U.S. patent application number 14/474626 was filed with the patent office on 2015-07-30 for apparatus and method for determining the depth of liquid in a drum.
The applicant listed for this patent is Roderick John Murphy. Invention is credited to Roderick John Murphy.
Application Number | 20150211910 14/474626 |
Document ID | / |
Family ID | 53678747 |
Filed Date | 2015-07-30 |
United States Patent
Application |
20150211910 |
Kind Code |
A1 |
Murphy; Roderick John |
July 30, 2015 |
APPARATUS AND METHOD FOR DETERMINING THE DEPTH OF LIQUID IN A
DRUM
Abstract
Apparatus and method for determining: proper operation of a
cleaning system, the depth of liquid in a drum, the predicted
failure of a pump, improving the ability to monitor cleaning
system, improving the ability to monitor dairy wash systems,
improving the ability to monitor animal husbandry systems, and/or
increasing the efficiency with which various types of equipment,
fluid levels, and/or systems can be serviced or monitored.
Inventors: |
Murphy; Roderick John;
(Columbia, MD) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Murphy; Roderick John |
Columbia |
MD |
US |
|
|
Family ID: |
53678747 |
Appl. No.: |
14/474626 |
Filed: |
September 2, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61954725 |
Mar 18, 2014 |
|
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61932334 |
Jan 28, 2014 |
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Current U.S.
Class: |
702/55 |
Current CPC
Class: |
G01F 23/18 20130101;
G01F 23/14 20130101; G01F 23/185 20130101 |
International
Class: |
G01F 23/14 20060101
G01F023/14 |
Claims
1: A sensor apparatus for measuring a depth of a liquid in a drum,
the sensor apparatus comprising: a tube having a first end and a
second end, the second end being configured for placement within
the liquid; a seal positioned in the tube and spaced from the
second end; a first sensor disposed in the tube between the seal
and the second end and configured to measure air pressure in the
tube; a processor in electronic communication with the first
sensor; a second sensor in electronic communication with the
processor, the second sensor being configured to measure
atmospheric pressure outside of the drum.
2: The sensor apparatus of claim 1, further comprising an opening
located in the second end of the tube configured to let the liquid
in the drum partially fill the tube between the second end and the
seal, the second end being irregular in shape such that positioning
of the second end on a flat bottom of the drum will not prevent
flow of liquid into the tube via the drum.
3: The sensor apparatus of claim 1, further comprising a shield
located between the second end and the seal, the shield being
configured to form a barrier between the first sensor and an inner
surface of the tube such that a drop of the liquid is less likely
to flow along the inner surface of the tube and contact the first
sensor, the shield is configured to leave at least one air
passageway between the first sensor and the second end so that the
air pressure measurements of the first sensor are not impeded by
the shield.
4: The sensor apparatus of claim 1, wherein the location of the
second sensor may be any one of on the first end, between the seal
and the first end, in a compartment attached to the tube, and
spaced from the sensor apparatus.
5: The sensor apparatus of claim 1, wherein the sensor apparatus is
configured for insertion via a hole in a top of the drum, and
wherein the sensor apparatus comprises an outer tube disposed over
the tube, the outer tube having a third end and a fourth end, the
outer tube configured to withdraw the liquid from the drum when the
sensor apparatus is inserted into the hole in the top of the
drum.
6: The sensor apparatus of claim 5, wherein the third end of the
outer tube is sealed to the tube at a location on the tube spaced
from the second end.
7: The sensor apparatus of claim 5, wherein at least a portion of
the tube protrudes from the fourth end of the outer tube so that
withdrawal of the liquid from the drum via the outer tube does not
create suction that seals the outer tube to a bottom of the
drum.
8: The sensor apparatus of claim 5, wherein a hose is located on
the outer tube and in fluid communication therewith such that
liquid withdrawn from the drum via the outer tube then traverses
the hose.
9: The sensor apparatus of claim 5, wherein a first area defined by
an axial cross section of the fourth end of the outer tube is
greater than a second area defined by an axial cross section of the
third end of the outer tube.
10: The sensor apparatus of claim 5, wherein the second sensor is
located in a container positioned on the first end of the tube, the
container forming a second seal between the outer tube and the
tube, and, the third end of the outer tube and the atmosphere.
11: The sensor apparatus of claim 9, further comprising at least
one device located within the fourth end and configured to prevent
the liquid in the outer tube from exiting the sensor apparatus
between the tube and the outer tube via the fourth end when the
sensor apparatus is withdrawn from the liquid in the drum, the at
least one device not preventing the liquid from entering the outer
tube through the fourth end.
12: The sensor apparatus of claim 1, wherein the processor is
configured to compute a volume of the liquid in the drum based on
the measurements of the first sensor and the second sensor, and,
also using a plurality of inputs representing at least one of a
dimension of the drum, a dimension of the sensor apparatus, and a
specific gravity of the liquid.
