PATENT ABSTRACT
An agricultural combine unloader extension is provided that can be used to extend the reach of conventional unloader tubes and for preventing the loss of crop material residing within the unloader tube from falling out and becoming waste. The unloader extension is hingedly connected to the unloader tube, wherein a drive mechanism is configured to rotate the unloader extension about a vertical axis from a discharging position to a closed or storage position.

PATENT DESCRIPTION
BACKGROUND OF THE INVENTION 
     The present invention relates generally to agricultural combine unloaders. In particular, the present invention relates to a hinged unloader extension that can pivot between a discharge position and a closed position. 
     An agricultural combine is a common and well-known machine for harvesting crop materials. Agricultural combines are available in various designs and models to perform the basic functions of reaping crop materials from a crop field, separating the grain from the non-grain crop materials, and discarding the non-grain crop materials back onto the crop field. 
     A typical combine includes a crop harvesting apparatus, or header, which reaps ripened crop plants from the crop field and feeds the crop materials to a separating or threshing system. Several different types of threshing systems are available, such as rotary threshers and straw walkers. Regardless of the type of threshing system used, the thresher separates the course non-grain materials from the grain heads. The course non-grain material primarily consists of grain stalks and exits the thresher along its rear end. The grain heads, on the other hand, exit the thresher along the bottom side of the thresher and pass to a series of moving sieves. The sieves separate the grain from the unwanted fine materials, sometimes referred to as chaff. After separation, the grain is directed to a grain bin through an auger system, and the unwanted fine materials exit the sieves along the rear end. 
     The grain bin serves as a temporary onboard storage location for the grain. Typically, the grain bin is positioned above the threshing system and can have a capacity of as much as 200 bushels for larger combines. As the combine harvests the crop field, the grain bin periodically becomes filled with grain and must be emptied to allow the combine to proceed. The grain is then transferred from the grain bin to a truck or a grain cart through an unloader tube. 
     The unloader tube is a well-known device to those skilled in the art of combines. Most manufacturers of combines have adopted a similar configuration for the unloader tube. In the common configuration, the unloader tube is positioned along the upper side of the combine with the infeed section of the auger located adjacent to the grain bin. The infeed section is pivotally attached to the combine to allow rotation about a nearly vertical axis. A 90 degree elbow connects the infeed section to a long horizontal section. The horizontal section can then rotate in a generally horizontal plane around the infeed end. With this design the unloader tube can be rotated out to a 90 degree angle from the combine to allow unloading into a truck or grain cart. After unloading, the unloader tube is rotated back so that the horizontal section trails towards the rear of the combine with the exit end located near the combine&#39;s rear end. 
     While this configuration for the unloader tube has been a convenient solution for the need to unload the combine&#39;s grain bin, the long length of such unloader tubes presents a number of problems for both the farmer and the manufacturer. These problems are exacerbated by the increasing production capacity of newer combines which require ever longer unloader tubes due to the increased header width of today&#39;s combines. 
     In order to satisfy farmers&#39; demands for more efficient harvesting equipment, manufacturers have regularly increased the width of the combine header. Currently, some combine headers are as wide as forty feet, and even larger widths are eventually possible. In addition, farmers are increasingly turning to the use of grain carts and unloading the combine&#39;s onboard grain bin into an adjacent travelling grain cart while the combine is still harvesting through the field. Frequently, the grain cart is towed by an agricultural tractor which has dual sets of tires installed on it. With this unloading arrangement, the unloading auger must extend over a substantial distance in order to reach the grain cart, including the width of the header, the safety clearance between the header and the tractor tires, and the width of the grain cart and tractor. 
     Current unloader tubes also prevent farmers from implementing a technique known as controlled traffic patterning. In a controlled traffic pattern, the combine unloads grain into an adjacent travelling grain cart like previously described. However to avoid additional soil compaction, the tow tractor and grain cart travel along the combine&#39;s prior tire path which is located one swath away from the combine&#39;s current travel path. Thus, by reusing the same tire path that has already been created by the combine, more ground soil is left uncompacted, which allows better growing conditions for subsequent crops. Controlled traffic pattern harvesting, however, requires even longer unloader tubes than are generally available in order to span the entire distance between the combine&#39;s current and prior tire paths. 
