Modern precision agriculture uses high-tech computer systems to maximize crop yields and minimize inputs of labor, equipment and supplies, especially fertilizer, pesticides and irrigation. In 2015 the the global agriculture and farm machinery market was about 144 000 000 000 USD and is forecast to grow at about 9% annually over the coming decade. The world market is served by a very small group of firms; in the US, there is a single dominant firm for precision ag machines and systems.
Generally, swathing or merging attachments for self-propelled ag machines are custom designed by each of the major equipment firms and are not easily interchangeable even over their own legacy models. In case of a breakdown during harvest season, this situation can create serious management problems for small producers operating a few costly machines of differing marques and vintages.
For premium alfalfa harvests, which must be accomplished within a few days during the peribloom stage, a failure of critical components of a header or swather can mean full or substantial loss of crop value, e.g., low protein level, high moisture content, loss of leaves during cutting and baling. Even with advanced over-night logistics for costly new parts and the possible option of 24-7 emergency field-repair service for current machines, every forage producer would welcome the availability of a universal swather mount adapted to work with all brands, models types and ages of machines. While such devices would facilitate emergency rental of attachments from any dealer and/or sharing of equipment between local producers, they would also increase competition with the oligarchic ag-machine industry. Attaching a new-design belly implement or adapting foreign merger for belly mounting on a third-party precision-ag machine is: (a) far from an obvious undertaking for a typical PHOSITA and (b) generally a very expensive shop project including multiple, sophisticated engineering-design challenges, especially network and safety features.
Typically belly-mounted attachments for low-powered and miniature hobby-farm tractors are: rotary mowers, transverse rotary brushes and transverse blade-like implements for landscape leveling or producing a textured, footing surface for training or racing of horses. On a garden tractor, such attachments are typically suspended by fixtures mounted on the extreme front of the frame. The opposite (rear) end of such attachment-support members is usually coupled to the lift arms of the rear three-point hitch (TPH) whereby the operator can achieve lift, or height control of the particular landscaping component. Since a typical precision-ag machine has no TPH and is fitted to mount wide front headers designed for large-scale planting, spraying and harvesting of crops, such configurations are manifestly inapplicable.
Careful searching on the USPTO databases for universal windrower-belly-mounting devices and systems designed for modern self-propelled ag machines revealed neither patent applications nor actual grants which disclose anything remotely similar to the present invention. A single Design grant that was found under word searching for Design and windrower or swather was D243948, granted to Hesston Corp. in 1977. As revealed in
While traditional family-farmers frequently utilize services of a local truck mechanic or blacksmith to repair broken tillage implements and stalled farm tractors, a modern precision-ag machine valued at over 150 000 USD is far too complex to be serviced by any but specially-trained technicians working in a shop provided with a plethora of special tools and digital testing equipment. Further, the liability risks of even simple MIG-welding on a broken steel feature on such complex systems typically is beyond the insurance coverage of all but large nation-wide dealerships. Considering these and a profusion of technical factors, it is irrational to speculate that a typical farmer-owner and local mechanics could design and fabricate hillbilly fixtures to accomplish coupling of attachments designed and sold for one marque onto a machine of a differing brand, function, model, vintage, or type. Moreover, even if such a MacGyver approach was apparently successful after a few days of early testing and revisions, there would be no repair parts for future in-service emergencies including wearout/breakdowns of the resulting one-off fixture.
The Unterface attachment-mounting system is a novel apparatus for coupling attachments to an ag machine and can become the basis for industry-standards for belly mounting of machine-and-crop-interoperable harvesting attachments.
Dimensional data for the JD W235 Windrower (Weight =7303 kg) include: Overall length without platform 5,900 mm; Overall height 3,760 mm; Under frame clearance 1,120 mm; Wheelbase 3,400 mm; Tread width 3,710 mm.