13: The sensor apparatus of claim 12, wherein the processor is
configured for entry of the plurality of inputs via a remote
electronic device.
14: The sensor apparatus of claim 13, further comprising an opening
located in one of between the seal and the second end of the tube
and in the second end of the tube, the opening configured to let
the liquid in the drum partially fill the tube, wherein the
processor is configured to automatically determine the depth of the
liquid in the drum, according to:
H=(P.sub.b-P.sub.a)/(PPIC*SG.sub.liquid) wherein P.sub.b is the
pressure in the drum at the opening of the tube as measured by the
first sensor, P.sub.a is the atmospheric pressure outside the drum
as measured by the second sensor, SG.sub.liquid is the specific
gravity of the liquid inside the drum, H is the depth, or height,
of the liquid inside the drum above the opening, PPIC is determined
by ((H-TUBE.sub.liquidinches)*249.17)/H) TUBE.sub.liquidinches is
the height of liquid in the tube above the opening, 249.17 is the
standard pressure exerted by a one inch column of water.
15: The sensor apparatus of claim 14, wherein the processor is
further configured to automatically determine the volume of the
liquid in the drum and take into account any adjustment needed due
to the presence of the sensor apparatus therein by using the depth
of the liquid in the drum and dimensions of the drum to determine
an initial volume of liquid in the drum, then the processor
automatically adjusts the initial volume of liquid in the drum to
get a final volume of liquid in the drum that takes into account
the sensor apparatus, according to:
Vdrum-final=Vdrum-initial-((H-Dliquid-in-sensor)*A), wherein H is
the depth of liquid in the drum above the opening; Vdrum-final is
the final volume of liquid in the drum above the opening;
Vdrum-initial is the initial volume of liquid in the drum above the
opening; A is a cross sectional area of the tube; Dliquid-in-sensor
is the depth of the liquid in the tube determined as follows:
Dliquid-in-sensor=(L-(((Pi*Vi/Ti)*(Tf/Pf))/A)), wherein L is a
length of the tube; Pi is the initial pressure in the tube prior to
insertion of the tube in the liquid; Vi is the initial volume of
the tube that is calculated by the dimensions of the tube; Ti is
the initial temperature of air in the tube; Pf is a pressure in the
tube when the tube is submerged in the liquid as calculated by the
first sensor; and Tf is the final temperature of the air inside the
tube when the tube is submerged.
16: The sensor apparatus of claim 15, wherein the processor is
configured to collect a plurality of usage data comprising at least
one of a time and a temperature of liquid withdrawn from the
drum.
17: The sensor apparatus of claim 16, wherein the processor is
configured to compare the plurality of usage data against a
plurality of predetermined data and issue an alert when a
discrepancy occurs.
18: The sensor apparatus of claim 11, wherein the second end of the
tube is located off-center in the fourth end of the outer tube to
provide additional room for the operation of the at least one
device.
19: A sensor apparatus for measuring a depth of a liquid in a drum,
the sensor apparatus comprising: a tube having a first end and a
second end, the second end being configured for placement within
the liquid; a seal positioned in the tube and spaced from the
second end; a first sensor disposed in the tube between the seal
and the second end and configured to measure air pressure in the
tube; a processor in electronic communication with the first
sensor; an outer tube disposed over the tube, the outer tube having
a third end and a fourth end, the outer tube configured to withdraw
the liquid from the drum when the sensor apparatus is inserted into
a hole in a top of the drum.
20: A sensor apparatus for measuring a depth of a liquid in a drum
above an initial drum liquid height, the drum including a sidewall,
the sensor apparatus comprising: a tube having a first end and a
second end, the second end being disposed on the sidewall of the
drum such that the tube and an inside of the drum are in fluid
communication, the second end being located on the sidewall
proximate the initial drum liquid height; a seal positioned in the
tube and spaced from the second end; a first sensor disposed in the
tube between the seal and the second end and configured to measure
air pressure in the tube; a processor in electronic communication
with the first sensor, wherein the processor automatically
determines the depth of liquid in the tank not including the
initial drum liquid height.
21: The sensor apparatus of claim 20: further comprising an outlet
for withdrawing liquid from the drum, the outlet being configured
to withdraw liquid from a bottom of the drum.
22: The sensor apparatus of claim 21, wherein the processor is
configured to compute a preferred volume of the liquid in the drum
based on the measurements of the first sensor and a second sensor
configured to measure pressure outside the drum, and, also using a
plurality of inputs representing at least one of a dimension of the
drum, a dimension of the sensor apparatus, and a specific gravity
of the liquid.
23: The sensor apparatus of claim 22, wherein the processor is
configured for entry of the plurality of inputs via a remote
electronic device.