     Typically, prior art unloader tubes are lengthened by extending the length of the horizontal section and allowing an extended portion to extend beyond the rear end of the combine. This extended portion can raise the manufacturer&#39;s shipping costs for the combine significantly. Shipping costs are often calculated based on the volume of the shipped product. This is especially true when a combine is shipped overseas on a ship. In these cases, if the manufacturer chooses to install the unloader tube at the factory, the extended portion can require as much as 10% more shipping volume than would otherwise be required, substantially increasing the cost of shipping. On the other hand, the manufacturer may choose to ship the unloader tube separately to avoid this cost penalty. However, this alternative suffers from the problems of ensuring that the correct parts are shipped to the customer and that they are properly installed once received. 
     The extended portion also requires additional storage space on the farm. Farmers typically store their agricultural equipment in large buildings when the equipment is not being used in order to minimize weather related deterioration. Hereto, the extended portion limits the amount of equipment that can be stored in the storage building because other equipment must be positioned behind the end of the unloader tube instead of directly behind the combine&#39;s rear end. 
     Problems also occur when the farmer is operating the combine during harvesting operations. The long horizontal section of the unloader tube makes the overall length of the combine extra long and creates a collision hazard for the extended portion. Farmers operate their combines around a variety of different obstacles, which can be accidentally struck by the extended portion. Examples of these obstacles include trees, telephone poles, buildings, and other vehicles. The risk of rear end collisions is especially great with combines because the large size of the combine and the minimum amount of rearward visibility makes it difficult to see nearby obstacles. When a collision does occur with the unloader tube, the cost to the farmer can be quite high. Not only is the object struck damaged, but the unloader tube will likely be disabled. As a result, the farmer incurs repair costs, and the harvesting operation is delayed until the unloader tube can be fixed. 
     To minimize the risk of rear end collisions, some countries have implemented transportation regulations that require a combine to be able to turn around within a specified radius without any portion of the combine passing outside the radius. This type of regulation requires that the combine be designed as compact as possible. Satisfying a regulation like this is especially difficult with an unloader tube that extends beyond the rear end of the combine. 
     Moreover, the ever increasing length of unloader tubes means that more residual grain is left in them after unloading to a grain cart is completed, as it may take several grain charts to unload the combine. The residual grain in the unloader tube falls out, or dibbles out, of the unloader tube as the combine continues harvesting due to the movement of the combine across the field. This loss of residual grain results in a substantial waste of harvested grain and ultimately revenue for farmers. 
     Therefore, there exits a need for a means to extend the unloader tube&#39;s reach for unloading grain in today&#39;s larger agricultural combines while minimizing waste associated with such larger unloader tubes. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention provides an agricultural combine unloader comprising: an unloader tube connected to the agricultural combine, the unloader tube including: an interior passageway, and an auger within the interior passageway for conveying crop material therethrough to a discharge end; an unloader extension that includes: an inlet end for receiving crop material from the discharge end of the unloader tube, and an outlet end for discharging the crop material; and a drive mechanism operatively connected to the discharge end of the unloader tube to position the unloader extension in at least a discharge position to discharge the crop material from the unloader tube and a closed position to cover the discharge end of the unloader tube, the drive mechanism including a turret, wherein the inlet end of the unloader extension is pivotably connected to the turret. 
