Abstract:
The present invention relates to an improved corn head with a reel device that prevents debris build-up in front of a feederhouse. The reel device includes support arms, a crossbar between the support arms, and a number of radial bars extending from the crossbar. The reel device has a number of adjustments to optimally position the radial bars for removing debris. The reel device rotates to reduce debris build-up in the feederhouse during harvesting. The reel device is moveable between operative and inoperative positions from the combine cab using hydraulics.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application claims priority under 35 U.S.C. § 119 of Provisional Application Ser. No. 60/654,132 filed Feb. 18, 2005, which application is hereby incorporated by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     The present invention relates generally to corn heads for use with combines and specifically to an improved corn head using a reel device to reduce debris build-up.  
         [0003]     Combines that harvest corn are provided with several snouts for directing rows of corn stalks to ear separation chambers, into an auger, through a feederhouse and into a combine&#39;s inner chambers which separate the corn kernels from the corn cob.  
         [0004]     Combine operators routinely encounter difficulties when harvesting corn especially with debris building up in front of a feederhouse of the combine. Previously, combines that harvested only 4 or 8 rows encountered this debris build-up only occasionally because the corn yields experienced were low, the varieties of hybrid corn dropped their leaves sooner, thicker plant spacing resulting in more corn fodder to process, the speed of the combine moving through the field was slow, and not as many rows of corn were being harvested.  
         [0005]     Advances in plant science have caused an increase in the amount of debris experienced by the combine operator. A modern combine experiences these problems much more frequently because today&#39;s corn varieties retain their leaves longer, utilizing corn planted more densely in the rows and more closely together, extremely high corn yields and operating the combine at much faster speeds. Much of the increase in corn yields has come from genetic improvements to the corn plant through biotechnology or genetic modifications. This yield increase has brought with it larger, healthier corn plants that produce larger amounts of debris that may potentially break off the stalk and have to be ingested by the combine. Still further creating problems, the typical size of a feederhouse has remained unchanged relative to the horsepower and threshing capacity of today&#39;s modem combines. Today&#39;s machines have in excess of 400 hp engines and can process more than 4000 bushels of corn per hour versus machines of 10 years ago that had 200 horsepower and could harvest 2000 bushels of corn per hour. While it would make sense to double the size of the feederhouse opening on these new machines in this process, that has not been the case. Instead the feederhouse opening has remained virtually unchanged.  
         [0006]     Further complicating this problem is the plastic material from which much of the “snouts” or row dividers are made. This plastic material when constantly rubbed by plant material may develop a static charge which potentially causes the debris to adhere to the plastic material, to the steel on the backboard of the head, and to other plant material. Relative humidity in the fall typically drops to 20% or less in the corn belt which aids the buildup of this static charge.  
         [0007]     Severe debris buildup results from dry harvest conditions. This debris is made up of corn stalks, leaves, and “fluff” which is fine particles of ground up stalks and leaves. The debris is not a problem once it moves past the feederhouse. Debris is processed by the combine into mulch and returned to the field to decay through the winter months. However, getting the debris into the feederhouse may be a problem because the debris and fluff together may form an obstruction which hinders and/or blocks corn from entering into a combine for processing. In order to prevent this obstruction, the operator must slow down or stop, thereby letting the feederhouse remove this debris. If the operator cannot prevent the debris from forming an obstruction, the operator must climb out of the combine cab and try to remove the debris by hand or using a tool. Any type of manual removal of this debris is hazardous to the operator and may cause injury or death to the operator. For example, the operator often must travel in between the snouts and reach up into the debris pile with a broom handle to clear the debris. Should the corn head be left on, the operator has risk of serious injury.  
         [0008]     Therefore, the debris problem creates two issues. One, a time issue in which the operator is losing valuable time because they are removing debris or slowing down and stopping to have the machine removes the debris. Two, a safety issue in that the operator is exposed to risk of injury by trying to manually unclog an obstruction of debris in the feederhouse.  
