Narrow row corn head with staggered height row units

The row crop header for a harvesting machine includes a frame and a first row unit supported by the frame in a row unit plane. The first row unit includes a first gatherer operating in a first gatherer plane oblique to the row unit plane and a second gatherer operating in a second gatherer plane parallel to the first gatherer plane and oblique to the row unit plane.

FIELD OF THE INVENTION 
This invention relates to a row crop harvesting machine. More particularly, 
this invention relates to a header for a row crop harvesting machine that 
is designed to harvest crops, such as corn, planted in rows spaced closer 
together than in the past. 
BACKGROUND OF THE INVENTION 
Several variations of header units have been used in combines or harvesting 
machines for harvesting row crops such as corn and cotton. One of the 
first such header units was a corn head with fixed spacing between the row 
units. Several other corn heads allowing variable spacing between the row 
units were then developed. 
With the advent of the variable row width header units, the last several 
years has seen a rapid increase in the research and development of the 
effect of varying row widths on the growth of corn and other row crops. 
The existing corn heads and harvesting machines are designed to 
efficiently harvest corn planted in rows having a row width of greater 
than 20 inches, because the existing corn heads have the gatherers of 
their row units in the same plane, thereby limiting how close the row 
units can be arranged together. 
For example, a typical existing corn head with a plurality of row units has 
both the gatherers of each row unit positioned in the same plane. Thus, 
the adjacent gatherers of any two adjacent row units are also positioned 
in the same plane. This limits how close the adjacent row units can be 
positioned as the adjacent gatherers of the adjacent row units interfere 
with each other if the adjacent row units are positioned too close to each 
other. As the technology to build the chains and gears required for 
efficient operation limits the minimum width of a row unit, the 
positioning of adjacent row units determines the minimum crop row width 
that can be efficiently harvested by the existing corn heads. Thus, 
current technology limits the row widths to about 20 inches because the 
gatherers in adjacent row units of the existing corn heads interfere with 
each other if they are brought any closer. 
Recent research on the spacing of the corn rows has indicated special 
benefits for narrower row spacings that are 12-15 inches apart. In 
addition to the obvious increase in yield and crop population, these 
benefits include improved erosion control and better weed control. The 
narrower rows also require less chemicals and pesticides per unit of yield 
thereby benefiting the environment. 
Existing header units are not designed to harvest rows having a spacing of 
15 inches or less. Consequently, they are very wasteful and inefficient in 
harvesting narrow rows leading to a sub-optimal harvesting efficiency. 
The problems identified above are not intended to be exhaustive but are 
among the many that reduce the effectiveness of current solutions to the 
problem of harvesting crops planted in narrow rows. Other problems may 
also exist; however, those presented above should be sufficient to 
demonstrate that currently known solutions are amenable to worthwhile 
improvement. 
SUMMARY OF THE INVENTION 
The present invention is directed to an improved row crop header for a 
harvesting machine. The row crop header includes a frame and a first row 
unit supported by the frame in a row unit plane. The first row unit 
includes a first gatherer operating a first gatherer plane oblique to the 
row unit plane and a second gatherer operating in a second gatherer plane 
parallel to the first gatherer plane and oblique to the row unit plane. 
The present invention provides a row crop header with a plurality of row 
units mounted on a frame of the row crop header. The plurality of row 
units includes a first row unit positioned in a first plane and an 
adjacent second row unit positioned in a second plane. The first plane and 
the second plane are offset. This configuration allows the two adjacent 
row units to be positioned closer together because they overlap along an 
axis that is substantially parallel to both the first plane and the second 
plane. This overlap determines how close the adjacent row units are 
positioned together. Therefore, increasing the overlap reduces the 
distance between the adjacent row units. 
The present invention also provides a method that provides a row crop 
header including a first row unit positioned in a first plane and a second 
row unit positioned in a second plane where the first plane and the second 
plane are offset and the first row unit is adjacent to the second row 
unit. The first row unit and second row unit are connected to the frame of 
the row crop header with the first row unit overlapping the second row 
unit along an axis that is substantially parallel to both the first plane 
and the second plane. This overlap permits the row crop header of the 
present invention to efficiently harvest narrower crop rows when the row 
crop header is mounted on a harvesting machine.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
In the figures, like numerals indicate like parts. FIG. 1 shows an improved 
row crop header, indicated generally as 15, connected to a combine or 
harvesting machine 10. The improved row crop header 15 has a unique 
configuration that permits the efficient harvesting of the crops planted 
in rows spaced closer together than in the past. 