     The present invention provides an agricultural combine unloader comprising: an unloader tube connected to the agricultural combine, the unloader tube including: an interior passageway, and an auger within the interior passageway for conveying crop material therethrough to a discharge end having a downwardly facing planar opening; an unloader extension that includes: an inlet end for receiving crop material from the discharge end of the unloader tube, an outlet end for discharging the crop material, and a planar surface connecting the inlet end and outlet end; a drive mechanism that includes: a turret operatively connected to the discharge end of the unloader tube for rotation about a substantially vertical axis, and a pivot mechanism, wherein the inlet end of the unloader extension is pivotably connected to the turret and the pivot mechanism is operatively connected to the unloader extension to pivot the unloader extension relative to the axis of rotation of the turret; and wherein the pivot mechanism pivots the unloader extension between a closed position wherein the planar surface of the unloader extension covers the downwardly facing planar opening of the discharge end of the unloader tube and an open position wherein the planar surface of the unloader extension is at an angle with respect to horizontal to allow for the flow of crop material from the discharge end of the unloader tube to the outlet end of the unloader extension. 
     The present invention solves the problems associated with longer unloader tubes and the impact such longer unloader tubes have on waste levels for harvested grain by engendering a unloader extension that can extend the reach of the unloader tube, yet can be retracted, and which can minimize waste of the harvested grain by sealing off the unloader tube when not in use. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       The foregoing summary, as well as the following detailed description of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there are shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. 
       In the drawings: 
         FIG. 1  is a side, elevational view of an agricultural combine with an unloader tube and unloader extension in a storage position in accordance with a preferred embodiment of the present invention; 
         FIG. 2  is a top plan view of the agricultural combine of  FIG. 1 ; 
         FIG. 3  is a top plan view of the agricultural combine of  FIG. 1  with the unloader tube and unloader extension in a discharge position and a grain cart positioned to receive grain from the unloader tube and extension; 
         FIG. 4  is a perspective view of an unloader extension in accordance with a preferred embodiment of the present invention; 
         FIG. 5  is a side, elevational cross-sectional view of the unloader tube of  FIG. 1 ; 
         FIG. 6A  is a top plan view of a drive mechanism for the unloader tube and unloader extension of  FIG. 1  that includes a turret and a pivot mechanism; 
         FIG. 6B  is a side, elevational view of the drive mechanism of  FIG. 6A ; 
         FIG. 7  is an enlarged side elevational view of the unloader extension of  FIG. 4  connected to the unloader tube of  FIG. 5  in a discharge position; 
         FIG. 7A  is an enlarged side elevational view of the unloader extension of  FIG. 4  connected to the unloader tube of  FIG. 5  in a discharge position in accordance with another preferred aspect of the present invention; 
         FIG. 8  is an enlarged side elevational view of the unloader extension of  FIG. 4  connected to the unloader tube of  FIG. 5  in a closed position; 
         FIG. 9  is a front, cross-sectional view of an unloader extension having a half-piped configuration in accordance with another preferred embodiment of the present invention; 
         FIG. 10  is a front, cross-sectional view of an unloader extension having a open trapezoidal configuration in accordance with yet another preferred embodiment of the present invention; 
         FIG. 11  is a side, elevational view of an unloader extension having a powered conveyor belt in accordance with another preferred embodiment of the present invention; 
         FIG. 12  is a side, elevational view of an unloader extension having a powered auger conveyor in accordance with yet another preferred embodiment of the present invention; and 
         FIG. 13  is a side, cross-sectional, elevational view of a turret in accordance with a preferred embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to  FIG. 1 , there is shown a self-propelled agricultural combine  10 . The combine  10  includes a body  12  supported by wheels  14  and an engine (not shown) for driving the wheels  14  to allow the combine  10  to move from place to place. An operator&#39;s station  16  is positioned towards the forward end of the combine body  12  and includes numerous controls to allow the operator to adjust the functions of the combine  10 . 
