Patent Description:
A corn header of an agricultural harvester in the form of a combine is provided with row dividers for directing rows of corn stalks to downstream separation devices known as row units. The row units include stalk receiving slots and stripping plates, snapping rolls, and opposed rearwardly moving gathering chains. Thus, e.g., following separation of ears from stalks by the snapping rolls and stripping plates (also known as stalk rolls and deck plates, respectively), the separated ears are delivered by the gathering chains to a conveying device, e.g., auger or draper belt, which conveys the harvested ears to a feeder housing of the combine. Harvested ears are then conveyed to the combine's inner sub-systems for downstream processing.

Row unit frames are typically constructed with forwardly projecting members that support several components of the row unit including the deck plates, the stalk roll support bearings, the front gathering chain idlers, the hoods and the row dividers. The deck plates are flat or planar with their shape being dictated by the geometry of the row unit frames. As is known, the stalk rolls are disposed beneath the deck plates and are cooperatively rotated to pull the corn stalks downwardly into the stalk receiving slots where the ears come into contact with the deck plates and are snapped off of the stalks by the deck plates. The deck plates lie generally tangent to the upper surfaces of the stalk rolls and the stalk rolls engage the corn stalks at "pinch points" situated below the upper surfaces of deck plates.

The deck plates are generally provided in pairs defining a gap therebetween, allowing the corn stalks to enter the gap before being pulled down to the deck plates so the corn ear snaps off the stalk. Many headers are equipped with flaps, known as "ear savers," that are mounted to a rear of the row dividers to prevent collected ears from being lost after snapping off the stalk. While ear savers are generally effective to reduce crop loss during harvesting, crop loss still does occur for various reasons.

What is needed in the art is a row unit of an agricultural harvester that can reduce crop loss during harvesting.

Patent publication document <CIT> is related to a corn header comprising row units, wherein each row unit comprises a slotted plate and a snapping wheel mechanism below the plate, for snapping off corn ears trapped in the slot of the plate.

Patent publication document <CIT> is related to a row unit for a corn header, comprising a first and second deck plate, and a gap adjustment mechanism for adjusting the gap between the deck plates.

<CIT> is related to a row unit for a corn header comprising a first and second deck plate, and a gap adjustment mechanism for adjusting the gap between the deck plates, and further comprising a kernel sensor to generate a signal representative of the presence of kernels that are detached from the corn ears.

In one exemplary embodiment formed in accordance with the present disclosure, there is provided a row unit side for a row unit of an agricultural harvester. The row unit side includes a row unit support having a leading end and a trailing end relative to a direction of travel. An idler sprocket rotatably attaches to the row unit support near the lead end. A drive sprocket rotatably attaches to the row unit support near the trailing end. A gather chain includes a plurality of gather chain lugs. The idler sprocket and the drive sprocket are enmeshed with the gather chain. A deck plate includes a harvest side plate and a deck plate extension in accordance with the appended claims.

In another exemplary embodiment formed in accordance with the present disclosure, there is provided a deck plate extension for a row unit side of a row unit for an agricultural harvester, in accordance with the appended claims.

The description also dicloses a method for reducing kernel loss from a row unit return side on an agricultural harvester.

Referring now to the drawings, and more particularly to <FIG> there is shown a row unit <NUM> as is known in the art. Row unit <NUM> is generally orientated to operate in a direction of travel <NUM>. The row unit <NUM> has a first side 100A and a second side 100B. The row unit sides 100A, 100B each have an idler sprocket <NUM> and a drive sprocket <NUM>. The idler sprocket <NUM> and drive sprocket <NUM> are enmeshed together via a gather chain <NUM>. The gather chain <NUM> includes a plurality of gather chain lugs <NUM>. The plurality of gather chain lugs <NUM> are configured to collect a kernel crop, e.g., corn, and direct the kernel crop to a conveying device <NUM>, e.g., auger or draper belt, disposed at one end of the row unit <NUM>. A harvest side plate <NUM> is included with each row unit side 100A, 100B and functions to prevent the kernel crop, e.g., corn, from falling to a ground surface as the gather chain lugs <NUM> direct the kernel crop to the conveying device <NUM>, e.g., auger or draper belt. Each harvest side plate <NUM> has a harvest plate first edge <NUM> and a harvest plate second edge <NUM>. The harvest plate second edges <NUM> of the row unit sides 100A, 100B form a harvesting channel <NUM> therebetween where the rows of crop, e.g., corn, are directed through while the harvested crop, e.g., ears of corn and/or kernel crop, travel along a top surface of the harvest side plate <NUM> to the conveying device <NUM>. A gap <NUM> is formed between the harvest plate first edge <NUM> of a row unit side 100A and a row unit side 100B of an adjacent row unit <NUM>. The gap <NUM> is open to the ground and allows any harvested crop not on the harvest side plate <NUM> to fall to the ground. The harvested crop falling on the ground represents lost revenues.