24: The sensor apparatus of claim 22, further comprising the second
end of the tube being configured to let the liquid in the drum
partially fill the tube, wherein the processor is configured to
automatically determine the depth of the liquid in the drum,
according to: H=(P.sub.b-P.sub.a)/(PPIC*SG.sub.liquid), wherein
P.sub.b is the pressure in the drum at the opening in the tube as
measured by the first sensor, P.sub.a is the atmospheric pressure
outside the drum as measured by the second sensor, SG.sub.liquid is
the specific gravity of the liquid inside the drum, H is the depth,
or height, of the liquid inside the drum above the effective
location on the tube, PPIC is determined by
((H-TUBE.sub.liquidinches)*249.17)/H) TUBE.sub.liquidinches is the
height of liquid in the tube above the effective location, 249.17
is the standard pressure exerted by a one inch column of water.
25: The sensor apparatus of claim 24, wherein the processor is
further configured to automatically determine the preferred volume
of the liquid in the drum and take into account any adjustment
needed due to the presence of the sensor apparatus therein by using
the depth of the liquid in the drum above the initial drum liquid
height and dimensions of the drum to determine an initial volume of
liquid in the drum, then the processor automatically adjusts the
initial volume of liquid in the drum to get a final volume of
liquid in the drum that takes into account the sensor apparatus,
according to: Vdrum-final=Vdrum-initial-((H-Dliquid-in-sensor)*A),
wherein H is the depth of liquid in the drum above the opening;
Vdrum-final is the final volume of liquid in the drum above the
opening; Vdrum-initial is the initial volume of liquid in the drum
above the opening; A is a cross sectional area of the tube;
Dliquid-in-sensor is the depth of the liquid in the tube over the
opening determined as follows:
Dliquid-in-sensor=(L-(((Pi*Vi/Ti)*(Tf/Pf))/A)), wherein L is a
length of the tube as measured from a point on the tube
corresponding to the effective location; Pi is the initial pressure
in the tube prior to liquid entering the tube; Vi is the initial
volume of the tube that is calculated by the dimensions of the
tube; Ti is the initial temperature of air in the tube; Pf is a
pressure in the tube when the tube is submerged in the liquid as
calculated by the first sensor; and Tf is the final temperature of
the air inside the tube when the tube is submerged.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and benefit of the
following patent applications: (1) U.S. Provisional Patent
Application 61/954,725, filed Mar. 18, 2014; and (2) U.S.
Provisional Patent Application 61/932,334, filed Jan. 28, 2014;
each of which is hereby incorporated by reference in its entirety
as if fully set forth herein.
BACKGROUND
[0002] The present invention is generally directed to sensors and,
more specifically, to sensors adapted to determine the depth of
liquid in a drum.
[0003] It may be advantageous to provide a sensor that is
preferably: simple to manufacture, relatively inexpensive to
manufacture, relatively reliable, relatively easy to install,
capable of determining the depth of liquid in a drum, capable of
determining the volume of liquid in a drum, capable of knowing when
liquid is being withdrawn from the drum instead of a non withdrawal
event, capable of monitoring withdrawals over time and detecting
trends or deviations from the norm so that gradual malfunctions or
changes in use can be detected, and/or capable of sending alerts if
the volume of liquid withdrawn from the drum is less than a
predetermined volume.
SUMMARY
[0004] Briefly speaking, one embodiment of the present invention is
directed to a sensor apparatus for measuring a depth of a liquid in
a drum. The sensor apparatus includes a tube that has first and
second ends. The second end is configured for placement within the
liquid. A seal is positioned in the tube and spaced from the second
end. A first sensor is disposed in the tube between the seal and
the second end and is configured to measure air pressure in the
tube. The tube has an opening that allows liquid in the drum to
partially fill the tube. A processor is in electronic communication
with the first sensor. A second sensor is in electronic
communication with the processor and is configured to measure
atmospheric pressure outside of the drum. An outer tube is disposed
over the tube, and, has third and fourth ends. The outer tube is
configured to withdraw liquid from the drum when the sensor
apparatus is inserted into a hole in a top of the drum. The
processor is configured to automatically determine the depth of the
liquid in the drum, according to:
H=(P.sub.b-P.sub.a)/(PPIC*SG.sub.liquid). Pb is the pressure in the
drum at the opening of the tube as measured by the first sensor.
P.sub.a is the atmospheric pressure outside the drum as measured by
the second sensor. SG.sub.liquid is the specific gravity of the
liquid inside the drum. H is the depth, or height, of the liquid
inside the drum generally above the opening in the tube. PPIC is
determined by ((H-TUBE.sub.liquidinches)*249.17)/H).
TUBE.sub.liquidinches is the height of liquid in the tube above the
opening. And 249.17 is the standard pressure exerted by a one inch
column of water. The processor is further configured to
automatically determine a volume of the liquid in the drum while
taking into account any adjustment needed due to the presence of
the sensor apparatus therein. By using the depth of the liquid in
the drum and dimensions of the drum to determine an initial volume
of liquid in the drum, the processor automatically adjusts the
initial volume of the liquid in the drum to get a final volume of
liquid in the drum that takes into account the volume of the sensor
apparatus, according to:
Vdrum-final=Vdrum-initial-((H-Dliquid-in-sensor)*A). H is the depth
of liquid in the drum generally above the opening in the tube.
