Patent Publication Number: US-10327386-B2

Title: Header for an agricultural harvester with independent sub-system drives

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is a divisional of U.S. patent application Ser. No. 14/259,464, entitled “Header for an Agricultural Harvester with Independent Sub-System Drives” and filed Apr. 23, 2014, the contents of which are incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present disclosure relates to agricultural harvesters, and, more particularly, to header configurations for such harvesters. 
     BACKGROUND OF THE INVENTION 
     An agricultural vehicle known as a “combine” harvester is historically termed such because it combines multiple harvesting functions with a single harvesting unit, such as picking, threshing, separating and cleaning. A combine includes a header which removes the crop from a field, and a feeder housing which transports the crop matter into a threshing rotor. The threshing rotor rotates within a perforated housing, which may be in the form of adjustable concaves, and performs a threshing operation on the crop to remove the grain. Once the grain is threshed it falls through perforations in the concaves onto a grain pan. From the grain pan the grain is cleaned using a cleaning system, and is then transported to a grain tank onboard the combine. The cleaning system includes a cleaning fan which blows air through oscillating sieves to discharge chaff and other debris toward the rear of the combine. Non-grain crop material such as straw from the threshing section proceeds through a straw chopper and out the rear of the combine. When the grain tank becomes full, the combine is positioned adjacent a vehicle into which the grain is to be unloaded, such as a semi-trailer, gravity box, straight truck, or the like; and an unloading system on the combine is actuated to transfer the grain into the vehicle. 
     A “header” can broadly include row crop headers (such as corn headers) and cutting platforms (such as bean headers). In the case of a corn header, the header typically includes a number of row units with each row unit including a feed/snapping unit positioned at the bottom side thereof. Each feed/snapping unit typically includes a pair of stripper plates spaced apart from each other and extending in a direction of the row crop, a pair of stalk rolls positioned underneath the stripper plates, and a pair of gathering chains for moving the stalks into the space between the stripper plates and moving the stripped ears of corn rearwardly. It is also known to provide the header with a number of chopping units, with each chopping unit being associated with a respective row unit. As the corn stalks are stripped downwardly through the stripper plates by the stalk rolls, the chopping units chop the stalks, leaves, etc. (also known as “material other than grain” or MOG) into finer pieces which are then distributed onto the field. 
     It is known to separate the mechanical input drive at the header between the feed/snapping units and the chopping units. A single mechanical input drive is provided on the header, and the input drive is split in a parallel manner onboard the header between the feed/snapping units and the chopping units. The parallel feed from the single input drive to the feed/snapping units can be configured with a variable operating speed by varying the shaft speed of the input drive, and the other parallel feed to the chopping units can be somewhat constant at a given input drive speed by varying a gear ratio within a transmission. However, as the operating speed of the single input drive changes the operating speed of the chopping units also changes. During this transitional speed change, this can result in an operating speed of the chopping units which is below a desired threshold operating speed as the input drive speed from the base unit changes. Moreover, since the shaft speed of the single input drive can infinitely vary between upper and lower operating ranges, but the transmission only has discrete stepped gear ratios, the operating speed of the chopping units is not constant. 
     What is needed in the art is a header for an agricultural harvester which better accommodates different drive needs of various sub-systems onboard the header. 
     SUMMARY OF THE INVENTION 
     The following presents a simplified summary in order to provide a basic understanding of some aspects of the disclosed examples. This summary is not an extensive overview and is intended to neither identify key or critical elements nor delineate the scope of such aspects. Its purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later. 
     The present disclosure, in one form, provides a header with multiple mechanical input drives on the header, with each input drive driving a separate sub-system on the header and being operated at independent operating speeds relative to each other. The operating speed of one of the input drives can be constant. 
     The invention in one form is directed to a header for an agricultural harvester, including a plurality of row units, a plurality of feed/snapping units, and a plurality of chopping units. Each feed/snapping unit is associated with a respective said row unit and operable at a first operating speed. Each chopping unit is associated with at least one respective feed/snapping unit and operable at a constant second operating speed, independent of the first operating speed. 
     The invention in another form is directed to a header which is couplable with a base unit of an agricultural harvester. The header includes a rotatably driven first sub-system, a rotatably driven second sub-system, a first input drive which is mechanically couplable with the base unit, and a second input drive which is mechanically couplable with the base unit. The first input drive is configured for driving the first sub-system at a first operating speed. The second input drive is configured for driving the second sub-system at a second operating speed which is independent of the first operating speed. 
     The invention in yet another form is directed to an agricultural harvester including a base unit and a header carried by the base unit. The header includes a plurality of row units, a plurality of feed/snapping units, and a plurality of chopping units. Each feed/snapping unit is associated with a respective row unit and operable at a first operating speed. Each chopping unit is associated with at least one respective feed/snapping unit and operable at a constant second operating speed, independent of the first operating speed. 
     An advantage of the present disclosure is that multiple mechanical input drives on the header allow segregated power from each input drive to one or more corresponding sub-systems onboard the header. 