         [0009]     Therefore, an objective of the present invention is to overcome the problem of debris build-up in front of the feederhouse.  
         [0010]     A further objective of the present invention is to provide an adjustable device which optimizes the removal of debris in front of the feederhouse.  
         [0011]     Still another objective of the present invention is the provision of rotating bars which can be actuated from the cab of the combine to unclog debris from the feederhouse.  
         [0012]     Yet another objective of the present invention is the provision of a frame with rotatable bars which is moveable between operative and inoperative positions.  
         [0013]     Another objective of the present invention is the provision of a debris clearing device which can be retrofit to various combines.  
         [0014]     A further objective of the present invention is the provision of a device that is economical to manufacture, simple to install, and effective and durable in use.  
         [0015]     These and other objectives will become apparent from the following specification and drawings.  
       SUMMARY OF THE INVENTION  
       [0016]     The foregoing objectives may be obtained using an improved corn head with a reel device that reduces debris build-up. The improved corn head includes a frame defining a feederhouse and a channel leading to the feederhouse, an auger within the channel for directing material toward the feederhouse, and a plurality of crop dividing snouts extending forward from the frame. The reel device is attached to the frame and extends forward from the frame. The reel device has first and second support arms attached to the frame outside the feederhouse and extending forward from the frame, a crossbar rotatably attached in the first and second support arms, radial bars attached to the crossbar positioned over the snouts and on top of the auger, and a crossbar drive to rotate the crossbar and radial bars.  
         [0017]     A feature of the present invention includes a 10°-15° bend in the radial bars 5 inches from the attachment point of the radial bars to the cross bar.  
         [0018]     A further feature of the present invention is a set of two radial bars for each corn head snout that are separately spaced approximately 180° from one another.  
         [0019]     A further feature of the present invention is offsetting adjacent sets of radial bars by 90°.  
         [0020]     A further feature of the present invention is a pivotal joint on each of the first and second support arms that permit the reel device to move between a raised position and a lowered position. This pivotal joint has multiple holes where a pin is inserted to allow adjustment of the down position.  
         [0021]     A further feature of the present invention are adjustable sections which permit changes in the position of the crossbar relative to the auger, adjustments to the length of the crossbar to permit changes in the position of the support arms relative to the feederhouse, and adjustments to the reel positions to allow changes in the position of the radial bars over the snouts.  
         [0022]     A further feature of the present invention is to provide radial bars over at least five snouts that define four crop rows especially those immediately in front of the feederhouse and adjacent the feederhouse. Corn heads configured to harvest 30 inch rows require one set of radial bars per row while 36 and 38 inch rows require 2 sets over the middle 3 snouts or hoods. Corn heads configured for 20 inch rows require one set of radial bars over the middle 7 hoods. The length of the axle or cross bar is the same for both 20″ and 30″ corn heads and longer for the 34″ and 36″ corn heads. Alternatively, the cross bar may have an adjustable length, through telescoping members or extension pieces.  
         [0023]     The foregoing objectives may also be achieved by a reel device that may be provided separately from the corn head for later attachment to the corn head. The reel device having support arms attached to the corn head frame, a crossbar rotatably attached between the support arms, radial bars having a first end attached to the crossbar with a 10°-15° bend 5 inches from the attachment point that is designed to move a great amount of debris towards the feederhouse with a minimal propensity to wrap crop debris around the crossbar.  
         [0024]     The foregoing objectives may also be achieved with a method of using an improved corn head with a reel device that includes the steps aligning the radial bars over the snouts, harvesting corn using the corn head when environmental conditions produce debris, and operating the reel device to reduce debris build-up.  
         [0025]     A further feature of the present invention includes the step of pivoting the reel device to an upper position when not required to remove debris.  
         [0026]     A further feature of the present invention is the step comprising adjusting the support bars to place the radial bars over the auger within the range of 1-2″ and preferably 1″ away from the auger flighting and 1-3″ and preferably 2″ away from the hood which is the cover separating each row gathering unit.  