The schematic front view
The schematic right view
The “Unterface system” of the present invention provides the possibility to utilize a wide range of attachments with differing mounting-base configurations by a self-propelled, 4-wheeled ag machine. The present invention provides a universal mounting-coupling system, i.e., Down- and Up-Facing elements, engagement features and coupling connections, to link an attachment actuator (or other mounting base) to the machine frame at a particular 3D location which provides power and required operational spaces for the actuator and other crop-management features such as the transverse belt on a merger. TABLES 1 and 2 provide full, clear, concise, and exact technical data on the invention disclosed.
As used herein, the coined word (noun) Unterface means the combination of a machine-unique Down-Facing component adapted to connect machine structures, hydraulics, DC power and CAN network matingly with an attachment-unique Up-Facing component fixed to the attachment whereby the attachment is efficiently, fully and safely interconnected and operable as an ordered combination with the machine.
The systems-mating features of the Unterface include: mechanical-mounting, driving/manipulation power links, electrical links, electronic/network control links, hydraulic links and alarms-status display coordination between all the connected components. The several systems-mating Unterface engagement features are configured congruently for all Down-and Up-Facing parts so that a single Unterface Down-Facing component fixed on a particular machine can adapt and connect effectively with functionally-mated Up-Facing components fixed on several different specialized attachments.
Typical modern self-propelled ag machines are fitted with an array of hydraulic motors able to steer and/or drive each wheel independently and do not have rigid axles transverse to the axis which may obstruct certain attachments. As used herein, the nomenclature frame_rail means the portions of machine structures which extend under the cab and between the four wheels, usually in the form of interconnected, robust steel channel sections which form a ladder frame. Generally, this belly area under such machines is completely available for installation and operation of an attachment or merger using the Unterface system of the present invention. Attachment of a Down-Facing Unterface element to a frame_rail of the machine is done with known, high-strength fasteners and alternative -devices, -technics considering the mechanical-strength standards required for ag or industrial machines. The plate-like elements of the Unterface Down-Facing element are formed and/or fabricated typically as weldments from known materials (usually steels) of size, stiffness and strength adequate to support the attachment and its in-use loads. Unterface fastening technics, including fastener material, size, count, tightening torque and spacing patterns are adapted to comply with standard engineering guidelines.
The vector-angle nomenclature convention used herein is the typical default for engineering drawings, i.e., horizontal=0 degrees and rotation of the vector CCW to vertical is is defined as a +90 degrees. Particular vector parameters are given from the coordinate origin and denoted in decimal degrees, polar form, 0-360. Angles defined on drawings are specified according to std. drafting conventions.
As used herein, attachment 3D loft-volume-space (LVS) is the 3D spatial volume which must be available between the Up and Down states generated by the attachment when the actuator as properly mounted under the machine. Generally an attachment or merger is used for crop management only in the full-Down state. For a Down merger, the ground clearance of both the actuator bottom portion and the distal tip of the cross belt are typically fixed by the original design; this means that the mounting arrangements for a different machine must consider these as requirements to be accommodated by the Unterface system. The LVS is a 3D-loft since horizontal cross-section shapes across and along through the fully-extended attachment (usually the Down state) vary widely between the top and bottom horizontal slices for the Up and Down states respectively. Typically, a merger attachment will have hydraulic power supplied from the machine for a four-bar actuator and other related features such as a cross belt for crop discharge. The LVS for a merger attachment is generated by creating a 3D wireframe model of the displacements of the actuator and then adding another wireframe for the resulting motions of the cross belt; this is done by using a known CAD program. A schematic view of the combined primitives of the LVS is shown in
The actuation for cross-belt positioning movements of a merger is typically provided by a hydraulic-drive, four-bar linkage actuator component, which must be securely mounted to the machine chassis under the cab and between the front and rear wheels. An oblique view of the front of a typical actuator in the Up-state is shown in