Vdrum-final is the final volume of liquid in the drum.
Vdrum-initial is the initial volume of liquid in the drum. A is a
cross sectional area of the tube. Dliquid-in-sensor is the depth of
the liquid in the tube determined as follows:
Dliquid-in-sensor=(L-(((Pi*Vi/Ti)*(Tf/Pf))/A)). Wherein L is a
length of the tube; Pi is the initial pressure in the tube prior to
insertion of the tube in the liquid; Vi is the initial volume of
the tube that is calculated by the dimensions of the tube; Ti is
the initial temperature of air in the tube; Pf is a pressure in the
tube when the tube is submerged in the liquid as calculated by the
first sensor; and Tf is the final temperature of the air inside the
tube when the tube is submerged.
[0005] In a separate aspect, one embodiment of the present
invention is directed to a sensor apparatus for measuring a depth
of a liquid in a drum. The sensor apparatus comprises a tube that
has first and second ends. The second end is configured for
placement within the liquid. A seal is positioned in the tube and
spaced from the second end. A first sensor is disposed in the tube
between the seal and the second end and is configured to measure
air pressure in the tube. A processor is in electronic
communication with the first sensor. A second sensor is in
electronic communication with the processor and is configured to
measure atmospheric pressure outside of the drum. An outer tube is
disposed over the tube, and, has third and fourth ends. The outer
tube is configured to withdraw liquid from the drum when the sensor
apparatus is inserted into a hole in a top of the drum.
[0006] In a separate aspect, one embodiment of the present
invention is directed to a sensor apparatus for measuring the depth
of a liquid in a drum. The sensor apparatus comprises a tube having
first and second ends. The second end is configured for placement
within the liquid. A seal is positioned in the tube and spaced from
the second end. A first sensor is disposed in the tube between the
seal and the second end and is configured to measure atmospheric
pressure in the tube. A processor is in electronic communication
with the first sensor. A second sensor is configured to measure
atmospheric pressure outside of the drum and is in electronic
communication with the processor.
[0007] In a separate aspect, one embodiment of the present
invention is directed to a sensor apparatus for measuring the depth
of a liquid in a drum. The sensor apparatus comprises a tube having
first and second ends. A first sensor is disposed in the tube and
is configured to measure atmospheric pressure in the tube. A
processor is in electronic communication with the first sensor.
[0008] In a separate aspect, one embodiment of the present
invention is directed to a method for providing a system for
measuring a depth of a liquid in a drum. The method comprises the
steps of: providing a first sensor configured to be located in
fluid communication with an inside of the drum, the first sensor is
an air pressure sensor generating a first signal corresponding to
the pressure of the liquid at a bottom of the drum; providing a at
least one software module stored on a non-transitory computer
readable storage medium, the software module is configured such
that when operating on a processor, the processor is configured to
automatically determine the depth of the liquid in the drum based
on at least one of the first signal and the second signal;
providing a processor having at least one software module thereon;
providing a tube including an opening therein, the opening
configured to let the liquid in the drum partially fill the tube;
the processor is configured to automatically determine the depth of
the liquid in the drum according to:
H=(P.sub.b-P.sub.a)/(PPIC*SG.sub.liquid), where P.sub.b is the
pressure in the drum at the opening of the tube as measured by the
first sensor, P.sub.a is the atmospheric pressure outside the drum
as measured by the second sensor, SG.sub.liquid is the specific
gravity of the liquid inside the drum, H is the depth, or height,
of the liquid inside the drum, PPIC is determined by
((H-TUBE.sub.liquidinches)*249.17)/H), where TUBE.sub.liquidinches
is the height of liquid in the tube above the opening, and 249.17
is the standard pressure exerted by a one inch column of water; the
processor is configured to automatically determine a volume of the
liquid in the drum while taking into account any adjustment needed
due to the presence of the first sensor therein by using the depth
of the liquid in the drum and dimensions of the drum to determine
an initial volume of liquid in the drum, then the processor
automatically adjusts the initial volume of liquid in the drum to
get a final volume of liquid in the drum that takes into account
the first sensor.
[0009] In a separate aspect, one embodiment of the present
invention is directed to a method for providing a system for
measuring a depth of a liquid in a drum. The method comprises the
steps of: providing a first sensor configured to be located in
fluid communication with an inside of the drum, the first sensor is
an air pressure sensor generating a first signal corresponding to
the pressure of the liquid at a bottom of the drum; providing a at
least one software module stored on a non-transitory computer
readable storage medium, the software module is configured such
that when operating on a processor, the processor is configured to
automatically determine the depth of the liquid in the drum based
on at least one of the first signal and the second signal;
providing a processor having at least one software module
thereon.
