Patent Description:
An agricultural harvester known as a "combine" 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 material 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. The threshing rotor is provided with rasp bars that interact with the crop material in order to further separate the grain from the crop material, and to provide positive crop movement. Once the grain is threshed, the grain is cleaned using a cleaning system. 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. Clean grain is transported to a grain tank onboard the combine.

A typical header generally includes a frame, a pair of end dividers at the lateral ends of the frame, a floor, a cutter to remove crop material from the field, and a conveyor to transport the cut crop material to the feeder housing for further downstream processing in the combine. Generally, the components of a header are specifically optimized to harvest a particular kind of crop. For instance, the header may be in the form of a draper header which is typically used to harvest fluffy or bushy crop such as soy beans or canola. A draper header generally includes a rotating reel assembly with tines, a cutter bar, and a conveyor in the form of one or more draper belts and/or augers. Some draper headers may also move, e.g. lower, raise, roll, pitch, and/or flex, to accommodate the undulating terrain of the field. For instance, a flexing draper header equipped with a flexible cutter bar may raise or lower the cutter bar at various points along the length of the cutter bar to harvest crop which otherwise would have been left on the field.

The rotating reel assembly of a draper header may be composed of a pair of arms, a reel that is rotatable by a motor, a pair of hydraulic cylinders respectively attached to the arms to set the height of the reel relative to the cutter bar, transverse tine bars, and multiple fingers, e.g. tines, movably attached to the tine bars for gathering the crop into the header. Generally, in harvesting a crop, an operator will set the height of the rotor so that the tines are as low to the cutter bar as possible without contacting the cutter bar and/or the ground. However, the resulting height of the reel may be too high to engage and inwardly convey down crop. In this regard, the spatial relationship between the reel and cutter bar may impede the ability of the reel to gather down crop. Furthermore, the ability of the reel to gather down crop may be especially hindered in regard to flexible draper headers. For example, to aggressively harvest down crop when operating a flexible draper header in a flex mode, the operator must generally set the floating height of the header too low to achieve a desired reel height for gathering down crop, which thereby limits the movable range of the flexible cutter bar. Thereby, the position of the reel relative to the cutter bar may limit the mobility of a flexible draper header and/or cause crop yield loss.

In the Japanese patent application published as <CIT>, a combine header is disclosed with a reel supported between two movable arms. The movable arms are connected to the header frame by two actuators each. A support arm is pivotable connected between the header frame and a first end of the respective movable arm. What is needed in the art is an improved reel assembly of a header for gathering down crop material.

In one exemplary embodiment formed in accordance with the present invention, there is provided a reel assembly with pivotable, two-member reel arms, a reel attached to the reel arms, and pivot actuators associated with each reel arm. The reel can be moved by the pivot actuators so that the reel can be lowered and positioned closer to and in front of the cutter bar for more aggressively picking up down crop without interfering with the movement of the cutter bar.

In another exemplary embodiment formed in accordance with the present invention, there is provided a reel assembly of a header for an agricultural vehicle. The header includes a frame and a cutter bar. The reel assembly includes a pair of reel arms each comprising a first member configured for pivotally connecting to the frame of the header and a second member pivotally connected to the first member. The reel assembly also includes a reel movably connected to and positioned in between the second members of the reel arms and a pair of actuators. Each actuator is operably connected in between the first member and the second member of a respective reel arm. The actuators are configured for pivoting the second members relative to the first members such that the reel is pivotable relative to the first members of the reel arms.

In yet another exemplary embodiment formed in accordance with the present invention, there is provided a header for an agricultural vehicle that includes a frame, a cutter bar connected to the frame, and a reel assembly. The reel assembly includes a pair of reel arms each comprising a first member pivotally connected to the frame of the header and a second member pivotally connected to the first member. The reel assembly also includes a reel movably connected to and positioned in between the second members of the reel arms and a pair of actuators. Each actuator is connected in between the first member and the second member of a respective reel arm. The actuators are configured for pivoting the second members relative to the first members such that the reel is pivotable relative to the first members of the reel arms.

