Patent ID: 12225851

DETAILED DESCRIPTION

Before the various embodiments of the present invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that phraseology and terminology used herein with reference to device or element orientation (such as, for example, terms like “front”, “back”, “up”, “down”, “top”, “bottom”, and the like) are only used to simplify description of the present invention, and do not alone indicate or imply that the device or element referred to must have a particular orientation. In addition, terms such as “first”, “second”, and “third” are used herein and in the appended claims for purposes of description and are not intended to indicate or imply relative importance or significance. “Stalk roll” 15, 16, 190, 192, 400 is not limited to any specific embodiment or feature disclosed herein, but is meant to include any present art stalk roll that is configured with one or more inventive feature as disclosed and claimed herein.

1. First Embodiment of Stalk Rolls with a Stalk Engagement Gap

Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, the general operation of corn heads having stalk rolls mounted thereon of the type illustrated inFIGS.6-9is similar to the operation of corn heads using stalk rolls12of the prior art (as illustrated inFIGS.1-5). As used herein, “left” and “right” are defined from the perspective of a corn plant with respect to a harvesting machine.

The power source for this corn head row unit is provided from a stalk roll drive shaft29through a gearbox, as described in the prior art and is well known to those skilled in the art and not pictured herein. Each corn head row unit on a corn header is provided with a first and second stalk roll15,16arranged parallel to one another to make an opposing pair. The first and second stalk rolls15,16are provided with nose cones5having transport vanes6. Immediately behind the nose cones5are cylindrical shells17having a first, second, third, and fourth flute18,19,20and21, respectively, mounted along the length of the first and second stalk rolls15,16(as can easily be seen inFIG.6). Each flute18,19,20,21may further be provided with a knife edge22, as is shown in detail in the embodiment depicted inFIG.11. The knife edges22are substantially parallel to the central longitudinal axis of the cylindrical shell17. As shown in the embodiment inFIGS.6-9, the stalk rolls15,16may be mounted in the cantilevered manner for rotation by their respective stalk roll drive shafts (not shown), thereby eliminating the need for support brackets or nose bearings.

As with corn headers employing stalk rolls12of the prior art, the stalk rolls15,16of the present disclosure pull the stalk320in a downward motion, causing the ears13to contact the stripper plates3and separate from the stalk320. The flutes18,19,20,21affixed to the stalk rolls15,16may also act to lacerate or crush the stalk320, and also facilitate ejection of the stalk320from the corn plant engagement chamber. Gathering chain paddles1affixed to gathering chains2transport the loose ears13to the cross auger trough8. The cross auger9moves the ears13from the cross auger trough8to the feeder house11, which moves the ears13into the remainder of the harvesting machine for further processing, all of which is well known to those skilled in the art.

In an embodiment not pictured herein, the stalk rolls15,16may be manufactured as one piece adapted for engagement upon the stalk roll drive shaft29. In another embodiment, the first and second stalk rolls15,16may be built as two continuous, integral, semi-cylindrical shells to be bolted to a stalk roll mounting base (not shown) into which the stalk roll drive shaft29is inserted, as is best illustrated inFIG.8. The cylindrical shell17may be comprised of two semi-cylindrical shell pieces, an upper semi-cylindrical shell27and a lower semi-cylindrical shell28, that are bolted to the intermediate drive shaft38. The long bolt holes37and long bolts36with nuts or other securing members, along with the short bolt holes31, short bolts32, and bolt receivers34, form a structure for mounting the cylindrical shell17to the intermediate drive shaft38, which then may be mounted to the stalk roll drive shaft29.

FIG.8best illustrates the mounting structure for an embodiment employing semi-cylindrical shells27,28. In one embodiment, each semi-cylindrical shell27,28is fashioned with two inwardly extending annular ridges30having short bolt holes31. Short bolts32pass through the short bolt holes31and engage bolt receivers34located on an intermediate drive shaft38. Long bolts36pass through the long bolt holes37of two corresponding upper and lower semi-cylindrical shells27,28, and with a nut or other securing member clamp the semi-cylindrical shells27,28together around the intermediate drive shaft38. The intermediate drive shaft38is clamped to the stalk roll drive shaft29by drive shaft bolts39. In addition, a small pin40and a large pin41prevent relative rotation between the intermediate drive shaft38and the stalk roll drive shaft (not shown inFIG.8).

Each semi-cylindrical shell27,28may be manufactured having at least two integral flutes. In one embodiment, the flutes are then machined to define the knife edge22. Each knife edge22has a leading surface23and a trailing surface24that form an acute angle between them of approximately forty degrees, as shown in the embodiment pictured inFIG.11. The leading surface is a rearward (with respect to the direction of rotation of one of the stalk rolls15,16of an opposing pair) sloping surface, sloping approximately ten degrees from a line passing though the central longitudinal axis of the cylindrical shell17and the vertex of the knife edge22. The trailing surface24is a forward (with respect to the direction of rotation of one of the stalk rolls15,16of an opposing pair) sloping surface, sloping approximately thirty degrees from a line passing through the central longitudinal axis of the cylindrical shell17and the vertex of the knife edge22. Other slopes and angles of the leading surface23and the trailing surface24may be used without departing from the spirit or scope of the stalk roll15,16. As is well known to those skilled in the art, tungsten carbide may be applied to the trailing surfaces24to make the knife edges22self-sharpening. Although not shown, the layer of tungsten carbide is generally between three and twenty thousandths of an inch thick and is induction hardened.

As illustrated inFIGS.6-9, the flutes18,19,20,21of the opposing first and second stalk rolls15,16are offset to one another but not interleaved. As those of ordinary skill in the art will appreciate, though not pictured, the stalk roll design disclosed herein may also be implemented with a rounded flute edge or edge that does not have knife-like characteristics. Accordingly, the scope of the stalk roll15,16is not limited by type of edge fashioned on the flute or the specific cross-sectional shape of the flute.

The present art alleviates the impediment to flow of stalks320into the corn plant engagement chamber (which impediment is a result of the egg-beater effect, as described above) by creating at least one stalk engagement gap25in the stalk slot7per revolution of the stalk roll15,16, which is explained in detail below. When the stalk engagement gap25is present, corn plant entry into the corn plant engagement chamber is not restricted.

