Abstract:
A crop merging machine includes a trailer frame, a drawbar assembly coupled to an axle, and a header assembly including a frame and a wheel. The merging machine further includes a pick-up assembly coupled to the header frame and a cross-conveyor assembly coupled to the header frame adjacent to the pick-up assembly. The pick-up and cross-conveyor assemblies are configured to cooperate to lift crop materials off the field surface and move the crop materials laterally to discharge onto the field surface to form a windrow. The merging machine includes a suspension assembly disposed between the trailer frame and header assembly, the suspension assembly being coupled to the header assembly and trailer frame and configured to allow the header assembly to pivot, relative to the trailer frame, about a first axis of rotation and to pivot about a second, distinct axis of rotation to follow a contour of the field surface.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    This invention relates to a windrow merger. In one embodiment, the invention relates to a merger for a single windrow. In one example, the invention relates to a ground contour following 3-D floatation header for enhanced collection of crop in the field. 
         [0003]    2. Description of the Related Art 
         [0004]    Windrow mergers are commonly used in the agricultural field for combining windrows or rows of crops. In some applications, the windrow merger is pulled along a direction of travel in the field by a towing vehicle such as a tractor or other motorized vehicle. The towing vehicle will typically make several passes with the windrow merger, combining windrows with each pass. Later, a forage harvester or baler harvests the combined windrows. By combining the windrows, the merger makes each pass with a forage harvester or baler more productive. The merger also operates to turn over the windrows, enhancing drying and conditioning of crops. Use of a merger also reduces fuel costs, man-hours, and wear and tear on the harvester or baler equipment. 
         [0005]    Conventional single windrow mergers may have certain drawbacks. For example, conventional mergers sometimes do not follow the ground contour very well and therefore wastefully leave crop in the field. Some conventional mergers have gage wheels on each side of a header that keeps the head at a certain distance from the ground, allowing the header to pivot about an axis that is perpendicular to the direction of travel. Allowing this rotation typically provides the ability to raise and lower the header. As the gage wheels encounter obstructions in a field position, the gage wheels raise the full header up and over the obstruction and back down on to the level ground. As the gage wheel rolls over the obstruction and the full head is raised, even the end of the header that does not encounter the obstruction. In other words, the right and left ends of the header travel in the vertical direction together, and crop in the windrow may be missed and not gathered into the newly formed windrow when one of the gage wheels encounters a small obstruction. Any crop left in the field amounts to lost productivity. Such losses include reduced overall yields of the field, delay of re-growth in these areas, and reduced cleanliness of the field. 
       SUMMARY OF THE INVENTION 
       [0006]    Accordingly, one aspect of the present invention provides a header with 3-D (pivotable about two distinct axes) floatation on a windrow merger, for example, a single windrow merger, that better follows the contour of the ground while in a field position so that crop is gathered in a relatively efficient manner. 
         [0007]    One example of an agricultural machine according to the invention includes at least one drawbar, a trailer frame, a lift arm, and a header that picks up crop. The header includes a unit to pick up material from the ground and move the material onto a cross conveyor. The header typically includes a float mechanism (suspension assembly) to allow movement about two axes (A) and (B) during field use. For example, the header is typically configured to pivot about an axis (A) perpendicular (as viewed from above) to the direction of travel. The header also pivots about an axis (B) parallel (as viewed from above) to the direction of travel. The unit typically includes a leveling, locking, or biasing mechanism to keep the head in a level position during transport outside of the field, for example, on public roads. 
