U.S. patent application number 13/272378 was filed with the patent office on 2012-04-26 for automatic start / stop controls for agricultural load and transfer equipment.
This patent application is currently assigned to Digi-Star, LLC, a Wisconsin Limited Liability Company. Invention is credited to Jerome Bump, Steven L. Johansen.
Application Number | 20120099948 13/272378 |
Document ID | / |
Family ID | 45973158 |
Filed Date | 2012-04-26 |
United States Patent
Application |
20120099948 |
Kind Code |
A1 |
Bump; Jerome ; et
al. |
April 26, 2012 |
AUTOMATIC START / STOP CONTROLS FOR AGRICULTURAL LOAD AND TRANSFER
EQUIPMENT
Abstract
A scale controller system and method of using the system is
disclosed. The scale controller is adapted for use with a grain
cart or similar implement that includes a discharge opening and
conveyor. The system includes a scale and a plurality of sensors
that work together to automate numerous functions that are
typically performed manually. For example, the present invention
discloses a system that automatically records the amount of
material loaded or unloaded by continuously monitoring the load on
a scale and the RPMs of a power take-off shaft that drives a
conveyor.
Inventors: |
Bump; Jerome; (Fort
Atkinson, WI) ; Johansen; Steven L.; (Waterford,
WI) |
Assignee: |
Digi-Star, LLC, a Wisconsin Limited
Liability Company
Fort Atkinson
WI
|
Family ID: |
45973158 |
Appl. No.: |
13/272378 |
Filed: |
October 13, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61405279 |
Oct 21, 2010 |
|
|
|
Current U.S.
Class: |
414/21 ;
414/813 |
Current CPC
Class: |
B65G 65/40 20130101;
G01G 13/16 20130101; B65G 65/42 20130101; G01G 11/003 20130101;
G01G 19/08 20130101; B60P 1/42 20130101; G01G 19/12 20130101; A01D
90/10 20130101; G01G 13/06 20130101; A01K 5/02 20130101; B65G 65/46
20130101; B65G 69/00 20130101; B60P 1/36 20130101 |
Class at
Publication: |
414/21 ;
414/813 |
International
Class: |
G01G 19/52 20060101
G01G019/52; B65G 69/00 20060101 B65G069/00 |
Claims
1. A system for automatically recording the amount of material
moved comprising: a storage carrier configured to store material
and having a discharge opening; a conveying device having an input
end and a discharge end, the input end of the conveying device
being positioned to receive material discharged from the discharge
opening of the storage carrier; a scale configured to measure the
weight of the material present in the storage carrier; a scale
controller electrically coupled to the scale, adapted to sense any
change in weight of the material in the storage carrier; the scale
controller further adapted to automatically determine when a
loading or unloading process starts or stops by entering a start
mode when the weight of the material in the storage carrier begins
to change and by entering a stop mode when the weight of the
material in the storage container stops changing; and an input
device configured to allow an operator to enter at least one
parameter.
2. The system of claim 1 wherein the conveying device is an
auger.
3. The system of claim 1 wherein the conveying device is a belt
conveyor.
4. The system of claim 1 wherein the conveying device is driven by
a Power Take-Off shaft.
5. The system of claim 4 further comprising a sensor, the sensor
configured to continuously monitor the speed of the Power Take-Off
shaft.
6. The system of claim 5 wherein upon the Power Take-Off shaft
achieving a first pre-determined speed, the scale controller enters
a start mode, the start mode configured to store the weight present
on the scale.
7. The system of claim 5 wherein upon the power take off shaft
decreasing in speed below a second pre-determined speed, the scale
controller enters a stop mode, the stop mode configured to
determine the weight loaded or unloaded by measuring the weight
present on the scale and subtracting the weight present on the
scale from the weight recorded when the scale controller entered
the start mode.
8. The system of claim 1 wherein the discharge opening includes a
door, the door configured to separate the material in the storage
carrier from the conveying device and including an actuation
mechanism.
9. The system of claim 8 wherein the door is mechanically
actuated.
10. The system of claim 8 wherein the door is hydraulically
actuated.
