Composite Stalk Roll with Variable Density for Harvesting

Solution Overview

Problem

Existing stalk roll configurations for corn harvesters are inefficient due to the lack of optimized material distribution, leading to higher energy consumption and reduced fuel efficiency, as they often use uniform materials without varying densities and tensile strengths to balance weight and performance.

Innovation Solution

A stalk roll configuration with a first portion made of a high-density, high-tensile-strength material for the support and engagement with the drive shaft, and a second portion made of a lower-density, lower-tensile-strength material positioned adjacent to the blades, which are lighter and softer, providing support without adding significant weight, allowing for efficient rotation and corn stalk engagement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If uniform high-density material is used throughout the stalk roll, then strength and durability are improved, but weight increases leading to higher energy consumption

Engineering Contradiction:

Improvestalk roll strengthVSAvoidenergy consumption

Core Design Contradiction:

StrengthVSUse of energy by moving object

Solution Approach 1:

The stalk roll is constructed with different materials in different regions: a high-density metallic material (such as steel) for the support portion that engages the drive shaft and provides structural strength, and a lower-density non-metallic material (such as polymer or composite) for the outer portion adjacent to the blades. This local differentiation allows the stalk roll to have sufficient strength where needed while reducing overall weight to decrease energy consumption during rotation.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The stalk roll employs a composite structure combining two distinct materials with different density and strength properties. The first material (metallic) provides high tensile strength and density for the support portion, while the second material (non-metallic) provides lower density for weight reduction. This composite approach resolves the contradiction by integrating materials that individually address different requirements (strength vs. weight).

Inventive Principle:

Principle #40Composite materials

2Use of energy by moving object

If lighter materials are used for the stalk roll, then energy consumption is reduced, but tensile strength decreases affecting blade support capability

Engineering Contradiction:

Improveenergy consumptionVSAvoidtensile strength

Core Design Contradiction:

Use of energy by moving objectVSStrength

Solution Approach 1:

The stalk roll is constructed with different materials in different regions: a high-density metallic material (such as steel) for the support portion that engages the drive shaft and provides structural strength, and a lower-density non-metallic material (such as polymer or composite) for the outer portion adjacent to the blades. This local differentiation allows the stalk roll to have sufficient strength where needed while reducing overall weight to decrease energy consumption during rotation.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The stalk roll employs a composite structure combining two distinct materials with different density and strength properties. The first material (metallic) provides high tensile strength and density for the support portion, while the second material (non-metallic) provides lower density for weight reduction. This composite approach resolves the contradiction by integrating materials that individually address different requirements (strength vs. weight).

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS11032971B2Composite stalk roll

Publication Date: 2021.06.15 DEERE & CO

AI summary

A stalk roll for a corn harvester has a first portion including a first material having a first material density, and a second portion including a second material having a second material density. The first density is at least fifty percent greater than the second density, or the first tensile strength is at least fifty percent greater than the second tensile strength. The first portion includes a support portion that engages a drive shaft, a first radial portion extending radially outward from the support portion, a first blade connected to the first radial portion, a second radial portion extending radially outward from the support portion opposite the first radial portion, and a second blade connected to the second radial portion. The first and second blade portions engage a corn stalk. The second portion is positioned between the first radial portion and the second radial portion.