse the shredding knife36-1, the fasteners82are removed from the support ledge80, the shredding knife36-1is flipped over, and the fasteners82are reinstalled to mount the shredding knife36-1to the support ledge80in reverse orientation.

Regardless whether the shredding knife36-1is reversible, the shredding knife36-1can be replaced readily. To do so, the fasteners82are removed, a fresh knife36-1is installed on the support ledge80, and the fasteners82are reinstalled to mount the shredding knife36-1to the support ledge80.

Turning to the second set of shredding knives36-2, the shredding knives36-2are mounted respectively to the vanes77. The shredding knives36-2are spaced evenly about the axis of rotation35.

Each of the shredding knives36-2includes an anchor portion94and a presenting portion96. The anchor portion94is mounted to the vane77. In the illustrated embodiment, the anchor portion94is mounted to the vane77in fixed relation thereto by welding, with an upper surface of the anchor portion94mounted to a lower surface of the vane77. In other embodiments, the anchor portion94may be mounted to the vane77with one or more fasteners (e.g., bolt(s)) or other suitable mounting mechanisms, in which case the shredding knife36-2may be replaceable.

The presenting portion96includes a cutting edge98to cut leaf material. The presenting portion96is angled upwardly from the anchor potion94to present the cutting edge98in proximity to the rotational path34of the fan blades33to cooperate with the cutting edges74of the fan blades33to shred leaf material by shearing action as the fan blades33rotate past the shredding knife36-2about the axis of rotation35. The cutting edge98is positioned at the top 110 of the shredding knife36-2.

The shredding knife36-2extends upwardly from the vane77and alongside a radially inner surface of the wear ring51. The shredding knife36-2, or at least a portion thereof, is spaced radially inward of the conduit42by at least a thickness112of the wear ring51such that the shredding knife36-2extends upwardly from the vane77to a position radially inward of the wear ring51relative to the axis of rotation35.

The shredding knife36-2is configured, for example, as a bent plate with a bend114between the anchor portion94and the presenting portion96. The bent plate projects axially away from the vane77toward the rotational path34relative to the axis of rotation35to present the cutting edge98at the top 110 of the bent plate in proximity to the rotational path34.

Referring toFIGS.10and11, each fan blade33and shredding knife36-1,36-2includes a cutting edge. The cutting edge74of each fan blade33includes a bevel116facing upwardly. The bevel116and a lower surface118of the fan blade33cooperate to provide the cutting edge74, with the bevel116extending between and interconnecting the lower surface118and an upper surface120of the fan blade33.

The cutting edge92of each shredding knife36-1includes a bevel122facing downwardly. The bevel122and an upper surface124of the shredding knife36-1cooperate to provide the cutting edge92, with the bevel122extending between and interconnecting the upper surface124and a lower surface126of the shredding knife36-1.

The cutting edge98of each shredding knife36-2includes a bevel128facing in the direction of rotation73of the fan blades33. The bevel128and an upstream surface130of the shredding knife36-2cooperate to provide the cutting edge98, with the bevel128extending between and interconnecting the upstream surface130and a downstream surface132of the shredding knife36-2(“upstream” and “downstream” here in relation to the direction of rotation73of the fan31and its fan blades33).

The fan blades33and the shredding knives36-1,36-2cooperate to shred leaf material. The fan blades33cooperate with the first set of shredding knives36-1to shred leaf material by shearing action as the fan blades33rotate past the shredding knives36-1about the axis of rotation35, and cooperate with the second set of shredding knives36-2to shred leaf material by shearing action as the fan blades33rotate past the shredding knives36-2about the axis of rotation35.

It is to be understood that the fan31may include any suitable number of fan blades33, and the leaf shredder32may include any suitable number of shredding knives36. The shredding knives36may be arranged in any suitable angular arrangement about the axis of rotation35.

Threads and welds are not shown for ease of illustration. However, it is to be appreciated that bolts, nuts, and corresponding mating surfaces would have threads.

While the above describes example embodiments of the present disclosure, these descriptions should not be viewed in a limiting sense. Rather, other variations and modifications can be made without departing from the scope and spirit of the present disclosure as defined in the appended claims.