Method and apparatus to reduce stalk shear

Abstract

The invention provides four (4) methods to reduce stalk shear in a corn head row unit that utilizes a non-variable or dependent drive system. The four methods described include altering the gearbox ratio, increasing the lengths of the fluted portion of the stalk roll, increasing stalk roll diameter or reducing the size of the gathering chain drive sprocket. The invention allows for a more balanced application of multi directional energy to be applied to the corn plant. The resultant effect is to reduce stalk shear which reduces trash intake to the harvester. This novel idea provides the first means and method to which genetically improved taller and healthier corn plants can be harvested with minimal amounts of material other than ears ultimately being transferred to the threshing unit.

1 . An improved method of processing corn plants with a corn head row unit compromising the steps of: 
 a. engaging the corn plant with a plurality of stalk rolls,    b. pinching the corn plant between said stalk rolls,    c. pulling the corn plant stalk down with said stalk rolls,    d. separating said ear of corn from the corn plant stalk,    e. engaging said ear of corn with at least one gathering chain paddle,    f. having the speed of said stalk rolls and gathering chain paddles fixed during operation;    g. wherein the maximum velocity of said gathering chain paddle creates minimal stalk shear; and,    h. wherein the maximum ear separation substantially vertical velocity creates minimal damage to the ear of corn upon impact with the stripper plates.    
   
   
       2 . An improved arrangement of a corn head row unit comprising: 
 a. a source of power for rotation,    b. at least one stalk roll for engagement with a corn plant stalk,    c. said stalk roll having at least one flute,    d. a stripper plate,    e. at least one gathering chain having paddles,    f. a gearbox fixing the speed of said gathering chain paddles and said stalk roll flute during operation,    g. wherein the gearbox ratio is selected to create minimal stalk shear; and,    h. wherein the resulting maximum ear separation velocity creates minimal damage to the ear of corn upon impact with the stripper plates.    
   
   
       3 . An improved arrangement of a corn head row unit according to  claim 2  having two opposing stalk rolls for engagement with a corn plant stalk.  
   
   
       4 . An improved arrangement of a corn head row unit according to  claim 2  wherein said stalk rolls have an enlarged length to minimize stalk shear.  
   
   
       5 . An improved arrangement of a corn head row unit according to  claim 2  wherein said gathering chain drive sprocket size has been reduced to minimize stalk shear.  
   
   
       6 . An improved arrangement of a corn head row unit according to  claim 2  wherein said stalk roll diameter has been increased to minimize stalk shear.  
   
   
       7 . An improved arrangement of a corn head row unit according to  claim 3  wherein said stalk rolls have an enlarged length to minimize stalk shear.  
   
   
       8 . An improved arrangement of a corn head row unit according to  claim 3  wherein said gathering chain drive sprocket size has been reduced to minimize stalk shear.  
   
   
       9 . An improved arrangement of a corn head row unit according to  claim 3  wherein said stalk roll diameter has been increased to minimize stalk shear.  
   
   
       10 . An improved arrangement of a corn head row unit according to claims  7 ,  8 , or  9  wherein said row unit has a shear point with a rounded edge.  
   
   
       11 . An improved method of processing corn plants with a corn head row unit compromising the steps of: 
 a. engaging the corn plant with a plurality of rotational elements,    b. pinching the corn plant between said rotational elements,    c. pulling the corn plant stalk down with said rotational elements,    d. separating said ear of corn from the corn plant stalk,    e. engaging said ear of corn with at least one horizontal element,    f. said horizontal element substantially moving only ears of corn for collection and further processing within the threshing unit of a combine,    g. wherein the velocity of said horizontal element minimizes the occurrence of corn plant stalk separation due to corn plant stalk movement restrictions created by said rotational and horizontal elements; and,    h. wherein the speed of said rotational and horizontal elements is fixed during operation.    
   
   
       12 . An improved arrangement of a corn head row unit comprising: 
 a. a source of power for rotation,    b. at least one stalk roll for engagement with a corn plant stalk,    c. said stalk roll having at least one flute,    d. a stripper plate,    e. at least one gathering chain having paddles,    f. a gearbox fixing the speed of said gathering chain paddles and said stalk roll flute during operation,    g. wherein the gearbox ratio is selected to produce a gathering chain paddle velocity which minimizes the occurrence of corn plant stalk separation due to corn plant stalk movement restrictions created by said stalk rolls and gathering chain paddles; and,    h. wherein the resulting maximum ear separation velocity creates minimal damage to the ear of corn upon impact with the stripper plates.    
   
   
       13 . An improved arrangement of a corn head row unit according to  claim 12  having two opposing stalk rolls for engagement with a corn plant stalk.  
   
   
       14 . An improved arrangement of a corn head row unit according to  claim 12  wherein said stalk rolls have an enlarged length to minimize stalk shear.  
   
   
       15 . An improved arrangement of a corn head row unit according to  claim 12  wherein said gathering chain drive sprocket size has been reduced to minimize stalk shear.  
   
   
       16 . An improved arrangement of a corn head row unit according to  claim 12  wherein said stalk roll diameter has been increased to minimize stalk shear.  
   
   
       17 . An improved arrangement of a corn head row unit according to  claim 13  wherein said stalk rolls have an enlarged length to minimize stalk shear.  
   
   
       18 . An improved arrangement of a corn head row unit according to  claim 13  wherein said gathering chain drive sprocket size has been reduced to minimize stalk shear.  
   
   
       19 . An improved arrangement of a corn head row unit according to  claim 13  wherein said stalk roll diameter has been increased to minimize stalk shear.  
   
   
       20 . An improved arrangement of a corn head row unit according to claims  17 ,  18  or  19  wherein said row unit has a shear point with a rounded edge.  
   
   
       21 . An improved arrangement of a corn head row unit according to  claim 20  wherein said shear point is removable allowing for replacement.  
   
   
       22 . An improved arrangement of a corn head row unit compromising: 
 a. means for engaging a corn plant with a plurality of rotational elements,    b. means for pinching a corn plant between said rotational elements,    c. means for pulling the corn plant stalk down with said rotational elements,    d. means for separating the corn plant ear from the corn plant stalk,    e. wherein the maximum ear velocity allowed creates minimal damage to the ear of corn upon impact with said separation means,    f. means for engaging an ear of corn for horizontal movement to an ear collection means and further processing within the threshing unit of a combine,    g. wherein the maximum velocity of said means for engaging an ear of corn for horizontal movement creates minimal stalk shear; and,    h. a power source for said engaging, pinching, pulling and horizontal movement means wherein the speed of said means is fixed during operation.