FIG. 2 shows the row crop header 15 having a plurality of row units 20 
connected to a frame 17 of the row crop header 15. The row units 20 are 
covered by a plurality of housings 16. 
As shown in FIG. 3, each row unit 20 has a frame end 21 and a head end 22. 
The frame end 21 of the row unit 20 attaches to the frame 17, while the 
head end 22 serves as the longitudinal extension of the row unit 20 and as 
a crop engagement device. That is, the row unit 20 extends forward from 
the frame end 21 to the head end 22. 
Each row unit 20 also has at least one gatherer 30. The preferred 
embodiment of the row crop header 15, has two gatherers 30. Each gatherer 
30 includes a gathering chain 31 with at least one sprocket 37. A 
plurality of fingers 32 are connected to and extend outward from the 
gathering chain 31. The fingers 32 are protuberances having at least one 
surface adapted to contact and move corn ears or other harvested crop. The 
gathering chain 31 traverses a substantially oval path and extends forward 
from proximate the frame end 21 to proximate the head end 22 of the row 
unit 20. 
Note that other embodiments of the gatherer 30 are possible, including but 
not limited to belts, ropes or other conveying mechanisms. These other 
conveying mechanisms can include, for example, an auger, a conveyor or any 
other mechanism that is suitable for moving corn ears or other crops. 
A pair of snapping rolls 40 pull the corn stalks so that the corn ears are 
removed from the stalks when they come into contact with a pair of 
stripper plates 50. The ears are then carried backwards by the fingers 32 
of gathering chain 31 to a conveying mechanism, such as a cross auger 25, 
which is seen in FIGS. 1 & 2. The auger 25 moves the ears to a grain 
housing or collection device (not shown) of the harvesting machine 10 on 
which the row crop header 15 is mounted. 
In the preferred embodiment, as shown in FIG. 3, each row unit 20 has two 
gathering chains 31 that are spaced apart by a distance 33 that is at 
least twice the width 32a of the fingers 32 of the gathering chains 31. 
Likewise, the minimum width of the gathering chain 31 is limited by the 
current technology to permit efficient operation of the row units. The 
spacing distance 33 and the width of the gathering chains 31 limit the 
minimum width of the row units 20. 
FIGS. 4 & 5 show the unique configuration of the row units 20 of row crop 
header 15. FIG. 4 is a schematic front view of a plurality of row units 20 
of the preferred embodiment of the row crop header 15. Each of the 
plurality of row units 20 is connected to the frame of the row crop header 
15 with a housing 16 covering the adjacent gatherers 30 of two adjacent 
row units 20. The housing 16 also serves as guides for the corn stalks as 
the row crop header is moved forward by the harvesting machine 10, shown 
in FIG. 1. 
It is to be understood that "adjacent" row units refer to two row units 20, 
such as row unit 20a and row unit 20b, that are placed next to each other 
along the frame although structural members or other elements could be 
interposed between the two adjacent row units 20. Thus, row unit 20a is 
adjacent to row unit 20b as long as no other row unit 20 is positioned 
between them even though other structural members or elements may be 
interposed between them. 
Each row unit 20 of the row crop header 15 is positioned so that it is in 
an offsetting plane from the row units 20 that are adjacent to it. Thus, 
as shown in FIG. 5, a first row unit 20a is positioned in a first plane 
AA. A second row unit 20b, adjacent to the first row unit 20a, is 
positioned in a second plane BB which is offset 34 from the first plane 
AA. The offset 34 measures the separation of the two planes AA, BB. 
In the preferred embodiment of the row crop header 15, the offset 34 always 
has a positive value as the two planes AA and BB are distinct and do not 
coincide. Also, in the preferred embodiment, the two planes AA and BB are 
substantially parallel to each other and the offset 34 is measured along 
an axis that is perpendicular to both the first plane AA and the second 
plane BB. 