As may be seen for the embodiment inFIGS.9A-9F, the width of the stalk slot7is defined as the distance between the inner periphery of the cylindrical shells17of the opposing stalk rolls15,16, which width is denoted “W” inFIGS.9A-10. Other embodiments described in detail below include an recess420, which may affect the width of the stalk slot7. The height of the stalk slot7is essentially infinite, though in practicality the ground surface provides a lower limit. The stalk engagement gap25, as shown inFIGS.9A,9D, and10, is then defined as the moment(s) during revolution of the first and second stalk rolls15,16in which none of the flutes18,19,20,21of the first or second stalk roll15,16are positioned within the stalk slot7.FIGS.9B,9C,9E, and9Fillustrate the stalk slot7after the stalk engagement gap25is closed.

FIGS.9A-9Fprovide six views of the stalk slot7at six different moments during one revolution of the stalk rolls15,16, with the direction of rotation of the stalk rolls15,16indicated by the respective arrows. As will be explained in detail below, the embodiment shown inFIGS.9A-9Fis configured so that the stalk engagement gap25is present at two different moments in time during one revolution of the stalk rolls15,16; and as will be apparent to those skilled in the art, this is but one of many embodiments the stalk rolls15,16may take. Throughout one revolution of the stalk rolls15,16, at any point in time, the flutes18,19,20,21may be engaged in five different modes of action upon a stalk320at any point along the axial length of the flute18,19,20,21(depending on the location and orientation of the flutes18,19,20,21and the particular embodiment). The five modes of action upon the stalk320are: (1) unrestricted entry of the stalk320into the corn plant engagement chamber (which occurs at the moment in time shown inFIGS.9A and9D, although restricted entry may occur at other moments in time); (2) flute18,19,20,21or knife engagement with the stalk320(which may occur at moments in time shown inFIGS.9B,9C,9E, and9F, but may also occur at other moments in time); (3) lacerating and crushing of the stalk320by the flutes18,19,20,21or knives (which may occur at the moments in time shown inFIGS.9B,9C,9E, and9F, but may also occur at other moments in time); (4) ear separation and stalk320ejection (which may occur at moments in time shown inFIGS.9B,9C,9E, and9F, but may also occur at other moments in time); (5) stalk320release by the stalk rolls15,16for lateral travel of the stalk320(which most often occurs at moments in time shown inFIGS.9A and9D, but may also occur at other moments in time).

FIG.9Ashows the stalk engagement gap25, and illustrates that when the stalk engagement gap25appears, no flutes18,19,20,21are located in the stalk slot7. When the stalk rolls15,16are in this position a stalk320(not shown) may freely enter the stalk slot7and the corn plant engagement chamber with no restriction. The stalk engagement gap25also allows stalks320already positioned between the stalk rolls15,16to travel in a lateral direction to compensate for the forward motion of the harvesting machine to which the corn head is attached.

FIG.9Bshows the stalk slot7at a later moment in time after the stalk rolls15,16have rotated from their positions shown inFIG.9A.FIG.9Bshows that at this point, the first flute18of each stalk roll15,16has moved into the stalk slot7so that there is no stalk engagement gap25, and the first flutes18of the respective stalk rolls15,16now engage any stalk320between the stalk rolls15,16. This engagement may serve to lacerate or crush the stalk320, or to pull the stalk320downward through the corn plant engagement chamber and subsequently eject the stalk320depending on the specific embodiment.

FIG.9Cshows the stalk slot7at still a later moment in time wherein the second flute19of each stalk roll15,16has moved into the stalk slot7so that there is still no stalk engagement gap25. The second flutes19of each respective stalk roll15,16now engage any stalk320between the stalk rolls15,16. This engagement may serve to lacerate or crush the stalk320, or to pull the stalk320downward through the corn plant engagement chamber and subsequently eject the stalk320depending on the specific embodiment.

FIG.9Dprovides a snapshot of the stalk slot7at a moment in time later than the moment depicted inFIG.9C, and shows the stalk engagement gap25present for the second time during this revolution of the stalk rolls15,16. The stalk engagement gap25is present since no flutes18,19,20,21are positioned within the stalk slot7when the stalk rolls15,16are positioned as inFIG.9D, and a stalk320(not shown) may again freely enter the stalk slot7and the corn plant engagement chamber with no restriction. Again, the stalk engagement gap25also allows stalks320already positioned between the stalk rolls15,16to travel in a lateral direction to compensate for the forward motion of the harvesting machine to which the corn head is attached.

FIG.9Eshows the stalk slot7at a later moment in time from the moment shown inFIG.9Dwherein the third flute20of each stalk roll15,16has moved into the stalk slot7so that there is no stalk engagement gap25. At this point, the third flutes20of the respective stalk rolls15,16now engage any stalk320between the stalk rolls15,16. As with similar moments in time already explained, this engagement may serve to lacerate or crush the stalk320, or to pull the stalk320downward through the corn plant engagement chamber and subsequently eject the stalk320depending on the specific embodiment.

FIG.9Fshows the stalk slot7at still a later moment in time wherein the fourth flute21of each stalk roll15,16have moved into the stalk slot7so that there is still no stalk engagement gap25. Here, the fourth flutes21of the respective stalk rolls15,16engage any stalk320between the stalk rolls15,16. Again, this engagement may serve to lacerate or crush the stalk320, or to pull the stalk320downward through the corn plant engagement chamber and subsequently eject the stalk320depending on the specific embodiment. As will be apparent to those skilled in the art, the next snapshot in time of the stalk slot7according to the pattern indicated byFIGS.9A-9Fwill be identical toFIG.9A, and would provide the last view of one full revolution of the stalk rolls15,16.

FIGS.6-9show an illustrative embodiment wherein the stalk rolls15,16and their respective flutes18,19,20,21are configured so that two stalk engagement gaps25appear per revolution of the stalk rolls15,16. As those of ordinary skill in the art will appreciate, the stalk rolls15,16and their respective flutes18,19,20,21may be configured so that nearly any number of stalk engagement gaps25appear per revolution of the stalk rolls15,16. For example, although not shown in the figures herein, one of ordinary skill in the art could easily add a fifth flute to the stalk rolls15,16between the fourth and first flutes18,21on each stalk roll15,16; and thereby reduce the number of stalk engagement gaps25per revolution of the stalk rolls15,16from two to one.

