First, the working principle of a flexible header
Unlike rigid headers, which are fixed to the header frame, flexible headers use a more dynamic and adaptable system. The cutter carriage remains in constant contact with the ground, allowing it to move up and down as well as side to side, making it ideal for uneven terrain. This flexibility helps the header maintain consistent pressure on the ground, adjusting automatically based on soil conditions. The weight of the cutting assembly is supported by the spring plate and the ground’s natural elasticity. When the header is lowered, the spring plate compresses, increasing the pressure from the drag plate on the ground. Conversely, when the header is raised, the spring plate expands, reducing the pressure. This mechanism ensures that the drag plate can effectively push loose soil away without forcing the blade into the ground, thus preventing damage and improving efficiency. Operators should constantly monitor the cutting height and adjust the header as needed to maintain optimal performance. Keeping the header as low as possible, while avoiding excessive soil pushing, helps ensure smooth operation and minimizes grain loss.
Second, the usage and adjustment of a flexible header
1. Adjusting the Cutting Height
The cutting height is determined by the position of the header relative to the ground. When the drag plate is in contact with the ground, the angle of the blades and their distance from the soil vary depending on the header's position. A deeper dip results in a lower cut, while a shallower dip increases the height. To adjust this, there are bolts located on the back of the header that allow you to raise or lower the blades. By loosening the headgear and turning the bolts upward, the adjustment plate moves up, lowering the blades. Turning them downward raises the blades. It's important to make sure all bolts are adjusted equally so that the blades remain level across the entire header. After adjustment, the typical cutting height ranges between 30-50mm. Too low a setting may cause the header to pile up, while too high may leave uncut residue or damage the crop.
2. Adjusting the Blade Balance Spring
The balance spring in the blade assembly plays a key role in maintaining even pressure across the header. Due to the way the system is designed, the blade box is suspended from the header body using a spring that supports most of the weight, allowing the blades to float freely. If the left side of the header becomes heavier due to soil buildup, the spring can be tightened to increase its tension. If this doesn’t resolve the issue, an additional spring may be added. On the right side, if the header is too heavy, raising it slightly can reduce the pressure. Each time the blade angle is adjusted, the balance spring must also be recalibrated to maintain proper function.
3. Adjusting the Stabilizer Spring
The stabilizer spring helps keep the drive belt of the swing ring box tight, ensuring smooth operation. If the belt becomes misaligned or the tension is incorrect, the spring needs to be adjusted. The spring length should be set to approximately 67mm to stabilize the swing ring box and minimize vibration. In muddy or soft conditions, the spring pressure should be reduced to avoid pushing soil, which can be done by loosening the nut on the bolt. Again, after any blade adjustment, the stabilizer spring must be readjusted for optimal performance.
4. Cleaning the Contoured Carriage
Regular cleaning of the contoured carriage is essential to prevent dirt buildup, which can affect the header’s flexibility and lead to issues like soil pushing. Keeping the carriage clean ensures smooth movement and better overall performance.
5. Adjusting the Auger Gap
The gap between the blade and the bottom plate of the auger should be maintained at around 13mm. If it’s too small, it may crush grains; if too large, it could lead to uneven feeding. The gap between the agitator blade and the splash guard is typically 10-15mm, adjustable based on conditions. The dragon blade and the anti-wrapping plate should have a 6mm gap. The telescopic jaw and the bottom shell usually have a 10mm gap, but this can be reduced for shorter or thinner crops, as long as it doesn't go below 5mm. These adjustments are made using the side adjustment lever.
6. Installing the Bridge Splash Shield
A splash shield should be installed at the junction between the header and the bridge to prevent the bridge and augers from hitting the ground, reducing grain loss during operation.
7. Measures to Prevent Mud Build-Up
To prevent mud accumulation, 3x40mm round holes should be drilled in the lower gate of the grain elevator and the inspection gate of the unloading cylinder, as well as in the bottom cover of the grain and surplus augers. This allows dirt and dust to escape. Additionally, the first half of the seed plate can be replaced with a punched sieve (3x25mm or 3x40mm) for soybean harvesting. This attachment must be cleaned regularly to prevent clogging and ensure proper drainage.
8. Loss Reduction Techniques for Flexible Headers
Attaching a plastic pipe behind the blade guard can help prevent beans from falling off the cutting table and reduce soil impact. Installing rubber sheets or canvas strips on the teeth can also minimize plant damage. For tall crops, a long wooden pole or thin iron pipe can be attached to the reel wheels to prevent wrapping. A steel flexible lift-up device can be used for crops that are easily pulled, helping to collect fallen plants and improve cutting accuracy.
9. Adjusting the Floating Roller Height
The height of the floating roller is crucial, especially when harvesting soybeans. The spring height should be set between 107-113mm. To reduce chain impacts and breakage, the bridge chain can be separated, leaving a 15-25mm gap between the chain roller and the floating roller. Both sides should be adjusted equally to avoid an increased breakage rate.
10. Pre-Tightening Adjustment of the Conveyor Chain
The conveyor chain should be lifted with 30kg of force, resulting in a deflection of 30-40mm. This is achieved by adjusting the bolts on both sides to change the center distance. All three chains should be adjusted evenly. If the chain is too loose, it may cause grain to be crushed or damaged during transport.
11. Checking the Swing Ring Box Oil Level
The oil level in the swing ring box should be checked every 10 days. If the oil level is less than 100mm below the vent hole, gear oil should be added to maintain proper lubrication and function.
12. Locking the Flexible Header
Flexible headers can be locked into a rigid configuration to replace other headers or to harvest crops on harder ground. The locking mechanism is located beneath the carriage, with a locking bolt in the center of each section. Starting from the end of the header, the nut should be screwed in until it fully engages the carriage, ensuring a secure connection.
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