[0010] In a separate aspect, one embodiment of the present
invention is directed to a method for providing a system for
measuring a depth of a liquid in a drum. The method comprises the
steps of: providing a first sensor configured to be located in
fluid communication with an inside of the drum, the first sensor
generating a first signal corresponding to the pressure of the
liquid at a bottom of the drum; providing a second sensor
configured to be in fluid communication with ambient atmosphere
outside of the drum, the second sensor generating a second signal
corresponding to ambient pressure outside the drum; providing a at
least one software module stored on a non-transitory computer
readable storage medium, the software module is configured such
that when operating on a processor, the processor is configured to
automatically determine the depth of the liquid in the drum based
on at least one of the first signal and the second signal.
[0011] In a separate aspect, one embodiment of the present
invention is directed to a method for providing a system for
measuring a depth of a liquid in a drum. The method comprises the
steps of: providing a first sensor configured to be located in
fluid communication with an inside of the drum; providing a second
sensor configured to be in fluid communication with ambient
atmosphere outside of the drum; providing a at least one software
module stored on a non-transitory computer readable storage medium,
the software module is configured such that when operating on a
processor, the processor is configured to automatically determine
the depth of the liquid in the drum based on the measurements of at
least one of the first sensor and the second sensor.
[0012] In a separate aspect, one embodiment of the present
invention is directed to a method for measuring a depth of a liquid
in a drum used as part of a system for use in at least one of
agricultural, equipment cleaning, and/or animal husbandry. The
method comprising the steps of: providing the drum configured to
contain the liquid used in the system; providing a first sensor
located in fluid communication with an inside of the drum, the
first sensor being an air pressure sensor generating a first signal
corresponding to the pressure of the liquid at a bottom of the
drum; determining the depth of the liquid in the drum based on the
first signal; providing at least one software module stored on a
non-transitory computer readable storage medium, the software
module being configured such that when operating on a processor,
the processor is configured to automatically determine the depth of
the liquid in the drum based on the first signal; providing a
processor including the at least one software module thereon such
that the processor automatically determines the depth of liquid in
the drum; providing a tube having an opening therein, the opening
configured to let the liquid in the drum partially fill the tube;
the processor is configured to automatically determine the depth of
the liquid in the drum according to:
H=(P.sub.b-P.sub.a)/(PPIC*SG.sub.liquid), where P.sub.b is the
pressure in the drum at the opening of the tube as measured by the
first sensor, P.sub.a is the atmospheric pressure outside the drum
as measured by the second sensor, SG.sub.liquid is the specific
gravity of the liquid inside the drum, H is the depth, or height,
of the liquid inside the drum, PPIC is determined by
((H-TUBE.sub.liquidinches)*249.17)/H), where TUBE.sub.liquidinches
is the height of liquid in the tube above the opening, and 249.17
is the standard pressure exerted by a one inch column of water; the
processor further being configured to automatically determine a
volume of the liquid in the drum and taking into account any
adjustment needed due to the presence of the first sensor therein
by using the depth of the liquid in the drum and dimensions of the
drum to determine an initial volume of liquid in the drum, then the
processor automatically adjusts the initial volume of liquid in the
drum to get a final volume of liquid in the drum that takes into
account the first sensor.
[0013] In a separate aspect, one embodiment of the present
invention is directed to a method for measuring a depth of a liquid
in a drum used as part of a system for use in at least one of
agricultural, equipment cleaning, and animal husbandry. The method
comprising the steps of: providing the drum configured to contain
the liquid used in the system; providing a first sensor located in
fluid communication with an inside of the drum, the first sensor
being an air pressure sensor generating a first signal
corresponding to the pressure of the liquid at a bottom of the
drum; determining the depth of the liquid in the drum based on the
first signal; providing at least one software module stored on a
non-transitory computer readable storage medium, the software
module being configured such that when operating on a processor,
the processor is configured to automatically determine the depth of
the liquid in the drum based on the first signal; providing a
processor including the at least one software module thereon such
that the processor automatically determines the depth of liquid in
the drum.
[0014] In a separate aspect, one embodiment of the present
invention is directed to a method for measuring a depth of a liquid
in a drum used as part of a system for use in at least one of
agricultural, equipment cleaning, and/or animal husbandry. The
method comprising the steps of: providing the drum configured to
contain the liquid used in the system; providing a first sensor
located in fluid communication with an inside of the drum, the
first sensor generating a first signal corresponding to the
pressure of the liquid at a bottom of the drum; providing a second
sensor in fluid communication with ambient atmosphere outside of
the drum, the second sensor generating a second signal
corresponding to ambient pressure outside the drum; determining the
depth of the liquid in the drum based on the first signal.