In the illustrative embodiment shown inFIGS.6-9, two structural features are necessary to create two stalk engagement gaps25per revolution of the stalk rolls15,16. First, the flutes18,19,20,21of each stalk roll15,16must be positioned around the circumference of the stalk roll15,16in a non-equidistant manner. That is, the circumferential distance between the first flute18and fourth flute21is greater than the circumferential distance between the third flute20and fourth flute21on each stalk roll15,16. Likewise, the circumferential distance between the second flute19and third flute20is greater than the circumferential distance between the first flute18and second flute19of each stalk roll15,16. However, this may be achieved using flutes18,19,20,21of different lengths so as to vary the circumferential distance between terminal ends of flutes18,19,20,21. Second, the first stalk roll15of an opposing pair is positioned on its respective stalk roll drive shaft29so that it is slightly advanced (with respect to rotational positions of the flutes18,19,20,21) compared to the second stalk roll16of the pair. During operation, the stalk rolls15,16operate at the same rotational speed so that the difference in positioning is maintained throughout operation. Because the stalk rolls12of the prior art and the flutes thereon are not configured to yield any stalk engagement gaps25, they essentially create a wall of rotating steel as previously described, which restricts the entry of the stalk320into stalk slot7and the corn plant engagement chamber.

FIG.10provides an end view of another embodiment of stalk rolls15,16. In this embodiment, a fifth flute26is added between the first flute18and second flute19so that the distance between the first flute18and the fifth flute26is equal to the distance between the second flute19and the fifth flute26. A sixth flute33has also been added between the third flute20and the fourth flute21so that the distance between the third flute20and the sixth flute33is equal to the distance between the fourth flute21and the sixth flute33.FIG.10depicts a moment when the stalk engagement gap25is present, thereby allowing stalks320to enter the corn plant engagement chamber. In this embodiment, as in the embodiment shown inFIGS.9A-9F, the stalk engagement gap25appears twice per revolution of the stalk rolls15,16.

In an alternative embodiment not shown herein, additional flutes that have a smaller axial length as compared to the axial length of flutes18,19,20,21could be placed between all or some of flutes18,19,20,21. (Alternatively some of the original flutes18,19,20,21could be fashioned with a smaller axial length than the axial length of adjacent flutes18,19,20,31.) Here, the additional flutes would not extend the entire distance of the cylindrical shell17. Instead, the additional flutes would only extend along the cylindrical shell17from a point proximal to the end of the cylindrical shell17closest to the cross auger9(which may be the same point from which the flutes18,19,20,21extend, as shown inFIG.6) to a point distal from the cross auger9, but not the entire length of the cylindrical shell7up to the interface between the cylindrical shell17and the nose cone5. That is, the additional flutes would not extend radially from the cylindrical shell17on a portion of the cylindrical shell17that is distal from the cross auger9(and also distal to the connection between the stalk roll drive shaft29and the corn header). This embodiment facilitates stalk rolls15,16that are configured so as to provide a stock engagement gap25along a predetermined axial portion of the stalk rolls15,16that first engage the stalk320(i.e., a portion distal from the cross auger9) while still providing more flutes to engage the stalk320in the corn plant engagement chamber on a portion of the stalk rolls15,16proximal to the corn header (which may assist in decomposition of the stalk320and harvesting speed).

As is apparent from the embodiment shown inFIG.10, the specific number and orientation of flutes18,19,20,21,26,33employed on a stalk roll15,16may vary. Therefore, the precise number of flutes18,19,20,21,26,33employed in a particular embodiment, or the specific orientation thereof in no way limits the scope of the present stalk roll15,16. As long as the flutes18,19,20,21,26,33are oriented upon the stalk rolls15,16and the stalk rolls15,16are orientated with respect to each other such that at least one stalk engagement gap25appears during one revolution of the stalk rolls15,16, the specific orientation or number of flutes18,19,20,21,26,33are not limiting to the scope of the present stalk roll15,16. Furthermore, what is referred to herein as a cylindrical shell17of the stalk rolls15,16need not be fashioned as a perfect cylinder; rather, it may be fashioned so that the cross-sectional area changes along the axial length (e.g., tapered), or be fashioned with any cross-sectional shape that performs in a relatively satisfactory manner.

2. Other Embodiments of Stalk Rolls with a Stalk Engagement Gap

Another embodiment of a pair of stalk rolls190implementing a stalk engagement gap25is shown inFIGS.13-14E. A pair of beveled stripper plates130is shown inFIG.12, and lines B-B, C-C, D-D, and E-E represent various zones along the lengths of the stripper plates130and stalk rolls190. The stalk rolls190and stripper plates130fromFIGS.12and13are shown in cross section at various positions along the lengths thereof inFIGS.14B-14E. The embodiment of the stalk rolls190and stripper plates130shown inFIGS.12-14Eare configured to create four distinct (but interrelated and overlapping) zones along the lengths thereof, each of which zone performs a separate function and purpose within the row unit. The combination of zones, relationships, and sub-function are designed to improve the performance of the corn head and harvesting machine by allowing better material flow through the row unit, reducing congestion and MOTE levels through the row unit, conveying systems, and the harvesting machine; thereby improving harvesting machine speeds and efficiencies. The four (4) current interrelated overlapping zones are the Alignment, Entry, Ear Separation, and Post-Ear Separation Plant Ejection Zones.

A) The Alignment Zone

In the embodiment pictured inFIGS.12-14E, the Alignment Zone is generally about the line B-B toward the front of the stalk rolls190and adjacent the nose cones5, which is best shown inFIGS.13and14B. In some embodiments, the Alignment Zone extends along the stalk rolls190from the front of the nose cones5to the line B-B. The purposes of this zone are to align, direct, and gather the corn plant for conveyance to the Entry and/or Ear Separation Zone with the ear300intact and positioned for recovery with minimal MOTE. In the Alignment Zone of the embodiment of the stripper plate130shown inFIGS.12and14B-14E, the stripper plates130are substantially flat, as best shown inFIGS.12and14B. This reduces the tendency of ears300to wedge below the stripper plates130. The transport vanes170on the nose cones4in front of the Alignment Zone serve to guide stalks320into the ear separation chamber140, which is best shown inFIG.20. The rotating transport vanes170may be either timed or non-meshing, so as to provide positive material flow in tough, damp, or high-speed harvesting conditions. One function of the transport vanes170generally is to center the stalk320in the ear separation chamber140.