         [0027]     A further feature is the provision of radial bars which are non-perpendicular to the axis of the cross bar so as to enhance debris clearance from the feederhouse. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0028]      FIG. 1  is a perspective view of the reel device of the present invention on a corn head of a combine.  
         [0029]      FIG. 2A  is a side elevation view of the improved corn head with the reel device of the present invention in a lowered, operative position.  
         [0030]      FIG. 2B  is a side elevation view of the improved corn head with the reel device in a raised, inoperative position.  
         [0031]      FIG. 3  is a front elevation view of the improved corn head with the reel device in a lowered position.  
         [0032]      FIG. 4  is a front view of an improved corn head with the reel device using radial bars having angled members at an outer end of the radial bars.  
         [0033]      FIG. 5  is an enlarged view of the crossbar drive for rotating the cross bar and radial bars and showing an alternative, straight bar embodiment.  
         [0034]      FIG. 6  is a view similar to  FIG. 3  showing another embodiment of the radial bars oriented at a non-perpendicular angle relative to the cross bar axis. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0035]     With reference to the figures and particularly to  FIG. 1 , the improved corn head is generally referred to by numeral  10 . The reel device  12  is an improvement to the corn head  10  of a combine  14  that prevents debris build-up in front of the feederhouse  18 .  
         [0036]     The corn head  10  has a frame  16  that provides a support structure for the reel  12 . The feederhouse  18  is defined in the frame  16  that provides an opening to move ears of corn and debris from the snouts  23  of the corn head into the internal workings of the combine. A channel  20  is provided on the frame  16  to receive harvested ears of corn and an auger  22  moves the material inwardly from the lateral sides of the corn head  10  to the feederhouse  18 . A hood  21  is the cover in front of the channel that separates each row unit. The frame  16 , feederhouse  18 , channel  20 , hood  21 , auger  22 , and snouts  23  are conventional.  
         [0037]     As ears of corn and debris move towards the feederhouse, the corn being heavier than the debris settles into the channel and moves into the feederhouse whereas the debris being lighter than the corn rises to the top of the channel. Under ideal operating conditions, the debris and corn cobs both are fed into the feederhouse simultaneously. Unfortunately, debris may continue to build-up in front of the feederhouse and on top of the hoods until it forms an obstruction and prevents corn from moving into the feederhouse. At this point, an operator would be required to remove the obstruction of debris from the feederhouse. However, with use of the reel device  12 , the debris does not form an obstruction. Instead, as the debris begins to accumulate in front of and on top of the cross auger  22 , it is moved rearward and into the feederhouse  18 .  
         [0038]     The reel device  12  has opposite support arms  24 . The support arms  24  are attached to the frame  16  in any convenient manner, such as a bracket or clamp  26 . The bracket or clamp  26  may utilize a threaded fastener, be welded to the frame, and/or utilize other attachment means. Differences in head manufacturer&#39;s frame designs are overcome by changing the design of the bracket or clamp  26 . For example, on certain combine models the bracket  26  may be bolted to the front side of the frame directly behind and above the cross auger. Different types of brackets  26  may be used on other corn heads.  
         [0039]     Extending between the support arms  24  is a crossbar  30 . The crossbar  30  is rotatably mounted between the support arms  24 . Radial bars  32  extend from the crossbar  30 . As illustrated, each set of two opposing radial bars  32  are spaced 180° apart on the crossbar  30 . These radial bars  32  that comprise a set of crossbars may be offset from one another by 90°. This offsetting provides interaction by the reel device  12  with a debris pile in 90° rotational increments.  
         [0040]     As seen in  FIGS. 2A and 2B , a pivot point  28  is provided on the support arms  24  that permit the movement of the reel device  12  between a raised inoperative position and a lowered operative position.  