The actuator wireframe top plane, 50t, depicts the attachment plane for fixing the Up-Facing elements of the present invention. For most attachments as mounted, this plane lies horizontal, parallel to the ground and parallel to the mounting surfaces of the machine frame. As shown in
The actuator-wireframe front plane, 50f, represents the extreme limit of forward travel of the linkage-mechanism in moving into the Down state. This surface also reflects the approximate location of the swivel-joint-yoke-and-pin in the Down state. This yoke coupler, 23, which connects the cross-belt frame to the actuator, can also be seen in;
The vertical side plane, 50s shown in
The Up state of a merger attachment is the condition when the cross-belt component is moved to its uppermost position relative to the ground under the machine; this state is illustrated schematically in
The cross-belt Down state is the condition when the cross-belt is deployed to its lower position for crop discharge just behind the right-front tire; this state is illustrated schematically in
In the Down state, the cross-belt-top surface is positioned aft and slightly below the header discharge and its yaw- and roll-angles are optimized by the swivel yoke to capture and redirect crop flow entering in the axial direction (from the header) into a transverse direction for discharge above ground level just behind the right-front machine tire. The actuator yoke, 24, can be seen in
The cross-belt component is also usually provided with an articulated, transversely-oriented shield-deflector to guide and retain axial crop flow onto the cross belt for discharge at its distal end. This shield is automatically raised_erected by links to the mounting fixtures of the cross belt in the Down state and similarly flattened against the top of the cross-belt in the Up state.
For a typical merger attachment, the cross belt is positioned between: (a) Up=crop flow passes below the belt and (b) Down=crop flow is captured, redirected and discharged in a direction generally perpendicular to the direction of machine travel behind the right front wheel of the machine.
The 3D wireframe envelope for the engaged, connected and coupled Down-Facing and Up-Facing elements is defined within the Unterface Primitive, (UP). The UP, (10) is illustrated in
The length of the UP wireframe along the machine axis, L10, corresponds generally to about the length of the actuator frame; typically L10 is less than L20a since actuators are normally mounted off the machine centerline and oriented with their forward stroke in the vector direction 110-120 deg polar, i.e., at a small incident angle to the machine axis. The width of this wireframe, measured perpendicular to the machine axis as L11, is dictated by the frame-rail spacing and the size of the actuator top frame, L20b, which is to be attached to the Down element. L10 and L11 are illustrated in
The thickness aspect of the defining UP wireframe, indicates whether there may be a need for vertical spacing devices, for example high-strength flat washers, to achieve robust actuator mounting at exactly the proper ground spacing. Typically, plate material of thickness L70 in the range 3-10 mm is used to form all portions of the Down- and Up-elements. If the UP wireframe thickness, (L5-L52), exceeds about (2.1×L70), high-strength spacers with flattened_parallel end faces are required at one or more of the key mechanical interfaces.
The Down-Facing element is secured across_under the frame or sub-frame of the machine so that it positions the actuator, guides its vector movements and supports the in-service loads of crop flow upon the cross belt which it sustains. Known square-bend U-bolts of appropriate size and strength are used to secure this element to the channel or box sections which are common for machine-frame rails. The Down-Facing element is typically prepared by cutting from a single piece of flat-plate material; for structural steel such as A-36 plate, thickness in the range 6-10 mm is used and tear-out safety factors are applied to all zones of high stress (around corners and bolt holes).
In a CAD program, the Down-Facing element plate profile is defined by a “sketch” on the top face of the “wireframe”; this sketch corresponds to the polygonal area above the actuator which extends across the rails and along the machine axis beyond the actuator on both ends. For most applications the center area of this sketch is removed; usually the remaining band of material inside the area defined by L10×L11 is about 20 t wide, i.e., there is a peripherial ribbon of plate material about twenty plate thicknesses in width. For additional rigidity and strength of this element, stiffening ribs and/or other members are added (welded or bolted transversely) across either_both the rear_front portions of the plate profile. These stiffening members are fixed into the free space between the rails (above, on the up-side of the Down-Facing element plate). Front and rear transverse stiffeners are illustrated in the Example. These strengtheners prevent overstress and possible buckling_crippling failure of either transverse portion of the Down-Facing element.