         [0008]    One example of the invention provides a crop processing unit suspension assembly. The suspension assembly includes a frame assembly, at least one linear actuator, such as a fluid powered cylinder, including first and second coupling portions, configured to change a distance between the first and second coupling portions. In the case of a fluid powered cylinder, the change in length is based on a change in fluid pressure within the at least one fluid powered cylinder. In the case of an electrical linear actuator, the change in length is based on an electrical signal. A first pivot device is disposed on the frame assembly and configured to rotate about a first axis. For example, the first pivot device may be a bushing, ball bearing, roller bearing etc. The suspension includes a second pivot device disposed on the frame assembly and configured to rotate about a second axis perpendicular to the first axis. Similar pivot devices may be used for both the first and second pivot devices, but the axes of rotation will be as defined above. The suspension includes at least one rotatable finger, preferably two fingers, coupled to the frame assembly and the at least one fluid powered cylinder via a rotatable linkage. The at least one rotatable finger is configured to rotate about a third axis relative to the frame assembly via a third pivot device in response to a change in distance between the first and second coupling portions. 
         [0009]    One aspect of the invention provides an agricultural crop merging machine configured to move in a direction of travel in a field. The merging machine includes a trailer frame including at least one axle, at least one trailer wheel coupled to the at least one axle and configured to rotate about a main axis of rotation and to roll along a field surface, and a drawbar assembly coupled to the at least one axle. The merging machine includes a header assembly including a header frame, at least one header ground-engaging unit coupled to the header frame, a pick-up assembly coupled to the header frame, and a cross-conveyor assembly coupled to the header frame adjacent to the pick-up assembly, the pick-up and cross-conveyor assemblies being configured to cooperate to lift crop materials off the field surface and move the crop materials laterally to discharge onto the field surface to form a windrow. The merger machine also includes a suspension assembly disposed between the trailer frame and header assembly, the suspension assembly being coupled to the header assembly and trailer frame and configured to allow the header assembly to pivot, relative to the trailer frame, about a first axis of rotation perpendicular to the main axis of rotation of the at least one wheel and to pivot about a second axis of rotation parallel to the main axis of rotation of the at least one wheel to follow a contour of the field surface. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    These and other advantages of the invention will become more apparent and more readily appreciated from the following detailed description of the exemplary embodiments of the invention taken in conjunction with the accompanying drawings where: 
           [0011]      FIG. 1  is a front-left elevated perspective view of one non-limiting example of the present invention; 
           [0012]      FIG. 2  is a front-right elevated perspective view of the example shown in  FIG. 1 ; 
           [0013]      FIG. 3  is a rear-right elevated perspective view of the example shown in  FIG. 1 ; 
           [0014]      FIG. 4  is a front view of the example shown in  FIG. 1 ; 
           [0015]      FIG. 5  is a rear view of the example shown in  FIG. 1 ; 
           [0016]      FIG. 6  is a top view of the example shown in  FIG. 1 ; 
           [0017]      FIG. 7  is a bottom view of the example shown in  FIG. 1 ; 
           [0018]      FIG. 8  is a bottom-left perspective view of the example shown in  FIG. 1  in a work state; 
           [0019]      FIG. 9   a  is a similar view to the one shown in  FIG. 8 , but with a section of detail identified; 
           [0020]      FIG. 9   b  is a detail view identified in  FIG. 9   a;    
           [0021]      FIG. 10  is a bottom-left perspective view of the example shown in  FIG. 1  in a transport state; 
           [0022]      FIG. 11  a is a similar view to the one shown in  FIG. 10 , but with a section of detail identified; 
           [0023]      FIG. 11   b  is a detail view identified in  FIG. 11   a;    
           [0024]      FIG. 12  is an exploded view of a header, floating suspension, and axle according to one example of the present invention; 
           [0025]      FIG. 13   a  is a similar view to the one shown in  FIG. 12 , but with a section of detail identified; 
           [0026]      FIG. 13   b  is a detail view identified in  FIG. 13   a;    
           [0027]      FIG. 14  is a left-side view of the example depicted in  FIG. 1  in the work state; 
           [0028]      FIG. 15  is a view of the example depicted in  FIG. 14  during transition from the work state to the transport state, shown from the left side; 
           [0029]      FIG. 16  is view of the example shown in  FIG. 15  after completion of the transition from the work state to the transport state; 
           [0030]      FIG. 17  is a left-side view of another embodiment of the invention; and 
           [0031]      FIG. 18  is a left-side view of yet another embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0032]    With reference to  FIGS. 1-3 , one example of a merger  1  according to the invention is shown in perspective view. The merger  1  includes at least one ground-engaging trailer wheel  10 , preferably at least two ground-engaging trailer wheels  10 , coupled to a main axle  70 , which is a component included in a trailer frame  80 . A drawbar assembly  30  is also coupled to the trailer frame  80  and is configured to removably connect with a pulling vehicle such as a tractor or truck via a conventional connection or coupling such as a clevis  35 , for example. The vehicle typically pulls the merger  1  in a direction D shown by arrows in  FIGS. 1-3  during a normal operation of merging crop material. The example of the merger  1  depicted in FIGS.  1 - 3  includes a pair of header ground-engaging units, header wheels  40  in this example, which are configured to roll in the direction D. 