The stalk rolls190shown inFIGS.13-14Ealso incorporate a stalk slot7in which a stalk engagement gap25occurs intermittently. The stalk slot7and stalk engagement gap25as defined for this embodiment of stalk rolls190is the same as those defined for the embodiment of stalk rolls15,16shown inFIGS.9-10. This embodiment of stalk rolls190facilitates a stalk engagement gap25that occurs along a specific length of the stalk rolls190. As shown inFIG.14B, the stalk engagement gap25first occurs toward the front of the stalk rolls190in the Alignment Zone and extends along the entire length thereof (which length is shown inFIG.13). This facilitates simple transport of the stalk320from the nose cones5to the ear separation chamber140between the stalk rolls190. The stalk engagement gap25in the Alignment Zone is formed by placing two short flutes180separated by 180 degrees on each stalk roll190, such that the short flutes180are arranged in a knife-to-knife configuration. Another function of the transport vanes170is to ensure that the stalk320does not fall forward out of the stalk engagement gap25.

B) The Entry Zone

In the embodiment pictured inFIGS.12-14E, the Entry Zone is generally about the line C-C toward the front of the stalk rolls190, but behind the Alignment Zone, which is best shown inFIGS.13and14C. In some embodiments, the Entry Zone extends along the stalk rolls190from the line C-C to the front portion of the stalk rolls190at the terminus of any intermediate flutes182, which are described in detail below. The primary purpose of this zone is to allow entry of the stalk320into the ear separation chamber140between the stalk rolls190. The rate at which stalks320are accepted into the row unit is a major factor in determining harvesting speed.

As explained above, prior art teaches that to increase the rate of entry, the rotating speed of the stalk roll12must be increased, which merely increases the egg-beater effect. If the stalk320is not pinched in the Entry Zone, the stalk320stalls in the row unit, which stalling allows the rotating flute edges to sever the stalk320. This stall also causes the stalk320to lean away from the row unit. Consequently, ear separation often occurs near the opening of the row unit, such that loose ears300fall to the ground and become irretrievable.

A stalk engagement gap25is also present in the Entry Zone in this embodiment of the stalk rolls190, which is best shown inFIG.14C. The short flutes180in the Alignment Zone extend into the Entry Zone, and the stalk engagement gap25in the Entry Zone is formed by placing two additional short flutes180adjacent to the short flutes180from the Alignment Zone. As shown inFIG.14C, the four short flutes180are not equally spaced about the periphery of the stalk rolls190, but instead are positioned in groups of two. This facilitates the stalk engagement gap25in the Entry Zone since adjacent short flutes180in each pair are close enough to each other that a stalk engagement gap25is present at least once during a full revolution of the stalk rolls190. In this embodiment a stalk engagement gap25is present twice during a full revolution in both the Alignment Zone and Entry Zone, as is evident fromFIGS.14B and14C.

C) The Ear Separation Zone

In the embodiment pictured inFIGS.12-14E, the Ear Separation Zone is generally about the line D-D on the front half of the stalk rolls190, which is best shown inFIGS.13and14D. In some embodiments, the Ear Separation Zone extends along the stalk rolls190from the terminus of an intermediate flute182toward the front of the stalk rolls190to the terminus of a long flute183, which is described in detail below. Generally, the Ear Separation Zone extends along a greater length of the stalk rolls190than does any other zone. The primary purpose of this zone is to separate the ear300from the stalk320and prevent any ears300from falling forward out of the row unit. In this zone, the embodiment of the stalk rolls190shown herein pull the stalk320through the stripper plates130without prematurely severing the stalk320. The maximum vertical speed at which the stalk rolls190consume the stalk320is determined by the damaging occurring to the ear300at a given speed, and will vary from one variety of corn to the next.

As best shown inFIGS.13and14D, intermediate flutes183that extend radially further from the stalk roll190than short flutes180may be positioned in the Ear Separation Zone. Because the intermediate flutes183are radially longer than the short flutes180, stalk rolls190engage stalks320more securely in this zone, which is evident fromFIG.14D. In the embodiment shown inFIGS.12-14E, like the short flutes180, the intermediate flutes182are not intermeshed but opposed with minimal clearance so that as a flute180,182on one stalk roll190begins to engage the stalk320, the opposing flute180,182on the other stalk roll190engages the stalk320at a point on the horizontally opposite side of the stalk320. This balanced engagement action reduces lateral stalk320whipping, which whipping can dislodge and toss the ear300from the stalk320, or cause the stalk320to prematurely break or sever. The balanced engagement action allows the stalk rolls190to evenly pull the stalk320down so that the stripper plates130may rapidly separate the ear300from the stalk320in the Ear Separation Zone.

Also apparent fromFIG.14Dis the fact that the Ear Separation Zone does not include a stalk engagement gap25. This is because the intermediate flutes182are positioned in the space between the two groups of short flutes180present in the Entry Zone. Accordingly, in the pictured embodiment a total of six flutes180,182are present in the Ear Separation Zone, and they are equally spaced about the periphery of the stalk roll190, such that each flute180,182is separated by sixty degrees. The two short flutes180in each pair in the Entry Zone are also separated by sixty degrees, and each pair of short flutes180is separated from the other by 120 degrees. A stalk engagement gap25is not required in the Ear Separation Zone because at this point the stalk320is securely positioned between the two stalk rolls320and the danger of the stalk320falling forward out of the ear separation chamber140has been alleviated. That is, the egg beater effect previously described has been eliminated by providing a stalk engagement gap25in the Alignment and Entry Zones.

D) The Post-Ear Separation Plant Ejection Zone

In the embodiment pictured inFIGS.12-14E, the Post-Ear Separation Plant Ejection Zone is generally about the line E-E toward the back of the stalk rolls190, which is best shown inFIGS.13and14E. In some embodiments, this zone extends along the stalk rolls190from the start of a long flute183to the terminus of a long flute183toward the back of the stalk roll190, which is described in detail below. The primary purpose of this zone is to rapidly eject the stalk320from the row unit to minimize interference between MOTE and ears300. No specific speed ratio controls the operating speed of this zone. After ear separation, increasing stalk320ejection speed effectively reduces MOTE entering the threshing (kernel separation) area of the harvesting machine, thereby increasing threshing efficiency and capacity.

