Leaf Harvester Pickup Conveyor With Air Flow Leaf Transfer
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Solution Overview
Problem
Existing baby leaf harvesters face issues with high friction and premature belt failure due to non-rotating nosebars, increased costs from using seamless belts, and complexity from endless conveyor designs, along with the risk of blade damage and water usage.
Innovation Solution
Employing a rotating idler roller at the forward end of the pick-up conveyor and utilizing a laminar flow air conveyor to propel cut leaves, eliminating the need for a small-diameter nosebar and allowing for jointed belts, which simplifies conveyor design and reduces costs while preventing belt damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a non-rotating nosebar is used at the forward end of the pick-up conveyor, then the conveyor can be positioned close behind the blade to receive cut leaves, but high friction occurs between the moving conveyor belt and the nosebar
Solution Approach 1:
The patent converts the static non-rotating nosebar into a dynamic rotating idler roller. This allows the roller to rotate in the direction of belt movement, dramatically reducing friction between the conveyor belt and the support element. The rotation capability transforms the interaction from sliding friction to rolling friction, solving the high friction problem while maintaining the conveyor's positioning close to the blade.
Solution Approach 2:
The patent replaces the mechanical nosebar support system with a rotating idler roller system. This substitution changes the mechanical interaction from a fixed support point to a rotating element, reducing friction and wear. The idler roller can be driven by the conveyor belt itself or by a separate drive mechanism, eliminating the need for water lubrication that was required in the original nosebar system.
2Reliability
If an endless or seamless conveyor belt is used with a non-rotating nosebar, then the belt can operate without joints, but the belt becomes significantly more expensive and harder to maintain
Solution Approach 1:
The patent enables the use of segmented or jointed conveyor belts by eliminating the requirement for a non-rotating nosebar. With the rotating idler roller in place, standard jointed belts can be used instead of expensive seamless belts. The segmentation principle allows the belt to be constructed from modular sections that can be easily replaced and maintained, significantly reducing costs while maintaining reliable operation.
Solution Approach 2:
The patent facilitates the use of more economical, replaceable belt sections instead of expensive seamless belts. The rotating idler roller system reduces wear on the belt, allowing standard jointed belts to achieve sufficient service life. When wear does occur, individual belt sections can be replaced independently rather than requiring complete belt replacement, aligning with the principle of using cost-effective, replaceable components.
3Volume of moving object
If a small-diameter nosebar is used to turn the conveyor belt around, then the conveyor can be compact, but proper tracking of the belt is hindered leading to premature failure
Solution Approach 1:
The patent replaces the static small-diameter nosebar with a dynamic rotating idler roller of larger diameter. The larger diameter provides better belt tracking capability, preventing premature failure while the rotation capability maintains system compactness. The idler roller can be positioned optimally to guide the belt properly, combining the benefits of compact size with reliable tracking performance.
Solution Approach 2:
The patent uses a cylindrical rotating idler roller instead of a small-diameter nosebar, providing a more favorable curvature for belt tracking. The larger cylindrical surface area of the roller better conforms to and guides the conveyor belt, improving tracking stability. The rotational movement of the cylindrical roller also helps center the belt and prevent edge wear, solving the tracking problems associated with small-diameter support elements.
4Force
If water is used to lubricate the belt/nosebar interface, then friction is reduced, but water is wasted and system complexity increases
Solution Approach 1:
The patent replaces the water-based lubrication system with a mechanical solution - a rotating idler roller. This substitution eliminates the need for water lubrication entirely, as the rolling contact naturally reduces friction to minimal levels. The system achieves low friction through the physical mechanism of rotation rather than through fluid lubrication, eliminating water consumption and the complexity of water delivery and drainage systems.
Solution Approach 2:
The rotating idler roller system is self-lubricating through its rotational mechanism. The roller's rotation creates natural rolling contact that minimizes friction without requiring external lubrication resources. The system serves itself by converting sliding friction into rolling friction through the rotational motion, eliminating the need for water or other lubricants that would require external supply and management systems.
5Productivity
If the rear edge of the blade contacts the conveyor belt during operation, then cutting is effective, but the belt is damaged significantly reducing its useful life
Solution Approach 1:
The patent introduces a rotating idler roller as an intermediary element between the blade and the conveyor belt. This intermediary protects the belt from direct contact with the blade's rear edge, preventing damage while allowing the blade to maintain its cutting position. The idler roller absorbs the contact stress and can be easily replaced if damaged, while the conveyor belt is protected and its service life is significantly extended.
Solution Approach 2:
The rotating idler roller provides beforehand protection against blade-to-belt contact. By positioning the roller between the blade and belt, the system pre-establishes a protective barrier that prevents damage before it occurs. The roller's rotation and positioning are designed to anticipate and prevent harmful contact, cushioning the belt against blade interference and extending its operational life.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances conveyor tracking, reduces maintenance costs, and eliminates the need for water lubrication, extending the life of the conveyor belts and simplifying the harvesting process.
Implementation Method 1
The air conveyor has a rearwardly sloped upper surface, and a forward air outlet configured to rearwardly discharge a laminar flow of air over the upper surface
Implementation Method 2
a forward air outlet configured to rearwardly discharge a laminar flow of air over the upper surface to propel leaves cut by the leaf cutter to the first conveyor
Data Source
AI summary
A leaf harvester includes a mobile vehicle, configured for moving on ground, having a leaf cutter at a front thereof, a first conveyor, and a laminar flow air conveyor, disposed between the leaf cutter and the first conveyor. The laminar flow air conveyor has a sloped upper surface, and is configured to rearwardly discharge a laminar flow of air over the upper surface to propel leaves cut by the leaf cutter to the first conveyor.