         [0033]    The merger  1  shown in  FIGS. 1-3  includes a header assembly  60  supported by a header frame  65  and the header wheels  40  (header ground-engaging units). The header assembly  60  includes a pick-up assembly  50  that picks up crop material in the field when the merger  1  is pulled in the direction D. The pick-up assembly  50  can be any of a variety of pick-up devices common to merger machines such as, for example, a tined wheel or rake. The pick-up assembly  50  deposits the crop material on the cross-conveyor  20 , which may comprise a conveyor belt, chain, or auger type device, and the cross-conveyor  20  moves the crop material either to the left or to the right with respect to the direction D, thus forming a windrow or composite windrow (combination of more than one windrow). In other words, the pick-up assembly  50  may be used to pick up material that has been cut and left in place, for example, in a cut swath, or the pick-up assembly  50  may be used to merge two or more pre-existing windrows. Typically, the merger  1  is coupled to a power-take-off (PTO) such as those frequently provided with standard tractors in order to apply power to the pick-up assembly  50  and/or cross-conveyor  20  in a conventional manner common to many existing agricultural machines. Alternatively or additionally, the pick-up assembly  50  and/or cross-conveyor  20  may be operated with one or more motors  52  (see  FIGS. 6 and 7 ), which can be either hydraulic or electric as is conventional in the art. For example, the motor  52  can operate a pulley and belt arrangement that rotates the cross-conveyor  20  in response to a hydraulic or electrical signal sent from the pulling vehicle. Similarly, the pick-up assembly  50  may be controlled based on a hydraulic or electrical signal from the pulling vehicle. 
         [0034]    The header assembly  60  typically includes a header frame  65  coupled to at least one header wheel  40 . The header wheels  40  are typically arranged to roll in the direction D, but may also be casters configured to pivot in order to change directions in order to follow the pulling vehicle. 
         [0035]    The header assembly  60  is configured to pivot about first and second pivots centered on first and second distinct axes (see  FIGS. 6 ,  7 ,  13   b,  and  15 ). The system that allows pivoting is the suspension assembly  100 , shown in detail in  FIGS. 9   b,    11   b,  and  13   b.  A first of the axes, axis B, about which the header assembly  60  pivots is parallel, as viewed from above the merger  1 , to the direction of travel D. A second of the axes about which the header assembly  60  pivots, axis A, is perpendicular, as viewed from above the merger  1 , to the direction of travel D. The ability to pivot about two different axes allows the header assembly  60  to follow the contour of the ground better and therefore, to pick up a relatively high percentage of the material lying on the ground while still being able to accommodate hilly, rocky, or pitted terrain. As shown in  FIGS. 13   b  and  15 , the axis B is not necessarily parallel to the direction of travel D in all views. Rather, the axis B may be parallel to the direction D only when viewed directly from the top or bottom and may be at a non-zero angle with respect to the direction D when viewed from the left or right side of the merger  1 . 