In yet another exemplary embodiment formed in accordance with the present invention, there is provided a method for harvesting a crop material. The method includes an initial step of providing a header for an agricultural vehicle. The header includes a frame, a cutter bar connected to the frame, and a reel assembly supported by the frame. The reel assembly includes a pair of reel arms each comprising a first member pivotally connected to the frame of the header and a second member pivotally connected to the first member, a reel movably connected to and positioned in between the second members of the reel arms, the reel comprising tines, and a pair of actuators. Each actuator is operably connected in between the first member and the second member of a respective reel arm. The method also includes the steps of pivoting the second members, by the actuators, relative to the first members for positioning the reel at least partially in front of the cutter bar of the header so that the tines extend below and in front of the cutter bar of the header for gathering a down crop, and pivoting the second members, by the actuators, relative to the first members for positioning the reel behind the cutter bar of the header.

One possible advantage of the exemplary embodiment of the header is that the reel assembly positions the reel in front of the cutter bar such that the reel may gather down crop without limiting the operation of the cutter bar and/or movement of the header.

Another possible advantage of the exemplary embodiment of the header is that the reel assembly may change the angle of the reel arms to aggressively pick up down crop material to increase crop yield.

Referring now to the drawings, and more particularly to <FIG>, there is shown a known agricultural vehicle <NUM>. The agricultural vehicle <NUM> is illustrated as a combine <NUM>, which generally includes a chassis <NUM> supported by wheels, a prime mover, a cab, a feeder housing, and a header <NUM>.

The header <NUM> is removably attached to the feeder housing. The header <NUM> is in the form of a draper header <NUM>. The draper header <NUM> generally includes a frame <NUM> with left and right lateral ends, a cutter bar <NUM> that severs the crop from a field, at least one conveyor <NUM>, for example a draper belt <NUM> and/or auger, which feeds the severed crop inwardly from each lateral end of the frame <NUM> toward the feeder housing, and a reel assembly <NUM> mounted to the frame <NUM>, which feeds the crop into the header <NUM>.

The reel assembly <NUM> generally includes a rotating reel <NUM> with fingers, e.g. tines <NUM>, a pair of "L"-shaped reel arms <NUM> mounting the reel <NUM> to the frame <NUM>, a pair of extension hydraulic cylinders <NUM>, a respective pair of lifting hydraulic cylinders <NUM>, and a reel bearing <NUM>. The reel assembly <NUM> may also include a reel drive mechanism for rotating the reel. Thereby, the reel <NUM> may be raised and lowered by the actuators <NUM> or extended and retracted by the actuators <NUM>. Each reel arm <NUM> has a proximal, i.e., rear, end and a distal, i.e., front, end. The proximal end of each reel arm <NUM> is pivotally connected to the frame <NUM>. The reel <NUM> is movably mounted onto each distal end of the reel arms <NUM> by way of the reel bearing <NUM>. Each reel arm <NUM> is a rigid, uniform part that is typically composed of metal.

Referring now to <FIG>, there is shown an exemplary embodiment of a header <NUM> which generally includes a frame <NUM>, a cutter bar <NUM>, at least one conveyor <NUM>, and a reel assembly <NUM> according to the present invention. The header <NUM> may be connected to any desired agricultural vehicle, such as a windrower or combine <NUM>, as discussed above. The header <NUM> may be in the form of any desired header, such as a draper header <NUM>. The draper header <NUM> may be a flex-draper header <NUM> which allows the floor and/or cutter bar <NUM> to flex, or otherwise move, to accommodate the undulations of the field.

The reel assembly <NUM> may generally include two multi-member reel arms <NUM> which each include a first and second member <NUM>, <NUM>, a reel <NUM> with tine bars <NUM> and tines <NUM> attached thereto, lift actuators <NUM>, extension actuators <NUM>, and pivot actuators <NUM>. The reel assembly <NUM> may also include at least one bracket <NUM>, <NUM> associated with each reel arm <NUM>. The pivot actuators <NUM> may be retracted to position the reel <NUM> in a raised position (<FIG>) or extended to position the reel <NUM> in one or more lowered positions (<FIG>). For example, the pivot actuators <NUM> can be extended to position the reel <NUM> closer to and behind the cutter bar (<FIG>) or in front of the cutter bar <NUM> such that at least a portion of the reel <NUM> is positioned in front of the cutter bar <NUM>, which thereby enables the reel <NUM> to more aggressively pickup down crop without interfering with the operation of the cutter bar <NUM> (<FIG>). It should be appreciated that although only the right side of the reel assembly <NUM> of the header <NUM> is shown the left side of the reel assembly <NUM> is exactly the same except that it is mirrored. It should be appreciated that the reel assembly <NUM> may be incorporated into any desired header <NUM>.

