Corn Head Conversion Kit with Counter-Rotating Cutting Disks
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional corn heads are not well-suited for harvesting crops other than corn and have limitations in terms of adaptability for different crop heights, leading to reduced efficiency and increased maintenance costs due to worn components and weight issues.
Innovation Solution
A kit and method for converting corn heads to include counter-rotating cutting disks and replacement deck plates, allowing for the adaptation of corn heads to harvest various row crops by positioning cutting disks near the rear or front of the row units, enabling efficient cutting and gathering of crops like sorghum, millet, sunflowers, and soybeans at different heights.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional corn head components (stalk rolls, trash knives, deck plates) are used to harvest corn, then the harvesting function for corn is optimized, but the system cannot effectively harvest other row crops such as sorghum, milo, millet, sunflowers, and soybeans
Solution Approach 1:
The patent applies universality by designing a multi-functional row crop head that can harvest multiple types of row crops (corn, sorghum, milo, millet, sunflowers, soybeans, and other cut-and-harvest crops) using a single unified system. The head incorporates adjustable cutting heights and configurable gathering mechanisms that adapt to different crop types and conditions, eliminating the need for separate specialized equipment for each crop type.
Solution Approach 2:
The patent applies dynamics through adjustable cutting heights and reconfigurable gathering chain configurations. The cutting height can be dynamically adjusted to leave different stalk lengths (e.g., 12 inches or more for sorghum, closer to ground for soybeans), and the gathering mechanism can be configured for different crop densities and conditions, allowing the system to adapt its behavior based on harvesting requirements.
2Ease of manufacture
If used corn heads are acquired on the secondary market, then cost is reduced, but the useful life is limited due to worn components
Solution Approach 1:
The patent applies parameter changes by offering a redesigned head with improved component specifications and materials that extend service life. The new design incorporates enhanced durability features while maintaining compatibility with existing combine platforms, allowing farmers to either purchase a cost-effective new design or refurbish existing heads with upgraded components.
Solution Approach 2:
The patent acknowledges the existing secondary market for used corn heads and provides guidance on refurbishment and component replacement strategies. The design allows for selective replacement of worn components (stalk rolls, trash knives, deck plates) while retaining serviceable parts, enabling cost-effective renewal of harvesting equipment.
3Device complexity
If conventional corn head components are used, then the harvesting system is simple, but the weight adds significant mass affecting fore-aft stability of the combine
Solution Approach 1:
The patent applies parameter changes by optimizing component dimensions and material selections to reduce overall head weight while maintaining structural integrity and harvesting performance. The redesigned head incorporates weight-reduced components that preserve functionality but decrease mass, improving combine stability and fuel efficiency.
Data Source
AI summary
A system for modifying a row unit of a harvesting head, the system including at least one cutting disk, a right angle gear set configured for being drivingly connected to the cutting disk, and a drive shaft between a row unit gear box and the right angle gear set. The system may drive two counter-rotating cutting disks that can be positioned either at near the rear or the front of the row unit. A method for modifying the row unit includes removing existing stalk rolls and housings, installing a cover plate over a gearbox to which the housings were mounted, removing existing trash knives, drilling holes in the row unit frame for mounting the cutting disks, installing the cutting disks.