[0015] In a separate aspect, one embodiment of the present
invention is directed to a method for measuring a depth of a liquid
in a drum used as part of a dairy wash system. The method
comprising the steps of: providing the drum configured to contain
the liquid used in the system; providing a first sensor located in
fluid communication with an inside of the drum, the first sensor
generating a first signal corresponding to the pressure of the
liquid at a bottom of the drum; providing a second sensor in fluid
communication with ambient atmosphere outside of the drum, the
second sensor generating a second signal corresponding to ambient
pressure outside the drum; determining the depth of the liquid in
the drum based on the first signal; the dairy wash system
performing a predetermined number of washes, the dairy wash system
only withdrawing liquid from the drum during a wash; the processor
being configured to collect a plurality of usage data comprising at
least one of a time, a temperature of liquid withdrawn from the
drum, and a volume of liquid withdrawn from the drum; the processor
being configured to compare the plurality of usage data against a
plurality of predetermined data and issue an alert when a
discrepancy occurs.
[0016] In a separate aspect, one embodiment of the present
invention is directed to a method for measuring a depth of a liquid
in a drum used as part of a dairy wash system. The method
comprising the steps of: providing the drum configured to contain
the liquid used in the system; providing a first sensor located in
fluid communication with an inside of the drum, the first sensor
generating a first signal corresponding to the pressure of the
liquid at a bottom of the drum; providing a second sensor in fluid
communication with ambient atmosphere outside of the drum, the
second sensor generating a second signal corresponding to ambient
pressure outside the drum; determining the depth of the liquid in
the drum based on the first signal; the processor being configured
to collect a plurality of usage data comprising at least one of a
time, a temperature of liquid withdrawn from the drum, and a volume
of liquid withdrawn from the drum; the processor being configured
to compare the plurality of usage data against a plurality of
predetermined data and issue an alert when a discrepancy
occurs.
[0017] In a separate aspect, one embodiment of the present
invention is directed to a method for measuring a depth of a liquid
in a drum used as part of a dairy wash system. The method
comprising the steps of: providing the drum configured to contain
the liquid used in the system; providing a first sensor located in
fluid communication with an inside of the drum, the first sensor
generating a first signal corresponding to the pressure of the
liquid at a bottom of the drum; providing a second sensor in fluid
communication with ambient atmosphere outside of the drum, the
second sensor generating a second signal corresponding to ambient
pressure outside the drum; determining the depth of the liquid in
the drum based on the first signal; the processor being configured
to compare a plurality of data collected on the liquid in the drum
against a plurality of predetermined data and issue an alert when a
discrepancy occurs.
[0018] In a separate aspect, one embodiment of the present
invention is directed to a method for providing a system for
measuring a depth of a liquid in a drum. The method comprising the
steps of: providing a first sensor configured to be located in
fluid communication with an inside of the drum, the first sensor
generating a first signal corresponding to the pressure of the
liquid at a bottom of the drum; providing a tube including an
opening that is configured to let liquid in the drum partially fill
the tube; providing at least one software module stored on a
non-transitory computer readable storage medium, the software
module being configured such that when operating on a processor,
the processor is configured to automatically determine the depth of
the liquid in the drum based on the first signal and to
automatically determine whether a liquid withdrawal has occurred or
whether changes in the first signal represent a non withdrawal
event; providing a processor including the at least one software
module thereon, the processor receiving the first signal and
automatically determining the depth of the liquid in the drum and
automatically determining whether a liquid withdrawal has occurred
or whether changes in the first signal represent a non withdrawal
event; wherein the processor is configured to automatically
determine the depth of the liquid in the drum according to:
H=(P.sub.b-P.sub.a)/(PPIC*SG.sub.liquid), where P.sub.b is the
pressure in the drum at the opening of the tube as measured by the
first sensor, P.sub.a is the atmospheric pressure outside the drum
as measured by the second sensor, SG.sub.liquid is the specific
gravity of the liquid inside the drum, H is the depth, or height,
of the liquid inside the drum, PPIC is determined by
((H-TUBE.sub.liquidinches)*249.17)/H), where TUBE.sub.liquidinches
is the height of liquid in the tube above the opening, and 249.17
is the standard pressure exerted by a one inch column of water; the
processor further being configured to automatically determine a
volume of the liquid in the drum and take into account any
adjustment needed due to the presence of the system therein by
using the depth of the liquid in the drum and dimensions of the
drum to determine an initial volume of liquid in the drum, then the
processor automatically adjusts the initial volume of liquid in the
drum to get a final volume of liquid in the drum that takes into
account the system.
[0019] In a separate aspect, one embodiment of the present
invention is directed to a method for providing a system for
measuring a depth of a liquid in a drum. The method comprising the
steps of: providing a first sensor configured to be located in
fluid communication with an inside of the drum, the first sensor
being an air pressure sensor generating a first signal
corresponding to the pressure of the liquid at a bottom of the
drum; providing at least one software module stored on a
non-transitory computer readable storage medium, the software
module being configured such that when operating on a processor,
the processor is configured to automatically determine the depth of
the liquid in the drum based on at least one of the first signal
and the second signal and to automatically determine whether a
liquid withdrawal has occurred or whether changes in the first
signal represent a non withdrawal event; providing a processor
including the at least one software module thereon, the processor
receiving the first signal and automatically determining the depth
of the liquid in the drum and automatically determining whether a
liquid withdrawal has occurred or whether changes in the first
signal represent a non withdrawal event.