     Another advantage is that the multiple input drives provide greater flexibility and control over the operating speed of the associated sub-systems onboard the header. 
     Yet another advantage is that when the sub-systems on the header are configured as feed/snapping units and chopping units, the chopping units can be operated at a constant operating speed regardless of the operating speed of the feed/snapping units (which can vary). 
     To the accomplishment of the foregoing and related ends, one or more examples comprise the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth in detail certain illustrative aspects and are indicative of but a few of the various ways in which the principles of the various aspects may be employed. Other advantages and novel features will become apparent from the following detailed description when considered in conjunction with the drawings and the disclosed examples are intended to include all such aspects and their equivalents. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings, wherein: 
         FIG. 1  is a top view of an agricultural harvester, including an embodiment of a header of the present disclosure coupled with a portion of a combine; 
         FIG. 2  is an end view of the header shown in  FIG. 1 , with some of the sheet metal removed to expose a row unit and chopping unit; 
         FIG. 3  is a top view of the header shown in  FIGS. 1 and 2 , with the snouts associated with the row units removed; and 
         FIG. 4  is a rear view of the header shown in  FIGS. 1-3 . 
     
    
    
     Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates an embodiment of the invention, in one form, and such exemplification is not to be construed as limiting the scope of the invention in any manner. 
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to the drawings, and more particularly to  FIG. 1 , there is shown an agricultural harvester  10  which generally includes a base unit  12  and an embodiment of a header  14  of the present disclosure. In the illustrated embodiment, base unit  12  is in the form of a combine with only a portion of a feeder housing  16  being shown for simplicity sake. The combine  12  may include a number of conventional systems and sub-systems for threshing, separating, cleaning, etc. It is also to be understood that agricultural harvester  10  may be configured as a different type of harvester, such as a sugar cane harvester, cotton harvester, forage harvester, etc. 
     Header  14  can include a frame  18  supporting a number of structural components. For example, when configured as a corn header as shown in  FIG. 1 , header  14  can include a number of row units  20  separated by snouts  22 . In the embodiment shown, header  14  is configured as a 12 row corn header. Each row unit  20  generally separates the ears of corn from most of the MOG and conveys the ears of corn and some MOG toward the rear of header  14 , where it is conveyed laterally inward toward feeder housing  16  using a double pitch cross auger  24 . The ears of corn and MOG can then transported into combine  12  for further threshing, separating and cleaning. 
     Referring now to  FIGS. 2 and 3 , each row unit  20  can include a feed/snapping unit  26  which together define a first sub-system of header  14 . Each feed/snapping unit  26  can include a pair of gathering chains  28 , stripper plates  30  and stalk rolls  32 . As the combine  12  moves in a forward travel direction while harvesting, the gathering chains  28  move the corn stalks (not shown) in a rearward direction in the space between stripper plates  30 . As the stalks move rearwardly, the stalk rolls  32  pull the stalks in a downward direction and as the ears of corn on the stalks hit the stripper plates  30 , the ears are stripped from the stalk and lie on top of the stripper plates  30 . The gathering chains  28  then move the ears of corn and some MOG in a rearward direction toward the cross auger  24 . 
     Positioned below each feed/snapping unit  26  can also be a chopping unit  34  which together define a second sub-system of header  14 . As the corn stalks are stripped downwardly through the stripper plates  30  by the stalk rolls  32 , the chopping units  34  chop the stalks, leaves, etc. (MOG) into finer pieces which are then distributed onto the field. Each chopping unit  34  is associated with at least one respective row unit  20  and includes one or more cutting blades  36 . In the illustrated embodiment, each chopping unit  34  includes a pair of cutting blades  36  which rotate at a desired rotational speed providing a desired cutting tip speed (velocity) at the outermost end of each blade. The illustrated chopping units  34 , for example, have a desired or target rotational speed of approximately 2800 RPM. 
     According to an aspect of the present application, multiple input drives are provided on the header  14  corresponding to the number of sub-systems which are separately driven on header  14  ( FIGS. 1-4 ). As indicated above, in the embodiment of header  14  shown and described herein, a first sub-system is assumed to correspond to the plurality of feed/snapping units  26  and a second sub-system is assumed to correspond to the plurality of chopping units  34 . The sub-systems onboard header  14  which are to be separately driven can also be differently configured, such as a cutter bar and/or reel on a bean header, etc. 
     More particularly, header  14  can include a first input drive  40  and a second input drive  42  which may each be mechanically coupled with corresponding output drives (not specifically shown) carried by combine  12 . First input drive  40  and second input drive  42  may each be coupled with the corresponding output drives on combine  12  using any suitable coupling structure, such as a telescoping power take off (PTO) shaft or other suitable coupler. Header  14  is shown with the first input drive  40  being located at one end (left) of the header  14  and the second input drive  42  being located at an opposite end (right) of the header  14 , on opposite sides of feeder housing  16 . However, the orientation of the first input drive  40  and second input drive  42  can be switched, or both input drives  40  and  42  can be located on the same side of the feeder housing  16 . Moreover, more than two input drives can also be provided. 