Each first member <NUM> of a respective reel arm <NUM> is pivotally connected to the frame <NUM>, and each second member <NUM> is pivotally connected to each first member <NUM> by way of the at least one bracket <NUM>, <NUM>. Each first member <NUM> may be in the form of a beam or plate with an irregular polygonal cross-section. For instance, each first member <NUM> may have one or more protrusions or angled end sections for mounting the respective pivot actuator <NUM>, lift actuator <NUM>, and/or bracket(s) <NUM>, <NUM>. Each second member <NUM> may be in the form of a rectangular or cylindrical beam. Each It should be appreciated that each second member <NUM> can be directly pivotally connected to each first member <NUM> without incorporating a bracket. Each second member <NUM> can be pivotally connected to each first member <NUM> by two brackets <NUM>, <NUM>. The first bracket <NUM> can be pivotally connected to the upper portion of a respective first member <NUM> at a middle section of the first bracket <NUM> and to a respective second member <NUM> at an end portion of the first bracket <NUM>. The second bracket <NUM> can be pivotally connected to the lower portion of the respective first member <NUM> and to the first bracket <NUM> and/or respective second member <NUM> by one or more links (unnumbered). Thus, each bracket <NUM>, <NUM> defines a respective pivot location of each second member <NUM>. The second bracket <NUM> may also function as a mechanical stop to thereby limit the pivotable range of each second member <NUM> relative to each first member <NUM>.

The reel <NUM> is positioned in between and movably connected, via a reel bearing <NUM>, to the second members <NUM> of the reel arms <NUM>. The reel <NUM> can be extended inwardly or outwardly, via the extension actuators <NUM>, and raised or lowered, via the lift and/or pivot actuators <NUM>, <NUM>. The reel <NUM> may be lowered such that at least a portion of the reel <NUM> extends beyond the cutter bar <NUM> for picking up down crop. In this regard, at least a portion of the tines <NUM> and/or the tine bars <NUM> may extend past, i.e. in front of, the cutter bar <NUM> (<FIG>).

Each lift actuator <NUM> may be connected in between the frame <NUM> and the respective first member <NUM>. The lift actuators <NUM> are configured for adjusting a vertical position of the reel <NUM>. Each extension <NUM> actuator is operably connected to the respective second member <NUM>. In other words, each extension actuator <NUM> is connected in between a respective bracket <NUM> and reel bearing <NUM>. The extension actuators <NUM> are configured for adjusting a horizontal position of the reel <NUM> relative to each second member <NUM>. Each pivot actuator <NUM> is operably connected in between the respective first member <NUM> and second member <NUM>. The first end of each pivot actuator <NUM> is connected to a respective first member <NUM> and the second end of each pivot actuator <NUM> is connected to a respective at least one bracket <NUM> and/or second member <NUM>. Each pivot actuator may be positioned on top of each first member <NUM>. The pivot actuators <NUM> are configured for pivoting the second members <NUM> relative to the first members <NUM> such that the reel <NUM> is pivotable relative to the first members <NUM>. The actuators <NUM>, <NUM>, <NUM> may be in the form of any desired actuators, such as hydraulic or electric cylinders.

In another exemplary embodiment, the header <NUM> or reel assembly <NUM> may further include an electronic control unit (ECU) <NUM>, with a memory <NUM>, and at least one sensor <NUM>. Thereby, the motion and/or float mode of the reel <NUM> may be automatically controlled by the ECU <NUM>.

The ECU <NUM> is operably connected to the actuators <NUM>, <NUM>, <NUM> and sensor(s) <NUM>. The ECU <NUM> may automatically control the actuation of the actuators <NUM>, <NUM>, <NUM>. The ECU <NUM> may prevent an actuation of the pivot actuators <NUM> unless the position signal of the position sensor <NUM> registers that the reel <NUM> is at least partially in front of the cutter bar <NUM>. Additionally, under normal flex mode conditions of the header <NUM>, the pivot actuators <NUM> would be retracted to keep the reel <NUM> lifted so that the tines <NUM> would not contact the ground (<FIG>). If reel <NUM> is in a lowered position (<FIG>), and the operator tries to then move the reel <NUM> back towards the cutter bar <NUM>, the ECU <NUM> would automatically retract the pivot actuators <NUM> to raise the reel <NUM> up so that the reel <NUM> does not interfere with the cutter bar <NUM>. Also, the reel assembly <NUM> allows the cutter bar <NUM> to be locked in a mid-float position when cutting in a rigid mode because so long as the header <NUM> remained in the rigid mode, the pivot actuators <NUM> could be unlocked and actuated by the ECU <NUM> to thereby keep the reel <NUM> at a desirable distance from the cutter bar <NUM>. Furthermore, if the header <NUM> senses that the cutter bar <NUM> is cutting on the ground in a rigid mode, the ECU <NUM> may automatically actuate the pivot actuators <NUM> to prevent contact between the reel <NUM> and the cutter bar <NUM>. In this regard, the reel assembly <NUM> may allow the operator to run a rigid header <NUM> which easily and efficiently functions as a flex header <NUM> with a limited range. The ECU <NUM> may be in the form of any desired analog or digital control unit. For example, the ECU <NUM> may be in the form of a controller. The ECU <NUM> may be incorporated into existing hardware and/or software of the agricultural vehicle <NUM> or header <NUM>.

The position sensor(s) <NUM> may be connected to the reel <NUM> and operably connected to the electronic control unit <NUM>. Each position sensor <NUM> is configured for sending a respective position signal, indicating the position of the reel <NUM>, to the ECU <NUM>. The position sensor <NUM> may be in the form of any desired sensor, such as an optical sensor, linear position sensor, GPS sensor, etc. It should be appreciated that the header <NUM> may include more than one position sensor. For example, the header <NUM> may include three or more sensors, in the form of linear sensors, that are incorporated into respective actuators <NUM>, <NUM>, <NUM>.

Referring now to <FIG>, there is shown a method <NUM> for harvesting a crop material with a draper header <NUM>. The method <NUM> may include an initial step of providing the reel assembly <NUM>, as discussed above (at block <NUM>). For simplicity of description, the method <NUM> will be discussed with respect to a single reel arm <NUM>; however, it should be appreciated that the method <NUM> applies to both reel arms <NUM> on each lateral end of the reel <NUM>. The method <NUM> may include the step of pivoting the second member <NUM> of the reel arm <NUM> downwardly, by extending the pivot actuator <NUM> and/or extension actuator <NUM>, in order to move the reel <NUM> down and in front of the cutter bar <NUM> for picking up down crop (at block <NUM>). The method <NUM> may also include the step of pivoting the second member <NUM> of the reel arm <NUM> upwardly, by retracting the pivot actuator <NUM>, in order to move the reel <NUM> up and behind the cutter bar <NUM> (at block <NUM>). The method <NUM> may also include the step of pivoting the second member <NUM> downwardly, by extending the pivot actuator <NUM>, in order to lower the reel <NUM> in any desired position such as positioning the reel <NUM> closer to the cutter bar <NUM> yet keeping the reel <NUM> behind the cutter bar <NUM>.

Claim 1:
A reel assembly (<NUM>) of a header (<NUM>) for an agricultural vehicle, the header (<NUM>) comprising a frame (<NUM>) and a cutter bar (<NUM>), the reel assembly (<NUM>) comprising:
a reel (<NUM>); and
a pair of reel arms (<NUM>) each comprising a first member (<NUM>) configured for pivotally connecting to the frame (<NUM>) of the header (<NUM>) and a second member (<NUM>) pivotally connected to the first member (<NUM>), the reel (<NUM>) is movably connected to and positioned in between the second members (<NUM>) of the reel arms (<NUM>);
characterized by:
a pair of actuators (<NUM>), and each actuator (<NUM>) is connected in between the first member (<NUM>) and the second member (<NUM>) of a respective reel arm (<NUM>), the actuators (<NUM>) are configured for pivoting the second members (<NUM>) relative to the first members (<NUM>) such that the reel (<NUM>) is pivotable relative to the first members (<NUM>) of the reel arms (<NUM>).