In
The length characteristic of the Down-Facing element profile is illustrated as L11, which is measured parallel to the machine axis. Generally, actuators are mounted offset and at a small angle oblique to the machine centerline; generally the actuator-motion-vector direction is about 110-120 deg. Spatial motions of the cross belt resulting from this actuator mounting also assure its proximal-end min. ground-clearance in the Down state and prevent obstruction of the header-discharge chute by the raised belt in the Up state.
Modern precision-ag machines are extremely complex and their unique attachments are custom-designed for each version; this is true even for different sizes of the same brand marque because of substantially different frame configurations under the cab. The main function of the Up-Facing element of the present invention is to provide a set of auxiliary, bolt-on mounting points for an attachment which was originally designed to bolt directly onto a particular foreign make model type of precision-ag machine. The combination of Up- and Down-Facing elements of the present invention forms a universal belly-mounting system which allows attachments to be used be usable with other machines.
The profile for the Up-Facing element is defined by a sketch on plane 50t; this sketch includes one or more transversal components, 15, and spacers, 81, as shown in
In addition to mating the alternative mechanical-suspension points with the Down-Facing element, the Up-Facing element also frequently provides opportunities for more-accessible points to reposition industry-standard hydraulic-, electrical- and network-fittings and controls. Adding new-technology interfaces to replace legacy components can also contribute significantly to increasing operational reliability and reduction of maintenance costs by replacing the original proprietary, obsolete or inappropriate components and connections.
The Up-Facing element is initially bolted onto the attachment or merger which is, in turn to be joined to the machine with the Down-Facing element already in place. It also may be configured with an array of mechanical projections especially located, sized and shaped to interact with mating socket features incorporated into the Down-Facing element as they are being lifted and aligned together for bolting. These features, which come into play during the last few mm of the joining phase of the two elements, serve to urge the bolt holes into accurate registration without special factory lifting jigs and guides or a secondary line-reaming operation. Consider 2-3 strategically-located cone-like features extending upward from the Up-Facing element becoming seated into mating conical sockets opening downward. These features serve to guide the Up-Facing element into exactly the correct x-y position and angular orientation with the Down-Facing element under realistic conditions which might be experienced during an urgent mid-harvest, field changeover.
The optimal placement, physical form, final hole pattern and mechanical properties of the Up-Facing element(s) is dictated by each particular machine attachment combination and further defined by the thickness aspect of the resulting UP wireframe. Generally, if the actuator top plane provides a flat, rectangular flange with an array of holes for original mounting bolts, the Up-Facing element can be an additional beam-like component (15) transverse to the machine axis and long enough to bolt onto the ends of the peripheral ribbon during final mounting. A single, channel-form, transversal Up-Facing component is illustrated in the Example. In this case, the Up-Facing element is located at the front of the actuator where it extends between the frame rails; after bolting to the Down-Facing element it shares some of the loads related to the merger and crop handling.
Engagement features guide the 3D positioning of the Down- and Up-Facing elements during field installation of an attachment or merger with simple lifting devices such as a jack or levers. Typical known engagement mating concepts for two flat_parallel surfaces include mating corner V-blocks and/or pin-and-funnel notch. When both elements become correctly positioned at contact, the critical bolt-holes are forced into alignment at the last stage of lifting; then the coupling components_fasteners are set and secured.
High-relief engagement features may also be integrated into the Down-Facing element and may project 2-10 mm. They also serve to distribute in-service loads on the attachment during typical use due to: machine vibrations, rough terrain, accidental light contact with ground-obstacles, and a plethora of crop-flow factors. Typical known engagement features include: corner-position reference block(s), cylinder-pin-and-notch alignment guide and tapered_pin-and-mating-socket positioning guide.
