Synchronized Sugarcane Buttlifter Paddles for Low-Ground Cutting

Solution Overview

Problem

The geometry of existing buttlifter assemblies in sugarcane harvesters limits the minimum angular position of the basecutter assembly due to the need to maintain paddles above the ground surface during their rotation cycle, thereby restricting the horizontal orientation of the basecutter assembly and affecting cut quality and harvest efficiency.

Innovation Solution

A synchronizer assembly, such as a planetary gear system, synchronizes the rotation of paddles about their central axis relative to the buttlifter axis, maintaining a consistent orientation with respect to the ground surface, allowing the buttlifter assembly to be positioned closer to the ground without contacting it, thus enabling a more horizontal basecutter assembly position.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the buttlifter assembly is positioned higher above the ground surface to allow paddles to rotate without contacting the ground, then the paddles can complete their rotation cycle without ground contact, but the basecutter assembly cannot be positioned closer to horizontal which reduces cut quality and harvest efficiency

Engineering Contradiction:

Improvepaddle ground contact avoidanceVSAvoidharvest efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The synchronizer assembly dynamically adjusts the paddle orientation during rotation. As the paddle rotates about the central buttlifter axis, the synchronizer simultaneously rotates the paddle about its central paddle axis, making the paddle's distance from the ground surface dynamic rather than static. This allows the paddle to clear the ground during the bottom half of rotation while maintaining proper orientation during the lifting portion of the cycle.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention adds a second rotational degree of freedom to the paddle system. Instead of simple rotation about the central buttlifter axis, the paddle now rotates about two axes simultaneously: the central buttlifter axis and the central paddle axis. This dimensional change allows the paddle to maintain optimal orientation while clearing the ground surface.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Manufacturing precision

If the basecutter assembly is positioned at a more horizontal angular position to improve cut quality, then cutting efficiency is improved, but the buttlifter assembly would require the paddles to contact the ground surface during rotation

Engineering Contradiction:

Improvecut qualityVSAvoidpaddle ground contact

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The synchronizer assembly dynamically adjusts the paddle orientation during rotation. As the paddle rotates about the central buttlifter axis, the synchronizer simultaneously rotates the paddle about its central paddle axis, making the paddle's distance from the ground surface dynamic rather than static. This allows the paddle to clear the ground during the bottom half of rotation while maintaining proper orientation during the lifting portion of the cycle.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention adds a second rotational degree of freedom to the paddle system. Instead of simple rotation about the central buttlifter axis, the paddle now rotates about two axes simultaneously: the central buttlifter axis and the central paddle axis. This dimensional change allows the paddle to maintain optimal orientation while clearing the ground surface.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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

This configuration enhances cut quality and harvest efficiency by allowing the basecutter assembly to be positioned closer to horizontal, improving the cutting process.

Implementation Method 1

A synchronizer assembly, such as a planetary gear system, synchronizes the rotation of paddles about their central axis relative to the buttlifter axis

Methodology Applied

Scientific EffectPlanetary gear mechanism: Epicyclic Gearing

Data Source

PatentUS20250386767A1Sugarcane buttlifter with synchronized paddles

Publication Date: 2025.12.25 DEERE & CO

AI summary

A buttlifter assembly for a sugarcane harvester includes an input that is rotatable about a central buttlifter axis. A paddle includes a first end and a second end, and extends therebetween along a central paddle axis. The paddle is operable to lift cut sugarcane stalks upward away from a ground surface and into a feed section of the sugarcane harvester. The buttlifter assembly includes a synchronizer assembly interconnecting the input and the paddle. The synchronizer assembly is configured for simultaneously rotating the paddle about the central paddle axis and the central buttlifter axis in response to the input rotating about the central buttlifter axis, whereby an orientation of the paddle relative to a vertical axis may be maintained during a lower half of a rotation cycle of the paddle about the central buttlifter axis.