         [0036]    The ability of the header assembly  60  to pivot about the axis B allows the header assembly  60  to accommodate bumps or holes encountered by either the side of the header assembly  60 . For example, if the merger  1  is pulled over a rock or small hill that impacts a first of the header wheels  40 , but that does not impact second of the header wheels  40 , the header assembly  60  will be able to rotate about the axis B to allow the second of the header wheels  40  to remain in contact with the ground, and therefore, the header assembly  60  will be able to continue to pick up crop material that otherwise would have been missed. In one example, each end of the header assembly  60  is able to travel approximately (±10%) ten inches upward relative to the normal level assumed during travel over perfectly level ground and six inches downward relative to this level. Additionally, if the header assembly  60  encounters a long ridge, furrow, or trough, both ends of the header assembly  60  are able to move upward or downward in unison by pivoting about the second of the pivots (around axis A). Thus, the header assembly  60  is able to “float” with a 3-dimensional (3D) effect in order to accommodate variances in the shape of the ground across which the header assembly  60  travels. 
         [0037]    In one embodiment, the drawbar assembly  30  is configured to pivot along arc P about a pivot point centered on an axis C (shown in  FIGS. 3 and 6 ) to switch between a narrow state and wide state. In one example, the drawbar assembly  30  pivots in response to a change in length of a linear actuator such as a pneumatic or hydraulic cylinder  31  (shown in  FIG. 6 ). The cylinder  31  may be replaced or supplemented by an electric linear actuator. The transport position is typically the narrowest arrangement of the merger  1  with respect to the direction D. This arrangement facilitates transport of the merger  1  on public roads. In other embodiments, the drawbar assembly  30  is rigidly fixed to the trailer frame  80  and cannot rotate relative to the main axle  70  of the trailer frame  80 . This arrangement simplifies the construction of the merger  1  and may reduce the number of pneumatic or hydraulic outputs the vehicle pulling the merger  1  must provide. 
         [0038]      FIG. 4  shows a front view of the merger  1 . As shown in  FIG. 4 , the drawbar assembly  30  is angled inward such that the clevis  35  is disposed between the two header wheel  40  as viewed along the direction D. In this narrow state, the vehicle travels directly in front of at least a portion of the pick-up assembly  50  and therefore, resides in the work path of the merger  1 . This state can be used for picking up crop material or for transport. 
         [0039]    In embodiments in which the drawbar assembly  30  can pivot with respect to the main axle  70  of the trailer frame  80 , the drawbar assembly  30  may be angled either inward or outward along arc P such that the clevis  35  is disposed between or outside of, respectively, the two header wheels  40 . When the drawbar assembly  30  is angled such that the clevis  35  is disposed outward of the two header wheels  40 , the vehicle used to pull the merger  1  may be disposed outside of the work path of the pick-up assembly  50  of the merger  1 . Therefore, the pick-up assembly  50  may be more effective than when the drawbar assembly  30  is angled inward inasmuch as the crop material intended to be picked up by the pick-up assembly  50  will typically be left untrampled by the wheels of the pulling vehicle. Additionally, the driver of the vehicle may be better able to see the work path directly in front of the merger  1  when the drawbar assembly  30  is in the outer position. 
         [0040]      FIG. 5  depicts the merger  1  from behind and identifies the location of the suspension assembly  100 . As shown in  FIG. 5 , the header wheels  40  are disposed in a downward position, and thus, the merger  1  is in a work state and not a transport state. 
         [0041]      FIGS. 6-7  depict the merger  1  from the top and bottom, respectively, and identify the first pivot axis B and second pivot axis A about which the header assembly  60  is configured to pivot. 
         [0042]      FIG. 8  depicts the merger  1  from a bottom-left perspective in the work state. In the work state, the header assembly  60  is not raised, and the suspension assembly  100  is not locked in place via the rotatable finger  120  (locking finger). In other words, in the work state, the header ground-engaging unit(s) are in contact with the field surface, and the header assembly  60  pivots about the axis B in response to vertical movement of the header ground-engaging unit(s) due to bumps, rocks, and holes, etc. 
