Stalk Puller Disc Tensioning and Depth Control

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Solution Overview

Problem

Existing farming implements fail to efficiently and effectively remove cotton stalks and roots post-harvest, leading to pest harborage, equipment damage, soil disruption, and inefficiencies due to issues like soil condition dependence, maintenance needs, and debris handling.

Innovation Solution

A self-adjusting disc puller system with a parallel linkage and compression spring mechanism that maintains disc tension, combined with a gauge wheel for depth control and a mower/shredder configuration to shred stalks before pulling, reducing soil disruption and enabling a single pass operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a ground contact cutter drum is used to pull stalks, then stalk removal is achieved, but the cutter drum balls up in wet soil rendering it useless

Engineering Contradiction:

Improvestalk removal efficiencyVSAvoidcutter drum functionality

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent introduces an intermediary mechanism - a chain-driven system with puller elements that transfer the cutting action from a ground-contact drum to a elevated chain assembly. This mediator allows the stalks to be engaged and pulled without the cutting drum directly contacting wet soil, preventing the balling-up problem while maintaining stalk removal capability.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the direct mechanical ground-contact cutting system with a chain-driven mechanical system that operates above ground level. This substitution eliminates the direct contact between the cutting mechanism and wet soil, preventing the drum from becoming inoperative in wet conditions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If an undercutting blade is used ahead of the cutter drum, then stalk cutting is improved, but too much soil is disturbed creating erosion problems

Engineering Contradiction:

Improvestalk cutting effectivenessVSAvoidsoil erosion

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent extracts the soil-disturbing undercutting blade function from the system and replaces it with a chain-driven puller mechanism that engages stalks above ground level. This removal of the blade eliminates the harmful soil disturbance and erosion while maintaining effective stalk cutting and pulling capability.

Inventive Principle:

Principle #2Taking out (Extraction)

3Productivity

If disc pullers are made rigid to firmly grasp stalks, then pulling effectiveness is improved, but shock loads from rocks damage bearings

Engineering Contradiction:

Improvestalk pulling effectivenessVSAvoidbearing durability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies dynamics by making the disc arms pivotable rather than rigid, allowing the system to adapt to varying conditions. The pivotable arms can flex and adjust when encountering rocks or debris, preventing excessive shock loads on bearings while maintaining effective stalk grasping and pulling capability through the chain-driven mechanism.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS11350555B2Stalk puller

Publication Date: 2022.06.07 KELLEY MFG CO

AI summary

A stalk puller to be used with or without a mower/shredder utilizes a pair of independently mounted discs converging along their lower edge to grasp and pull stalks from the ground as the stalk puller is moved down the row by a prime mover. At least one of the discs is urged against the other by a spring such that the associated disc may allow rocks and debris to pass between the discs without damage. The spring mounting reduces adjustments due to normal wear as well as damage from debris.