Corn Ear Harvester Deck Plate and Chain Arrangement
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Solution Overview
Problem
Existing corn ear harvester devices often jam, causing corn kernels to be lost and disrupting the harvesting process due to corn ears getting stuck between deck plates, leading to inefficiencies in corn kernel collection and processing.
Innovation Solution
The design features two deck plates with ear blocking and stalk guide surfaces, spaced to prevent corn ears from passing through, and gathering chain devices with opposing directional endless chains to ensure corn ears are pulled away from potential jamming points, allowing for smooth separation and transport of corn ears without kernel detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the corn stalk channel width is reduced to prevent ear passage, then ear jamming is prevented, but the channel becomes too narrow for proper stalk guidance
Solution Approach 1:
The corn stalk channel is divided into two distinct sections: a deck plate channel section for initial stalk reception and guidance, and a gathering chain channel section for ear removal and transport. This segmentation allows each section to be optimized for its specific function - the deck plate section provides wide stalk guidance while the gathering chain section prevents ear passage, resolving the contradiction between guidance ease and jamming prevention
Solution Approach 2:
The patent introduces a vertical dimension to the channel design by stacking the deck plate channel section above the gathering chain channel section. This dimensional arrangement allows the upper deck plate section to guide stalks horizontally while the lower gathering chain section, with its narrower width and opposing chain movement, prevents ear passage in the vertical direction, thus resolving the width contradiction
2Productivity
If gathering chain devices are placed on top of deck plates, then ear transport is efficient, but ears get jammed between deck plates and paddles
Solution Approach 1:
Instead of placing the gathering chain devices on top of the deck plates as in conventional designs, the patent inverts the arrangement by positioning the gathering chain channel section below the deck plate channel section. The endless chains are arranged to engage ears from underneath and transport them laterally, eliminating the jamming problem that occurs when chains and ears interact on top of the deck plates, while maintaining transport efficiency through the inverted configuration
3Reliability
If opposite directional chains are used, then ears are pulled away from jamming points, but chain synchronization becomes complex
Solution Approach 1:
The patent employs asymmetric chain arrangement where the endless chains are positioned at different lateral locations and move in opposite directions. This asymmetric configuration naturally creates opposing forces that effectively pull ears away from jamming points at the deck plate interfaces. The asymmetry is designed so that the chains engage ears at different positions, creating a balanced force system that prevents jamming without requiring complex synchronization mechanisms
Data Source
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AI summary
The invention pertains to a corn ear harvester which comprises two deck plates and two gathering chain devices. The gathering chain devices each comprise an endless chain which forms a chain loop which comprises a straight operational part; a corn ear paddle and paddle connector which connects the corn ear paddle to the chain. The device further comprises a corn stalk channel having a deck plate channel section extends between the deck plates and a gathering chain channel section between the gathering chain devices. The deck plate channel section is too narrow for a corn ear to pass through. The corn ear paddles are arranged adjacent to a deck plate on the side of the ear blocking surface of said first deck plate and the endless chains of the gathering chain devices are arranged adjacent to the deck plates on the opposite side.