Referring now to the drawings, are more particularly to <FIG> there is shown a row unit side 100A of row unit <NUM> that is not according to the invention. It is to be understood that row unit side 100A and row unit side 100B, shown in <FIG>, together form the row unit <NUM> where row unit side 100B is symmetrical to row unit 100A about the harvesting channel <NUM>. The row unit side 100A includes an idler sprocket <NUM> and a drive sprocket <NUM>. The idler sprocket <NUM> and drive sprocket <NUM> are enmeshed together via a gather chain <NUM>. The gather chain <NUM> includes a plurality of gather chain lugs <NUM>. The plurality of gather chain lugs <NUM> are configured to collect a kernel crop, e.g., corn, and direct the kernel crop to a conveying device <NUM>, e.g., auger or draper belt, disposed at one end of the row unit side 100A. The row unit side 100A further includes a deck plate <NUM> with a harvest side <NUM> and a return side <NUM>. The return side <NUM> covers a portion of the gap <NUM> thereby providing a surface to prevent the harvested crop from falling to the ground. The return side <NUM> of the present row unit side 100A may be in contact or sufficiently close to contact with a return side <NUM> of a row unit side 100B of an adjacent row unit <NUM> thereby providing that the gap <NUM> is completely covered or sufficiently covered. The deck plate <NUM> may be a single plate or of multiple plates. The deck plate <NUM> has a first end <NUM> and a second end <NUM> where the first end <NUM> is disposed at the end of the row unit <NUM> closest to the conveying device <NUM>. A kernel channel <NUM> is disposed on an edge of the return side of the deck plate <NUM>. The kernel channel <NUM> may be formed integral to or attached to the deck plate <NUM>. Examples of being formed integral include but are not limited to: a stamping with a rolled edge, a forging with a raised edge, a casting with a raised edge or a machined surface with a raised edge. Methods of attachment include but are not limited to, welding, the use of fasteners or press fit. The kernel channel <NUM> may be formed of the same or different material of the deck plate <NUM>. A plurality of attachment holes <NUM> through the deck plate <NUM> may be used to attach the deck plate <NUM> to the row unit <NUM> with fasteners (not shown). The deck plate <NUM> may be permanently attached to the row unit <NUM> via a method such as welding.

The row unit side 100A may be configured to operate in a way that a rotation of the drive sprocket <NUM> causes the gather chain <NUM> and gather chain lugs <NUM> to move around the deck plate <NUM> from the second end <NUM> to the first end <NUM> along the harvest side <NUM>. Movement of the gather chain lugs <NUM> moves most of the kernel crop along the harvest side <NUM> until it reaches the conveying device <NUM>. Kernel crop may also land on the return side <NUM> of the deck plate <NUM>. Any kernel crop on the return side <NUM> of the deck plate <NUM> is forced to move from the first end <NUM> towards the second end <NUM> by the gather chain lugs <NUM>. The kernel channel <NUM> prevents the kernel crop from falling off of the edge of the deck plate <NUM> and directs the kernel crop to collect at the second end <NUM> of the deck plate <NUM>. Additional kernel crop being moved by the gather chain lugs <NUM> on the return side <NUM> of the deck plate <NUM> may force the kernel crop already collected at the second end <NUM> of the deck plate <NUM> to move from the return side <NUM> to the harvest side <NUM>. The idler sprocket <NUM> may be provided with a plurality of idler sprocket propellers <NUM> (<FIG>). The idler sprocket propellers <NUM> are configured to move the kernel crop from the return side <NUM> to the harvest side <NUM> with or without additional kernel crop being moved along the return side <NUM>.