         [0043]      FIG. 9   a  provides the same view of the merger  1  as  FIG. 8 , but with an area of detail identified, which is provided in  FIG. 9   b.  A suspension assembly  100  is depicted in  FIG. 9   b  and includes a linear actuator  110  coupled to the trailer frame  80  via a second cylinder pivot  116  disposed within a slot  118  at one end. The linear actuator may be an electric linear actuator or a fluid powered cylinder, such as a pneumatic or hydraulic cylinder. Typically, the linear actuator  110  is controlled via a signal, either fluid or electric, from the vehicle pulling the merger  1 . The linear actuator  110  is coupled to the header assembly  60  via a first actuator pivot  115  and linkage  112  at an opposite end. The linkage  112  is connected to a pair of rotatable fingers  120  via a finger pivot  122 . The finger pivot  122  is configured to rotate about an axis parallel to the axis A in response to a change in length to the linear actuator  110 . As the finger pivot  122  rotates clockwise in  FIG. 9   b,  the rotatable finger  120  rotates and impacts or abuts the abutting surface  130 , which is rigidly attached to the header assembly  60 . By abutting the abutting surface  130 , the rotatable finger  120  lock the header frame  65  in place relative to the axis B. Additionally, the linear actuator  110  will continue to extend and cause the entire header assembly  60  to rotate about the axis A until the header assembly  60  reaches a maximum amount of possible travel, which is defined by another abutting surface, by a limit on the stroke of the linear actuator  110 , or by a mechanical linkage. At this point, the header assembly  60  is locked in place relative to the axis A in addition to being locked in place relative to the axis B. Thus, by extending the linear actuator  110 , the linear actuator  110  applies pressure to the header frame  65 , locks the header assembly  60  in place relative to the axis B, then locks the header assembly  60  in place relative to the axis A. Additionally, the extension of the linear actuator  110  lifts the header assembly  60 . One benefit of the above-noted arrangement is that a single electric, hydraulic, or pneumatic signal can cause the linear actuator  110  to move the header assembly  60  back and forth from a transport state to a working state in addition to providing a locking mechanism for the header assembly  60  in the transport state. During the working state, the rotatable fingers  120  are disengaged from the abutting surface  130  and allow the header assembly  60  to rotate about the axis B and the header assembly is also free to rotate about the axis A. 
         [0044]    As shown in  FIGS. 11   b - 13   b,  the suspension assembly  100  is configured to couple to the header assembly  60  via first pivot formed by a main longitudinal pivot  140 , which defines the axis B. The main longitudinal pivot  140  may comprise a fixed shaft configured to rotate within a bearing. In the depicted example, the main longitudinal pivot  140  comprises two shafts, each disposed within a bracket  145 . The bearing may be disposed within a pillow block attached to the header assembly  60  via the bracket  145 . Alternatively, the pillow block and bearing may be disposed on the suspension assembly  100  while the shaft is disposed on the header assembly via the bracket  145 . In another example, the longitudinal pivot may comprise a ball or universal joint. Thus, the main longitudinal pivot  140  supports the header assembly  60  from the rear while the header wheels  40  support the header assembly  60  from the front. The main longitudinal pivot  140  is mechanically connected to the trailer frame  80  via a pivot frame  105 . As shown in  FIG. 13   b,  the pivot frame  105  also supports the finger pivot  122 , which is configured to pivot relative to the pivot frame  105  in response to a change in length of the linear actuator  110 . At the rear of the pivot frame  105  are disposed a pair of stubs  150 . The stubs  150  are configured to couple with the ears  160  via a long bolt, rod, or shaft (not shown). Once the stubs  150  are coupled to the ears  160 , the entire suspension assembly  100  can rotate about the axis A when the header assembly  60  is in the work state. It should be noted that the particular stub and ear combination described in  FIG. 13   b  may be replaced with other types of pivotable connections. For example, the stubs may be replaced with a shaft, bushing, ball or other mechanical connection that provides a similar rotation between the pivot frame  105  and the trailer frame  80 . 