Typical engagement connections between the machine and the attachment include: mechanical links: cross-belt yaw angle control and minimum ground clearance, other; electrical power and/or signals: flashing-light “Cross Belt-ON” indicator, belt overspeed and overload warning lights, crop-flow blockage sensing, other;
hydraulic power and/or signals: belt drive, status indicator and auto ground-contact warning and cross-belt lift;
Coupling components are the known fasteners which accomplish mechanical connections between the attachment, the Down- and Up-Facing elements and the structure of the machine. These components are typically threaded fasteners, but other mechanical-coupling options may be used, especially for coupling the Up-Facing element to the attachment, i.e., rivets, welding, etc. All such joints are designed according to known engineering standards (SAE, ANSI, DIN, ISO) for the particular materials involved, specific fastener count_pattern and extreme service conditions for the attachment. Coupling components may include: std. high strength bolts, nuts, washers, studs, pins, other and special threaded fastening components with non-std. shape, size, thread parameters, other.
Because the present invention is intended to couple an attachment to machines which may lack automatic safety-shutdown interlocks between the machine and the attachment, this feature is included as an Unterface option. The first safety interlock senses: (a) the machine state, i.e., header Up/Down and power available for header and discharge belt and (b) the attachment state, i.e., Up_Down, hydraulic power available for cross-belt drive. This feature prevents starting the header and related crop discharge until the attachment is fully Up (no belt power) or fully Down.
The second safety interlock senses malfunctions and operational blockages of the cross-flow belt in the Down state, i.e., excessive forces building upon the transverse shield due to a crop-flow rate quantity mismatch between the machine discharge and the attachment cross-belt.
Unterface Kits. It is anticipated that variations of the present invention will be marketed in the form of particular matched sets of Up- and Down-Facing components, which have been: (a) sized and designed using the methods disclosed, and (b) precisely fabricated using appropriate materials and technics to allow connection and productive use of a particular attachment on a specific machine. Such kits will include user-friendly, illustrated technical guidelines (intended for an experienced mechanic or a dealer technician with modern training) detailing the various attachment and function adjustment processes (mechanical, electrical, hydraulic, network, other) along with required safety notices to be attached to the assembled Unterface adapter, to the attachment and to the machine, especially its controls. It is envisioned that some kits will be heavy enough to justify packaging and shipment in the form of a wrapped pallet or completely encased within a strong crate. Either embodiment would require delivery and handling by a fork-lift; as appropriate, such kits will also be packaged along with with certain unique jigs_fixtures to facilitate safe, accurate and rapid mounting and attachment/calibration in the field or in a shop.
“MacJohn” Unterface Example. This example illustrates application of the Unterface method to a specific commercial machine (JD W235 windrower) for mounting of a foreign, third-party attachment (MacDon DWA, which was originally designed for various MacDon headers, augers, drapers and rotary disc). The result of using the method is the “MacJohn” apparatus for coupling the particular machine and specific attachment.
The initial step in this exemplary Unterface adaptation process is to map the operational characteristics of the DWA into a 3D CAD model to locate the exact x-y-z coordinates of the top edges of the actuator (and all of its mounting-bolt holes) as well as its orientation re the machine axis as correctly mounted .AND. in the Down state. This merger loft model will define: L220, L221, L222, L223, L251, L252, L253 and L260. The height difference, between the top plane of the actuator, 50t, and the bottom plane of the machine frame rails, 61, is the key factor which fixes the thickness aspect of the Unterface primitive, 10.
Knowing the general area of the mounting zone, the pseudo-rectangular wireframe of the Unterface Primitive (UP) can be extruded upward from the actuator frame .OR. downward from the frame rails to fill the available space allowable for the engaged elements. The resulting UP envelope between planes 50t and 61 defines: (a) the 3D space within which the Down- and Up-Facing elements must fit and (b) how far the edges of plane 50f must lie to the rear of the axis of the machine front wheels.