[0020] In a separate aspect, one embodiment of the present
invention is directed to a method for providing a system for
measuring a depth of a liquid in a drum. The method comprising the
steps of: providing a first sensor configured to be located in
fluid communication with an inside of the drum, the first sensor
generating a first signal corresponding to the pressure of the
liquid at a bottom of the drum; providing a second sensor
configured to be in fluid communication with ambient atmosphere
outside of the drum, the second sensor generating a second signal
corresponding to ambient pressure outside the drum; providing at
least one software module stored on a non-transitory computer
readable storage medium, the software module being configured such
that when operating on a processor, the processor is configured to
automatically determine the depth of the liquid in the drum based
on at least one of the first signal and the second signal and to
automatically determine whether a liquid withdrawal has occurred or
whether changes in the first signal represent a non withdrawal
event.
[0021] In a separate aspect, one embodiment of the present
invention is directed to a method for providing a system for
measuring a depth of a liquid in a drum. The method comprising the
steps of: providing a first sensor configured to be located in
fluid communication with an inside of the drum, the first sensor
being an air pressure sensor generating a first signal
corresponding to the pressure of the liquid at a bottom of the
drum; providing a second sensor configured to be in fluid
communication with ambient atmosphere outside of the drum, the
second sensor being an air pressure sensor generating a second
signal corresponding to ambient pressure outside the drum;
providing at least one software module stored on a non-transitory
computer readable storage medium, the software module being
configured such that when operating on a processor, the processor
is configured to automatically determine the depth of the liquid in
the drum based on at least one of the first signal and the second
signal and to automatically determine whether a liquid withdrawal
has occurred or whether changes in the first signal represent a non
withdrawal event; generating the first signal at a predetermined
interval and the second sensor generating the second signal at the
predetermined interval; the processor being configured to compile a
report, the report being an average of the plurality of readings
over a predetermined time; the processor being configured to store
at least three of the reports, the at least three reports being the
newest at least three reports compiled; the processor being
configured to determine a pressure difference between at least two
of the reports; the processor being configured to recognize the
liquid withdrawal when the pressure difference between at least two
of the reports is greater than a predetermined pressure; the
processor being configured to determine a volume of the liquid
withdrawn in the liquid withdrawal by analyzing the total pressure
difference.
[0022] In a separate aspect, one embodiment of the present
invention is directed to a method for providing a system for
measuring a depth of a liquid in a drum. The method comprising the
steps of: providing a first sensor configured to be located in
fluid communication with an inside of the drum, the first sensor
being an air pressure sensor generating a first signal
corresponding to the pressure of the liquid at a bottom of the
drum; providing a second sensor configured to be in fluid
communication with ambient atmosphere outside of the drum, the
second sensor being an air pressure sensor generating a second
signal corresponding to ambient pressure outside the drum;
generating the first signal at a predetermined interval and the
second sensor generating the second signal at the predetermined
interval; providing a processor being configured to compile a
report, the report being an average of the plurality of readings
over a predetermined time; the processor being configured to store
at least three of the reports, the at least three reports being the
newest at least three reports compiled; the processor being
configured to determine a pressure difference between at least two
of the reports; the processor being configured to recognize a
liquid withdrawal when the pressure difference between at least two
of the reports is greater than a predetermined pressure; the
processor being configured to determine a volume of the liquid
withdrawn in the liquid withdrawal by analyzing the total pressure
difference.
[0023] In a separate aspect, one embodiment of the present
invention is directed to a method for providing a system for
measuring a depth of a liquid in a drum. The method comprising the
steps of: providing a first sensor configured to be located in
fluid communication with an inside of the drum, the first sensor
being an air pressure sensor generating a first signal
corresponding to the pressure of the liquid at a bottom of the
drum; providing a second sensor configured to be in fluid
communication with ambient atmosphere outside of the drum, the
second sensor being an air pressure sensor generating a second
signal corresponding to ambient pressure outside the drum;
providing a processor configured to recognize a liquid withdrawal
when a change in pressure is greater than a predetermined amount;
the processor being configured to determine a volume of the liquid
withdrawn in the liquid withdrawal by analyzing the total pressure
difference.
[0024] In a separate aspect, one embodiment of the present
invention is directed to a method for providing a system for
measuring a depth of a liquid in a drum. The method comprising the
steps of: providing a first sensor configured to be located in
fluid communication with an inside of the drum, the first sensor
being an air pressure sensor generating a first signal
corresponding to the pressure of the liquid at a bottom of the
drum; providing a processor configured to recognize a liquid
withdrawal when a change in pressure is greater than a
predetermined amount; the processor being configured to determine a
volume of the liquid withdrawn in the liquid withdrawal by
analyzing the total pressure difference.