The offset 34 between the two planes AA, BB can be made adjustable to 
optimize the effectiveness of the gathering chains 31 in moving the 
harvested crop backward to the cross auger 25 and thereon to the grain 
collection device. Such an adjustment mechanism could be provided by 
having a supporting bracket (not shown) for both the gathering chains 31 
of a row unit 20. The supporting bracket could be provided with a 
plurality of slots so that the gathering chains 31 could be positioned in 
any of the slots to increase or decrease the offset 34. 
As shown in FIG. 5, two adjacent row units, a first row unit 20a and a 
second row unit 20b are arranged closer together than in the existing corn 
heads because the adjacent chains 31a, 31b of two adjacent row units 20a, 
20b are in the first plane AA and the second plane BB, respectively. The 
first plane AA and the second plane BB are substantially parallel to each 
other and spaced by the offset 34. This offset 34 permits the adjacent 
gathering chains 31a, 31b to overlap 36 along an imaginary axis that is 
substantially parallel to both the first plane AA and the second plane BB. 
The fingers 32 of the adjacent chains 31a, 31b of adjacent row units 20a, 
20b overlap as the chain 31a of row unit 20a is offset 34 from the 
adjacent chain 31b of row unit 2Ob. The overlap 36 permits the distance 35 
between two adjacent row units 20a, 20b to be reduced by the amount of the 
overlap 36. Thus, the overlap 36 allows a closer arrangement of the row 
units 20 so that the crop row width 38 is less than minimum crop row width 
achievable in the existing corn heads. 
In the preferred embodiment of the row crop header 15, the overlap 36 is 
approximately 5 inches to permit the reduction of the crop row width 38 to 
15 inches. In the preferred embodiment, the offset 34 is approximately 1.5 
inches which allows the two adjacent gathering chains 31a, 31b to overlap 
36 sufficiently to reduce the crop row width 38 of the row crop header 15. 
The offset 34 should also preferably be greater than the finger height 32a 
to ensure that the fingers of adjacent gathering chains, such as 31a and 
31b, do not interfere with each other during the operation of the row crop 
header 15. 
The gatherers 30 and the snapping rolls 40 are driven by a power source 60, 
shown schematically in FIG. 4. In the preferred embodiment, the power 
source 60 includes a drive shaft 61 with a plurality of gear boxes 62 
adapted so that the power outputs from the gear boxes 62 drive the 
gatherers 30 and the snapping rolls 40. Other embodiments of the power 
source 60 are also possible, for example, different power sources could be 
used to drive the snapping rolls 40 and the gatherers 30. Alternatively, a 
single power source could be used with a plurality of drive shafts and 
drive means. Such gear boxes 62 and drive means are described in several 
U.S. Patents and any of them could be easily adapted for use with the row 
crop header of the present invention. For example, these include the drive 
means shown in U.S. Pat. No. 3,462,928 issued to L. D. Schreiner and in 
U.S. Pat. No. 3,599,409 issued to Martin J. Whitney, the disclosures of 
which are incorporated, in their entirety, by reference. 
It is to be understood that the drive mechanism 65 is suitably installed 
within the row crop header and connected to the row unit components. The 
drive mechanism 65 is shown schematically in FIG. 4 as being separate for 
purposes of clarity. 
In an alternative embodiment of the drive mechanism 65, a single drive 
shaft could be provided with gatherer shafts 63 of different lengths to 
drive the gatherers 30 positioned in the offset planes AA and BB, shown in 
FIG. 5. that is, longer gatherer shafts 63 would drive the gatherers 30 
operating in the upper plane AA while shorter or standard gatherer shafts 
63 would drive the gatherers 30 operating in the lower plane BB. 
In another alternative embodiment of the drive mechanism 65, two drive 
shafts can be provided so that each drive shaft drives the row unit 
components of the row units 20 that are positioned in the same plane. 
Therefore, the driven components of row unit 20a would be driven by one of 
the two drive shafts. The driven components of row unit 20b, located in an 
offset plane from row unit 20a, would be driven by the other of the two 
drive shafts. 