     At the forward end of the combine  10  is a crop harvesting header  18  that severs and gathers the ripened crop materials from the crop field. After cutting the stems of the crop materials or collecting the crop materials from a prepared windrow, the crop materials are fed rearward through a feeder housing  20  to the combine&#39;s internal threshing systems (not shown). The threshing systems then separate the grain from the unwanted crop residue. Because the present invention is applicable to a variety of different threshing systems and because threshing systems are generally well-known to those skilled in the art, a detailed discussion of the structure, function and operation of such threshing systems is not necessary for a complete understanding of the present invention. After the threshing systems have separated the grain from the crop residue, the grain is transferred to an onboard storage bin  22  by a transfer system, such as an augering system, and the unwanted crop residue is discharged from the rear end of the combine  10  onto the harvested crop field. 
     When the onboard storage bin  22  becomes full with grain, an unloader tube  24  empties the grain from the storage bin  22  into a truck or a grain cart  100  ( FIG. 3 ). Most manufacturers use a similar configuration for the unloader tube  24  that is well-known in the art. The unloader tube  24  includes an infeed section  26  that is positioned adjacent to the storage bin  22  and is oriented along a substantially vertical axis that leans rearward about 12 degrees. The input end (not shown) of the infeed section  26  is positioned within the storage bin  22  near its bottom side so that the grain will feed up into the infeed section  26  when the unloader tube  24  is turned on. The unloader tube  24  is part of the combine&#39;s unloader system (i.e., unloader). Such unloaders are well known in the art and a detailed description of their structure, function and operation is not necessary for a complete understanding of the present invention. An exemplary unloader is described in U.S. Pat. No. 7,452,180, the disclosure of which is hereby incorporated by reference in its entirety. 
     The infeed section  26  is pivotally connected to the combine  10  around the infeed section&#39;s  26  vertical axis. The infeed section  26  can then be rotated about its vertical axis by a hydraulic cylinder (not shown) that is connected on one end to a lever (not shown) attached to the infeed section  26 . At the top end of the infeed section  26 , an elbow  28  connects the infeed section  26  to the horizontal outfeed section  30  of the unloader tube  24 . The horizontal outfeed section  30  is oriented 90 degrees from the infeed section  26  and lies along a substantially horizontal axis. Thus, when the infeed section  26  is pivoted, the horizontal outfeed section  30  rotates around the infeed section  26  in a generally horizontal plane with the outfeed section  30  rising slightly as it is rotated outwards. 
     The combine operator controls the position of the unloader tube  24  with remote controls provided in the operator&#39;s station  16 . The unloader tube  24  rotates between a storage or closed position ( FIG. 2 ) and an unloading or discharge position ( FIG. 3 ). In the unloading position, the horizontal section  30  is rotated out so that it is substantially transverse to the longitudinal axis of the combine body  12 . A truck or grain cart  100  ( FIG. 3 ) is then positioned to receive the grain from the unloader tube  24  in order to unload the onboard storage bin  22 . When the unloader tube  24  is not being used, the horizontal section  30  is rotated back into the storage position so that it is generally parallel to the longitudinal axis of the combine body  12 . 
       FIG. 4  illustrates a preferred embodiment of the unloader extension  32  that is pivotably and rotatably connected to the unloader tube  24 . The extension  32  is generally configured with three sides, a bottom portion  34 , and two side portions  36  and  38 . Preferably, the extension  32  is configured with a bottom portion  34  that is a substantially horizontal planar surface  34 . The extension  34  includes an inlet end  40  for receiving a flow of crop material from a discharge end  44  of the unloader tube  24  and an outlet end  42  for discharging the crop material from the extension  32 . The planar surface  34  connects the inlet end  40  and outlet end  42 . Extension  32  generally functions as chute for discharging crop material feed from the unloader tube  24 . The extension  32  can be configured with a length L that is sufficient for its intended use. For example, the length L can range from one feet to over twenty five (25) feet. The extension  32  can be formed from any rigid material suitable for its intended use, such as metal (e.g., stainless steel), plastics, composites, or the like. 
     The extension  32  is operatively connected to the discharge end  44  of the unloader tube  24 . Referring to  FIG. 5 , the unloader tube  24  is generally configured with a tubular housing  42  having an interior passageway  43  and a discharge end  44 . The tubular housing  42  houses an auger  46  for conveying the crop material through the unloader tube  24 . The unloader tube  24  is configured to extend generally horizontally from the combine  10 . 
     The discharge end  44  is generally configured with a substantially planar and circular discharge opening  48 . The discharge opening  48  can be configured with any orientation relative to the unloader tube  24 , but is preferably configured with a downwardly facing planar opening  48  orientation, as shown in  FIG. 5 . That is, the discharge end  44  is preferably configured with about a 90 degree elbow  50 , such that the discharge opening  48  is facing substantially downwardly. 
     Referring to  FIGS. 6A ,  6 B and  7  the extension  32  is connected to the unloader tube  24  by a drive mechanism  52  that positions the extension  32  in a plurality of positions, such as a discharge position for unloading the grain and a closed position to close off and seal the discharge end  44  of the unloader tube  24 . The drive mechanism  52  is operatively connected to the extension  32  to selectively position the extension  32  in at least a discharge position ( FIG. 7 ) and a close position ( FIG. 8 ). The drive mechanism  52  can include a pivot mechanism  60  that is connected to a power supply  56 , such as the combine&#39;s general power supply (i.e., battery or alternator), for powering the pivot mechanism  60 . The drive mechanism  52  is preferably a remotely controlled drive mechanism  52  that can be controlled by a user in the operator&#39;s station  16  of the combine  10 . The drive mechanism  52  is also operatively connected to a motor  62  for driving rotation of the drive mechanism  52 . 
     The drive mechanism  52  ( FIGS. 6A and 6B ) includes a turret  58  and at least one pivot mechanism  60 . The drive mechanism  52  ( FIG. 6A ) via turret  58  rotates about a substantially vertical central axis B ( FIG. 5 ) of the discharge end  44  so as to provide rotation of the extension  32 . The drive mechanism  52  is also configured to pivot via pivot mechanism  60  about central axis B ( FIG. 5 ). The turret  58  is configured to pivot about a pivot joint  59  ( FIG. 13 ) so as to rotate about axis B. The turret  58  can also include a motor  62  or actuator for providing rotational movement and securing the extension  32  in a fixed position. The pivot mechanism  60  provides for pivotal movement of the extension  32  relative to axis B i.e., the axis of rotation of turret  58 . The pivot mechanism  60  can be any an electro-mechanical actuator, a linear actuator, hydraulic cylinder, or the like. The turret  58  and pivot mechanism  60  can also be configured as manually operated mechanical mechanisms. 
     The pivot mechanism  60  can be attached to one of the lateral sides  36  or  38  of the extension  32 , such that the extension  32  can be raised or lowered relative to its pivot end, as further described below. The pivot mechanism  60  can optionally be configured with two pivot mechanisms (only one shown in  FIG. 6B ) for attachment with each of the lateral sides  36 ,  38 . 
     As shown in  FIG. 7 , the extension  32  is pivotably connected to the unloader tube  24  about its inlet end  40  via turret  58 . Alternatively, the extension  32  can be pivotably connected to the unloader  24  about diametrically opposite sides of the turret  58 , as shown in  FIG. 7A . The extension  32  can be pivotally attached by a nut and bolt configuration  64 ,  64 ′.  FIGS. 7 and 7A  illustrate the extension  32  in the discharge position so as to allow for the flow of crop material from the discharge end  44  of the unloader  24  to the outlet end  42  of the extension  32 .  FIG. 8  illustrates the extension  32  in the closed position. In addition to the benefits further described below, the drive mechanism  52  also allows for the extension  32  to be folded substantially parallel to the unloader tube  24  when in the closed position, such that the unloading system does not extend further out or rearward than on conventional combines. 
     As shown in  FIG. 8 , the discharge end  44  is correspondingly configured with the extension  32  to prevent crop material from discharging from the unloader tube  24  when the extension  32  is in the closed position. That is, the extension  32  includes a surface, such as the bottom portion  34 , that is configured to sealingly engage the discharge opening  48  of the unloader tube  24  when in the closed position. This advantageously prevents any residual crop material remaining in the unloader tube  24 , after the unloading operation has ceased, from dribbling or falling out while the combine  10  is thereafter used for further harvesting. 
     The extension  32  can alternatively be configured with various configurations, such as a half pipe configuration  40 ′ ( FIG. 9 ), an open trapezoidal configuration  40 ″ ( FIG. 10 ) and the like. 
     In yet another embodiment, the extension  32  can be configured as a powered extension  132  (see  FIG. 11 ). The powered extension  132  can be configured with a powered drive conveyor  134  to further propel the grain during unloading into the grain cart  100 . The conveyor  134  can be a belt conveyor  134 , a screw auger  134 ′ ( FIG. 12 ), or the like. Preferably, the conveyor  134  is a belt conveyor  134  that includes an endless belt  136  that travels around a pair of rollers  138 ,  140  at opposite ends of the powered extension  132 . The powered extension  132  can be driven by a motor  144  operatively connected to the rollers  138 ,  140  for driving the belt conveyor  134  ( FIG. 11 ) or a motor  144 ′ operatively connected to the screw auger  134 ′ ( FIG. 12 ). The motor  144 ,  144 ′ in turn can be connected to any power source, such an electrical battery or engine alternator (not shown) located on the combine  10  and remotely controlled by the operator. 
     In operation, the unloader tube  24  is moved from its initial storage or closed position, as shown in  FIG. 2  to its unloading or discharging position, as shown in  FIG. 3 . That is, the unloader tube  24  is moved substantially outwardly to the combine&#39;s lateral side for unloading operations. For use with a grain cart  100  for example, the length of the horizontal section  30  of the unloader tube  24  and extension  32  extends from the unloader tube&#39;s infeed section  26  to the center of the grain cart  100 . This extension length of the unloader tube  24  and extension  32  includes one-half the width of the header  18 , the safety gap between the end  106  of the header  18  and the tractor&#39;s tires  104 , and half of the width of the tractor  102 . In sum, the unloader tube  24  and extension  32  extend beyond the ends of the header  18 . 
     Referring back to  FIGS. 6A and 6B , the drive mechanism  52  is activated to move the extension  32  from the closed/storage position, to the discharge position, as shown in  FIGS. 3 and 7 . The turret  58  rotates the extension  32  to extend further outwardly such that the outlet end  42  substantially reaches the grain cart  100 . The pivot mechanism  60  pivots the extension  32  to allow the passage of crop material to flow out of the unloader tube  24  and thereafter pass through the extension  32 . Preferably, the extension  32  is pivoted and angled downwardly from the discharge end  44  such that the flow of crop material travels downhill. 
     If the extension is a powered extension  132  ( FIG. 11 ), then the powered extension  132  can be turned on to further facilitate the flow of crop material through the powered extension  132 . In operation with the powered extension  132 , in addition to being angled downwards, the powered extension  132  can also be angled upwards to project the crop material about an arc into the grain cart  100 . When angled upwards the turret  58  is configured to lower the powered extension  132  sufficiently to allow for clearance of the crop material between the discharge end  142  and the powered extension  132 . Once the combine&#39;s onboard storage bin  22  has been emptied or the grain cart  100  has been filled, the previously explained steps can be reversed to place the powered extension  132  in the closed position to prevent dribbling waste of the grain and the unloader tube  24  back in the storage position. 
     The unloader tube  24  can also be used to fill a grain cart  100  that is towed behind the combine  10  instead of an adjacent truck or grain cart  100 . In this alternative, the extension  32  would be rotated rearward so that it is basically coaxial with the unloader tube  24 . However, the fully extended unloader tube  24  and extension  32  would not be rotated out into the previously described laterally extending position. Instead, the unloader tube  24  and extension  32  would be left to extend rearwardly beyond the rear end of the combine  10  so that the extension  32  can access a grain cart  100  being towed behind the combine  10 . 
     It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.