11. A method for automatically recording the amount of material
discharged from a storage carrier comprising the steps of: a.
storing material in the storage carrier, the storage carrier
including a scale and a closeable discharge opening; b. measuring
the weight of the material in the storage carrier; c. starting a
conveying device, the conveying device having an input end and a
discharge end, the input end positioned at the discharge opening of
the storage carrier; d. pre-setting the rate at which the conveying
device may be loaded with material without stalling; e.
continuously monitoring the speed of the conveying device; f.
opening the discharge opening of the storage carrier when the
conveying device is at or above the pre-set speed; g. receiving the
material discharged from the storage carrier at the input end of
the conveying device; h. conveying the material via the conveying
device and discharging the material from the discharge end of the
conveying device; i. closing the discharge opening when a
predetermined amount of material has been discharged from the
storage carrier; j. disabling the conveying device when any
remaining material on the conveyor has been discharged; and k.
recording the amount of material unloaded when the unloading
sequence is complete.
12. The method of claim 11, further comprising the step of:
displaying the current weight of any material present in the
storage carrier on a scale display.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is based on and claims priority from U.S.
Provisional Patent Application No. 61/405,279 filed on Oct. 21,
2010, and patent application Ser. No. 12/366,204 filed on Feb. 1,
2009, all of which are incorporated herein by reference in their
entirety for all purposes.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of
scale indicators and load cells for agricultural equipment. More
particularly, the present invention relates to a scale system that
includes start/stop controls.
BACKGROUND
[0003] In the field of agricultural scale indicators and load
cells, there is a need to mix, blend, apply, or transport a variety
of forage products (such as hay, corn, wheat, cotton seed, etc.).
In certain applications, it is important to know the weight of
certain materials, and it is also important to know the amount of
materials that have been loaded onto or off of a scale. Scales are
used as data management tools as well as material management tools
to help the operator load or unload the correct amount of material
and provide data to managers for record keeping. Certain
conventional scale controls have a number of control buttons that
must be pressed, in a particular order and at predetermined times,
in order to ensure the proper operation of the scale and the
carrier to which the scale is applied, and in order to ensure
proper collection of the data as the material is being loaded,
transported and unloaded. It is desirable to simplify the actions
required by the operator to control a process, and to reliably
record the transfer of material to or from the grain cart.
[0004] The scales and scale indicators described above are commonly
used in conjunction with grain carts and other implements that load
and unload bulk material. Grain carts are farm implements that are
typically towed behind a tractor or other engine-driven vehicle and
include a number of components. Farmers use grain carts to
transport harvested grain from other implements, such as combines,
and deliver the grain to trucks or other hauling devices away from
the harvest field. The use of grain carts allows the harvester to
remain in the field without having to return to a grain storage
area to unload.
[0005] Grain carts typically include a storage carrier that further
includes a hopper with a capacity ranging from several hundred to
over one thousand bushels of grain. To unload the grain from the
cart, grain carts employ a conveying device such as an auger or
conveyor ("conveyor") to draw grain from the bottom of the hopper
and convey it through a chute that deposits the grain wherever it
is needed. The conveyor transports grain from the base of the
hopper upward so that it may be deposited into another
container.
[0006] At the bottom of the hopper, where the conveyor meets the
hopper, is typically a door that must be opened in order for grain
to flow onto the conveyor. The door serves the important purpose of
keeping the grain or other material in the hopper until the
operator desires to remove the material, and also of allowing the
conveyor to come up to speed while under minimal load before the
grain is loaded onto the conveyor. To provide power to the
conveyor, grain carts are typically driven by a Power Take-Off
("PTO") driveshaft typically located at the rear end of a tractor.
A PTO is typically powered by the tractor's engine.
[0007] Without a door separating the grain in the hopper from the
conveyor, the conveyor would have to bear the entire weight of the
grain present in the grain cart to begin conveying grain up the
conveyor. Typical PTOs are not capable of generating the necessary
torque to overcome such a load. In fact, if the conveyor is not up
to the proper speed prior to opening of the door, the increased
load may cause the PTO, or the engine driving the PTO, to stall, or
other equipment to malfunction. To minimize the risk of stalling
and malfunction, grain cart operators must be cognizant of their
engine RPMs before starting the unloading process.