As shown inFIGS.13and14E, this zone may include a plurality of long flutes183, three of which are shown on each stalk roll190. The long flutes183extend radially further from the stalk roll190than any other flutes180,182. Within this zone, the long flutes183may be both meshing and non-meshing so as to create a high-speed clean out zone. The stalk rolls190may also be aerodynamically designed to create a suction effect so that unattached MOTE from the ear separation chamber140is pulled downward and returned to the field. The Post-Ear Separation Plant Ejection Zone may also be configured to sever, crush, chop, or otherwise manipulate the stalk320to speed decomposition thereof. The various functions of this zone may be achieved through different orientations and/or configurations of flutes180,182,183in the zone, as well as the number of flutes180,182,183therein. Accordingly, the scope of the stalk rolls190is not limited by the number of flutes180,182,183in any zone, nor it is limited by the configuration and/or orientation of flutes180,182,183in any zone.

As shown inFIGS.12and14E, this zone may be configured as a clean-out zone by adding short lengths of long flutes183between the short and/or intermediate flutes180,182. Using inter-meshing long flutes183allows faster ejection of small diameter stalks320, normally found at the upper-most portion of the corn plant. The intermeshing long flutes183of stalk rolls190or192are aerodynamically designed and assembled to create a down draft through the ear separation chamber140, which further enhances removal of any MOTE.

The short flutes180, intermediate flutes182, and/or long flutes183may be integrally formed with one another such that a short flute180and/or intermediate flute182is formed by removing a portion of a long flute183. As a corollary, a short flute180may be formed by removing a portion of an intermediate flute182. Conversely, the various flutes180,182,183may be separately formed. Additionally, short and/or intermediate flutes180,182present in either the Alignment or Entry Zones may extend to the Ear Separation and Post-Ear Separation Plant Ejection Zones, as shown in the embodiment inFIGS.13-14E.

The height and width of the stalk engagement gap25have been defined previously herein with respect toFIGS.9-10. The length of the stalk engagement gap25may vary from one embodiment of stalk rolls190to the next. For example, in the embodiment of stalk rolls190pictured inFIGS.13-14E, the stalk engagement gap25extends from the Alignment Zone to the front of the Ear Separation Zone, which is less than half the overall length of the stalk rolls190. However, in other embodiments of the stalk rolls190, the length of the stalk engagement gap25may be different. Accordingly, the scope of the stalk rolls190as disclosed and claimed herein is in no way limited by the length of the stalk engagement gap25.

As described and specifically claimed in other patents and patent applications owned by Applicant, the stripper plates130used with any of the stalk rolls15,16,190,400or any other stalk rolls190may be beveled along their lengths, as shown inFIGS.12and14B-14E. The stripper plates130as shown herein have a rounded or contoured surface to emulate the arched under side of the corn leaf310with two positive effects. First, this allows the corn leaf to stay attached to the stalk320, reducing the level of MOTE retained in the ear separation chamber140. Secondly, this shape also improves separation of the husk from the ear300, further reducing the level of MOTE in the ear separation chamber140. As shown inFIGS.14B and14C, the stripper plates130are substantially flat in the Alignment and Entry Zones, which reduces ear300wedging below stripper plates130, and above the transport vanes170of the stalk rolls190when ears300are being gathered from near ground level. As shown inFIGS.14D and14E, in the Ear Separation and Post-Ear Separation Plant Ejection Zones the stripper plates130are normally directly above the fluted portion of stalk rolls190and are slightly curved down. This curve may specifically emulate the arched portion or underside of leaf310. This improved curved shape allows smooth flow of unwanted portions of the corn plants to pass between stripper plates130and exit the ear separation chamber140while retaining the ear300.

As shown inFIG.18, the embodiment shown inFIGS.12-14Eallows the flutes180,182,183and stripper plates130to positioned closely to one another, which reduces the amount of MOTE retained in the ear separation chamber140in the event that stalk320separation (which is defined as a cutting of the stalk320, or other action that causes a portion of the stalk320to be separated from another portion thereof) takes place before ear300separation.

FIGS.16-16Cshow another embodiment of stalk rolls190featuring certain aspects of the present disclosure. In this embodiment, the short flutes180(adjacent the area bisected by line A-A and best shown inFIG.16A) of the stalk rolls190are opposed with one another so that they meet during operation. They do not, however, ever touch during normal operation. The distance between the stalk rolls190decreases along their length from line A-A to line B-B as shown byFIGS.16A-16C. Additionally, long flutes183are positioned on the stalk rolls190adjacent the back thereof about line C-C. This configuration provides optimum balanced pressure against the stalk320in certain conditions to first engage the stalk320and then pull it down while penetrating the stalk outer shell321, thus avoiding stalk whip during engagement of the stalk320.

In this embodiment of stalk rolls190, the short and intermediate flutes180,183may be integrally formed with one another and distinguished from one another via a stair-step configuration. The distance between opposing flutes180,182,183may be reduced in discrete increments along the length of the stalk rolls190, as best shown inFIG.16. These stalk rolls190could also be configured to have a stalk engagement gap25as previously described. Furthermore, any of the stalk rolls15,16,190,400described or pictured herein may have any number of flutes180,181,182,183extending radially any suitable distance from the stalk roll15,16,190,400, and may have a combination of tapered flutes181and other flutes180,182,183. For example, in one embodiment of a stalk roll190not pictured herein, the Ear Separation Zone may include flutes180,182,183having four different radial dimensions, with tapered flutes181interspersed there about. Accordingly, the scope of the stalk rolls15,16,190,400as disclosed and claimed herein is not limited by the number of different radial dimensions by which flutes180,181,182,183extend from the stalk rolls190. In another embodiment of the stalk rolls190, the distance between the flutes180,182,183may be reduced discretely but there may also be a taper between those discrete points.