         [0045]    As discussed previously, when the linear actuator  110  extends, the linkage  112  rotates the pair of rotatable fingers  120  to abut the abutting surface  130  and prevent the header assembly  60  from rotating about the axis B. It should be noted that the linkage  112  is coupled to the linear actuator  110 , but also rotates relative to the linear actuator  110  as the linear actuator  110  changes length. As the linear actuator  110  further extends, the header assembly  60  is lifted and eventually locks with respect to the axis A. Thus, the header assembly is placed in the transport state. Accordingly, the two header wheels  40  provide two points of support for the header assembly  60 , and the suspension assembly  100  provides a third point of support. In one example, only the three points of contact defined by the two header wheels  40  and the suspension assembly  100  are used to support the header assembly  60 . Because the suspension assembly  100 , the third contact point, allows the header assembly  60  to pivot about two distinct axes A and B, the suspension assembly  100  allows the header assembly  60  to accommodate for vertical movement of each of the header wheel  40  and thus provides a 3D floating effect. In response to a change in length of the linear actuator  110 , the header assembly  60  is eventually restricted in rotational movement with respect to the axes A and B and is ultimately moved from a work state to a transport state in which the header wheels  40  are not in contact with the ground. 
         [0046]      FIG. 14  depicts the merger  1  in a work state. In the work state, the rotatable fingers  120  are in a counterclockwise rotated state as shown in  FIG. 14 .  FIG. 15  depicts the beginning of the transition between the merger  1  from a work state to a transport state. The rotatable fingers  120  have rotated clockwise. In other words, the linear actuator  110  has extended sufficiently to cause the rotatable fingers  120  to abut the abutting surface  130 .  FIG. 16  shows the header assembly  60  after completion of the transition from the work state to the transport state. Thus, the header wheels  40  are lifted from the ground, and the header assembly  60  is locked in place by the rotatable fingers  120 , which are fully engaged. 
         [0047]      FIG. 17  depicts the header assembly  60  with a variation of the header ground-engaging unit. In this embodiment, the header wheels  40  are replaced with skid-shoe  40   a.  In some applications, it is preferable to place the header ground-engaging units below the cross-conveyor  20  and/or the pick-up unit  50 . This is so because this location allows the pick-up unit  50  to pick up crop material before the ground-engaging unit reaches the location of the crop material while the merger  1  is pulled in the direction D. In other words, placement of the ground engaging units below the pick-up unit  50  reduces trampling of the crop material. When placed below the cross-conveyor  20  and/or the pick-up unit  50 , it is preferable that the ground engaging units are short (vertically) so as to allow the pick-up unit  50  to stay close to the ground and pick up material. Accordingly, in some cases, skis or rollers will function better than header wheels  40  as the header ground-engaging units. As the skid-shoe  40   a  is typically not used while the merger  1  is in the transport state, the skid-shoe  40   a  will contact the ground only when the merger  1  is in the work state, and therefore, will usually be used on soil or grass, not pavement. 
         [0048]      FIG. 18  depicts the header assembly  60  with another variation of the header ground-engaging unit. In this embodiment, the header wheels  40  are replaced with at least one roller  40   b  functioning as the ground engaging unit. The roller  40   b  is typically wider relative to its height than is the header wheel  40 . One example of the roller  40   b  is a broad cylinder coated with a layer of rubber. In the case of both the skid-shoe  40   a  and the roller  40   b,  there is typically an improvement in resistance to becoming clogged with mud in the field in comparison to the header wheel  40 , which is typically a tire. Additionally, the roller  40   b  typically provides similar dimensional benefits to those discussed above regarding the skid-shoe  40   a.    
         [0049]    Regarding the pivot points described above, it should be noted that the pivot points are typically either provided with shaft and bushing arrangements or with shaft and ball-bearing mechanisms. However, other configurations of the bushings are also available, such as, for example, roller-bearing and shaft arrangements. 
         [0050]    Although only certain embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiment without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention.