Note: Descriptions are shown in the official language in which they were submitted.
TITLE OF INVENTION
Stalk Roll
FIELD OF THE INVENTION
The apparatus described herein is generally applicable to the field of
agricultural equipment.
The embodiments shown and described herein are more particularly for improved
harvesting
of corn plants.
BACKGROUND OF THE INVENTION
Modern agriculture techniques require that during separation of a corn plant
ear (or "ear")
from a stalk (or "stalk") corn harvesting machines optimize the following
considerations: (1)
increase the rate of ear separation; (2) increase the speed at which stalks
are ejected from the
row unit; (3) retain minimal amounts of material other than ears ("MOTE") in
the
heterogeneous material being delivered to the harvesting machine for
threshing; and, (4)
lacerate, cut, and/or penetrate the shell of the stalk to expose the internal
portions for
accelerated decomposition of the stalk.
As shown in FIG. 1, modern corn headers are provided with a plurality of row
crop dividers
for retrieving, lifting, and directing the rows of stalks toward their
respective corn plant
engagement chambers. The corn plant engagement chamber is defined herein as
the portion
of the corn head row unit that engages the stalk and separates the ear from
the corn plant.
FIG. IA shows the top view of two stalk rolls found in the prior art.
Gathering chains located
in the corn plant engagement chamber draw the stalks and/or ears towards the
header. Stalk
rolls located beneath the gathering chains pull the stalks rapidly downward,
returning the
stalk to the field. These stalk rolls are typically powered by a gearbox. As
the stalk rolls
rotate, the flutes on the stalk rolls engage and pull the stalks downward. Two
stripper plates
located above the stalk rolls, with one stripper plate on either side of the
corn row, are spaced
wide enough to allow the stalks and leaves to pass between them but narrow
enough to retain
the ears. This causes the ears to be separated from the corn plant as the
stalk is pulled down
Date Recue/Date Received 2022-09-13
through the stripper plates. The stalk rolls continue to rotate and eject the
unwanted portions
of the corn plant below the corn plant engagement chamber, thereby returning
the unwanted
portions of the corn plant to the field.
The performance of stalk rolls found in the prior art, as shown in FIGS. 3-5,
has been found
to be less than optimal. Attempts at increasing stalk roll performance and
increasing ear
separation speed have been made by increasing rotational speed of the stalk
rolls. These
attempts have been largely unsuccessful because stalk rolls having uniform
length flutes
rotating at high speeds simulate a solid rotating cylinder (sometimes referred
to as an "egg-
beater effect"), which restricts entry of the corn plant into the corn plant
engagement
chamber. The diameter of the simulated rotating cylinder is approximately
equal to the
distance from the tip of a first flute on a given stalk roll to the tip of a
second flute oriented
closest to 180 degrees from the first flute (i.e., two opposed flutes on a
given stalk roll). This
rotating-cylinder effect prevents individual flutes from engaging the stalk
and restricts corn
plants from entering the corn plant engagement chamber. Thus, stalk engagement
is hindered
and the corn plant hesitates and does not enter the corn plant engagement
chamber.
The prior art has attempted to increase the performance of cutting or chopping
stalk rolls by
simply adding more flutes to the stalk rolls. In prior art applications, this
reduces the
performance of the stalk rolls because during rotation of the stalk rolls, a
semi-continuous
wall of steel restricts entry of the stalk into the corn plant engagement
chamber, as noted
above. Adding flutes decreases the likelihood of a stalk entering the space
between two
opposing stalk rolls. That is, as more flutes are added to the stalk roll,
rotation of the stalk roll
causes the stalk roll to more closely simulate a rotating cylinder. When
viewed along the axis
of rotation of the stalk roll (the direction from which the stalk rolls would
approach the stalk),
adding more flutes restricts the ability of the stalks to enter the corn plant
engagement
chamber due to interference from the ends of the flutes.
When the gathering chain paddle passes above the stripper plates and engages a
stalk that is
restricted from entering the corn plant engagement chamber, the gathering
chain paddle will
likely break or sever the stalk prior to ear separation. Stalk severance prior
to ear separation
increases intake of MOTE to the harvesting machine, thereby increasing
horsepower and fuel
requirements. Difficulty in stalks entering the area between to stalk rolls
may also cause ear
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Date Recue/Date Received 2020-04-27
separation to take place near the opening of the row unit and allow loose ears
to fall to the
ground, thereby becoming irretrievable.
Figure 3 shows prior art opposing stalk roll designs utilizing six flutes that
inter-mesh and
overlap. When the flutes of this type engage the stalk, the flutes alternately
apply opposing
force. This knife-edge relationship causes at least two problems. First, the
corn plants are
violently tossed from side to side causing premature separation of loosely
attached ears,
thereby permitting the ear to fall to the ground and become irretrievable.
Second, the stalk is
cut or snapped at a node causing long, unwanted portions of the stalk and
leaves to stay
attachcd to the car and remain in the row unit. This increases the amount of
MOTE the
harvesting machine must process. This problem is compounded as the number of
row units
per corn head is increased.
Figure 4 shows the prior art stalk roll design with intermeshing knife edges
as described in
U.S. Patent No. 5,404,699. As shown, the stalk rolls have six outwardly
extending integral
flutes. Each flute has a knife edge that is provided with a leading surface
and a trailing
surface. The leading surface of the knife edge has a ten degree forward (with
respect to the
rotation of the stalk roll) slope and the trailing surface has a thirty degree
reverse slope (with
respect to the rotation of the stalk roll), both of which slopes are defined
with respect to a line
extending through the vertex of the knife edge and the central longitudinal
axis of the stalk
roll. Therefore, the leading surface is steeper than the trailing surface of
each knife edge. The
radially extending flutes are interleaved with one another in an intermeshing-
type
arrangement. The stalk rolls may be mounted in a cantilevered arrangement; or
alternatively,
in an arrangement employing nose bearings. The stalk roll comprises a
cylindrical shell
formed by two semi-cylindrical pieces that are clamped about a drive shaft.
Bolts extend
between the two semi-cylindrical pieces to pull the pieces together, thereby
clamping the
stalk rolls to the drive shaft.
This design, upon restricted engagement of the stalk roll with the stalk,
allows the knife edges
to cut stalks before pulling the stalks through the stripper plates to
separate the ear from the
stalk, effectively leaving the upper portion of the corn plant free to float
in the corn row unit
as shown in FIG. 3. This requires the harvesting machine threshing components
to process a
3
Date Recue/Date Received 2020-04-27
substantial portion of the stalk, which increases harvesting machine
horsepower and fuel
requirements.
Figure 5 shows the design disclosed by U.S. Pat. No. 6,216,428, which is a
stalk roll having
bilaterally symmetric flutes with knife edges that are adjacent and overlap in
the shear zone
area. This design produces a shearing and cutting of the stalk using a scissor
configuration
produced by the leading and trailing edges of the opposing knife-edged flutes.
Again, the
stalks are cut off prior to ear separation. This is sometimes referred to as a
"scissor effect"
and also results in the need to process increased amounts of MOTE.
Case IH corn heads built prior to development of U.S. Pat. No. 6,216,428 used
stalk rolls
having four knives that are bolted to a solid shaft. Adjacent stalk rolls are
registered with one
another so that as the stalk rolls are rotated, the knives of the opposing
stalk rolls are also
opposing rather than intermeshing. In an opposing arrangement, the knives come
into contact
with opposite sides of the stalk at the same general height of the stalk,
thereby lacerating the
stalk for accelerated decomposition. It is important that the blades are
correctly registered
with one another, and that the blades are correctly spaced from one another.
The stalk rolls
used on Case IH corn heads require nose bearings at the forward end (with
respect to the
direction of travel of the harvesting machine during threshing) of the stalk
rolls to operate
properly and may not be mounted in a cantilevered arrangement.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the advantages of the invention will be readily understood, a
more particular
description of the invention briefly described above will be rendered by
reference to specific
embodiments illustrated in the appended drawings. Understanding that these
drawings depict
only typical embodiments of the invention and are not therefore to be
considered limited of
its scope, the invention will be described and explained with additional
specificity and detail
through the use of the accompanying drawings.
FIG. 1 is a top view of one embodiment of a corn head that contains a cross
auger, a feeder
house, a frame, and multiple row units of the prior art.
FIG. IA is an exploded top view of a portion of one row unit of FIG. 1 of the
prior art
showing a portion of the corn plant engagement chamber.
4
Date Recue/Date Received 2020-04-27
FIG. 2 is a cross-sectional view along the plane of A-A of one row unit, the
cross auger, the
cross auger trough, the feeder house, and the gathering chain from FIG. 1, as
disclosed in the
prior art.
FIG. 3 is a cross-sectional view of a portion of the corn head shown in FIG. 1
along the plane
F highlighting the stalk rolls and stripper plates of one row unit of the
prior art engaged with
and shearing a corn plant.
FIG. 4 is an end view of a pair of cutting-type stalk rolls as disclosed in
the prior art.
FIG. 5 is an end view of a pair of shearing-type stalk rolls as disclosed in
the prior art.
FIG. 6 is a top view of an illustrative embodiment of a pair of opposing stalk
rolls
incorporating certain aspects of the present disclosure.
FIG. 7 is a perspective view of an illustrative embodiment of a pair opposing
of stalk rolls
incorporating certain aspects of the present disclosure, wherein the nose
cones have been
removed for clarity.
FIG. 8 is an exploded view of a pair of stalk rolls shown in FIGS. 6 & 7.
FIG. 9A is an end view of an opposing pair of one illustrative embodiment of
the present art
stalk rolls positioned to illustrate a first moment during which the stalk
engagement gap is
present.
FIG. 9B is an end view of an opposing pair of one illustrative embodiment of
the present art
stalk rolls at a moment in time later than that depicted in FIG. 9A showing
the stalk rolls
rotated so that the stalk engagement gap is no longer present due to the first
opposing flutes
positioned in the stalk slot.
FIG. 9C provides an end view an opposing pair of one illustrative embodiment
of the present
art stalk rolls at a moment in time later than that depicted in FIG. 9B
showing the stalk rolls
rotated so that the stalk engagement gap is not present due to the second
opposing flutes
positioned in the stalk slot.
FIG. 9D is an end view of an opposing pair of one illustrative embodiment of
the present art
stalk rolls at a moment in time later than that depicted in FIG. 9C showing
the stalk rolls
rotated to a position where the stalk engagement gap is present for the second
time during one
revolution of the stalk rolls.
FIG. 9E is an end view of an opposing pair of one illustrative embodiment of
the present art
stalk rolls at a moment in time later than that depicted in FIG. 9D showing
the stalk rolls
rotated so that the stalk engagement gap is no longer present due to the third
opposing flutes
positioned in the stalk slot.
Date Recue/Date Received 2020-04-27
FIG. 9F is an end view of an opposing pair of one illustrative embodiment of
the present art
stalk rolls at a moment in time later than that depicted in FIG. 9E showing
the stalk rolls
rotated so that the stalk engagement gap is not present due to the fourth
opposing flutes
positioned in the stalk slot.
FIG. 10 is an end view of a another illustrative embodiment of an opposing
pair of the present
art stalk rolls having fifth and sixth flutes with a rotational position
corresponding to the
position of the stalk rolls in FIG. 9A.
FIG. 11 is an end view of an opposing pair of one illustrative embodiment of
the present art
stalk rolls illustrating flutes with knife edges.
FIG. 12 is a top view of an illustrative embodiment of a pair of stripper
plates that may be
used with various embodiments of the present art stalk roll showing various
zones along the
length of the stripper plates.
FIG. 13 is a top view of another illustrative embodiment of a pair of stalk
rolls according to
the present disclosure showing various zones along the length of the stalk
rolls.
FIG. 14A is a cross-sectional view of the stripper plates and stalk rolls from
FIGS. 12 & 13,
respectively, at line 14A.
FIG. 14B is a cross-sectional view of the stripper plates and stalk rolls from
FIGS. 12 & 13,
respectively, at line 14B.
FIG. 14C is a cross-sectional view of the stripper plates and stalk rolls from
FIGS. 12 & 13,
respectively, at line 14C.
FIG. 14D is a cross-sectional view of the stripper plates and stalk rolls from
FIGS. 12 & 13,
respectively, at line 14D.
FIG. 15 is a top view of another illustrative embodiment of stalk rolls
incorporating certain
aspects of the present disclosure having tapered flutes showing various zones
along the length
of the stalk rolls.
FIG. 15A is a cross-sectional view of the stalk rolls from FIG. 15 at line
15A.
FIG. 15B is a cross-sectional view of the stalk rolls from FIG. 15 at line
15B.
FIG. 15C is a cross-sectional view of the stalk rolls from FIG. 15 at line
15C.
FIG. 16 is a top view of another illustrative embodiment of stalk rolls
incorporating certain
aspects of the present disclosure having stepped flutes showing various zones
along the
length of the stalk rolls.
FIG. I6A is a cross-sectional view of the stalk rolls from FIG. 16 at line
16A.
FIG. 16B is a cross-sectional view of the stalk rolls from FIG. 16 at line
16B.
6
Date Recue/Date Received 2020-04-27
FIG. 16C is a cross-sectional view of the stalk rolls from FIG. 16 at line
16C.
FIG. 17 is a top view of another illustrative embodiment of stalk rolls
incorporating certain
aspects of the present disclosure having tapered flutes showing various zones
along the length
of the stalk rolls.
FIG. 17A is a cross-sectional view of the stalk rolls from FIG. 17 at line
17A.
FIG. 17B is a cross-sectional view of the stalk rolls from FIG. 17 at line
17B.
FIG. 18 is a cross-sectional view of FIG. 13 along line 14D with a stalk
engaged with the
stalk rolls.
FIG. 18A is a detailed view of the stalk after penetration of the stalk by the
stalk roll.
FIG. 19A is a cross-sectional view of another illustrative embodiment of stalk
rolls
incorporating certain aspects of the present disclosure showing the angle of
the flute edges
prior to engagement with a stalk.
FIG. 19B is a cross-sectional view of the embodiment of stalk rolls shown in
FIG. 19A
incorporating certain aspects of the present disclosure showing the angle of
the flute edges as
they would be during engagement with a stalk.
FIG. 20 is a cross-sectional view of one illustrative embodiment of a corn
head incorporating
certain aspects of the present disclosure.
FIG. 21A is a perspective view of a first illustrative embodiment of a stalk
roll having a
recess.
FIG. 21B is a second perspective view of the first illustrative embodiment of
a stalk roll
having a recess.
FIG. 21C provides a detailed view of a flute in the first illustrative
embodiment of a stalk roll
having a recess.
FIG. 22A is an end view of the first illustrative embodiment of two stalk
rolls having recesses
intermeshed with one another.
FIG. 22B is another end view of the first illustrative embodiment of two stalk
rolls having
recesses intermeshed with one another wherein the nose cone has been removed
for clarity.
FIG. 23 is a cross-sectional view of a second illustrative embodiment of two
stalk rolls
having a recess intermeshed with one another.
FIG. 24A is perspective view of another illustrative embodiment of a stalk
roll that may be
employed as the right stalk roll (from the perspective of an operator) may be
intermeshed
with an adjacent stalk roll to form a pair.
FIG. 24B is a side view of the illustrative embodiment of a stalk roll shown
in FIG. 24A
7
Date Recue/Date Received 2020-04-27
FIG. 24C is an end view of the illustrative embodiment of a stalk roll shown
in FIG. 24A
with the nose cone removed.
FIG. 25A is a perspective view of an illustrative embodiment of a stalk roll
that may be
employed as the left stalk roll with the illustrative embodiment of a stalk
roll shown in FIGS.
24A-24C to create a cooperating pair.
FIG. 25B is a side view of the illustrative embodiment of a stalk roll shown
in FIG. 25A.
FIG. 25C is an end view of the illustrative embodiment of a stalk roll shown
in FIG. 25A
with the nose cone removed.
FIG. 26A is a perspective view of an illustrative embodiment of a hybrid flute
that may be
employed on the stalk roll shown in FIGS. 24A-24C.
FIG. 26B is a perspective view of an illustrative embodiment of a full flute
that may be
employed on the stalk roll shown in FIGS. 24A-24C.
FIG. 26C is a perspective view of an illustrative embodiment of a reduced
flute that may be
employed on the stalk roll shown in FIGS. 24A-24C.
FIG. 26D is a perspective view of an illustrative embodiment of a second
reduced flute that
may be employed on the stalk roll shown in FIGS. 24A-24C.
FIG. 26E is a perspective view of an illustrative embodiment of a short flute
that may be
employed on the stalk roll shown in FIGS. 24A-24C.
FIG. 26F is a perspective view of the flutes shown in FIGS. 26A-26B positioned
relative to
one another as shown in the illustrative embodiment of a stalk roll in FIGS.
24A-24C.
FIG. 26G is a side view of the illustrative embodiment of an arrangement of
flutes shown in
FIG. 26F.
FIG. 27A is a perspective view of the illustrative embodiment of stalk rolls
shown in FIGS.
24 and 25 positioned adjacent one another.
FIG. 27B is an end view of the illustrative embodiment of a stalk roll
arrangement shown in
FIG. 27A.
FIG. 28A is a perspective view of another illustrative embodiment of a pair of
stalk rolls
according to the present disclosure.
FIG. 28B is an end view of the illustrative embodiment of a pair of stalk
rolls shown in FIG.
28A
FIG. 28C is a perspective view of a five adjacent flutes of the right stalk
roll of the illustrative
embodiment of a pair of stalk rolls shown in FIG. 28A.
8
Date Recue/Date Received 2020-04-27
FIG. 29A is a perspective view of an illustrative embodiment of a hub assembly
and nose
cone that may be used with certain illustrative embodiments of the stalk roll.
FIG. 29B is a cross-sectional view of the illustrative embodiment of a hub
assembly and nose
cone shown in FIG. 29A.
FIG. 30A is a perspective view of another illustrative embodiment of a hub
assembly and
nose cone that may be used with certain illustrative embodiments of the stalk
roll.
FIG. 30B is a cross-sectional view of the illustrative embodiment of a hub
assembly and nose
cone shown in FIG. 30A.
DETAILED DESCRIPTION ¨ ELEMENT LISTING
ELEMENT DESCRIPTION ELEMENT #
Gathering chain paddle 1 (110)
Gathering chain 2 (120)
Stripper plate 3 (130)
Row divider 4 (100)
Nose cone 5
Transport vane 6 (170)
Stalk slot 7
Cross auger trough 8 (200)
Cross auger 9 (220)
Cross auger fighting 10 (230)
Feeder house 11
Stalk roll (Prior Art) 12
Ear 13(300)
Outer shell of stalk 14 (321)
First (right) stalk roll 15
Second (left) stalk roll 16
Cylindrical shell 17
First flute 18
Second flute 19
Third flute 20
Fourth flute 21
Knife edge 22
9
Date Recue/Date Received 2020-04-27
Leading surface 23
Trailing surface 24
Stalk engagement gap 25
Fifth flute 26
Semi-cylindrical shell (Upper) 27
Semi-cylindrical shell (Lower) 28
Stalk roll drive shaft 29
Annular ridge 30
Short bolt hole 31
Short bolt 32
Sixth flute 33
Bolt receiver 34
Long bolts 36
Long bolt hole 37
Intermediate drive shaft 38
Drive shaft bolt 39
Small pin 40
Large pin 41
Row unit cover 100
Ear separation chamber 140
Short flute 180
Tapered flute 181
Intermediate flute 182
Long flute 183
Stalk roll 190 (192)
Underside of leaf 310
Stalk 320
Stalk outer shell 321
First grasp point 322
Second grasp 323
Stalk cut point 324
Date Recue/Date Received 2020-04-27
Stalk piece 326
Stalk node 330
Stalk roll 400
Nose cone 410
Flighting 412
Flighting/flute interface 412a
Sleeve 414
Recess 420
Bladeless area 422
Main cylinder 430
Retainer 432
Full flute 440
Hybrid flute 440a
Axial face 441
Flute edge 442
Radius 443
Leading surface 444
Trailing surface 445
Leading wall 446
Trailing wall 447
Beveled edge 448
Flute base 449
Aperture 449a
Base bevel 449b
Reduced flute 450
Second reduced flute 450a
Short flute 460
Notch 462
Axial point 464
11
Date Recue/Date Received 2020-04-27
Hub assembly 470
Aperture 471
Flange 472
Shelf 472a
Engagement surface 473
Recessed surface 474
Central bore 475
Coupler section 475a
Slot 476
End ring 478
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 dcsipate
identical or
corresponding parts throughout the several views, the general operation of
corn heads having
stalk rolls mounted thereon of the type illustrated in FIGS. 6-9 is similar to
the operation of
corn heads using stalk rolls 12 of the prior art (as illustrated in FIGS. 1-
5). As used herein,
12
Date Recue/Date Received 2020-04-27
"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 shaft 29
through 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 roll 15, 16 arranged parallel to one another to make an opposing
pair. The first
and second stalk rolls 15, 16 are provided with nose cones 5 having transport
vanes 6.
Immediately behind the nose cones 5 are cylindrical shells 17 having a first,
second, third,
and fourth flute 18, 19, 20 and 21, respectively, mounted along the length of
the first and
second stalk rolls 15, 16 (as can easily be seen in FIG. 6). Each flute 18,
19, 20, 21 may
further be provided with a knife edge 22, as is shown in detail in the
embodiment depicted in
FIG. 11. The knife edges 22 are substantially parallel to the central
longitudinal axis of the
cylindrical shell 17. As shown in the embodiment in FIGS. 6-9, the stalk rolls
15, 16 may 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 rolls 12 of the prior art, the stalk
rolls 15, 16 of the
present disclosure pull the stalk 320 in a downward motion, causing the ears
13 to contact the
stripper plates 3 and separate from the stalk 320. The flutes 18, 19, 20, 21
affixed to the stalk
rolls 15, 16 may also act to lacerate or crush the stalk 320, and also
facilitate ejection of the
stalk 320 from the corn plant engagement chamber. Gathering chain paddles 1
affixed to
gathering chains 2 transport the loose ears 13 to the cross auger trough 8.
The cross auger 9
moves the ears 13 from the cross auger trough 8 to the feeder house 11, which
moves the ears
13 into 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 rolls 15, 16 may be
manufactured as one
piece adapted for engagement upon the stalk roll drive shaft 29. In another
embodiment, the
first and second stalk rolls 15, 16 may 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
shaft 29 is inserted, as is best illustrated in FIG. 8. The cylindrical shell
17 may be comprised
of two semi-cylindrical shell pieces, an upper semi-cylindrical shell 27 and a
lower semi-
13
Date Recue/Date Received 2020-04-27
cylindrical shell 28, that are bolted to the intermediate drive shaft 38. The
long bolt holes 37
and long bolts 36 with nuts or other securing members, along with the short
bolt holes 31,
short bolts 32, and bolt receivers 34, form a structure for mounting the
cylindrical shell 17 to
the intermediate drive shaft 38, which then may be mounted to the stalk roll
drive shaft 29.
FIG. 8 best illustrates the mounting structure for an embodiment employing
semi-cylindrical
shells 27, 28. In one embodiment, each semi-cylindrical shell 27, 28 is
fashioned with two
inwardly extending annular ridges 30 having short bolt holes 31. Short bolts
32 pass through
the short bolt holes 31 and engage bolt receivers 34 located on an
intermediate drive shaft 38.
Long bolts 36 pass through the long bolt holes 37 of two corresponding upper
and lower
semi-cylindrical shells 27, 28, and with a nut or other securing member clamp
the semi-
cylindrical shells 27, 28 together around the intermediate drive shaft 38. The
intermediate
drive shaft 38 is clamped to the stalk roll drive shaft 29 by drive shaft
bolts 39. In addition, a
small pin 40 and a large pin 41 prevent relative rotation between the
intermediate drive shaft
38 and the stalk roll drive shaft (not shown in FIG. 8).
Each semi-cylindrical shell 27, 28 may be manufactured having at least two
integral flutes. In
one embodiment, the flutes are then machined to define the knife edge 22. Each
knife edge 22
has a leading surface 23 and a trailing surface 24 that form an acute angle
between them of
approximately forty degrees, as shown in the embodiment pictured in FIG. 11.
The leading
surface is a rearward (with respect to the direction of rotation of one of the
stalk rolls 15, 16
of an opposing pair) sloping surface, sloping approximately ten degrees from a
line passing
rhough the central longitudinal axis of the cylindrical shell 17 and the
vertex of the knife edge
22. The trailing surface 24 is a forward (with respect to the direction of
rotation of one of the
stalk rolls 15, 16 of an opposing pair) sloping surface, sloping approximately
thirty degrees
from a line passing through the central longitudinal axis of the cylindrical
shell 17 and the
vertex of the knife edge 22. Other slopes and angles of the leading surface 23
and the trailing
surface 24 may be used without departing from the spirit or scope of the stalk
roll 15, 16. As
is well known to those skilled in the art, tungsten carbide may be applied to
the trailing
surfaces 24 to make the knife edges 22 self-sharpening. Although not shown,
the layer of
tungsten carbide is generally between three and twenty thousandths of an inch
thick and is
induction hardened.
14
Date Recue/Date Received 2020-04-27
As illustrated in FIGS. 6-9, the flutes 18, 19, 20, 21 of the opposing first
and second stalk
rolls 15, 16 are 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 roll 15, 16 is 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 stalks 320 into 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 gap 25 in the stalk slot 7
per revolution of
the stalk roll 15, 16, which is explained in detail below. When the stalk
engagement gap 25 is
present, corn plant entry into the corn plant engagement chamber is not
restricted.
As may be seen for the embodiment in FIGS. 9A-9F, the width of the stalk slot
7 is defined
as the distance between the inner periphery of the cylindrical shells 17 of
the opposing stalk
rolls 15, 16, which width is denoted "W" in FIGS. 9A-10. Other embodiments
described in
detail below include an recess 420, which may affect the width of the stalk
slot 7. The height
of the stalk slot 7 is essentially infinite, though in practicality the ground
surface provides a
lower limit. The stalk engagement gap 25, as shown in FIGS. 9A, 9D, and 10, is
then defined
as the moment(s) during revolution of the first and second stalk rolls 15, 16
in which none of
the flutes 18, 19, 20, 21 of the first or second stalk roll 15, 16 are
positioned within the stalk
slot 7. FIGS. 9B, 9C, 9E, and 9F illustrate the stalk slot 7 after the stalk
engagement gap 25 is
closed.
FIGS. 9A-9F provide six views of the stalk slot 7 at six different moments
during one
revolution of the stalk rolls 15, 16, with the direction of rotation of the
stalk rolls 15, 16
indicated by the respective arrows. As will be explained in detail below, the
embodiment
shown in FIGS. 9A-9F is configured so that the stalk engagement gap 25 is
present at two
different moments in time during one revolution of the stalk rolls 15, 16; and
as will be
apparent to those skilled in the art, this is but one of many embodiments the
stalk rolls 15, 16
may take. Throughout one revolution of the stalk rolls 15, 16, at any point in
time, the flutes
18, 19, 20, 21 may be engaged in five different modes of action upon a stalk
320 at any point
along the axial length of the flute 18, 19, 20, 21 (depending on the location
and orientation of
Date Recue/Date Received 2020-04-27
the flutes 18, 19, 20, 21 and the particular embodiment). The five modes of
action upon the
stalk 320 are: (1) unrestricted entry of the stalk 320 into the corn plant
engagement chamber
(which occurs at the moment in time shown in FIGS. 9A and 9D, although
restricted entry
may occur at other moments in time); (2) flute 18, 19, 20, 21 or knife
engagement with the
stalk 320 (which may occur at moments in time shown in FIGS. 9B, 9C, 9E, and
9F, but may
also occur at other moments in time); (3) lacerating and crushing of the stalk
320 by the flutes
18, 19, 20, 21 or knives (which may occur at the moments in time shown in
FIGS. 9B, 9C,
9E, and 9F, but may also occur at other moments in time); (4) ear separation
and stalk 320
ejection (which may occur at moments in time shown in FIGS. 9B, 9C, 9E, and
9F, but may
also occur at other moments in time); (5) stalk 320 release by the stalk rolls
15, 16 for lateral
travel of the stalk 320 (which most often occurs at moments in time shown in
FIGS. 9A and
9D, but may also occur at other moments in time).
FIG. 9A shows the stalk engagement gap 25, and illustrates that when the stalk
engagement
gap 25 appears, no flutes 18, 19, 20,21 are located in the stalk slot 7. When
the stalk rolls 15,
16 are in this position a stalk 320 (not shown) may freely enter the stalk
slot 7 and the corn
plant engagement chamber with no restriction. The stalk engagement gap 25 also
allows
stalks 320 already positioned between the stalk rolls 15, 16 to travel in a
lateral direction to
compensate for the forward motion of the harvesting machine to which the corn
head is
attached.
FIG. 9B shows the stalk slot 7 at a later moment in time after the stalk rolls
15, 16 have
rotated from their positions shown in FIG. 9A. FIG. 9B shows that at this
point, the first flute
18 of each stalk roll 15, 16 has moved into the stalk slot 7 so that there is
no stalk
engagement gap 25, and the first flutes 18 of the respective stalk rolls 15,
16 now engage any
stalk 320 between the stalk rolls 15, 16. This engagement may serve to
lacerate or crush the
stalk 320, or to pull the stalk 320 downward through the corn plant engagement
chamber and
subsequently eject the stalk 320 depending on the specific embodiment.
FIG. 9C shows the stalk slot 7 at still a later moment in time wherein the
second flute 19 of
each stalk roll 15, 16 has moved into the stalk slot 7 so that there is still
no stalk engagement
gap 25. The second flutes 19 of each respective stalk roll 15, 16 now engage
any stalk 320
between the stalk rolls 15, 16. This engagement may serve to lacerate or crush
the stalk 320,
16
Date Recue/Date Received 2020-04-27
or to pull the stalk 320 downward through the corn plant engagement chamber
and
subsequently eject the stalk 320 depending on the specific embodiment.
FIG. 9D provides a snapshot of the stalk slot 7 at a moment in time later than
the moment
depicted in FIG. 9C, and shows the stalk engagement gap 25 present for the
second time
during this revolution of the stalk rolls 15, 16. The stalk engagement gap 25
is present since
no flutes 18, 19, 20, 21 are positioned within the stalk slot 7 when the stalk
rolls 15, 16 are
positioned as in FIG. 9D, and a stalk 320 (not shown) may again freely enter
the stalk slot 7
and the corn plant engagement chamber with no restriction. Again, the stalk
engagement gap
25 also allows stalks 320 already positioned between the stalk rolls 15, 16 to
travel in a lateral
direction to compensate for the forward motion of the harvesting machine to
which the corn
head is attached.
FIG. 9E shows the stalk slot 7 at a later moment in time from the moment shown
in FIG. 9D
wherein the third flute 20 of each stalk roll 15, 16 has moved into the stalk
slot 7 so that there
is no stalk engagement gap 25. At this point, the third flutes 20 of the
respective stalk rolls
15, 16 now engage any stalk 320 between the stalk rolls 15, 16. As with
similar moments in
time already explained, this engagement may serve to lacerate or crush the
stalk 320, or to
pull the stalk 320 downward through the corn plant engagement chamber and
subsequently
eject the stalk 320 depending on the specific embodiment.
FIG. 9F shows the stalk slot 7 at still a later moment in time wherein the
fourth flute 21 of
each stalk roll 15, 16 have moved into the stalk slot 7 so that there is still
no stalk engagement
gap 25. Here, the fourth flutes 21 of the respective stalk rolls 15, 16 engage
any stalk 320
between the stalk rolls 15, 16. Again, this engagement may serve to lacerate
or crush the stalk
320, or to pull the stalk 320 downward through the corn plant engagement
chamber and
subsequently eject the stalk 320 depending on the specific embodiment. As will
be apparent
to those skilled in the art, the next snapshot in time of the stalk slot 7
according to the pattern
indicated by FIGS. 9A-9F will be identical to FIG. 9A, and would provide the
last view of
one full revolution of the stalk rolls 15, 16.
FIGS. 6-9 show an illustrative embodiment wherein the stalk rolls 15, 16 and
their respective
flutes 18, 19, 20, 21 are configured so that two stalk engagement gaps 25
appear per
17
Date Recue/Date Received 2020-04-27
revolution of the stalk rolls 15, 16. As those of ordinary skill in the art
will appreciate, the
stalk rolls 15, 16 and their respective flutes 18, 19, 20, 21 may be
configured so that nearly
any number of stalk engagement gaps 25 appear per revolution of the stalk
rolls 15, 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 rolls 15, 16 between the fourth and first
flutes 18, 21 on each stalk
roll 15, 16; and thereby reduce the number of stalk engagement gaps 25 per
revolution of the
stalk rolls 15, 16 from two to one.
In the illustrative embodiment shown in FIGS. 6-9, two structural features are
necessary to
create two stalk engagement gaps 25 per revolution of the stalk rolls 15, 16.
First, the flutes
18, 19, 20, 21 of each stalk roll 15, 16 must be positioned around the
circumference of the
stalk roll 15, 16 in a non-equidistant manner. That is, the circumferential
distance between
the first flute 18 and fourth flute 21 is greater than the circumferential
distance between the
third flute 20 and fourth flute 21 on each stalk roll 15, 16. Likewise, the
circumferential
distance between the second flute 19 and third flute 20 is greater than the
circumferential
distance between the first flute 18 and second flute 19 of each stalk roll 15,
16. However, this
may be achieved using flutes 18, 19, 20, 21 of different lengths so as to vary
the
circumferential distance between terminal ends of flutes 18, 19, 20, 21.
Second, the first stalk
roll 15 of an opposing pair is positioned on its respective stalk roll drive
shaft 29 so that it is
slightly advanced (with respect to rotational positions of the flutes 18, 19,
20, 21) compared
to the second stalk roll 16 of the pair. During operation, the stalk rolls 15,
16 operate at the
same rotational speed so that the difference in positioning is maintained
throughout
operation. Because the stalk rolls 12 of the prior art and the flutes thereon
are not configured
to yield any stalk engagement gaps 25, they essentially create a wall of
rotating steel as
previously described, which restricts the entry of the stalk 320 into stalk
slot 7 and the corn
plant engagement chamber.
FIG. 10 provides an end view of another embodiment of stalk rolls 15, 16. In
this
embodiment, a fifth flute 26 is added between the first flute 18 and second
flute 19 so that the
distance between the first flute 18 and the fifth flute 26 is equal to the
distance between the
second flute 19 and the fifth flute 26. A sixth flute 33 has also been added
between the third
flute 20 and the fourth flute 21 so that the distance between the third flute
20 and the sixth
flute 33 is equal to the distance between the fourth flute 21 and the sixth
flute 33. FIG. 10
18
Date Recue/Date Received 2020-04-27
depicts a moment when the stalk engagement gap 25 is present, thereby allowing
stalks 320
to enter the corn plant engagement chamber. In this embodiment, as in the
embodiment
shown in FIGS. 9A-9F, the stalk engagement gap 25 appears twice per revolution
of the stalk
rolls 15, 16.
In an alternative embodiment not shown herein, additional flutes that have a
smaller axial
length as compared to the axial length of flutes 18, 19, 20, 21 could be
placed between all or
some of flutes 18, 19, 20, 21. (Alternatively some of the original flutes 18,
19, 20, 21 could
be fashioned with a smaller axial length than the axial length of adjacent
flutes 18, 19, 20,
31.) Here, the additional flutes would not extend the entire distance of the
cylindrical shell
17. Instead, the additional flutes would only extend along the cylindrical
shell 17 from a point
proximal to the end of the cylindrical shell 17 closest to the cross auger 9
(which may be the
same point from which the flutes 18, 19, 20, 21 extend, as shown in FIG. 6) to
a point distal
from the cross auger 9, but not the entire length of the cylindrical shell 7
up to the interface
between the cylindrical shell 17 and the nose cone 5. That is, the additional
flutes would not
extend radially from the cylindrical shell 17 on a portion of the cylindrical
shell 17 that is
distal from the cross auger 9 (and also distal to the connection between the
stalk roll drive
shaft 29 and the corn header). This embodiment facilitates stalk rolls 15, 16
that are
configured so as to provide a stock engagement gap 25 along a predetermined
axial portion of
the stalk rolls 15, 16 that first engage the stalk 320 (i.e., a portion distal
from the cross auger
9) while still providing more flutes to engage the stalk 320 in the corn plant
engagement
chamber on a portion of the stalk rolls 15, 16 proximal to the corn header
(which may assist
in decomposition of the stalk 320 and harvesting speed).
As is apparent from the embodiment shown in FIG. 10, the specific number and
orientation
of flutes 18, 19, 20, 21, 26, 33 employed on a stalk roll 15, 16 may vary.
Therefore, the
precise number of flutes 18, 19, 20, 21, 26, 33 employed in a particular
embodiment, or the
specific orientation thereof in no way limits the scope of the present stalk
roll 15, 16. As long
as the flutes 18, 19, 20, 21, 26, 33 are oriented upon the stalk rolls 15, 16
and the stalk rolls
15, 16 are orientated with respect to each other such that at least one stalk
engagement gap 25
appears during one revolution of the stalk rolls 15, 16, the specific
orientation or number of
flutes 18, 19, 20, 21, 26, 33 are not limiting to the scope of the present
stalk roll 15, 16.
Furthermore, what is referred to herein as a cylindrical shell 17 of the stalk
rolls 15, 16 need
19
Date Recue/Date Received 2020-04-27
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 rolls 190 implementing a stalk
engagement gap 25 is shown in
FIGS. 13-14D. A pair of beveled stripper plates 130 is shown in FIG. 12, and
lines 14A-14A, 14B-14B,
14C-14C, and 14D-14D, represent various zones along the lengths of the
stripper plates 130 and stalk
rolls 190. The stalk rolls 190 and stripper plates 130 from FIGS. 12 and 13
are shown in cross section at
various positions along the lengths thereof in FIGS. 14A-14D. The embodiment
of the stalk rolls 190 and
stripper plates 130 shown in FIGS. 12-14D are 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 in FIGS. 12-14D, the Alignment Zone is generally
about the line 14A-14A
toward the front of the stalk rolls 190 and adjacent the nose cones 5, which
is best shown in FIGS. 13 and
14A. In some embodiments, the Alignment Zone extends along the stalk rolls 190
from the front of the
nose cones 5 to the line 14A-14A. 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 ear 300 intact
and positioned for
recovery with minimal MOTE. In the Alignment Zone of the embodiment of the
stripper plate 130 shown
in FIGS. 12 and 14A-14D, the stripper plates 130 are substantially flat, as
best shown in FIG. 12 and 14A.
This reduces the tendency of ears 300 to wedge below the stripper plates 130.
The transport vanes 170 on
the nose cones 4 in front of the Alignment Zone serve to guide stalks 320 into
the ear separation chamber
140, which is best shown in FIG. 20. The rotating transport vanes 170 may 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 vanes 170 generally is to center the stalk 320 in
the ear separation chamber 140.
Date Recue/Date Received 2020-04-27
The stalk rolls 190 shown in FIGS. 13-14D also incorporate a stalk slot 7 in
which a stalk engagement
gap 25 occurs intermittently. The stalk slot 7 and stalk engagement gap 25 as
defined for this embodiment
of stalk rolls 190 is the same as those defined for the embodiment of stalk
rolls 15, 16 shown in FIGS. 9-
10. This embodiment of stalk rolls 190 facilitates a stalk engagement gap 25
that occurs along a specific
length of the stalk rolls 190. As shown in FIG. 14A, the stalk engagement gap
25 first occurs toward the
front of the stalk rolls 190 in the Alignment Zone and extends along the
entire length thereof (which
length is shown in FIG. 13). This facilitates simple transport of the stalk
320 from the nose cones 5 to the
ear separation chamber 140 between the stalk rolls 190. The stalk engagement
gap 25 in the Alignment
Zone is formed by placing two short flutes 180 separated by 180 degrees on
each stalk roll 190, such that
the short flutes 180 are arranged in a knife-to-knife configuration. Another
function of the transport vanes
170 is to ensure that the stalk 320 does not fall forward out of the stalk
engagement gap 25.
B. The Entry Zone
In the embodiment pictured in FIGS. 12-14D, the Entry Zone is generally about
the line 14B-14B toward
the front of the stalk rolls 190, but behind the Alignment Zone, which is best
shown in FIGS. 13 and 14A.
In some embodiments, the Entry Zone extends along the stalk rolls 190 from the
line 14B-14B to the front
portion of the stalk rolls 190 at the terminus of any intermediate flutes 182,
which are described in detail
below. The primary purpose of this zone is to allow entry of the stalk 320
into the ear separation chamber
140 between the stalk rolls 190. The rate at which stalks 320 are 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 roll
12 must be increased, which merely increases the egg-beater effect. If the
stalk 320 is not pinched in the
Entry Zone, the stalk 320 stalls in the row unit, which stalling allows the
rotating flute edges to sever the
stalk 320. This stall also causes the stalk 320 to lean away from the row
unit. Consequently, ear
separation often occurs near the opening of the row unit, such that loose ears
300 fall to the ground and
become irretrievable.
A stalk engagement gap 25 is also present in the Entry Zone in this embodiment
of the stalk rolls 190,
which is best shown in FIG. 14B. The short flutes 180 in the Alignment Zone
extend into the Entry Zone,
and the stalk engagement gap 25 in the Entry Zone is formed by placing two
additional short flutes 180
adjacent to the short flutes 180 from the Alignment Zone. As shown in FIG.
14B, the four short flutes 180
are not equally spaced about the periphery of the stalk rolls 190, but instead
are positioned in groups of
two. This facilitates the stalk engagement gap 25 in the Entry Zone since
adjacent short flutes 180 in each
21
Date Recue/Date Received 2020-04-27
pair are close enough to each other that a stalk engagement gap 25 is present
at least once during a full
revolution of the stalk rolls 190. In this embodiment a stalk engagement gap
25 is present twice during a
full revolution in both the Alignment Zone and Entry Zone, as is evident from
FIGS. 14A and 14B.
C. The Ear Separation Zone
In the embodiment pictured in FIGS. 12-14D, the Ear Separation Zone is
generally about the line 14C-
MC on the front half of the stalk rolls 190, which is best shown in FIGS. 13
and 14C. In some
embodiments, the Ear Separation Zone extends along the stalk rolls 190 from
the terminus of an
intermediate flute 182 toward the front of the stalk rolls 190 to the terminus
of a long flute 183, which is
described in detail below. Generally, the Ear Separation Zone extends along a
greater length of the stalk
rolls 190 than does any other zone. The primary purpose of this zone is to
separate the ear 300 from the
stalk 320 and prevent any ears 300 from falling forward out of the row unit.
In this zone, the embodiment
of the stalk rolls 190 shown herein pull the stalk 320 through the stripper
plates 130 without prematurely
severing the stalk 320. The maximum vertical speed at which the stalk rolls
190 consume the stalk 320 is
determined by the damaging occurring to the ear 300 at a given speed, and will
vary from one variety of
corn to the next.
As best shown in FIGS. 13 and MC, intermediate flutes 183 that extend radially
further from the stalk roll
190 than short flutes 180 may be positioned in the Ear Separation Zone.
Because the intermediate flutes
183 are radially longer than the short flutes 180, stalk rolls 190 engage
stalks 320 more securely in this
zone, which is evident from FIG. 14C. In the embodiment shown in FIGS. 12-14D,
like the short flutes
180, the intermediate flutes 182 are not intermeshed but opposed with minimal
clearance so that as a flute
180, 182 on one stalk roll 190 begins to engage the stalk 320, the opposing
flute 180, 182 on the other
stalk roll 190 engages the stalk 320 at a point on the horizontally opposite
side of the stalk 320. This
balanced engagement action reduces lateral stalk 320 whipping, which whipping
can dislodge and toss the
ear 300 from the stalk 320, or cause the stalk 320 to prematurely break or
sever. The balanced
engagement action allows the stalk rolls 190 to evenly pull the stalk 320 down
so that the stripper plates
130 may rapidly separate the ear 300 from the stalk 320 in the Ear Separation
Zone.
Also apparent from FIG. 14C is the fact that the Ear Separation Zone does not
include a stalk engagement
gap 25. This is because the intermediate flutes 182 are positioned in the
space between the two groups of
short flutes 180 present in the Entry Zone. Accordingly, in the pictured
embodiment a total of six flutes
180, 182 are present in the Ear Separation Zone, and they are equally spaced
about the periphery of the
stalk roll 190, such that each flute 180, 182 is separated by sixty degrees.
The two short flutes 180 in each
22
Date Recue/Date Received 2020-04-27
pair in the Entry Zone are also separated by sixty degrees, and each pair of
short flutes 180 is separated
from the other by 120 degrees. A stalk engagement gap 25 is not required in
the Ear Separation Zone
because at this point the stalk 320 is securely positioned between the two
stalk rolls 320 and the danger of
the stalk 320 falling forward out of the ear separation chamber 140 has been
alleviated. That is, the egg
beater effect previously described has been eliminated by providing a stalk
engagement gap 25 in the
Alignment and Entry Zones.
D. The Post-Ear Separation Plant Ejection Zone
In the embodiment pictured in FIGS. 12-14D, the Post-Ear Separation Plant
Ejection Zone is generally
about the line E-E toward the back of the stalk rolls 190, which is best shown
in FIGS. 13 and 14D. In
some embodiments, this zone extends along the stalk rolls 190 from the start
of a long flute 183 to the
terminus of a long flute 183 toward the back of the stalk roll 190, which is
described in detail below. The
primary purpose of this zone is to rapidly eject the stalk 320 from the row
unit to minimize interference
between MOTE and ears 300. No specific speed ratio controls the operating
speed of this zone. After ear
separation, increasing stalk 320 ejection speed effectively reduces MOTE
entering the threshing (kernel
separation) area of the harvesting machine, thereby increasing threshing
efficiency and capacity.
As shown in FIGS. 13 and 14D, this zone may include a plurality of long flutes
183, three of which are
shown on each stalk roll 190. The long flutes 183 extend radially further from
the stalk roll 190 than any
other flutes 180, 182. Within this zone, the long flutes 183 may be both
meshing and non-meshing so as
to create a high-speed clean out zone. The stalk rolls 190 may also be
aerodynamically designed to create
a suction effect so that unattached MOTE from the ear separation chamber 140
is 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 stalk 320 to speed decomposition thereof The
various functions of this
zone may be achieved through different orientations and/or configurations of
flutes 180, 182, 183 in the
zone, as well as the number of flutes 180, 182, 183 therein. Accordingly, the
scope of the stalk rolls 190 is
not limited by the number of flutes 180, 182, 183 in any zone, nor it is
limited by the configuration and/or
orientation of flutes 180, 182, 183 in any zone.
As shown in FIGS. 12 and 14D, this zone may be configured as a clean-out zone
by adding short lengths
of long flutes 183 between the short and/or intermediate flutes 180, 182.
Using inter-meshing long flutes
183 allows faster ejection of small diameter stalks 320, normally found at the
upper-most portion of the
corn plant. The intermeshing long flutes 183 of stalk rolls 190 or 192 are
aerodynamically designed and
assembled to create a down draft through the ear separation chamber 140, which
further enhances
23
Date Recue/Date Received 2020-04-27
removal of any MOTE. The short flutes 180, intermediate flutes 182, and/or
long flutes 183 may be
integrally formed with one another such that a short flute 180 and/or
intermediate flute 182 is formed by
removing a portion of a long flute 183. As a corollary, a short flute 180 may
be formed by removing a
portion of an intermediate flute 182. Conversely, the various flutes 180, 182,
183 may be separately
formed. Additionally, short and/or intermediate flutes 180, 182 present 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 in FIGS. 13-14D.
The height and width of the stalk engagement gap 25 have been defined
previously herein with respect to
FIGS. 9-10. The length of the stalk engagement gap 25 may vary from one
embodiment of stalk rolls 190
to the next. For example, in the embodiment of stalk rolls 190 pictured in
FIGS. 13-14D, the stalk
engagement gap 25 extends from the Alignment Zone to the front of the Ear
Separation Zone, which is less
than half the overall length of the stalk rolls 190. However, in other
embodiments of the stalk rolls 190, the
length of the stalk engagement gap 25 may be different. Accordingly, the scope
of the stalk rolls 190 as
disclosed and claimed herein is in no way limited by the length of the stalk
engagement gap 25.
As described and specifically claimed in other patents and patent applications
owned by Applicant, the
stripper plates 130 used with any of the stalk rolls 15, 16, 190, 400 or any
other stalk rolls 130 may be
beveled along their lengths, as shown in FIGS. 12 and 14A-14D. The stripper
plates 130 as shown herein
have a rounded or contoured surface to emulate the arched under side of the
corn leaf 310 with two positive
effects. First, this allows the corn leaf to stay attached to the stalk 320,
reducing the level of MOTE retained
in the ear separation chamber 140. Secondly, this shape also improves
separation of the husk from the ear
300, further reducing the level of MOTE in the ear separation chamber 140. As
shown in FIGS. 14A and
14B, the stripper plates 130 are substantially flat in the Alignment and Entry
Zones, which reduces ear 300
wedging below stripper plates 130, and above the transport vanes 170 of the
stalk rolls 190 when ears 300
are being gathered from near ground level. As shown in FIGS. 14C and 14D, in
the Ear Separation and
Post-Ear Separation Plant Ejection Zones the stripper plates 130 are normally
directly above the fluted
portion of stalk rolls 190 and are slightly curved down. This curve may
specifically emulate the arched
portion or underside of leaf 310. This improved curved shape allows smooth
flow of unwanted portions of
the corn plants to pass between stripper plates 130 and exit the ear
separation chamber 140 while retaining
the ear 300.
As shown in FIG. 18, the embodiment shown in FIGS. 12-14D allows the flutes
180, 182, 183 and stripper
plates 130 to positioned closely to one another, which reduces the amount of
MOTE retained in the ear
separation chamber 140 in the event that stalk 320 separation (which is
defined as a cutting of the stalk 320,
24
Date Recue/Date Received 2020-04-27
or other action that causes a portion of the stalk 320 to be separated from
another portion thereof) takes
place before ear 300 separation.
FIGS. 16-16C show another embodiment of stalk rolls 190 featuring certain
aspects of the present
disclosure. In this embodiment, the short flutes 180 (adjacent the area
bisected by line 16A-16A and best
shown in FIG. 16A) of the stalk rolls 190 are opposed with one another so that
they meet during operation.
They do not, however, ever touch during normal operation. The
Date Recue/Date Received 2020-04-27
distance between the stalk rolls 190 decreases along their length from line A-
A to line B-B as
shown by FIGS. 16A-16C. Additionally, long flutes 183 are positioned on the
stalk rolls 190
adjacent the back thereof about line C-C. This configuration provides optimum
balanced
pressure against the stalk 320 in certain conditions to first engage the stalk
320 and then pull
it down while penetrating the stalk outer shell 321, thus avoiding stalk whip
during
engagement of the stalk 320.
In this embodiment of stalk rolls 190, the short and intermediate flutes 180,
183 may be
integrally formed with one another and distinguished from one another via a
stair-step
configuration. The distance between opposing flutes 180, 182, 183 may be
reduced in
discrete increments along the length of the stalk rolls 190, as best shown in
FIG. 16. These
stalk rolls 190 could also be configured to have a stalk engagement gap 25 as
previously
described. Furthermore, any of the stalk rolls 15, 16, 190, 400 described or
pictured herein
may have any number of flutes 180, 181, 182, 183 extending radially any
suitable distance
from the stalk roll 15, 16, 190, 400, and may have a combination of tapered
flutes 181 and
other flutes 180, 182, 183. For example, in one embodiment of a stalk roll 190
not pictured
herein, the Ear Separation Zone may include flutes 180, 182, 183 having four
different radial
dimensions, with tapered flutes 181 interspersed there about. Accordingly, the
scope of the
stalk rolls 15, 16, 190, 400 as disclosed and claimed herein is not limited by
the number of
different radial dimensions by which flutes 180, 181, 182, 183 extend from the
stalk rolls
190.In another embodiment of the stalk rolls 190, the distance between the
flutes 180, 182,
183 may 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 rolls 192 shown in FIGS. 15-15C exploit a natural attribute
present in standing
corn __ the diameter of the stalk 320 at its base (i.e., ground level) is
larger than its diameter
toward the tip or tassel. The largest gap between the tapered stalk rolls 192
is at the entry to
the stalk rolls 192 near the front; the smallest gap is at the point of exit
of the stalk rolls 192
near the rear. This taper in the stalk rolls 192 balances the outward forces
created by the stalk
320 against the tapered flutes 181 and the inward force of the tapered flute
181 against the
stalk 320. An imbalance of the forces can create a pulsation in the stalk
rolls 192 during
26
Date Recue/Date Received 2020-04-27
operation. This pulsation creates a moment about the gearbox that can produce
premature
failure in the gearbox or its supporting mechanisms. Tapering the stalk rolls
192 reduces the
potential for pulsation while promoting entry of the stalks 320 between the
stalk rolls 192 and
allowing aggressive engagement between the stalk rolls 192 and the stalk 320.
The tapering
may be achieved by changing the diameter of the stalk rolls 192 along their
length or the
radial distance that the tapered flutes 181 extend from the stalk roll 192.
The embodiment of stalk rolls 192 having tapered flutes 181 shown in FIGS. 15-
15C are
configured for the tapered flutes 181 in 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 in FIGS.
15B and 15A. Conversely, the tapered flutes 181 in the Post-Ear Separation
Plant Ejection
Zone (the area about line C-C) are intermeshing, as best shown in FIG. 15C.
During
operation, as a stalk 320 is engaged by the stalk rolls 192, the distance
between the tapered
flutes 181 and the opposing stalk roll 192 is reduced, thereby increasing
penetration of the
stalk 320 by the tapered flutes 181 and exerting continuous pressure against
the stalk 320
during engagement.
Another embodiment of stalk rolls 192 having tapered flutes 181 is shown in
FIGS. 17-17B.
In this embodiment, all the tapered flutes 181 are intermeshing with one
another, as is clearly
shown in FIGS. 17A and 17B. In this embodiment of stalk rolls 192, 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 rolls 192 may be configured with a stalk
engagement gap 25 by
simply removing a portion of certain tapered flutes 181.
Both the tapered stalk rolls 192 and the stalk rolls 190 shown in FIGS. 13,
14, and 16 are
configured to achieve variable circumferential speeds along the length of the
stalk rolls 190,
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 speed 120 (the
gathering chain
120 speed must be the same as or faster than the ground speed); (2) Harvesting
machine
ground speed to the speed at which the transport vanes 170 horizontally guide
stalks 320 into
the ear separation chamber 140; and, (3) harvesting machine ground speed to
row unit
27
Date Recue/Date Received 2020-04-27
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 ear 300 separation is the highest speed at
which the ears
300 are 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 stalk 320 conditions, may require the
effective
circumferential speed and interaction of the multi-length, multi-angled, multi-
fluted, multi-
vaned stalk rolls 15, 16, 190, 192, 400 described 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 ears 300 falling forward out of the corn
head row unit
and onto the ground; thereby becoming irretrievable.
4. Recessed Stalk Rolls
Another embodiment of a stalk roll 400 having a stalk engagement gap 25 is
shown in FIGS.
21-22. FIGS. 21A and 21B provide corresponding perspective views of the stalk
roll 400,
which is designed to be one of a pair of opposed, counter-rotating stalk rolls
400 mounted to
a corn head row unit in a manner previously described. The stalk rolls 400 are
shown with
nose cones 410 having fighting 412 attached thereto. Typically, the nose cone
410 is shaped
substantially as a cone, as shown in the embodiments of stalk rolls 400
pictured herein. The
fighting 412 is configured to guide stalks 320 into the ear separation chamber
140 as
previously described. FIGS. 21-22 illustrate a first embodiment of a stalk
roll 400 having a
recess 420, as described in detail below.
Each stalk roll 400 may be formed with a main cylinder 430 having a recess 420
formed
therein between the front end of the main cylinder 430 and the nose cone 410
as shown in
FIGS. 21A and 21B. The recess 420 may extend along the entire circumference of
the stalk
28
Date Recue/Date Received 2020-04-27
roll 400 (i.e., an annular recess 420). The recess 420 may be formed in the
nose cone 410, or
it may be formed as a separate cylinder that is later affixed to both the main
cylinder 430 and
the nose cone 410. The diameter of the recess 420 is less than the diameter of
either the main
cylinder 430 or the rearward end of the nose cone 410, which is apparent from
FIGS. 21A
and 21B. The length of the recess 420 may vary from one embodiment of the
stalk roll 400 to
the next, but it is contemplated that for most embodiments the length of the
recess 420 will be
from 1.5 to 6 inches in length. Additionally, for certain embodiments it is
contemplated that
the diameter of the recess 420 will vary along its length. Accordingly, the
specific dimensions
of the recess 420 are in no way limiting.
The embodiment of the stalk rolls 400 shown in FIGS. 21-22 include a total of
ten flutes 440,
450, wherein six of those are full flutes 440 and four of those are reduced
flutes 450.
However, other embodiments of the stalk rolls 400 may have other numbers of
full flutes 440
and/or reduced flutes 450 to achieve a different number of total flutes 440,
450 and/or ratio of
full flutes 440 to reduced flutes 450. Additionally, the reduced flutes 450
need not be the
same length. The flutes 440, 450 extend in a radial direction from the main
cylinder 430
and/or recess 420. The flutes 440, 450 in the embodiment shown in FIGS. 21-22
are
substantially parallel to the longitudinal axis of the stalk roll 400 and
substantially
perpendicular to a line tangent to the main cylinder 430 at the flute base
449.
In a second embodiment of the stalk roll the flutes 440, 450 arc oriented
differently with
respect to lines that are tangent to the main cylinder 430 at the flute base
449. For example,
FIG. 23 provides an end view of two stalk rolls 400 intermeshed with one
another wherein
the flutes 440, 450 are angled forward with respect to the direction of
rotation of the stalk
rolls 400. Accordingly, the angle of the flutes 440, 450 with respect to lines
that are tangent
to the main cylinder 430 at the flute base 449 in no way limits the scope of
the stalk rolls 400
as disclosed and claimed herein.
In the first embodiment of the stalk roll 400, the full flutes 440 extend from
the rearward end
of the main cylinder 430 through the recess 420 and to the rearward end of the
nose cone 410,
as shown in FIGS. 21A and 21B. The reduced flutes 450 may extend from the
rearward end
of the main cylinder 430 to the rearward end of the recess 420. In the first
embodiment of the
stalk roll 400, the reduced flutes 450 are oriented in two pairs on opposite
sides of the stalk
29
Date Recue/Date Received 2020-04-27
roll 400 and the full flutes 440 are arranged in groups of three on opposite
sides of the stalk
roll 400. The circumferential distance between the flutes 440, 450 may be
equal, and in the
first embodiment the flutes 440, 450 are positioned at thirty six degrees from
each adjacent
flute 440, 450.
A detailed view of the flutes 440, 450 is shown in FIG. 21C. As shown, each
flute 440, 450
includes a flute edge 442 at the vertex of a leading surface 444 and a
trailing surface 445. The
leading and trailing surfaces 444, 445 may be connected to the main cylinder
430 and/or
recess 420 (depending on whether it is a full flute 440 or reduced flute 450)
with a flute base
449. The flute base 449 may have a leading wall 446 adjacent the leading
surface 444 and a
trailing wall 447 adjacent the trailing surface 445. In the first embodiment
of the stalk roll
400, a pair of stalk rolls 400 is mounted such that stalk roll 400 rotates
toward the leading
surface 444 and leading wall 446, as shown by the arrows in FIG. 22.
Each flute 440, 450 may be formed with a beveled edge 448 on the front axial
surface
thereof. In certain conditions, a beveled edge 448 provides easier entry for a
stalk 320 into the
corn plant engagement chamber. In the embodiment shown in FIGS. 21-22, the
beveled edge
448 is angled at 30 degrees with respect to the vertical. However, in other
embodiments the
beveled edge 448 may be differently configured without limitation.
In the first embodiment of the stalk roll 400 the trailing wall 447 and
trailing surface 445 arc
integral and linear, but may have other configurations in other embodiments of
the stalk roll
400. In the first embodiment the leading surface 444 is angled at thirty
degrees with respect
to the leading wall 446, which also creates an angle of thirty degrees between
the leading
surface 444 and trailing surface 445 (and trailing wall 447 in the first
embodiment). Through
testing, Applicant has found that this orientation allows the flutes 440, 452
to effectively
secure the stalk 320 during ear 321 removal and subsequently process the stalk
320 for
accelerated decomposition. Additionally, this orientation allows the stalk
rolls 400 to
properly release the stalk 320 after the ear 321 has been removed so that the
stalk 320 does
not wrap around the stalk roll 400. Other orientations and/or configurations
of leading
surfaces 444, trailing surfaces 445, leading walls 446, trailing walls 447,
and/or flute bases
449 may be used in other embodiments of the stalk roll 400 without limitation.
Date Recue/Date Received 2020-04-27
The embodiment shown in FIG. 23 includes leading and trailing surfaces 444,
445 that are
substantially parallel to one another and create a flute edge 442 that is
substantially flat,
which may be optimal in conditions in which it is desired that the stalk 320
be pulverized
rather than cut/lacerated. The angle between the leading and trailing surfaces
444, 445 and
the flute edge 442 in the embodiment in FIG. 23 may 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 edge 442 is perpendicular
with respect to
both the leading and trailing edges 444, 445 so that the stalk rolls 400
properly release the
stalk 320 after processing. However, other configurations will be preferred
for other
operating conditions.
FIG. 22 shows an end view of two cooperating stalk rolls 400 configured
according to the
first embodiment. The stalk rolls 400 in this figure are shown substantially
as they would
appear when mounted on a corn head row unit. As shown, the stalk rolls 400 are
mounted
such that one pair of reduced flutes 450 on opposing stalk rolls 400 are
adjacent one another
twice during a full revolution of the stalk rolls 400. This creates two stalk
engagement gaps
25 per revolution that extend the length of the recess 420. That is, the
length of the stalk
engagement gap 25 in the first embodiment of the stalk rolls 400 is equal to
the difference in
the length between the full flutes 440 and reduced flutes 450, which is also
equal to the length
of the recess 420. In the first embodiment of the stalk roll 400 having a
recess 420, the width
of the stalk slot 7 is defined by the distance between the inner peripheries
of the main
cylinders 430 of the opposing stalk rolls 400. The recess 420 increases the
effective width of
the stalk engagement gap 25 by two times the difference in diameter between
the main
cylinder 430 and the recess 420. Furthermore, the recess 420 facilitates the
positioning of a
stalk 320 between the flute edge 442 of a full flute 440 and the recess 420
when the stalk
engagement gap 25 is not present in the stalk slot 7. This ensures that stalks
320 will move
rearward along the length of the stalk rolls 400 during harvesting rather than
stalling at the
front of the stalk rolls 400 or being pushed forward to the nose cone 410. In
embodiments of
the stalk roll 400 in which the depth of the recess 420 is not constant along
its length, the
width of the stalk slot 7 is also not constant.
The embodiment of stalk rolls 400 shown in FIGS. 21-22 effectively remove cars
300 from a
stalk 320 and also cut the stalk 320 upon ejection from the stalk rolls 400.
This is achieved
31
Date Recue/Date Received 2020-04-27
through the simultaneous grasp and control of the stalk 320 by a first pair of
flutes 440, 450
while a second flute 440, 450 below the first pair cuts the stalk 320. This
situation is shown
schematically in FIG. 22B. The first pair of flutes 440, 450 secure the stalk
320 by engaging
at it first and second grasp points 322, 323. This grasp and control of the
stalk 320 allows
another flute 440, 450 positioned below but adjacent the second grasp point
323 to produce a
stalk cut point 324. This functionality requires a plurality of flutes 440,
450 spaced less than
sixty degrees from adjacent flutes 440, 450. That is, at least seven flutes
440, 450 are
required, and the embodiment pictured herein employs ten flutes 440, 450.
Applicant expected stalk rolls 400 as shown in FIGS. 21-22 to 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 rolls 400 actually produced less
MOTE while
simultaneously more effectively mutilating the stalk 320 than did the six-
flute stalk rolls.
Moreover, the ten-flute stalk rolls 400 operated 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 point 324 is enhanced by the secure
engagement of the
stalk 320 at the first and second grasp points 322, 323 and the forward slope
of the leading
surface 444. Instead of slipping past the flute edge 442 at the stalk cut
point 324, the stalk 320
is secured by the first and second grasp points 322, 323 so that the flute
edge 442 at the stalk
cut point 324 can fully penetrate the stalk 320. This allows the stalk rolls
400 to eject a
plurality of stalk pieces 326 that resemble confetti.
Other embodiments of stalk rolls 400 incorporating a recess 420 may have
additional or
fewer flutes 440, 450 extending other distances along the length of the stalk
roll 400.
Additionally, any considerations, designs, and/or orientations previously
discussed for other
stalk rolls 15, 16, 190, 192 may be incorporated with stalk rolls 400 having a
recess 420. For
example, intermediate flutes 182, tapered flutes 181, and/or long flutes 183
may be
positioned on the stalk roll 400 at various positions thereof. Additionally,
the considerations
of the various zones described in detail above may be incorporated into the
design of the stalk
rolls 400.
32
Date Recue/Date Received 2020-04-27
5. Other Row Unit Considerations
As shown in the embodiment of a corn head row unit in FIG. 20 the stalks 320
are lifted and
guided toward the row unit by dividers 100. Gathering chain 120 may be formed
with
enlarged gathering chain paddles 110, which help to direct the stalks 320
and/or ears 300
toward the ear separation chamber 140. The stalks 320 may be further centered
into the ear
separation chamber 140 by improved stripper plates 130 described in detail
above. Enlarged
gathering chain paddles 110 have an increased angle relative to the gathering
chain 120,
which allow the gathering chain paddles 110 to engagement a larger number of
stalks 320
and/or corn plants, especially when harvesting leaning and/or lodged corn.
Stalks 320 are gathered and further propelled rearwardly by means of the force
imparted by
transport vanes 170 on the nose cones 5, which are oppositely wound and
strategically timed
to be horizontally opposite. The transport vanes 170 positively direct and
lock the stalk 320
into the Alignment and Entry Zones, both of which may be configured with a
stalk
engagement gap 25. Alternatively, the stalk engagement gap 25 may be replaced
and/or
supplemented with stalk rolls 190 having tapered flutes 181 as shown in FIGS.
15-15C and
17-17B. The strategic lateral speed imparted to the stalk 320 by rotating
transport vanes 170
is determined by the angle of the transport vanes 170. This lateral speed may
be equal to or
faster than the lateral speed imparted to the stalk 320 by gathering chain
paddles 110.
In the embodiment of a row unit shown in FIG. 20, the reduced number of
enlarged gathering
chain paddles 110 increases the conveying capacity of the row unit in the ear
separation
chamber 140 to carry separated ears 300 rearward. This improved capacity
increases the
conveying efficiency of the gathering chain paddles 110 to the cross auger
trough 200, which
contains auger 220 and flighting 230 for conveying ears 300 to the feeder
house area.
FIGS. 18 and 18A show how the tapered flute-to-flute design stalk rolls 192
may work in
certain conditions. As the stalk rolls 192 rotate, the sharpened edges of the
flutes 181
penetrate the stalk outer shell 321. The penetration of the tapered flutes 181
combined with
the rotation of the stalk rolls 192 may simultaneously pull and lacerate the
stalk 320. Because
the entire row unit is moving forward during operation, the tapered flutes 181
penetrate
deeper and deeper into the stalk 320 as it is pulled down into the row unit.
The difference in
height between the tapered flutes 181 and the stalk roll 192 results in a
continuous
33
Date Recue/Date Received 2020-04-27
compressing/decompressing action against the stalk 320, which may crimp the
stalk 320.
FIGS. 19A and B illustrate the non-meshing stalk rolls 190 as they rotate
during operation. In
FIG. 18A, flutes 180 are marked at the top of the rotation prior to contact
with the stalk 320.
As the stalk roll 190 rotates, the edge of the flutes 180 will engage and
begin to pinch the
stalk 320. In FIG. 19B, flutes 180 have been rotated ninety degrees. The
opposing flutes 180
are directly opposite each other. The pressure exerted by flutes 180 on the
stalk 320 has lead
to penetration of the stalk 320. The rotation of the stalk roll 190 has pulled
the stalk 320
down into the corn row unit. Penetration by the flutes 180 is at maximum depth
in FIG. 18B.
Opposing flutes 180 do not touch each other during the cycle to avoid cutting
through the
stalk 320 in this embodiment. The angle of the knife edges of the flutes 180
have a
predetermined slope, as described. The angle of the slopes are forward with
respect to the
direction of rotation of the stalk rolls 190.
6. Further Stalk Roll Embodiments
Another illustrative embodiment of a stalk roll 400 that may have a recess 420
formed therein
is shown in FIGS. 24A-24C. It is contemplated that this particular embodiment
of a stalk roll
400 may be specifically adapted for use with either a John Deere brand Series
40-90 corn
head and/or a Case-IH 2200 and/or 2400 series corn head. It is contemplated
that the stalk
rolls 400 shown in FIGS. 28A-28C may be specifically adapted for use with a
John Deere
brand Series 600 corn head. However, the specific type of corn head for which
a stalk roll
400 according to the present disclosure is adapted in no way limits the scope
of the stalk roll
400 as disclosed and claimed herein. Accordingly, the various features and/or
aspects of the
stalk roll 400 according to the present disclosure may be employed on a stalk
roll 400
configured for engagement with any corn bead, whether currently existing for
later
developed, without limitation. Additionally, the illustrative embodiment of a
stalk roll 400
shown in FIGS. 24A-24C may be especially useful if configured as the right
stalk roll 400
(from the vantage of an operator positioned in the harvesting machine with
which the stalk
roll 400 is engaged, which vantage is used from herein when referring to
"right" and/or "left"
directions) of a pair of cooperating stalk rolls 400. Conversely, the
illustrative embodiment of
a stalk roll 400 shown in FIGS. 25A-25C may be especially useful if configured
as the left
stalk roll 400 of a pair of cooperating stalk rolls 400, which illustrative
embodiment of a pair
of stalk rolls 400 is shown in FIGS. 27A & 27B. However, the specific relative
orientation,
34
Date Recue/Date Received 2020-04-27
configurations, etc. of stalk rolls 400 employing any of the various features
disclosed herein
in no way limit the scope of the stalk roll 400 as disclosed and claimed
herein.
Those of ordinary skill in the art will appreciate how to adapt the features
of either illustrative
embodiment of a stalk roll 400 shown in FIGS. 24A-24C and/or 25A-25C to
configure a pair
off cooperating stalk rolls 400, such as the illustrative embodiment thereof
shown in FIGS.
27A & 27B. Accordingly, reference to either the illustrative embodiment of a
right or left
stalk roll 400 in no way limits the broader inventive features disclosed
herein, and those
features may be adapted to a cooperating stalk roll 400 without limitation.
It will be appreciated by persons of ordinary skill in the art that any stalk
roll 400 according
to the present disclosure may be engaged with complimentary stalk roll drive
shafts 29,
which may receive rotational power from a gearbox. The gearbox may have a
fixed speed
ratio for components receiving rotational power therefrom, or it may have
variable speed
ratios for any component receiving rotational power therefrom without
limitation. Referring
now to FIG. 24C, which provides an end view of the embodiment of a stalk roll
400 show in
perspective in FIG. 24A with the nose cone 410 removed, that embodiment of a
stalk roll 400
may include ten flutes 440, 440a, 450, 450a, 460 in total. In the embodiment
shown, the stalk
roll 400 specifically includes two hybrid flutes 440a, two full flutes 440,
two reduced flutes
450, two second reduced flutes 450a, and two short flutes 460. However, other
embodiments
of the stalk roll 400 according to the present disclosure may have different
numbers,
orientations, and/or configurations of flutes 440, 440a, 450, 450a, 460
without departing from
the spirit and scope of the stalk roll 400 as disclosed and claimed herein.
In certain illustrative embodiments, each flute 440, 440a, 450, 450a, 460 may
include a flute
base 449, which may be angled with respect to each flute 440, 440a, 450, 450a,
460. The
flutes 440, 440a, 450, 450a, 460 may be integrally formed with the
corresponding flute base
449 (as shown in the illustrative embodiments of flutes 440, 440a, 450, 450a,
460 shown in
FIGS. 26A-26G), or they may be separately formed and later engaged with one
another.
Alternatively, any stalk roll 400 according to the present disclosure may be
cast, forged,
and/or formed via any other suitable fabrication technique and/or
manufacturing method
without limitation.
Date Recue/Date Received 2020-04-27
In the illustrative embodiments shown in FIGS. 26A-26G, each flute 440, 440a,
450, 450a,
460 may include a radius 443 as a transition from the leading and trailing
walls 446, 447 of
the flute 440, 440a, 450, 450a, 460 to the corresponding flute base 449. In
the pictured
embodiments, the radius 443 may be configured such that the angle between the
leading
and/or trailing walls 446, 447 of a flute 440, 440a, 450, 450a, 460 and the
corresponding flute
base 449 is greater than 90 degrees, which is evident from FIGS. 24C, 25C, and
27B.
However, the scope of the stalk roll 400 as disclosed and claimed herein is
not limited by the
specific configuration of the radius 443 and/or the resulting orientation
between the leading
and/or trailing walls 446, 447 of each flute 440, 440a, 450, 450a, 460 and
corresponding flute
base 449, and the scope of the stalk roll 400 extends to all configurations
and/or orientations
between flutes 440, 440a, 450, 450a, 460 and corresponding flute bases 449.
For certain
embodiments, it is contemplated that the radius 443 may be configured such
that a flute 440,
440a, 450, 450a, 460 may be formed from a flat, stock piece of iron without
the need to
anneal the flute 440, 440a, 450, 450a, 460.
In certain illustrative embodiments of a stalk roll 400 shown herein, it is
contemplated that
adjacent flutes 440, 440a, 450, 450a, 460 may be engaged and/or secured with
one another
such that adjacent flute bases 449 generally form a cylindrical structure from
which the
leading and trailing walls 446, 447 of the flutes radially extend. This may be
done via
engaging a distal end of a first flute base 449 to an adjacent second flute
440, 440a, 450,
450a, 460 in an area near the radius 443 of the second flute 440, 440a, 450,
450a, 460. This
engagement and/or securement may be accomplished via any suitable structure
and/or
method, including but not limited to mechanical fasteners, welding, chemical
adhesion,
and/or combinations thereof without limitation.
As shown in FIGS. 24A-24C, an illustrative embodiment of a stalk roll 400 may
include a
nose cone 410 on the front portion of the stalk roll 400. Flighting 412 may be
engaged with a
portion of the nose cone 410. Typically, the nose cone 410 is shaped
substantially as a cone,
as shown in the embodiments of stalk rolls 400 pictured herein. The fighting
412 may be
configured to guide stalks 320 into the ear separation chamber 140 as
previously described.
As previously described, each stalk roll 400 may be formed via a plurality of
flutes 440,
440a, 450, 450a, 460 engaged with one another. The plurality of flutes 440,
440a, 450, 450a,
36
Date Recue/Date Received 2020-04-27
460 may subsequently be engaged with a hub assembly 470, one illustrative
embodiment of
which is described in further detail below. The flutes 440, 440a, 450, 450a,
460, nose cone
410, and hub assembly 470 may be configured such that a recess 420 exists
between the front
end of one or more flutes 440, 440a, 450, 450a, 460 and the nose cone 410 as
shown in FIG.
24B. The recess 420 may extend along the entire circumference of the stalk
roll 400 (i.e., an
annular recess 420), or along only a portion thereof. The recess 420 may be
formed in the
nose cone 410 (e.g., in the sleeve 414 thereof) and/or a portion of the flutes
440, 440a, 450,
450a, 460, or it may be formed as a separate cylinder that is later affixed to
the flutes 440,
440a, 450, 450a, 460 and/or the nose cone 410. Accordingly, the specific
elements of the
stalk roll 400 used to create a recess 420 in no way limits thc scope of the
stalk roll 400 as
disclosed and claimed herein.
An illustrative embodiment of a hybrid flute 440a is shown in FIG. 26A. As
shown, this
embodiment of a hybrid flute 440a may include an axial face 441 that is angled
backward
with respect to the direction of travel of a harvesting machine to create a
leading beveled
edge 448. In certain embodiments the beveled edge 448 may be advantageously
angled at 30
degrees with respect to the vertical. However, in other embodiments the
beveled edge 448
may be differently configured without limitation. For example, in other
embodiments of the
hybrid flute 440a the beveled edge 448 may be angled at 20 degrees with
respect to the
vertical or it may be angled at 45 degrees with respect to the vertical.
Still referring to FIG. 26A, the illustrative embodiment of a hybrid flute
440a may include a
trailing wall 447 and trailing surface 445 that may be integral and linear,
but which may have
other configurations in other embodiments of the stalk roll 400. The hybrid
flute 440a may
also include a leading wall 446 and a leading surface 444. As shown, the
leading and trailing
walls 446, 447 may extend beyond the flute base 449, such that a portion of
the leading and
trailing walls 446, 447 may be positioned over the exterior surface of the
sleeve 414 and/or
other portion of the nose cone 410 and/or stalk roll 400. Furthermore, a first
portion of the
flute edge 442 toward the nose cone 410 may be formed as a blunt edge and a
rear portion of
the flute edge 442 may be formed as a sharp, knife edge.
The blunt flute edge 442 may be formed via leading and trailing surfaces 444,
445 that are
substantially parallel to one another so as to create a flute edge 442 that is
substantially flat,
37
Date Recue/Date Received 2020-04-27
which flute edge 442 may be generally perpendicular to the leading and
trailing surfaces 444,
445. The sharp flute edge 442 may be formed by angling the leading surface
with respect to
the leading wall 446. The optimal angle for this will vary depending on the
specific
harvesting conditions, but it is contemplated that for most applications the
optimal angle may
be between 2 and 65 degrees. Other orientations and/or configurations of
leading surfaces
444, trailing surfaces 445, leading walls 446, trailing walls 447, and/or
flute bases 449 may
be used in other embodiments of the stalk roll 400 without limitation.
In the stalk roll 40 and flute 440, 440a, 450, 450a, 460 embodiments pictured
in FIGS. 24A-
27B, it is contemplated that the blunt flute edge 442 may extend along the
length of the stalk
roll 400 from an area adjacent the fighting/flute interface 412a backward to
an area just past
the start of the shortest flute 440, 440a, 450, 450a, 460 on the stalk roll
400 (which may be
the short flute 460 as shown in the illustrative embodiment in FIGS. 24A-27B).
This
configuration may ensure that the portion of any flute 440, 440a, 450, 450a,
460 that initially
engages a stalk is a blunt flute edge 442 rather than a sharp flute edge 442,
which may
mitigate wear on the flutes 440, 440a, 450, 450a, 460.
An illustrative embodiment of a full flute 440 is shown in perspective view in
FIG. 26B. The
full flute 440 may be positioned adjacent a hybrid flute 440a in the
illustrative embodiments
of stalk rolls 400 shown in FIGS. 24A-25C, 27A, and 27B, and in which
embodiments the
full flute 440 may be shorter in length than the hybrid flute 440a. The
illustrative embodiment
of a full flute 440 may include a trailing wall 447 and trailing surface 445
that may be
integral and linear, but which may have other configurations in other
embodiments of the
stalk roll 400. The full flute 440 may also include a leading wall 446 and a
leading surface
444. As shown, the leading and trailing walls 446, 447 may extend beyond the
flute base 449,
such that a portion of the leading and trailing walls 446, 447 may be
positioned over the
exterior surface of the sleeve 414 and/or other portion of the nose cone 410
and/or stalk roll
400. The entire flute edge 442 of the full flute 440 may be formed as a sharp,
knife edge.
Alternatively, the full flute 400 may be formed with a portion that includes a
blunt flute edge
442 and another portion that includes a sharp flute edge 442 as previously
described for the
hybrid flute 440a.
38
Date Recue/Date Received 2020-04-27
An illustrative embodiment of a reduced flute 450 is shown in perspective view
in FIG. 26C.
The reduced flute 450 may be positioned adjacent a full flute 440 in the
illustrative
embodiments of stalk rolls 400 shown in FIGS. 24A-25C, 27A, and 27B, and in
which
embodiments the reduced flute 450 may be shorter in length than the full flute
440. The
illustrative embodiment of a reduced flute 450 may include a trailing wall 447
and trailing
surface 445 that may be integral and linear, but which may have other
configurations in other
embodiments of the stalk roll 400. The reduced flute 450 may also include a
leading wall 446
and a leading surface 444. As shown, the leading and trailing walls 446, 447
may extend
beyond the flute base 449, such that a portion of the leading and trailing
walls 446, 447 may
be positioned over the exterior surface of the sleeve 414 and/or other portion
of the nose cone
410 and/or stalk roll 400. The entire flute edge 442 of the reduced flute 450
may be formed as
a sharp, knife edge. Alternatively, the reduced flute 450 may be formed with a
portion that
includes a blunt flute edge 442 and another portion that includes a sharp
flute edge 442 as
previously described for the hybrid flute 440a.
An illustrative embodiment of a second reduced flute 450a is shown in
perspective view in
FIG. 26D. The second reduced flute 450a may be positioned adjacent a reduced
flute 450 in
the illustrative embodiments of stalk rolls 400 shown in FIGS. 24A-25C, 27A,
and 27B, and
in which embodiments the second reduced flute 450a may be shorter in length
than the
reduced flute 450. The illustrative embodiment of a second reduced flute 450a
may include a
trailing wall 447 and trailing surface 445 that may be integral and linear,
but which may have
other configurations in other embodiments of the stalk roll 400. The second
reduced flute
450a may also include a leading wall 446 and a leading surface 444. As shown,
the leading
and trailing walls 446, 447 may extend beyond the flute base 449, such that a
portion of the
leading and trailing walls 446, 447 may be positioned over the exterior
surface of the sleeve
414 and/or other portion of the nose cone 410 and/or stalk roll 400. The
entire flute edge 442
of the second reduced flute 450a may be formed as a sharp, knife edge.
Alternatively, the
second reduced flute 450a may be formed with a portion that includes a blunt
flute edge 442
and another portion that includes a sharp flute edge 442 as previously
described for the
hybrid flute 440a.
An illustrative embodiment of a short flute 460 is shown in perspective view
in FIG. 26E.
The short flute 460 may be positioned adjacent a second reduced flute 450a in
the illustrative
39
Date Recue/Date Received 2020-04-27
embodiments of stalk rolls 400 shown in FIGS. 24A-25C, 27A, and 27B, and in
which
embodiments the short flute 460 may be shorter in length than the second
reduced flute 450a.
The illustrative embodiment of a short flute 460 may include a trailing wall
447 and trailing
surface 445 that may be integral and linear, but which may have other
configurations in other
embodiments of the stalk roll 400. The short flute 460 may also include a
leading wall 446
and a leading surface 444. As shown, the leading and trailing walls 446, 447
may extend
beyond the flute base 449, such that a portion of the leading and trailing
walls 446, 447 may
be positioned over the exterior surface of the sleeve 414 and/or other portion
of the nose cone
410 and/or stalk roll 400. The entire flute edge 442 of the short flute 460
may be formed as a
sharp, knife edge. Alternatively, the short flute 460 may be formed with a
portion that
includes a blunt flute edge 442 and another portion that includes a sharp
flute edge 442 as
previously described for the hybrid flute 440a. As shown, all or some of the
flutes 440, 440a,
450, 450a, 460may be formed with an axial face 441 that is angled with respect
to the flute
edge 442 at an angle greater than 90 degrees to reduce the likelihood of stalk
shear or
degradation upon first contact with a flute 440, 440a, 450, 450a, 460. It is
contemplated that
in one embodiment this axial face 441 may be angled at 120 degrees with
respect to the flute
edge 442.
Although the illustrative embodiments shown in FIGS. 24A-25C, 27A, and 27B
depict stalk
rolls 400 having two hybrid flutes 440a, two full flutes 440, two reduced
flutes 450, two
second reduced flutes 450a, and two short flutes 460, other numbers,
configurations, and/or
orientations of flutes 440, 440a, 450, 450a, 460 may be used without
limitation. For example,
in some embodiments of a stalk roll 400 according to the present disclosure it
is contemplated
that the full flutes 440 may be configured as having a portion configured with
a blunt flute
edge 442 and a portion configured with a sharp flute edge 442.
In the illustrative embodiments of stalk rolls 400 shown in FIGS. 24A-25C,
27A, and 27B,
another hybrid flute 440a may be positioned adjacent a short flute 460, such
that each hybrid
flute 440a is positioned between a short flute 460 and a full flute 440 and so
on to configure a
stalk roll 400 with ten flutes 440, 440a, 450, 450a, 460. However, other
configurations,
orientations, and/or relative positions and/or dimensions of the flutes 440,
440a, 450, 450a,
460 may be used without departing from the spirit and scope of the stalk roll
400 as disclosed
and claimed herein. As shown, the configuration of illustrative embodiments of
flutes 440,
Date Recue/Date Received 2020-04-27
440a, 450, 450a, 460 may create a stair-stepped window. Additionally, the
fighting 412 on
the nose cone 410 may cooperate with the flutes 440, 440a, 450, 450a, 460 such
that the
fighting/flute interface 412a leads to an open area in the stalk roll 40010
facilitate entry of a
stalk into the ear separation chamber 140 with minimal interference from any
flutes 440,
440a, 450, 450a, 460. This may be accomplished by placing the forward facing
axial face 441
of the most forward-extending flute 440, 440a, 450, 450a, 460 (which in this
illustrative
embodiment is the hybrid flute 440a) as rotationally aligned as possible with
the rearward end
of the fighting 412. In the illustrative embodiment of a stalk roll 400 shown
in FIG. 24A, the
hybrid flute 440a and the rearward end of the fighting 412 may have little to
no rotational
offset therebetween.
Because the illustrative embodiment of a pair of stalk rolls 400 shown in
FIGS. 27A and 27B
are configured to be intermeshed, the illustrative embodiment of a stalk roll
400 shown in
FIGS. 25A-25C may require that there is a certain amount of rotational offset
between the
rearward end of the fighting 412 and the hybrid flute 440a to prevent
interference between
nose cones 410 and/or flutes 440, 440a, 450, 450a, 460 of opposing stalk rolls
400
cooperating as a pair. Accordingly, the embodiment of a stalk roll 400 shown
in FIGS. 25A-
25C may be configured such that the rearward end of the fighting 412 is
positioned so that it
does not feed a stalk directly into a flute 440, 440a, 450, 450a, 460, which
may result in the
rearward end of the fighting 412 to approximately rotationally aligned with a
second reduced
flute 450a. However, in other embodiments it is possible that both stalk rolls
400 of a
cooperating pair may have little to no rotational offset between most forward-
extending flute
440, 440a, 450, 450a, 460 and the rearward end of the fighting 412. In still
other
embodiments, the rearward end of the fighting 412 may be approximately
rotationally
aligned with a different flute 440, 440a, 450, 450a, 460, such as a short
flute 460 or reduced
flute 450 without limitation. Accordingly, the specific and/or relative
rotational positions of
the fighting 412 and various flutes 440, 440a, 450, 450a, 460 in no way limit
the scope of the
stalk roll 400 as disclosed and claimed herein.
Referring now to FIGS. 26A-26G, each flute base 449 may include a base bevel
44911 The
base bevel 449b may be configured to facilitate movement of a stalk from an
area adjacent a
recess 420 to the car separation chamber 140. Configuring a stalk roll 400
with flutes 440,
440a, 450, 450a, 460 shown in FIGS. 26A-26G may allow for a recess 420 in the
stalk roll
41
Date Recue/Date Received 2020-04-27
400 of varying length depending on the rotational position on the stalk roll
400 (which may
also affect the depth of a stalk engagement gap 25, as described in detail
below). For
example, in the illustrative embodiment of a configuration of flutes 440,
440a, 450, 450a, 460
shown in FIG. 26G, the portion of the leading and trailing walls 446, 447
extending forward
beyond the flute base 449 of a first flute 440, 440a, 450, 450a, 460 may
cooperate with the
portion of the leading and trailing walls 446, 447 extending forward beyond
the flute base
449 of a second, adjacent flute 440, 440a, 450, 450a, 460 such that a portion
of the recess 420
resides between the two flutes 440, 440a, 450, 450a, 460 in the space absent
any flute base
449. This configuration allows for a recess 420 that extends further backward
along the
length of thc stalk roll 400 from the longest flute 440, 440a, 450, 450a, 460
to the shortest
flute 440, 440a, 450, 450a, 460 (which happens to be from the hybrid flute
440a to the short
flute 460 in the illustrative embodiments). That is, in the illustrative
embodiments of a stalk
roll 400 the recess 420 may extend further backward along the length of the
stalk roll 400
between the second reduced flute 450a and reduced flute 450 than the recess
420 extends
between the reduced flute 450 and full flute 440. Additionally, the recess 420
may extend
further backward along the length of the stalk roll 400 between the reduced
flute 450 and full
flute 440 than the recess 420 extends between the full flute 440 and hybrid
flute 440a.
However, other configurations of flutes 440, 440a, 450, 450a, 460, flute bases
449, nose
cones 410, andlor hub assemblies 470 may be used to manipulate the
configuration andlor
orientation of the recess 420 without limitation.
As with other embodiments of the stalk roll 400, the diameter of the recess
420 generally may
be less than the outside diameter of either the general cylinder formed by
adjacent flute bases
449 or the rearward end of the nose cone 410. The length of the recess 420 may
vary from
one embodiment of the stalk roll 400 to the next and may vary on a given stalk
roll 400
depending on the rotational position about the stalk roll 400 as described
above. Accordingly,
the specific dimensions of the recess 420 are in no way limiting to the scope
of the present
disclosure.
One or more flute bases 449 may be formed with various apertures 449a therein
to allow for
access to a key pin (not shown), retainer 432, and/or other structures. One or
more flute bases
449 may also be formed with a tapped hole, such that a retainer 432 may pass
through an
aperture 449a and engage the tapped hole. Tightening the retainer 432 may
cause the area
42
Date Recue/Date Received 2020-04-27
between a notch 462 (shown formed in the hybrid flute 440a of the illustrative
embodiment
pictured in FIGS. 24A-27B) and an adjacent flute base 449 to constrict, which
in turn may
cause the slot 476 to constrict around the stalk roll drive shaft 29, thereby
securing a portion
of the stalk roll 400 to the stalk roll drive shaft 29. Of course, those of
ordinary skill in the art
will appreciate that the specific mounting method and/or structures used to
engage a stallc roll
400 will a stalk roll drive shaft 29 will vary from one application to the
next, and is therefore
in no way limiting to the scope of the present disclosure.
In this embodiments pictured in FIGS. 24A-27B, the configuration and
orientation of the
flutes 440, 440a, 450, 450a, 460 may provide a stalk engagement gap 25 with
dynamic
geometry. As two cooperating stalk rolls 400 rotate, the hybrid flutes 440a
eventually become
present within stalk slot 7. Continuing to rotate the stalk rolls 400 causes
the full flutes 440
(or a portion thereof) to become present in the stalk slot 7, such that a
portion of the full flutes
440 and a portion of the hybrid flutes 440a may be simultaneously present in
the stalk slot 7.
Continuing to rotate the stalk rolls 400 causes the reduced flutes 450 (or a
portion thereof) to
become present in the stalk slot 7, such that a portion of the reduced flutes
450 and a portion
of the full flutes 440 may be simultaneously present in the stalk slot 7.
Additional rotation
causes the second reduced flutes 450a (or a portion thereof) to become present
in the stalk
slot 7, such that a portion of the reduced flutes 450 and second reduced
flutes 450a may be
simultaneously present in the stalk slot 7. Finally, rotating the stalk rolls
400 further causes
the short flutes 460 (or a portion thereof) to become present in the stalk
slot 7, such that a
portion of the short flutes 460 and a portion of the second reduced flutes
450a may be
simultaneously present in the stalk slot 7.
As this rotation occurs, it will be apparent to those of ordinary skill in the
art that the stalk
engagement gap 25 may first appear (at a moment approximately when the hybrid
flutes 440a
exit the stalk slot 7) and may have a constant width (which width may be
approximately
equal to the horizontal distance between the sleeves 414 of opposing nose
cones 410).
However, the depth of the stalk engagement gap 25 may progressively increase
as the
rotation above occurs. That is, the depth of the stalk engagement gap 25 at a
moment in time
when the short flutes 460 and second reduced flutes 450a are present in the
stalk slot 7 may
be greater than the depth of the stalk engagement gap 25 at a moment in time
when the full
flutes 440 and reduced flutes 450 are present in the stalk slot 7. The base
bevels 449b, bevel
43
Date Recue/Date Received 2020-04-27
positions on the axial faces 441, lengths of flute bases 449, lengths of
flutes 440, 440a, 450,
450a, 460, and/or distance that the leading and trailing walls 446, 447 extend
beyond the
corresponding flute bases 449 may be configured to provide a relatively smooth
transition
from one depth of a stalk engagement gap 25 (or length of recess 420) to the
next, which is
clearly shown at least in FIG. 26G. Other arrangements of the various elements
described
herein may be used without departing from the spirit and scope of the stalk
roll 400 as
disclosed and claimed herein. It is contemplated that this configuration may
facilitate the
positioning of a stalk 320 between the blunt flute edges 442 of hybrid flutes
440a on
opposing stalk rolls 440, which may ensure that stalks 320 will move rearward
along the
length of the stalk rolls 400 during harvesting rather than stalling at the
front of the stalk rolls
400 or being pushed forward to the nose cone 410.
In other embodiments the width of the stalk engagement gap 25 may vary with
the rotational
position of the opposing stalk rolls 400. For example, one or more flutes 440,
440a, 450,
450a, 460 may be configured with a flute base 449 extending forward beyond the
leading and
trailing walls 4446, 447 to create a bladeless area adjacent that portion of
the flute base 449.
The difference in the diameter of the stalk roll 400 at the recess 420 as
compared to the
diameter at the bladeless area 422 may create a stalk engagement gap 25 having
two or more
distinct widths, wherein the stalk engagement gap 25 has a first width along a
generally
horizontal line drawn from the recess 420 on a first stalk roll 400 to the
recess 420 on the
opposing stalk roll 400 and a second width along a generally horizontal line
drawn from the
bladeless area on the first stalk roll 40 to the bladeless area 422 on the
opposing stalk roll
400. In one embodiment the width of the stalk engagement gap 25 between
opposite recesses
420 may be 1.25 inches and the width of the window between opposite bladeless
areas 422
may be 7/8 inch, but such dimensions are in no way limiting. It is
contemplated that in some
embodiments the width of the stalk engagement gap 25 between opposite recesses
420 may
be equal to the shortest distance between opposite nose cones 410.
Another illustrative embodiment of stalk rolls 400 according to the present
disclosure is
shown in FIGS. 28A & 28B. It is contemplated that this embodiment of stalk
rolls 400 may
be specifically configured for use on John Deere brand Series 600 corn heads.
However, the
specific make, model, and/or configuration of corn head with which any stalk
roll 400
according to the present disclosure is engaged in no way limits the scope of
the stalk roll 400
44
Date Recue/Date Received 2020-04-27
as disclosed and claimed herein. This embodiment may include hybrid blades
440a as
previously disclosed for other embodiments, or it may be configured with no
flutes 440,
440a, 450, 450a, 460 having a blunt flute edge 442 without limitation. As may
be seen in
FIG. 28B, a hub assembly 470 engaged with the illustrative embodiment of the
stalk rolls 400
shown in FIGS. 28A & 28B may be formed with a central bore 475 having one or
more
coupler sections 475a (which may be formed as four keyways offset by 90
degrees from one
another) therein. The coupler sections 475a may serve to engage and/or secure
at least the
rotational position of the stalk roll 400 with respect to the stalk roll drive
shaft 29.
As shown, the stalk rolls 400 in FIGS. 28A & 28B may have a nose cone 410 that
is slightly
longer than the nose cone 410 on the stalk rolls 400 shown in FIGS. 27A & 27B.
The pitch
and depth of the fighting 412 on any of the nose cones 410 pictured herein is
for illustrative
purposes only, and therefore is in no way limiting to the scope of the present
disclosure. It is
contemplated that in one embodiment, the pitch of the fighting 412 will be
configured such
that when the stalk rolls 400 are spinning at operating speed, a corn stalk
engaged with the
fighting 412may travel at approximately 6 miles per hour in the generally
horizontal
dimension. Other nose cones 410 may be used without limitation. If formed
separately from
the hub assembly 470, the nose cone 410 may be later secured to the hub
assembly 470,
which may be done using any structure and/or method now known to those skilled
in the art
or later developed, including but not limited to welding, mechanical
fasteners, chemical
adhesives, and/or combinations thereof It is contemplated that the optimal
rotational position
of the nose cone 410 may be determined by the configuration of the fighting
412 and the
position of the key pin, but such considerations are in no way limiting to the
present
disclosure.
The flutes 440, 440a, 450, 450a, 460 on the embodiment of the stalk roll 400
shown in FIGS.
28A & 28B may have a rearward axial point 464, which may be accomplished via
removing
the flute base 449 from that portion and removing both a top and bottom
portion of the
leading and trailing walls 446, 447. This configuration of the rearward axial
end of the flutes
440, 440a, 450, 450a, 460 may allow the flutes 440, 440a, 450, 450a, 460 to
engage an end
ring 478 adjacent the most rearward end of the flutes 440, 440a, 450, 450a,
460 for structural
integrity and proper mounting and/or positioning of the stalk rolls 400 on the
corn head.
However, other configurations of the rearward axial end of the flutes MO,
440a, 450, 450a,
Date Recue/Date Received 2020-04-27
460 and/or end ring 478 may be used without departing from the spirit and
scope of the stalk
roll 400 as disclosed and claimed herein. As with the embodiments shown in
FIGS. 27A &
27B, the stalk rolls 400 shown in FIGS. 28A & 28B may be configured such that
a stalk
engagement gap 25 forms at least once during a full revolution of the stalk
rolls 400, as best
described in U.S. Pat. Nos. 7,886,510 and 8,220,237 .
As with other embodiments of stalk rolls 400 disclosed herein, the embodiment
shown in
FIGS. 28A & 28B, the configuration of flutes 440, 440a, 450, 450a, 460 may
provide a stair-
stepped stalk engagement gap 25. A first boundary to the depth this stalk
engagement gap 25
may be formed at the rear end of the fighting 412 at a fighting/flute
interface 412a.
Although not shown for the pictured embodiment, in other embodiments of the
stalk roll 400
the axial face 441 of one of the full flutes 440 (or whatever flute 440, 440a,
450, 450a, 460
extends forward the furthest) may be engaged with the flighting 412 such that
during rotation
of the stalk roll 400, a stalk 320 may easily travel from the nose cone 410 to
the recess 420
(or stalk engagement gap 25) and along the length of the stalk roll 400.
A first illustrative embodiment of a hub assembly 470 that may be used to
couple the stalk
roll 400 to a stalk roll drive shaft 29 is shown in perspective in FIG. 29A an
in axial cross-
section in FIG. 29B. This illustrative embodiment may be specifically adapted
for engaging a
stalk roll 400 with a stalk roll drive shaft 29 of a John Deere brand Series
40-90 corn head. It
is contemplated that the nose cone 410, hub assembly 470, and flutes 440,
440a, 450, 450a,
460 may be formed separately and later engaged with one another. However, in
other
embodiments all or some of those elements may be formed integrally with one
another via
any suitable fabrication and/or manufacturing method now known or later
developed.
Accordingly, the specific method of manufacture in no way limits the scope of
the present
disclosure.
The hub assembly 470 may be formed with a central bore 475 along the
longitudinal axis
thereof for receiving a stalk roll drive shaft 29. The hub assembly may also
include at least
one key pin that may be configured to pass through the hub assembly 470 and
corresponding
apertures formed in the stalk roll drive shaft 29 and apertures 471 formed in
the hub assembly
470 so as to secure at least the rotational position of the hub assembly 470
with respect to the
46
Date Recue/Date Received 2020-04-27
stalk roll drive shaft 29 such that the hub assembly 470 rotates therewith.
The key pin may
also serve to secure the axial position of the hub assembly 470 with respect
to the stalk roll
drive shaft 29.
A flange 472 may be formed at the front end of the hub assembly 470 to fit
within the nose
cone 410 and engage the interior surface of the sleeve 414, which is shown in
FIG. 29B. An
engagement surface 473 may be positioned on either side of a recessed surface
474. The
engagement surface(s) 473 may be configured to engage one or more flute bases
449 via any
engagement and/or securement methods and/or structures now known or later
developed. A
slot 476 may be formed along the longitudinal axis of the hub assembly 470 on
the end
thereof opposite the flange 472. The hub assembly 470 may be formed with a
shelf 472a
adjacent the proximal end of the flange 472 to provide an engagement point for
the distal end
of the sleeve 414 of the nose cone 410.
One or more flutes 440, 440a, 450, 450a, 460 may be secured to the hub
assembly 470 if they
are not integrally formed therewith. This may be done using any structure
and/or method
known to those skilled in the art or later developed, including but not
limited to welding,
mechanical fasteners, chemical adhesives, and/or combinations thereof. For
example, it is
contemplated that the flute base 449 may be welded to the engagement surfaces
473 of the
hub assembly 470. The flute base 449 of one or more flutes 440, 440a, 450,
450a, 460 may be
formed with a notch 462 therein (such as shown in a hybrid flute 440a in FIG.
26A), which
notch 462 may be adjacent an aperture 449a through which a retainer 432 may
pass. The
notch 462 may extend along a specific length of the flute 440, 440a, 450,
450a, 460 and
inward toward the leading and trailing walls 446, 447 by a specific amount.
One or more flute
bases 449 may be formed with various apertures 449a therein to allow for
access to a key pin,
retainer 432, and/or other structures. One or more flute bases 449 may also be
formed with a
tapped hole, such that a retainer 432 may pass through an aperture 449a and
engage the
tapped hole. Tightening the retainer 432 may cause the area between a notch
462 and an
adjacent flute base 449 to constrict, which in turn may cause the slot 476 to
constrict around
the stalk roll drive shaft 29, thereby securing a portion of the stalk roll
400 to the stalk roll
drive shaft 29. However, any suitable method and/or structure now know or
later developed
may be used to adequately secure and/or engage a stalk roll 400 with a stalk
roll drive shaft
29 without limitation.
47
Date Recue/Date Received 2020-04-27
Another illustrative embodiment of a hub assembly 470 that may be used to
couple the stalk
roll 400 to a stalk roll drive shaft 29 is shown in perspective in FIG. 30A an
in axial cross-
section in FIG. 30B. This illustrative embodiment may be specifically adapted
for engaging a
stalk roll 400 with a stalk roll drive shaft 29 of a Case-1H brand 2200 or
2400 series corn
head. It is contemplated that the nose cone 410, hub assembly 470, and flutes
440, 440a, 450,
450a, 460 may be formed separately and later engaged with one another.
However, in other
embodiments all or some of those elements may be formed integrally with one
another via
any suitable fabrication and/or manufacturing method now known or later
developed.
Accordingly, the specific method of manufacture in no way limits the scope of
the present
disclosure.
The hub assembly 470 may be formed with a central bore 475 along the
longitudinal axis
thereof for receiving a stalk roll drive shaft 29. The central bore 475 may
include a coupler
section 475a along a specific length thereof having a different cross-
sectional shape than the
remainder of the central bore 475. For example, in the illustrative embodiment
of a hub
assembly 470 shown in FIGS. 30A & 30B, the coupler section 475a may be formed
with a
substantially oval cross-sectional shape and the remainder of the central bore
475 may be
formed with a substantially circular cross-sectional shape. The stalk roll
drive shaft 29
configured to engage such an embodiment of a hub assembly 470 may have
corresponding
sections of differing cross-sectional shapes so as to secure at least the
rotational position of
the hub assembly 470 with respect to the stalk roll drive shaft 29 such that
the hub assembly
470 rotates therewith.
A flange 472 may be formed at the front end of the hub assembly 470 to fit
within the nose
cone 410 and engage the interior surface of the sleeve 414, which is shown in
FIG. 30B. An
engagement surface 473 may be positioned adjacent the flange 472. The
engagement
surface(s) 473 may be configured to engage one or more flute bases 449 via any
engagement
and/or securement methods and/or structures now known or later developed.
One or more flutes 440, 440a, 450, 450a, 460 may be secured to the hub
assembly 470 if they
arc not integrally formed therewith. This may be done using any structure
and/or method
known to those skilled in the art or later developed, including but not
limited to welding,
48
Date Recue/Date Received 2020-04-27
mechanical fasteners, chemical adhesives, and/or combinations thereof. For
example, it is
contemplated that the flute base 449 may be welded to the engagement surfaces
473 of the
hub assembly 470. The flute base 449 of one or more flutes 440, 440a, 450,
450a, 460 may be
formed with a notch 462 therein (such as shown in a hybrid flute 440a in FIG.
26A), which
notch 462 may be adjacent an aperture 449a through which a retainer 432 may
pass. The
notch 462 may extend along a specific length of the flute 440, 440a, 450,
450a, 460 and
inward toward the leading and trailing walls 446, 447 by a specific amount.
One or more flute
bases 449 may be formed with various apertures 449a therein to allow for
access to a key pin,
retainer 432, and/or other structures. One or more flute bases 449 may also be
formed with a
tapped hole, such that a retainer 432 may pass through an aperture 449a and
engage the
tapped hole. However, any suitable method and/or structure now know or later
developed
may be used to adequately secure and/or engage a stalk roll 400 with a stalk
roll drive shaft
29 without limitation.
It is contemplated that the embodiments of stalk rolls 400 shown in FIGS. 27A-
28B may
effectively remove ears 300 from a stalk 320 and also cut the stalk 320 upon
ejection from
the stalk rolls 400 in a variety of harvesting conditions. This may be
achieved through the
simultaneous grasp and control of the stalk 320 by a first pair of flutes 440,
440a, 450, 450a,
460 while a second flute 440, 440a, 450, 450a, 460 below the first pair cuts
the stalk 320. The
first pair of flutes 440, 440a, 450, 450a, 460 may secure the stalk 320 by
engaging at it first
and second grasp points 322, 323. This grasp and control of the stalk 320 may
allow another
flute 440, 440a, 450, 450a, 460 positioned below but adjacent the second grasp
point 323 to
produce a stalk cut point 324. This functionality may require a plurality of
flutes 440, 440a,
450, 450a, 460 spaced less than sixty degrees from adjacent flutes 440, 440a,
450, 450a, 460
about the circumference of the stalk roll 400. That is, at least seven flutes
440, 440a, 450,
450a, 460 may be required for such functionality.
The cutting function at the stalk cut point 324 may be enhanced by the secure
engagement of
the stalk 320 at the first and second grasp points 322, 323 and the forward
slope of the
leading surface 444. Instead of slipping past the flute edge 442 at the stalk
cut point 324, the
stalk 320 may be secured by the first and second grasp points 322, 323 so that
the flute edge
442 at the stalk cut point 324 may fully penetrate the stalk 320. This may
allow the stalk rolls
49
Date Recue/Date Received 2020-04-27
400 to eject a plurality of stalk pieces 326 that resemble confetti, which is
shown
schematically in FIG. 22B for one snapshot in time during the rotation of the
stalk rolls 400.
It is also contemplated that the embodiments of stalk rolls 400 as shown in
FIGS. 27A-28B
will decrease the amount of MOTE produced during harvesting compared to
otherwise-
identical six-flute stalk rolls. Moreover, it is contemplated that the
embodiments of stalk rolls
400 as shown in FIGS. 27A-28B may operate consistently in multiple conditions,
including
high moisture (e.g., early morning or late evening harvesting), low moisture,
and various
varieties of corn plants than other stalk rolls. Because the outer diameter of
each flute edge
442 with respect to the rotational axis of each stalk roll 400 may be equal,
and because the
rotational speed of each stalk roll 400 may be equal, the linear velocity of
each flute edge 442
may be equal. However, the relative angular and/or linear speeds thereof may
be different as
experienced by various stalks 320 depending on the position of the stalk 320
relative to the
stalk rolls 400 and the degree of processing that the stalk 320 has
experienced from the stalk
rolls 400 (e.g., cutting, shearing, etc.).
Other embodiments of stalk rolls 400 incorporating a recess 420 and/or
configured to provide
a stalk engagement gap 25 may have additional or fewer flutes 440, 440a, 450,
450a, 460
extending other distances along the length of the stalk roll 400.
Additionally, any
considerations, designs, and/or orientations previously discussed for other
stalk rolls 15, 16,
190, 192 may be incorporated with stalk rolls 400 having a recess 420 and/or
stalk
engagement gap 25. For example, intermediate flutes 182, tapered flutes 181,
and/or long
flutes 183 may be positioned on the stalk roll 400 at various positions
thereof. Additionally,
the considerations of the various zones described in detail above may be
incorporated into the
design of any embodiments of the stalk rolls 400. The various features
disclosed herein may
be used alone or in combination with one another. Additionally, some of the
features
disclosed herein may be especially useful to moving stalk 320 from the nose
cone 410 to an
area between two opposing stalk rolls 400 with minimal risk of shearing the
stalk 320 or
otherwise damaging it in an unwanted fashion.
Any of the illustrative embodiments of stalk rolls 15, 16, 190, 192, 400 may
be mounted
either in a cantilevered or non-cantilevered manner, with or without nose
bearings.
Additionally, any of the illustrative embodiments of stalk rolls 15, 16, 190,
192, 400 may be
Date Recue/Date Received 2020-04-27
oriented in opposing, knife-to-knife configurations or intermeshed and/or
interleaved
configurations. As previously mentioned, non-meshing and horizontally opposite
configured
flutes 180, 181, 182, 183 may cause the flute edges to pinch the stalk 320
simultaneously as
they rotate, which may result in equal forces being applied to both sides of
the engaged stalk
320 so as to mitigate stalk 320 whip. This may keep the stalk 320 generally
perpendicular to
the ground surface and may reduce any whipping action that may prematurely
dislodge cars
300 from the stalk 320 or snap the stalk 320 at the stalk node 330. The
remaining flutes 180,
181, 182, 183 of stalk roll 190 may then further pinch the stalk 320 pulling
it down and
rearward so that the ears 300 are removed from the stalks 320 as they come
into contact with
the stripper plates 130 in the Ear Separation Zone.
In any of the embodiments of stalk rolls 15, 16, 190, 192, 400 the various
flutes 18, 19, 20,
21, 26, 33, 180, 181, 182, 183, 440, 440a, 450, 450a, 460 may be self-
sharpening, or may
have a work hardened knife/flute edge 22, 442. Furthermore, any of the
knife/flute edges 22,
442 disclosed herein may be coated with various materials, such as chrome,
tungsten carbide,
or any other materials that is suitable for the specific application.
Additionally or
alternatively, any of the knife/flute edges 22, 442 may be processed in such a
manner that the
knife/flute edge 22, 442 is more wear-resistant than without such processing
without
limitation.
The stalk rolls 15, 16, 190, 192, 400 and 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 rolls 15, 16, 190, 192, 400; flutes 18, 19,
20, 21, 26, 33, 180,
181, 182, 183, 440, 440a, 450, 450a, 460; stripper plates 3, 130; gathering
chain paddles 1,
110; nose cones 5, 410; row dividers 4, 100 and 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 arc not limited to increasing the
harvesting quality
and/or speed of a harvesting machine. Modifications and alterations from the
described
51
Date Recue/Date Received 2020-04-27
embodiments will occur to those skilled in the art without departure from the
spirit and scope
of the stalk rolls 15, 16, 190, 192, 400 or the present disclosure.
Furthermore, variations and modifications of the foregoing are within the
scope of the stalk
rolls 15, 16, 190, 192, 400. It is understood that the scope of the stalk
rolls 15, 16, 190, 192,
400 as disclosed 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 rolls 15, 16,
190, 192, 400.
The embodiments described herein explain the best modes known for practicing
the stalk
rolls 15, 16, 190, 192, 400 and 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 rolls 15, 16, 190, 192, 400 will 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
rolls 15, 16,
190, 192, 400 or the present disclosure.
52
Date Recue/Date Received 2020-04-27