3. Tapered Stalk Rolls

A further improvement described herein compromises tapering the stalk rolls to modify the configuration of the Entry Zone to further improve performance of the Entry Zone. The tapered stalk rolls192shown inFIGS.15-15Cexploit a natural attribute present in standing corn—the diameter of the stalk320at its base (i.e., ground level) is larger than its diameter toward the tip or tassel. The largest gap between the tapered stalk rolls192is at the entry to the stalk rolls192near the front; the smallest gap is at the point of exit of the stalk rolls192near the rear. This taper in the stalk rolls192balances the outward forces created by the stalk320against the tapered flutes181and the inward force of the tapered flute181against the stalk320. An imbalance of the forces can create a pulsation in the stalk rolls192during operation. This pulsation creates a moment about the gearbox that can produce premature failure in the gearbox or its supporting mechanisms. Tapering the stalk rolls192reduces the potential for pulsation while promoting entry of the stalks320between the stalk rolls192and allowing aggressive engagement between the stalk rolls192and the stalk320. The tapering may be achieved by changing the diameter of the stalk rolls192along their length or the radial distance that the tapered flutes181extend from the stalk roll192.

The embodiment of stalk rolls192having tapered flutes181shown inFIGS.15-15Care configured for the tapered flutes181in the Alignment/Entry Zone (the area about line A-A) and Ear Separation Zones (the area about line B-B) to be opposed, as clearly shown inFIGS.15B and15A. Conversely, the tapered flutes181in the Post-Ear Separation Plant Ejection Zone (the area about line C-C) are intermeshing, as best shown inFIG.15C. During operation, as a stalk320is engaged by the stalk rolls192, the distance between the tapered flutes181and the opposing stalk roll192is reduced, thereby increasing penetration of the stalk320by the tapered flutes181and exerting continuous pressure against the stalk320during engagement.

Another embodiment of stalk rolls192having tapered flutes181is shown inFIGS.17-17B. In this embodiment, all the tapered flutes181are intermeshing with one another, as is clearly shown inFIGS.17A and17B. In this embodiment of stalk rolls192, the various zones previously described are comingled such that clear boundaries between the zones do not exist. Instead, the transition from one zone to the next is smooth and seamless. However, any embodiment of tapered stalk rolls192may be configured with a stalk engagement gap25by simply removing a portion of certain tapered flutes181.

Both the tapered stalk rolls192and the stalk rolls190shown inFIGS.13,14, and16are configured to achieve variable circumferential speeds along the length of the stalk rolls190,192. There are at least three critical circumferential speed ratios related to ground speed for optimum high efficiency harvesting. The three critical speed ratios are: (1) Harvesting machine ground speed to row unit horizontal gathering chain speed120(the gathering chain120speed must be the same as or faster than the ground speed); (2) Harvesting machine ground speed to the speed at which the transport vanes170horizontally guide stalks320into the ear separation chamber140; and, (3) harvesting machine ground speed to row unit vertical ear separation speed. The vertical ear separation speed (sometimes referred to as vertical stalk speed) must be the same as or faster than the ground speed. However, the maximum vertical stalk speed before ear300separation is the highest speed at which the ears300are not damaged upon impact within the row unit. Each of these critical speed ratios constrains the operating speed of each zone described herein. Operating outside the critical speed ratio constraints within each zone produces sub-optimal performance.

Optimizing all the critical speed ratios, as required by high-speed, high-yield, and/or harvesting in leaning, lodged, or broken stalk320conditions, may require the effective circumferential speed and interaction of the multi-length, multi-angled, multi-fluted, multi-vaned stalk rolls15,16,190,192,400described in each in zone to vary while accomplishing the functions described in each zone. Applicant understands that the various speed ratios are interrelated and effective row unit designs must recognize and incorporate these varied speed ratios to ensure corn plant(s) remain vertical or lean slightly toward the corn head upon engagement. Harvesting corn plants in this manner promotes ear separation in the targeted Ear Separation Zone and away from the front of the row unit. Targeting ear separation in this zone, and manner, reduces losses from ears300falling forward out of the corn head row unit and onto the ground; thereby becoming irretrievable.

4. Recessed Stalk Rolls

Another embodiment of a stalk roll400having a stalk engagement gap25is shown inFIGS.21-22.FIGS.21A and21Bprovide corresponding perspective views of the stalk roll400, which is designed to be one of a pair of opposed, counter-rotating stalk rolls400mounted to a corn head row unit in a manner previously described. The stalk rolls400are shown with nose cones410having flighting412attached thereto. Typically, the nose cone410is shaped substantially as a cone, as shown in the embodiments of stalk rolls400pictured herein. The flighting412is configured to guide stalks320into the ear separation chamber140as previously described.FIGS.21-22illustrate a first embodiment of a stalk roll400having a recess420, as described in detail below.

Each stalk roll400may be formed with a main cylinder430having a recess420formed therein between the front end of the main cylinder430and the nose cone410as shown inFIGS.21A and21B. The recess420may extend along the entire circumference of the stalk roll400(i.e., an annular recess420). The recess420may be formed in the nose cone410, or it may be formed as a separate cylinder that is later affixed to both the main cylinder430and the nose cone410. The diameter of the recess420is less than the diameter of either the main cylinder430or the rearward end of the nose cone410, which is apparent fromFIGS.21A and21B. The length of the recess420may vary from one embodiment of the stalk roll400to the next, but it is contemplated that for most embodiments the length of the recess420will be from 1.5 to 6 inches in length. Additionally, for certain embodiments it is contemplated that the diameter of the recess420will vary along its length. Accordingly, the specific dimensions of the recess420are in no way limiting.

The embodiment of the stalk rolls400shown inFIGS.21-22include a total of ten flutes440,450, wherein six of those are full flutes440and four of those are reduced flutes450. However, other embodiments of the stalk rolls400may have other numbers of full flutes440and/or reduced flutes450to achieve a different number of total flutes440,450and/or ratio of full flutes440to reduced flutes450. Additionally, the reduced flutes450need not be the same length. The flutes440,450extend in a radial direction from the main cylinder430and/or recess420. The flutes440,450in the embodiment shown inFIGS.21-22are substantially parallel to the longitudinal axis of the stalk roll400and substantially perpendicular to a line tangent to the main cylinder430at the flute base449.

In a second embodiment of the stalk roll the flutes440,450are oriented differently with respect to lines that are tangent to the main cylinder430at the flute base449. For example,FIG.23provides an end view of two stalk rolls400intermeshed with one another wherein the flutes440,450are angled forward with respect to the direction of rotation of the stalk rolls400. Accordingly, the angle of the flutes440,450with respect to lines that are tangent to the main cylinder430at the flute base449in no way limits the scope of the stalk rolls400as disclosed and claimed herein.

In the first embodiment of the stalk roll400, the full flutes440extend from the rearward end of the main cylinder430through the recess420and to the rearward end of the nose cone410, as shown inFIGS.21A and21B. The reduced flutes450may extend from the rearward end of the main cylinder430to the rearward end of the recess420. In the first embodiment of the stalk roll400, the reduced flutes450are oriented in two pairs on opposite sides of the stalk roll400and the full flutes440are arranged in groups of three on opposite sides of the stalk roll400. The circumferential distance between the flutes440,450may be equal, and in the first embodiment the flutes440,450are positioned at thirty-six degrees from each adjacent flute440,450.

A detailed view of the flutes440,450is shown inFIG.21C. As shown, each flute440,450includes a flute edge442at the vertex of a leading surface444and a trailing surface445. The leading and trailing surfaces444,445may be connected to the main cylinder430and/or recess420(depending on whether it is a full flute440or reduced flute450) with a flute base449. The flute base449may have a leading wall446adjacent the leading surface444and a trailing wall447adjacent the trailing surface445. In the first embodiment of the stalk roll400, a pair of stalk rolls400is mounted such that stalk roll400rotates toward the leading surface444and leading wall446, as shown by the arrows inFIG.22B.

Each flute440,450may be formed with a beveled edge448on the front axial surface thereof. In certain conditions, a beveled edge448provides easier entry for a stalk320into the corn plant engagement chamber. In the embodiment shown inFIGS.21-22, the beveled edge448is angled at 30 degrees with respect to the vertical. However, in other embodiments the beveled edge448may be differently configured without limitation.

In the first embodiment of the stalk roll400the trailing wall447and trailing surface445are integral and linear, but may have other configurations in other embodiments of the stalk roll400. In the first embodiment the leading surface444is angled at thirty degrees with respect to the leading wall446, which also creates an angle of thirty degrees between the leading surface444and trailing surface445(and trailing wall447in the first embodiment). Through testing, Applicant has found that this orientation allows the flutes440,452to effectively secure the stalk320during ear321removal and subsequently process the stalk320for accelerated decomposition. Additionally, this orientation allows the stalk rolls400to properly release the stalk320after the ear321has been removed so that the stalk320does not wrap around the stalk roll400. Other orientations and/or configurations of leading surfaces444, trailing surfaces445, leading walls446, trailing walls447, and/or flute bases449may be used in other embodiments of the stalk roll400without limitation.

The embodiment shown inFIG.23includes leading and trailing surfaces444,445that are substantially parallel to one another and create a flute edge442that is substantially flat, which may be optimal in conditions in which it is desired that the stalk320be pulverized rather than cut/lacerated. The angle between the leading and trailing surfaces444,445and the flute edge442in the embodiment inFIG.23may be different than shown herein without limitation. The optimal configuration will vary at least based on the threshing conditions and plant variety. In the pictured embodiment, the flute edge442is perpendicular with respect to both the leading and trailing edges444,445so that the stalk rolls400properly release the stalk320after processing. However, other configurations will be preferred for other operating conditions.

FIG.22shows an end view of two cooperating stalk rolls400configured according to the first embodiment. The stalk rolls400in this figure are shown substantially as they would appear when mounted on a corn head row unit. As shown, the stalk rolls400are mounted such that one pair of reduced flutes450on opposing stalk rolls400are adjacent one another twice during a full revolution of the stalk rolls400. This creates two stalk engagement gaps25per revolution that extend the length of the recess420. That is, the length of the stalk engagement gap25in the first embodiment of the stalk rolls400is equal to the difference in the length between the full flutes440and reduced flutes450, which is also equal to the length of the recess420. In the first embodiment of the stalk roll400having a recess420, the width of the stalk slot7is defined by the distance between the inner peripheries of the main cylinders430of the opposing stalk rolls400. The recess420increases the effective width of the stalk engagement gap25by two times the difference in diameter between the main cylinder430and the recess420. Furthermore, the recess420facilitates the positioning of a stalk320between the flute edge442of a full flute440and the recess420when the stalk engagement gap25is not present in the stalk slot7. This ensures that stalks320will move rearward along the length of the stalk rolls400during harvesting rather than stalling at the front of the stalk rolls400or being pushed forward to the nose cone410. In embodiments of the stalk roll400in which the depth of the recess420is not constant along its length, the width of the stalk slot7is also not constant.

The embodiment of stalk rolls400shown inFIGS.21-22effectively remove ears300from a stalk320and also cut the stalk320upon ejection from the stalk rolls400. This is achieved through the simultaneous grasp and control of the stalk320by a first pair of flutes440,450while a second flute440,450below the first pair cuts the stalk320. This situation is shown schematically inFIG.22B. The first pair of flutes440,450secure the stalk320by engaging at it first and second grasp points322,323. This grasp and control of the stalk320allows another flute440,450positioned below but adjacent the second grasp point323to produce a stalk cut point324. This functionality requires a plurality of flutes440,450spaced less than sixty degrees from adjacent flutes440,450. That is, at least seven flutes440,450are required, and the embodiment pictured herein employs ten flutes440,450.

Applicant expected stalk rolls400as shown inFIGS.21-22to increase the amount of MOTE produced during harvesting compared to otherwise-identical six-flute stalk rolls. However, field testing showed that the ten-flute stalk rolls400actually produced less MOTE while simultaneously more effectively mutilating the stalk320than did the six-flute stalk rolls. Moreover, the ten-flute stalk rolls400operated consistently in multiple conditions, including high moisture (e.g., early morning or late evening harvesting), low moisture, and various varieties of corn plants.

The cutting function at the stalk cut point324is enhanced by the secure engagement of the stalk320at the first and second grasp points322,323and the forward slope of the leading surface444. Instead of slipping past the flute edge442at the stalk cut point324, the stalk320is secured by the first and second grasp points322,323so that the flute edge442at the stalk cut point324can fully penetrate the stalk320. This allows the stalk rolls400to eject a plurality of stalk pieces326that resemble confetti.