Referring now to <FIG> there is shown a row unit side 200a according to an embodiment of the invention. It is to be understood that row unit side 200a and a row unit side 200b together form the row unit <NUM> where row unit side 200b is symmetrical to row unit 200a about the harvesting channel <NUM>. The row unit side 200a includes an idler sprocket <NUM> and a drive sprocket <NUM>. The idler sprocket <NUM> and drive sprocket <NUM> are enmeshed via a gather chain <NUM>. The gather chain <NUM> includes a plurality of gather chain lugs <NUM>. The gather chain lugs <NUM> are configured to collect a kernel crop, i.e. corn, and direct the kernel crop to an auger trough <NUM> disposed at one end of the row unit side 200a. The row unit side 200a further includes a deck plate <NUM> with a harvest side <NUM> and a return side <NUM>. The deck plate <NUM> has a first end <NUM> and a second end <NUM> where the first end <NUM> is disposed at the end of the row unit <NUM> closest to the auger trough <NUM>. A kernel channel <NUM> is disposed on an edge of the return side of the deck plate <NUM>. The kernel channel <NUM> may be formed integral to or attached to the deck plate <NUM>. Examples of being formed integral include but are not limited to: a stamping with a rolled edge, a forging with a raised edge, a casting with a raised edge or a machined surface with a raised edge. Methods of attachment include but are not limited to: welding, the use of fasteners or press fit. The kernel channel <NUM> may be formed of the same or different material of the deck plate <NUM>. The deck plate <NUM> may be removably attached to the to the row unit side 200a with fasteners (not shown) through a plurality of attachment holes <NUM> or the deck plate <NUM> may be permanently attached via a method such as welding. The deck plate <NUM> is formed by two plates, a harvest side plate <NUM> and a deck plate extension <NUM>. The deck plate extension <NUM> may be added to the row unit side 200a as original equipment or the deck plate extension <NUM> may be added as an aftermarket part to an existing row unit side 200a. The harvest side plate <NUM> includes a harvest side plate first edge that may align or overlap with a deck plate extension first edge <NUM> when the harvest side plate <NUM> and the deck plate extension <NUM> are installed. The deck plate extension <NUM> may be further provided to have a width that is wider than a width of the harvest side plate <NUM>. The deck plate extension <NUM> of the present row unit side 200a may be in contact or sufficiently close to contact with a deck plate extension <NUM> of a row unit side 200b of an adjacent row unit <NUM> thereby providing that the gap <NUM> is completely covered or sufficiently covered.

Referring now to <FIG>, there is shown a deck plate extension <NUM> having a kernel channel <NUM> formed on a deck plate extension second edge <NUM>. The kernel channel <NUM> may be formed integral or may be attached to the deck plate extension second edge <NUM>. Examples of being formed integral include but are not limited to: a stamping with a rolled edge, a forging with a raised edge, a casting with a raised edge or a machined surface with a raised edge. Methods of attachment include but are not limited to: welding, use of fasteners or press fit. The kernel channel <NUM> may be formed of the same or different material of the deck plate extension <NUM>. The kernel channel <NUM> may be configured to extend over a portion of the harvest side plate <NUM>. An idler sprocket notch <NUM> is formed near a deck plate extension second end <NUM> to provide clearance for an idler sprocket <NUM>.

Referring now to <FIG>, there is shown a second end <NUM> of the row unit side 100A with an idler sprocket <NUM>. The idler sprocket <NUM> is shown with a plurality of idler sprocket propellers <NUM> attached to the idler sprocket <NUM> between a top surface of the deck plate <NUM> and a bottom surface (not shown) of the idler sprocket <NUM>. The plurality of idler sprocket propellers <NUM> are configured to push the kernel crop from the return side to the harvest side while being guided by the kernel channel <NUM>.

Claim 1:
A row unit side (200a,200b) of a row unit (<NUM>) for an agricultural harvester, comprising,
a row unit support having a leading end and a trailing end relative to a direction of travel (<NUM>);
an idler sprocket (<NUM>) rotatably attaching to the row unit support near the lead end;
a drive sprocket (<NUM>) rotatably attaching to the row unit support near the trailing end;
a gather chain (<NUM>) having a plurality of gather chain lugs (<NUM>), the gather chain (<NUM>) enmeshed with the idler sprocket (<NUM>) and the drive sprocket (<NUM>);
a deck plate (<NUM>) having a harvest side (<NUM>), a return side (<NUM>), a first end (<NUM>) and a second end (<NUM>), the deck plate (<NUM>) attaching to the row unit support,
characterized in that :
the deck plate (<NUM>) comprises a harvest side plate (<NUM>) on the harvest side and a deck plate extension (<NUM>) on the return side, wherein said deck plate extension (<NUM>) :
- is aligned to or overlaps an edge of the harvest side plate (<NUM>),
- includes an idler notch (<NUM>) being formed near the second end (<NUM>) of the deck plate (<NUM>)
- includes a kernel channel (<NUM>) formed on at least a portion of the return side (<NUM>) of the deck plate (<NUM>), the kernel channel (<NUM>) being configured for guiding a kernel from the deck plate extension (<NUM>) to the harvest side deck plate (<NUM>).