[0008] The current procedure for loading or unloading grain is
complicated, involving a multitude of steps. As one specific
example, using a Digi-Star Weigh Scale system to unload material
already present in a carrier, where the display shows the current
weight in the carrier includes the following steps: (1) the
operator pressing the [Tare] button to zero-out the weight display,
(2) the operator engaging the tractor PTO shaft to start the
conveyor/auger, (3) the operator opening the hopper door to begin
the grain flow, (4) when unloading is complete, the operator
closing the hopper door, (5) the operator disengaging the PTO shaft
to stop the conveyor/auger, (6) the operator pressing the [Print]
button to save to a storage medium the amount that was off-loaded,
and (7) the operator pressing the [Gross/Net] button, causing the
display to show the weight of the materials remaining in the
carrier.
[0009] This procedure is complicated, and is not easily explained
or taught to an untrained, casual or part-time operator, and so a
need exists for a simpler and more understandable scale control
system. For example, there may be times when the operator forgets
to press the [Tare] or [Print] key, causing the records reported to
management to be inaccurate. The present invention provides an
improvement over conventional operation of these scales.
SUMMARY
[0010] The present invention relates to a scale that includes an
automatic start/stop function. According to the invention, an
automatic start/stop control uses weight change, one or more
sensors, or both the weight change and the sensor(s), to
automatically start or stop a process. The invention also includes
one or more sensors that monitor the PTO RPMs. This automatic
start/stop control can be used to automatically start and stop the
control process for applying manure, unloading grain, feeding
animals, etc. from a storage carrier. Weight changes and process
control information may be displayed to the operator during or in
connection with use.
[0011] The Automatic Start/Stop control works similarly to pressing
the [Start/Stop] key on the indicator, but eliminates the
requirement of having the operator manually press the [Start/Stop]
key during the load/unload operation. Once the operator has
positioned the implement and is ready to begin the unloading
process, the operator simply starts the equipment by engaging the
PTO to start the conveyor. Next, the scale automatically determines
that the process has started and either enters the "Start" mode or
the "Stop" mode, as appropriate, depending on the state of the
process. The Automatic Start/Stop control can be overridden by
manually pressing the [Start/Stop] key.
[0012] The Automatic Start/Stop control system includes one or more
sensors that continuously monitor the PTO RPMs and the load present
on the conveyor. The entrance to the conveyor is separated from the
material by the hopper door. The hopper door may be mechanically or
hydraulically activated. In the present invention, the scale
controller continuously monitors the RPMs of the PTO. Once the PTO
speed reaches a level at which a stall is unlikely, the operator
may open the door, thus starting the unloading process.
[0013] Depending on the implement, it may be possible to determine
the weight of the material that is contained on the conveyor when
the cart is unloading. Knowing that weight allows the operator to
close the hopper door when the unloading process is nearing
completion so that a minimal amount of material remains on the
conveyor when the unloading process is complete. This is
advantageous because it helps minimize waste and simplifies cleanup
of the conveyor.
[0014] The Automatic Start/Stop control therefore ensures that the
process will start or stop even if the operator forgets to press
the [Start/Stop] key. Further, the Automatic Start/Stop control
simplifies the actions required by the operator to control a
process. Throughout the lifetime of the scale, the addition of the
Automatic Start/Stop control would save hundreds, if not thousands
of button presses.
[0015] It will be understood by those skilled in the art that one
or more aspects of this invention can meet certain objectives,
while one or more other aspects can lead to certain other
objectives. Other objects, features, benefits and advantages of the
present invention will be apparent in this summary and descriptions
of the disclosed embodiment, and will be readily apparent to those
skilled in the art. Such objects, features, benefits and advantages
will be apparent from the above as taken in conjunction with the
accompanying figures and all reasonable inferences to be drawn
therefrom.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a view of a typical tractor/grain cart
configuration in accordance with the present invention.
[0017] FIG. 2 is a view of the control panel on a scale controller
in accordance with the present invention.
[0018] FIG. 3 is a block schematic showing the unloading process of
grain in accordance with the present invention.
DETAILED DESCRIPTION
[0019] The present invention may be susceptible to embodiments in
different forms. For example, a storage carrier for storing bulk
material may be included in a variety of implements, including
those that may be mobile or stationary. Such implements include but
are not limited to grain carts, feed mixers, manure spreaders,
grain bins, and seed tenders.
[0020] Referring now to FIG. 1, one embodiment of the automatic
start/stop control in accordance with the invention is shown. A
grain cart 100 comprises a storage carrier 105 that is configured
to store material in a hopper 110 and discharge the material
through an opening 120 at the base of the hopper 110. The storage
carrier 105 includes a loadcell 130 that continuously monitors the
weight of material present in the storage carrier 110. The loadcell
130 may be located in a number of locations, including but not
limited to a hitch 132 or wheel axle 134. The opening 120 at the
base of the carrier 110 is separated from a conveyor 140 by a
hopper door 150. The hopper door 150 may be mechanically,
hydraulically, or electrically actuated. The conveyor 140 is
typically either an auger or belt conveyor. The conveyor 140 is
driven by a PTO shaft 210 which is in turn driven by the engine or
other power source of a tractor 200. There is a sensor 160 on the
grain cart 100 that monitors the RPMs of the PTO shaft 210. The
entire system is controlled by an operator 220 who sits in the cab
230 of the tractor 200. Inside the cab 230 is a scale control panel
300 that includes a plurality of buttons and a display.
[0021] Turning now to FIG. 2, a view of the scale control panel 300
is shown in accordance with the present invention. The scale
control panel 300 includes a display 310, on which various
information is displayed. The scale control panel 300 also includes
a plurality of buttons 320 on its face that control various
functions of the automatic start/stop system.
[0022] FIG. 3 is a flow chart 400 that illustrates a typical
unloading sequence performed in accordance with the present
invention. First, at step 410, the control panel 300 is turned on
when the operator 220 starts the tractor 200. Next, at step 415 the
operator 220 starts the PTO shaft 210. At decision gate 420, the
sensor 160 that monitors the RPM's of the PTO shaft 210 is
configured such that when the RPM's of the PTO shaft 210 reach a
pre-determined speed at which the conveyor 140 may be safely loaded
with material, the scale control system, at step 430, enters a
"start" sequence. Next, at step 440, upon entering the "start"
sequence, the operator 220 opens hopper door 150 to load the
conveyor 140 with material. During the unloading sequence, at
decision gate 445, the loadcell 130 continuously monitors the
weight present in the hopper 110. Additionally, the sensor 160 on
the PTO shaft 210 continuously monitors the RPM's of the PTO shaft
210. The system may notify the operator 220 if the RPM's of the PTO
shaft 210 drop below a pre-determined value, prompting the operator
220 to manually adjust the opening of the hopper door 150 to
decrease the flow rate of material onto the conveyor 140 to prevent
a stall.
[0023] At step 450, when a pre-determined amount of material is
unloaded from the hopper 110, the hopper door 150 may be closed, at
which time any remaining material on the conveyor 140 is unloaded.
Next, at step 460, the operator 220 disengages the PTO shaft 210.
At step 470, when the conveyor 140 is completely unloaded, the
system enters a "stop" sequence, thus completing the unloading
sequence. Finally, at step 480, the amount of weight unloaded is
recorded onto storage media.
Example #1
[0024] The Automatic Start/Stop control can be used to
automatically start, stop and record unloading material, such as
grains, from a grain cart into a truck. The following is an example
to demonstrate how the control would be used in this process.
[0025] The scale would have already been turned on and
zero/balanced prior to obtaining the load from the combine. Once
that load is obtained, and the operator of the grain cart decides
to unload, the operator cart would pull alongside a truck and
extend the grain cart auger over the truck hopper. The scale keeps
a record of the gross weight and continuously monitors the load for
weight changes. Once the conveyor is positioned properly, the
operator begins the unloading process by engaging the PTO, thus
starting the conveyor. When the system senses that the PTO is
turning at or above a pre-designated RPM, and the operator confirms
that the cart is properly positioned for unloading the grain from
the cart, and opens the hopper door to allow grain to flow onto the
conveyor. Thus the "Start" process is automatically begun by the
scale. The operator continues to unload the amount desired and the
scale continues to monitor the weight of the grain cart. Once the
desired amount has been unloaded, the operator will stop unloading
by closing the hopper door. The scale will sense that the weight
stops changing and the scale will perform various checks to verify
that the operator has finished unloading grain from the cart and
automatically activate the "Stop" process for the scale. The data
associated with this process, such as total weight unloaded, date,
time, location, etc., is recorded at this time and the scale
returns to weighing.
Example #2
[0026] This example is similar to Example #1, but is used to unload
manure.
[0027] The scale would have already been turned on and
zero/balanced prior to being loaded with manure. To unload, the
operator of a manure spreader would enter the field and activate
the PTO and hydraulics. Up to this point, the scale has been
keeping a record of the gross weight loaded and continuously
monitors the load for weight changes and changes in PTO RPM and
hydraulic pressure. When the operator starts the manure spreading
process, the sensors change states, which indicates that the
operator has started unloading manure. The scale senses the
activated sensors, does various checks to confirm that the operator
is actually unloading the manure from the spreader and
automatically begins the "Start" process. The operator continues to
unload the amount of manure desired and the scale continues to
monitor the sensors and the weight of the manure. Once the sensor
is de-activated or the desired amount of manure has been unloaded,
the scale will perform various checks to verify that the operator
has finished unloading manure from the spreader and automatically
activate the "Stop" process for the scale. The data associated with
this process, such as total weight unloaded, date, time, location,
etc., is recorded at this time and the scale returns to
weighing.
Example #3
[0028] This example is similar to Example #1, but is used to unload
feed for livestock.
[0029] The Automatic Start/Stop control can be used to
automatically start, stop and record unloading material, such as
feed from a feed mixer into a feed bunk in a pen. The following is
an example to demonstrate how the control would be used in this
process.
[0030] The scale would have already been turned on and
zero/balanced prior to the feed mixer being loaded with the various
components of the rations to be mixed, and the mixer will have
already mixed the components to arrive at the mixed ration. To
unload, the operator of the feed mixer would pull alongside the
feed bunk for the pen and start the feed mixer. The scale maintains
a record of the gross weight when loaded and continuously monitors
the mixer for weight changes. When the operator starts unloading
feed to the feed bunk, the scale senses the weight changing and
does various checks to verify that the operator is actually
unloading feed from the mixer. When the scale senses a change in
weight, it automatically begins recording, thus automatically
beginning the "Start" process. The operator continues to unload the
amount desired and the scale continues to monitor the weight of the
feed mixer. Once the desired amount has been unloaded to that feed
bunk, the system will automatically stop the unload process. When
the weight stops changing, the scale will perform various checks to
verify that the unloading process is complete and automatically
activate the "Stop" process for the scale. The data associated with
this process, such as total weight unloaded, date, time, location,
etc., is recorded at this time and the scale returns to
weighing.
Example #4
[0031] This example is similar to Example #3, but includes a PTO
sensor attached to the machine that helps identify when the
operator is able to start and stop unloading by monitoring the
speed at which the PTO shaft is spinning at any given time.
[0032] The scale would have already been turned on and
zero/balanced prior to the feed mixer being loaded with the rations
to be mixed, and the mixer will have mixed the components. To
unload, the operator of the feed mixer would pull alongside the
feed bunk for the pen and start the feed mixer. The scale maintains
a record of the gross weight when the feed mixer is loaded and
continuously monitors the weight and sensor for changes that
indicate that the operator has activated the feed mixer for
unloading. When the scale senses the sensor activate, it does
various checks to verify that the operator is actually unloading
the feed from the mixer. Thus the scale automatically begins the
"Start" process. The operator continues to unload the amount
desired and the scale continues to monitor the weight of the feed
mixer and the sensor. Once the sensor is de-activated or the
desired amount has been unloaded, the scale will perform various
checks to verify that the operator has finished unloading feed from
the feed mixer and automatically activate the "Stop" process for
the scale. The data associated with this process, such as total
weight unloaded, date, time, location, etc., is recorded at this
time and the scale returns to weighing.
[0033] Although the invention has been herein described in what is
presently perceived to be the most practical and preferred
embodiments, it is to be understood that the invention is not
intended to be limited to the specific embodiments set forth above.
Rather, it is recognized that modifications may be made by one of
skill in the art of the invention without departing from the spirit
or intent of the invention and, therefore, the invention is to be
taken as including all reasonable equivalents to the subject matter
of the appended claims and the description of the invention
herein.
* * * * *