Other embodiments of stalk rolls400incorporating a recess420may have additional or fewer flutes440,450extending other distances along the length of the stalk roll400. Additionally, any considerations, designs, and/or orientations previously discussed for other stalk rolls15,16,190,192may be incorporated with stalk rolls400having a recess420. For example, intermediate flutes182, tapered flutes181, and/or long flutes183may be positioned on the stalk roll400at various positions thereof. Additionally, the considerations of the various zones described in detail above may be incorporated into the design of the stalk rolls400.

5. Other Row Unit Considerations

As shown in the embodiment of a corn head row unit inFIG.20the stalks320are lifted and guided toward the row unit by dividers100. Gathering chain120may be formed with enlarged gathering chain paddles110, which help to direct the stalks320and/or ears300toward the ear separation chamber140. The stalks320may be further centered into the ear separation chamber140by improved stripper plates130described in detail above. Enlarged gathering chain paddles110have an increased angle relative to the gathering chain120, which allow the gathering chain paddles110to engagement a larger number of stalks320and/or corn plants, especially when harvesting leaning and/or lodged corn.

Stalks320are gathered and further propelled rearwardly by means of the force imparted by transport vanes170on the nose cones5, which are oppositely wound and strategically timed to be horizontally opposite. The transport vanes170positively direct and lock the stalk320into the Alignment and Entry Zones, both of which may be configured with a stalk engagement gap25. Alternatively, the stalk engagement gap25may be replaced and/or supplemented with stalk rolls190having tapered flutes181as shown inFIGS.15-15C and17-17B. The strategic lateral speed imparted to the stalk320by rotating transport vanes170is determined by the angle of the transport vanes170. This lateral speed may be equal to or faster than the lateral speed imparted to the stalk320by gathering chain paddles110.

In the embodiment of a row unit shown inFIG.20, the reduced number of enlarged gathering chain paddles110increases the conveying capacity of the row unit in the ear separation chamber140to carry separated ears300rearward. This improved capacity increases the conveying efficiency of the gathering chain paddles110to the cross auger trough200, which contains auger220and flighting230for conveying ears300to the feeder house area.

FIGS.18and18Ashow how the tapered flute-to-flute design stalk rolls192may work in certain conditions. As the stalk rolls192rotate, the sharpened edges of the flutes181penetrate the stalk outer shell321. The penetration of the tapered flutes181combined with the rotation of the stalk rolls192may simultaneously pull and lacerate the stalk320. Because the entire row unit is moving forward during operation, the tapered flutes181penetrate deeper and deeper into the stalk320as it is pulled down into the row unit. The difference in height between the tapered flutes181and the stalk roll192results in a continuous compressing/decompressing action against the stalk320, which may crimp the stalk320.

FIGS.19Aand B illustrate the non-meshing stalk rolls190as they rotate during operation. InFIG.18A, flutes180are marked at the top of the rotation prior to contact with the stalk320. As the stalk roll190rotates, the edge of the flutes180will engage and begin to pinch the stalk320. InFIG.19B, flutes180have been rotated ninety degrees. The opposing flutes180are directly opposite each other. The pressure exerted by flutes180on the stalk320has lead to penetration of the stalk320. The rotation of the stalk roll190has pulled the stalk320down into the corn row unit. Penetration by the flutes180is at maximum depth inFIG.18B. Opposing flutes180do not touch each other during the cycle to avoid cutting through the stalk320in this embodiment. The angle of the knife edges of the flutes180have a predetermined slope, as described. The angle of the slopes are forward with respect to the direction of rotation of the stalk rolls190.

Any of the stalk rolls15,16,190,192,400may be mounted either in a cantilevered or non-cantilevered manner, with or without nose bearings. Additionally, any of the stalk rolls15,16,190,192,400may be oriented in opposing, knife-to-knife configurations or intermeshed and/or interleaved configurations. As previously mentioned, non-meshing and horizontally opposite configured flutes180,181,182,183cause the flute edges to pinch the stalk320simultaneously as they rotate, thus providing that the resultant equal forces are applied to both sides of the engaged stalk320so as to eliminate corn plant whip. This keeps the stalk320perpendicular and reduces any whipping action that prematurely dislodges ears300from the stalk320or snaps the stalk320at the stalk node330. The remaining flutes180,181,182,183of stalk roll190may then further pinch the stalk320pulling it down and rearward so that the ears300are removed from the stalks320as they come into contact with the desired Ear Separation Zone of stripper plates130.

In any of the embodiments of stalk rolls15,16,190,192,400the various flutes18,19,20,21,26,33,180,181,182,183,440,450may be self sharpening, or may have a work hardened knife/flute edge22,442. Furthermore, any of the knife/flute edges22,442disclosed herein may be coated with various materials, such as chrome, tungsten carbide, or any other materials that is suitable for the specific application.

The stalk rolls15,16,190,192,400and various elements thereof may be constructed of any suitable material known to those skilled in the art or suitable for a specific application. In the embodiment as pictured herein, it is contemplated that most elements will be constructed of metal or metallic alloys, polymers, or combinations thereof. However, other suitable materials may be used.

It should be noted that the stalk rolls15,16,190,192,400; flutes18,19,20,21,26,33,180,181,182,183,440,450; stripper plates3,130; gathering chain paddles1,110; nose cones5,410; row dividers4,100and any other element and/or feature described herein are not limited to the specific embodiments pictured and described herein, but is intended to apply to all similar apparatuses and methods for providing the various benefits of those elements, which benefits include but are not limited to increasing the harvesting quality and/or speed of a harvesting machine. Modifications and alterations from the described embodiments will occur to those skilled in the art without departure from the spirit and scope of the stalk rolls15,16,190,192,400.

Furthermore, variations and modifications of the foregoing are within the scope of the stalk rolls15,16,190,192,400. It is understood that the stalk rolls15,16,190,192,400as disclosed and defined herein extends to all alternative combinations of one or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the stalk rolls15,16,190,192,400. The embodiments described herein explain the best modes known for practicing the stalk rolls15,16,190,192,400and will enable others skilled in the art to utilize the same. The claims are to be construed to include alternative embodiments to the extent permitted by the prior art.

Having described the preferred embodiment, other features, advantages, and/or efficiencies of the stalk rolls15,16,190,192,400will undoubtedly occur to those versed in the art, as will numerous modifications and alterations of the disclosed embodiments and methods, all of which may be achieved without departing from the spirit and scope of the stalk rolls15,16,190,192,400.