     First input drive  40  can be configured as an input drive shaft which is coupled with a common drive shaft  44  which extends across header  14  and mechanically drives each of the feed/snapping units  26  at a first operating speed ( FIG. 2 ). Suitable gears, belts, pulleys, etc within a housing  46  at the left end of header  14  can be used to interconnect the first input drive  40  with common drive shaft  44 . The operating speed of feed/snapping units  26  can be variable to accommodate varying field conditions during harvesting. For example, header  14  can include a controllable component used to control the operating speed of feed/snapping units  26 , such as a continuously variable transmission (CVT), different sized chain drive sprockets, belt drive pulleys, interchangeable gears to modify drive ratios, a shiftable planetary gear set, etc. Alternatively, the operating speed of the output shaft from combine  12  which drives the first input drive  40  can be varied, while the output shaft from combine  12  which drives the second input drive  42  can be maintaining substantially constant. This results in the drive for the chopping units  34  and feed/snapping units  26  being split onboard the combine  12  rather than the header  14 . 
     Second input drive  42  can likewise be configured as an input drive shaft which is coupled with a common drive shaft  48  which extends across header  14  and mechanically drives each of the chopping units  34  at a second operating speed ( FIG. 2 ). Suitable gears, belts, pulleys, etc within a housing  50  at the right end of header  14  can be used to interconnect the second input drive  42  with common drive shaft  48 . Each chopping unit  34  can be operated at a desired operating speed to provide adequate cutting of the MOG conveyed downwardly by an associated feed/snapping unit  26 . Accordingly, each chopping unit  34  can be operated at a constant operating speed which is independent of the rotational speed of the feed/snapping units  26 . The second input drive  42  is set at a desired constant operating speed, and effective cutting of the MOG always occurs regardless of the selected variable operating speed of the feed/snapping units  26 . The phrase “constant operating speed” as used in this disclosure is meant to be the selected speed at which the chopping units  34  operate, by way of the second input drive  42 , which can vary through operator input by up to +/−20% (e.g., by throttling up or throttling down the internal combustion engine, or maintaining a rated engine speed and adjusting the output speed of the output drive shaft from the base unit). Once set by the operator, the chopping units  34  then operate at a corresponding substantially constant operating speed. 
     At a rated operating (PTO) speed of combine  12 , the chopping units  34  can be configured to be incapable of being adjusted by an operator. Using a second input drive  42  as described above, and with the combine  12  operating at the rated PTO speed, the second input drive  42  has no provisions which would allow the operator to adjust the operating speed of the chopping units  34 . In this manner, the chopping units  34  always have a predetermined blade tip operating speed to ensure that the crop material is adequately chopped prior to being returned to the ground. In the embodiment described above, the chopping units  34  are driven in a direct drive manner by the second input drive  42  that is driven at a constant operating speed from the combine  12 . Neither the combine  12  nor the header  14  has any adjustment feature that would allow the rotational speed of the chopping units  34  to be adjusted. 
     In the embodiment shown and described above, the combine includes two output shafts which drive a first input drive  40  and second input drive  42  onboard the header  14 . However, in another embodiment (not shown), it is also possible to use a single output shaft from the combine  12  which drives both the first input drive  40  and second input drive  42  onboard the header  14 . For example, a single output shaft from the combine  12  can directly drive the first input drive  40  associated with the chopping units  34 , and a gearbox or the like in the driveline can split the rotational power in a parallel manner to drive the second input drive  42  associated with the feed/snapping units  26 . A CVT or other suitable controllable component as described above can be used to vary the operating speed of the feed/snapping units  26 . In the case of a combine having two output shafts, the first and second input drives  40  and  42  are directly coupled with the combine, whereas in the case of a combine having a single output shaft, the first input drive  40  would be directly coupled with the combine and the second input drive  42  would be indirectly coupled with the combine by way of the first input drive  40 . 
     In another embodiment, such as a smaller corn header (e.g., a 6 row header), it might not be cost effective to run separate output shafts from the combine, with two separate input drives on the header to the chopping units and to the row units. The smaller headers are more likely to be used with a combine having a fixed speed feeder drive and again it would not be cost effective to add a variable speed unit to the row unit drive. One possibility on such a header might be to run a series configuration from the combine, to the chopper units, and then to the feed/snapping units, with a manual adjustment for the operator to adjust the speed of the feed/snapping units. For example, the combine can have a single output shaft which would connect to one end of the header (e.g., right end). From the right end, the drive shaft for the chopping units would extend across to the other end of the header (e.g., left end) and operate at a fixed speed for the chopping units. Then from the other end of the header, this drive shaft would connect with another drive shaft extending across the header for the feed/snapping units. A manually adjustable component, such as chain drive with changeable sprockets or a small gearbox with a 2 or 3 speed ratio could be placed on the header between the two drive shafts, accessible to an operator. Configured as such, the chopping units would always run at a constant speed and the operator could manually change the row unit speed by changing a sprocket or gear level on the end of the header. This would eliminate the need for two input drives on the smaller headers. 
     While this invention has been described with respect to at least one embodiment, the present disclosure can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.