Assuming that the thickness aspect of the resulting UP is at least 20 mm, it will be possible to use the Unterface system for mounting the DWA with “MacJohn” elements fabricated from flat plate in the thickness range 6-10 mm. The front-transversal component of Up-Facing element is a steel channel which is needed to support the front of the actuator; the rear portion of the Up-Facing element includes an array of unique stabilizing spacers 81, which match the height of the transversal component.
Details of the “MacJohn” Down- and Up-Facing elements are shown in
The “MacJohn” Down-Facing element profile is defined by a 4-sided UP primitive having its ends perpendicular to the machine axis; the two end portions are parallel and about 1.3 m and 1.5 m long, respectively. The non-parallel lateral portions are each about 1.3 m long and the incident angle between them is about 9 deg; they are centered lengthwise about the machine axis. The thickness aspect of this primitive is about 20-30 mm; spacers are used on the rear bolts which connect between 11 and 20; no spacers are needed on 15, the Up-facing transversal component(s) (in this case, is a single, inverted-U channel of equal height extending across the front of the actuator and anchoring its two front bolts to 11. The final profile of the main portion of Down-Facing element, complete with the rationalized bolt-hole pattern is shown in
The main portion of the Down-Facing element, 11, is defined by U-shaped profile sketch on plane 61; this component is cut from flat A36 steel plate about 9 mm thick and the center is removed to leave a peripheral ribbon of width about 180-190 mm. Because of the particular loadings which occur in heavy use, transverse stiffener-members, 71 and 72 are welded across both ends of this element. For clarity, both these elements are shown in
The profile of the Up-Facing element of the MacJohn is defined by a sketch on plane 50t; the main portion is a transversal component, 15, which connects between 11 and 20. As shown in
The MacDon Double Windrow Attachment is designed to mount on their M-series machines such as the M205 Self-Propelled Windrower. This unit is built on a unique box frame which supports the cab, engine and under carriage. For compatibility with multiple machines, the DWA mounting parts include a special-shape support weldment with multiple holes, slots and an integrated, threaded post fastener to secure it to the actuator. For the several prescribed target MacDon models versions, this component attaches to the crossbar surface of each distinctive box frame below the engine mounts. While this part (176060) was tested with prototypes of the Down-Facing element of the Unterface, the openings and length-variations of section stiffness are recognized as a source of stress concentration which—as loaded in the transversal Up-Facing component—may lead to undamped resonant vibrations and premature development of fatigue cracks. Unterface and MacJohn design practice for conservative transversal section area has led to specification of several A36 alternate Up-Facing transverse components free of geometric discontinuities and other stress raisers.
The assembled pair of Unterface elements is designed to support: (a) axial forces on the shield and cross-belt due to max crop flow input from header, (b) torsional loads (transverse plane) on cross-belt swivel due to crop-flow re-direction, (c) bending loads (vertical plane) on cross-belt swivel due to rough field terrain, and (d) bending loads (horizontal plane) on cross-belt swivel due to accidental, brief ground contact. These goals are achieved by careful adjustment of the elastic rigidity characteristics (flexure and torsion) of the two transverse stiffeners, 71 and 72, i.e., their elastic and shear moduli, and section profile/area. The geometric rigidity factors of these components include specific-axis moments of inertia, and specific torsional-rigidity multipliers. Further, continuous fillet MIG welds are used on both sides where they are joined perpendicular to the surface of the main-plate member.
Sets of custom-shaped, high-strength U-bolts provided for MacJohn Unterfaces are selected from types 1,2 and 5 (the particular shape depending on the form of machine frame members) and coined/flattened across the contact surface; the material may be of either grades 5 and 8 depending on the attachment and intended field operations.
This application claims the benefit of U.S. Provisional Application No. 62/485522, filed 14 Apr 2017, the contents of which are incorporated herein by reference. Not applicable. Not applicable. Not applicable. Not applicable.
Number | Date | Country | |
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62485522 | Apr 2017 | US |