With reference to FIGS. 4 & 5, an improved method is also provided which 
includes providing a row crop header 15 with two adjacent row units 20a, 
20b such that a first row unit 20a is positioned in a first plane AA and a 
second row unit 20b is positioned in a second plane BB. The first plane AA 
and the second plane BB are substantially parallel to each other and 
spaced apart by an offset 34. 
The method also provides for attaching the row crop header 15 to a 
harvesting machine 10, such as the one shown in FIG. 1, and operating the 
row crop header 15 using a power source 60 to harvest row crops planted in 
narrower rows than in the past. Note that the preferred embodiment of the 
row crop header is discussed as operating on rows of corn. However, the 
instant row crop header could be easily adapted to work with other row 
crops, such as cotton and sunflower. 
FIG. 6 is a detailed front view of row units 120a, 120b, alternate 
embodiments of row units 20a and 20b shown in FIGS. 1-5. Row units 120a, 
120b are similar to row units 20a, 20b except that row units 120a, 120b 
include gatherers 130a, 130b. For ease of illustration, those remaining 
elements of row units 120a, 120b which correspond to similar elements of 
row units 20a, 20b are numbered similarly. Row units 120a, 120b are 
supported by frame 18 along a row unit plane 140. In the preferred 
embodiment, row unit plane 140 is generally horizontal. Gatherers 130a, 
130b of row units 120a, 120b are similar to gatherers 30a, 30b except that 
gatherers 130a, 130b operate in gatherer planes which are oblique to row 
unit plane 140. In the preferred embodiment illustrated, gatherers 130a, 
130b of each row unit 120a, 120b operate in gatherer planes substantially 
parallel to one another and oblique to row unit plane 140. In particular, 
gatherer 130a of each row unit 120a, 120b operates in a plane downwardly 
sloped towards stalk rolls 40 and stripper plates 50. Gatherer 130b of 
each row unit 120a, 120b operates in a gatherer plane downwardly sloped 
from stalk rolls 40 and stripper plates 50 towards an adjacent row unit. 
In the preferred embodiment illustrated, gatherers 130a, 130b operate in 
gatherer planes sloped or angled with respect to row unit plane 140 by 
approximately 20 degrees. As further shown by FIG. 6, gatherer 130a of 
each row unit 120a, 120b operates in a gatherer plane parallel to and 
slightly above the gatherer plane in which gatherer 130b of the same row 
unit operates. Adjacent gatherers 130a, 130b of adjacent row units 120a, 
120b operate in gatherer planes parallel to and offset from one another. 
Because gatherers 130a, 130b of each row unit 120a, 120b operate in 
gatherer planes parallel to one another and oblique to row unit plane 140, 
gatherers 130a, 130b occupy less space parallel to row unit plane 140. As 
a result, row units 120a, 120b may be more closely spaced together for 
better accommodating narrower crop rows. Because adjacent gatherers 130a, 
130b of adjacent row units 120a, 120b operate in gatherer planes parallel 
to one another and oblique to row unit plane 140, adjacent gatherers 130a, 
130b of adjacent row units 120a, 120b may be supported so as to overlap 
one another. Consequently, row units 120a, 120b are additionally 
positioned even more closer together to better accommodate narrow crop row 
spacings. 
Thus, the instant row crop header 15 permits a closer arrangement of the 
row units 20, 120 to harvest crop rows that are 15 inches apart or less. 
Existing corn heads with the row units in substantially the same plane are 
unable to efficiently harvest rows that are narrower than 20 inches. 
Therefore, some of the major advantages of the instant row crop header 
include the unique combination of providing an improved apparatus and 
method that: 
(i) permits the harvesting of narrower crop rows by allowing the row units 
to be arranged closer together on the row crop header frame; 
(ii) benefits the environment by reducing the requirement for chemicals and 
pesticides per unit of crop harvested; and 
(iii) improves soil control and erosion by allowing crop rows to be planted 
closer together. 
Other embodiments of the row crop header will be apparent to those skilled 
in the art from consideration of the specification disclosed herein. It is 
intended that the specification be considered as exemplary only, with the 
true scope and spirit of the invention being indicated by the following 
claims.