Hillside leveling
In the Palouse region of the Pacific Northwest of the United States the combine is retrofitted with a hydraulic hillside leveling system. This allows the combine to harvest the steep but fertile soil in the region. Hillsides can be as steep as a 50% slope. Gleaner, IH and Case IH, John Deere, and others all have made combines with this hillside leveling system, and local machine shops have fabricated them as an aftermarket add-on.
The first leveling technology was developed by Holt Co., a California firm, in 1891. Modern leveling came into being with the invention and patent of a level sensitive mercury switch system invented by Raymond Alvah Hanson in 1946. Raymond’s son, Raymond, Jr., produced leveling systems exclusively for John Deere combines until 1995 as R. A. Hanson Company, Inc. In 1995, his son, Richard, purchased the company from his father and renamed it RAHCO International, Inc. In April, 2007, the company was renamed The Factory Company International, Inc. Production continues to this day.
Hillside leveling has several advantages. Primary among them is an increased threshing efficiency on hillsides. Without leveling, grain and chaff slide to one side of separator and come through the machine in a large ball rather than being separated, dumping large amounts of grain on the ground. By keeping the machinery level, the straw-walker is able to operate more efficiently, making for more efficient threshing. IH produced the 453 combine which leveled both side-to-side and front-to-back, enabling efficient threshing whether on a hillsides or climbing a hill head on.
Secondarily, leveling changes a combine’s center of gravity relative to the hill and allows the combine to harvest along the contour of a hill without tipping, a very real danger on the steeper slopes of the region; it is not uncommon for combines to roll on extremely steep hills.
Newer leveling systems do not have as much tilt as the older ones. A John Deere 9600 combine equipped with a Rahco hillside conversion kit will level over to 44%, while the newer STS combines will only go to 35%. These modern combines use the rotary grain separator which makes leveling less critical. Most combines on the Palouse have dual drive wheels on each side to stabilize them.
Sidehill leveling system in Europe was developed by Italian combines’ manifacturer Laverda that still today produces those systems as a leader.
Sidehill leveling
Sidehill combines are very similar to hillside combines in that they level the combine to the ground so that the threshing can be efficiently conducted; however, they have some very distinct differences. Modern hillside combines level around 35% on average, older machines were closer to 50%. Sidehill combines only level to 18%. They are sparsely used in the Palouse region. Rather, they are used on the gentle rolling slopes of the mid-west. Sidehill combines are much more mass produced than their hillside counterparts. The height of a sidehill machine is the same height as a level-land combine. Hillside combines have added steel that sets them up approximately 2–5 feet higher than a level-land combine.
Maintaining threshing speed
Another technology that is sometimes used on combines is a continuously variable transmission. This allows the ground speed of the machine to be varied while maintaining a constant engine and threshing speed. It is desirable to keep the threshing speed constant since the machine will typically have been adjusted to operate best at a certain speed.
Self-propelled combines started with standard manual transmissions that provided one speed based on input rpm. Deficiencies were noted and in the early 1950s combines were equipped with what John Deere called the “Variable Speed Drive”. This was simply a variable width sheave controlled by spring and hydraulic pressures. This sheave was attached to the input shaft of the transmission. A standard 4 speed manual transmission was still used in this drive system. The operator would select a gear, typically 3rd. An extra control was provided to the operator to allow him to speed up and slow down the machine within the limits provided by the variable speed drive system. By decreasing the width of the sheave on the input shaft of the transmission, the belt would ride higher in the groove. This slowed the rotating speed on the input shaft of the transmission, thus slowing the ground speed for that gear. A clutch was still provided to allow the operator to stop the machine and change transmission gears.
Later, as hydraulic technology improved, hydrostatic transmissions were introduced by Versatile Mfg for use on swathers but later this technology was applied to combines as well. This drive retained the 4 speed manual transmission as before, but this time used a system of hydraulic pumps and motors to drive the input shaft of the transmission. This system is called a Hydrostatic drive system. The engine turns the hydraulic pump capable of high flow rates at up to 4000 psi. This pressure is then directed to the hydraulic motor that is connected to the input shaft of the transmission. The operator is provided with a lever in the cab that allows for the control of the hydraulic motor’s ability to use the energy provided by the pump. By adjusting the swash plate in the motor, the stroke of its pistons are changed. If the swash plate is set to neutral, the pistons do not move in their bores and no rotation is allowed, thus the machine does not move. By moving the lever, the swash plate moves its attached pistons forward, thus allowing them to move within the bore and causing the motor to turn. This provides an infinitely variable speed control from 0 ground speed to what ever the maximum speed is allowed by the gear selection of the transmission. The standard clutch was removed from this drive system as it was no longer needed.
Most if not all modern combines are equipped with hydrostatic drives. These are larger versions of the same system used in consumer and commercial lawn mowers that most are familiar with today. In fact, it was the downsizing of the combine drive system that placed these drive systems into mowers and other machines.
The threshing process
Despite great advances mechanically and in computer control, the basic operation of the combine harvester has remained unchanged almost since it was invented.
First, the header, described above, cuts the crop and feeds it into the threshing cylinder. This consists of a series of horizontal rasp bars fixed across the path of the crop and in the shape of a quarter cylinder. Moving rasp bars or rub bars pull the crop through concaved grates that separate the grain and chaff from the straw. The grain heads fall through the fixed concaves. What happens next is dependent on the type of combine in question. In most modern combines, the grain is transported to the shoe by a set of 2, 3, or 4 (possibly more on the largest machines) augers, set parallel or semi-parallel to the rotor on axial mounted rotors and perpendicular to the cylinder on conventionals (or perpendicular to the cross mounted rotor of Gleaner brand “Natural Flow” combines.) In older Gleaner machines, these augers were not present. These combines are unique in that the cylinder and concave is set inside the feederhouse instead of in the machine directly behind the feederhouse. Consequently, the material was moved by a “raddle chain” from underneath the concave to the walkers. The clean grain fell between the raddle and the walkers onto the shoe, while the straw, being longer and lighter, floated across onto the walkers to be expelled. On most other older machines, the cylinder was placed higher and farther back in the machine, and the grain moved to the shoe by falling down a “clean grain pan”, and the straw “floated” across the concaves to the back of the walkers.
Since the Sperry-New Holland TR70 Twin-Rotor Combine came out in 1975, most manufacturers have combines with rotors in place of conventional cylinders. However, makers have now returned to the market with conventional models alongside their rotary line-up. A rotor is a long, longitudinally mounted rotating cylinder with plates similar to rub bars (except for in the above mentioned Gleaner rotaries).
There are usually two sieves, one above the other. The sieves and basically a metal frame, that has many rows of “fingers” set reasonably close together. The angle of the fingers is adjustable as to change the clearance and control the size of material passing through. The top is set with more clearance than the bottom as to allow a gradual cleaning action. Setting the concave clearance, fan speed, and sieve size is critical to ensure that the crop is threshed properly, the grain is clean of debris, and that all of the grain entering the machine reaches the grain tank. ( Observe, for example, that when travelling uphill the fan speed must be reduced to account for the shallower gradient of the sieves.)
Heavy material, e.g., unthreshed heads, fall off the front of the sieves and are returned to the concave for re-threshing. The straw walkers are located above the sieves, and also have holes in them. Any grain remaining attached to the straw is shaken off and falls onto the top sieve. When the straw reaches the end of the walkers it falls out the rear of the combine. It can then be baled for cattle bedding or spread by two rotating straw spreaders with rubber arms. Most modern combines are equipped with a straw spreader.
Rotary and conventional designs
For some time, combine harvesters used the conventional design, which used a rotating cylinder at the front-end which knocked the seeds out of the heads, and then used the rest of the machine to separate the straw from the chaff, and the chaff from the grain. The TR70 from Sperry-New Holland was brought out in 1975 as the first rotary combine. Other manufacturers soon followed, IH with their ‘Axial Flow’ in 1977 and Gleaner with their N6 in 1979.
In the decades before the widespread adoption of the rotary combine in the late seventies, several inventors had pioneered designs which relied more on centrifugal force for grain separation and less on gravity alone. By the early eighties, most major manufacturers had settled on a “walkerless” design with much larger threshing cylinders to do most of the work. Advantages were faster grain harvesting and gentler treatment of fragile seeds, which were often cracked by the faster rotational speeds of conventional combine threshing cylinders.
It was the disadvantages of the rotary combine (increased power requirements and over-pulverization of the straw by-product) which prompted a resurgence of conventional combines in the late nineties. Perhaps overlooked but nonetheless true, when the large engines that powered the rotary machines were employed in conventional machines, the two types of machines delivered similar production capacities. Also, research was beginning to show that incorporating above-ground crop residue (straw) into the soil is less useful for rebuilding soil fertility than previously believed. This meant that working pulverized straw into the soil became more of a hindrance than a benefit. An increase in feedlot beef production also created a higher demand for straw as fodder. Conventional combines, which use straw walkers, preserve the quality of straw and allow it to be baled and removed from the field.
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