         [0041]     The reel device  12  has a variety of different adjustments possible. Each of the support arms  24  is adjustable in length to permit the radial bars  32  to be moved close to or away from the auger  22 . As best seen in  FIG. 5 , the arms  24  include telescoping segments  24 A and  24 B with a plurality of holes  25 . A pin or bolt (not shown) extends through one of the holes to secure the segments  24 A and B for a selected length of the arm  24 .  
         [0042]     A pair of hinge plates  28  are welded or otherwise fixed to the outer end of the segment  24 B of the support arms  24 , as best seen in  FIG. 5 . Each hinge plate has a plurality of holes  29 , which provide numerous pin placements to allow proper positioning or placement of the outer ends of the segments  24 C of the arms  24  relative to the hoods  21  and the auger  22 . More particularly, a pin (not shown) extends through one of the holes  29 , and through the segment  24 C of the arm  24  to pivotally connect the segment  24 C to the hinge plates  28 . A plurality of holes  31  at the forward end of the plates are adapted to receive a pin (not shown) which extends beneath the segment  24 C of the arm  24  to further allow adjustment of the position of the outer end of the segment  24  relative to the hoods  21  and the auger  22 . A hole  31  in the plates  28  is adapted to receive a pin (not shown) to limit upward movement of the reel  12  when the reel is in the lowered, operative position. Another hole  35  on the upper portion of the plates  28  is adapted to receive a pin (not shown) so as to limit rearward movement of the arm segment  24 C when the reel  24  is in the raised, inoperative position. If desired, the arm segments  24 C can be maintained in a substantially vertical position when folded upwardly by a pair of pins received in holes  37  in the upper portion of the hinge plates  28 , with the pins being on opposite sides of the segment  24 C.  
         [0043]     As seen in  FIGS. 3 and 4 , adjustments may be provided to the crossbar  30  to align the radial bars  32  with the snouts  23 . Additionally, adjustments may be made to the crossbar  30  to assure placement on the outside of the feederhouse  18 .  
         [0044]     Each radial bar  32  has a first end  34  connected to the crossbar  30  and a second end spaced outward from the crossbar  30 . The second end may be a blunt end or it may have V-shaped fork  38  which has two angled snouts  40  or may have a single angled snout. In a preferred embodiment, the radial bar is bent approximately 10°-15°, and preferably 12°, 5″ from the attachment point of the ends  34  to the cross bar  30 . This bend in the bars  32  helps to prevent wrapping of cornstalks around the cross bar  30 . The outer end  34  of each radial bar  32  is preferably blunt. In an alternative embodiment, the radial bars  32 A are straight, as seen in  FIG. 5 , without the 10°-15° bend. In yet another embodiment, the radial bars  32 B are secured to the cross bar  30  so as to be disposed at a non-perpendicular angle relative to the axis of the cross bar  30 , as seen in  FIG. 6 . With such an angle, the bars  32 B cover a wider swath as the cross bar  30  rotates, as compared to the bars  32 .  
         [0045]     As illustrated in  FIG. 5 , the crossbar  30  is rotated by a drive chain  42 . The drive chain  42  is powered by hydraulic hoses  46  and a hydraulic motor  48 . The hydraulic motor  48  turns the chain  42  which is trained about a sprocket on  44  on the end of the cross bar  30  and a sprocket  50  on the end of the motor  48 . A chain guard  52  prevents the chain from becoming clogged with debris and later falling off and processed through the combine. The hydraulic hoses  46  may be connected to the hydraulic system of the corn head  10 .  
         [0046]     In the drawings and specification there has been set forth a preferred embodiment of the invention, and although specific terms are employed, their use is in a generic descriptive sense only and not for purposes of limitation. Changes in the form in proportion and parts as well as in substitution of equivalent are contemplated as a circumstance may suggest or render expedience without departing from the spirit or scope of the invention and various claims. For example, the present invention contemplates variations in the drive system, the number of radial bars utilized, the position of the radial bars  32  relative to the corn head snouts, and other variations in structure and function.