[0025] In a separate aspect, one embodiment of the present
invention is directed to a method for providing a system for
measuring a depth of a liquid in a drum. The method comprising the
steps of: providing a first sensor configured to be located in
fluid communication with an inside of the drum, the first sensor
generating a first signal corresponding to the pressure of the
liquid at a bottom of the drum; providing at least one software
module stored on a non-transitory computer readable storage medium,
the software module being configured such that when operating on a
processor, the processor is configured to automatically determine
the depth of the liquid in the drum based on the first signal and
to automatically determine whether a liquid withdrawal has occurred
or whether changes in the first signal represent a non withdrawal
event; providing a processor including the at least one software
module thereon, the processor receiving the first signal and
automatically determining the depth of the liquid in the drum and
automatically determining whether a liquid withdrawal has occurred
or whether changes in the first signal represent a non withdrawal
event.
[0026] In a separate aspect, one embodiment of the present
invention is directed to a method for providing a system for
measuring a depth of a liquid in a drum. The method comprising the
steps of: providing a first sensor configured to be located in
fluid communication with an inside of the drum, the first sensor
generating a first signal corresponding to the pressure of the
liquid at a bottom of the drum; providing at least one software
module stored on a non-transitory computer readable storage medium,
the software module being configured such that when operating on a
processor, the processor is configured to automatically determine
the depth of the liquid in the drum based on the first signal and
to automatically determine whether a liquid withdrawal has occurred
or whether changes in the first signal represent a non withdrawal
event
[0027] In a separate aspect, one embodiment of the present
invention is directed to a method for providing a system for
measuring a depth of a liquid in a drum. The method comprising the
steps of: receiving data corresponding to the pressure of the
liquid at a bottom of the drum; automatically determining the depth
of the liquid in the drum based on the data and automatically
determining whether a liquid withdrawal has occurred or whether
changes in the data represent a non withdrawal event.
[0028] In a separate aspect, one embodiment of the present
invention is directed to providing at least one software module
stored on a non-transitory computer readable storage medium, the
software module containing instructions operable on a processor for
automatically determining the depth of the liquid in a drum and to
automatically determining whether a liquid withdrawal has occurred
or whether a non withdrawal event has occurred.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The foregoing summary, as well as the following detailed
description of the preferred embodiment of the present invention
will be better understood when read in conjunction with the
appended drawings. For the purpose of illustrating the invention,
there are shown in the drawings embodiments which are presently
preferred. It is understood, however, that the invention is not
limited to the precise arrangements and instrumentalities shown. In
the drawings:
[0030] FIG. 1 is a front view of a sensor apparatus in combination
with a system for use with agriculture, cleaning, and/or animal
husbandry according to a first preferred embodiment of the present
invention; the sensor apparatus includes a tube having first and
second ends; the second end of the tube is configured for placement
within the liquid of the drum such that the second end rests
against the bottom of the drum; although a preferred configuration
of the seal is shown, those of ordinary skill in the art will
appreciate from this disclosure that the seal may be at any
location in the tube spaced from the second end without departing
from the scope of the present invention;
[0031] FIG. 2 is a front view of a sensor apparatus according to a
first preferred embodiment of the present invention; the sensor
apparatus may include a tube having first and second ends; the
second end of the tube may be configured for placement within the
liquid of the drum via a hole in the top of the drum such that the
second end rests against the bottom of the drum; the tube may have
a seal positioned at the first end, the seal being a printed
circuit board; although a preferred configuration of the seal is
shown, those of ordinary skill in the art will appreciate from this
disclosure that the seal may be at any location in the tube spaced
from the second end without departing from the scope of the present
invention; a first sensor may be located on the printed circuit
board such that the first sensor is between the printed circuit
board and the second end, and, configured to measure air pressure
in the tube; the tube may have an opening located in the second
end; the opening allows the liquid in the drum partially fill the
tube between the second end and the seal when the sensor apparatus
is placed in the liquid; the area of the opening may be relatively
small compared to the area of the second end, the area of the
opening may be similar to the area of the second end, or, the area
of the opening may be any size in between relatively small and
similar to the area of the second end; the second end may be
irregular in shape such that positioning of the second end on a
flat bottom of the drum will not prevent flow of liquid into the
tube; as shown, the second end of the tube has an angled second end
with respect to the flat, horizontal bottom of the drum; although a
preferred configuration of the second end is shown, those of
ordinary skill in the art will appreciate from this disclosure that
the second end may be rounded, have dimples or protrusions, or be
any other suitable shape without departing from the scope of the
present invention; the tube may contain a shield located between
the second end and the seal; the shield may be configured to form a
barrier between the first sensor and an inner surface of the tube
such that a drop of the liquid is less likely to flow down the
inner surface of the tube and contact the first sensor; the shield
may be further configured to leave at least one air passageway
between the first sensor and the second end so that the air
pressure measurements of the first sensor are not impeded by the
shield; the sensor apparatus may include a container positioned on
the first end of the tube; the container may have an opening on at
least one side such that the air pressure in the container is
similar to the ambient air pressure around the drum; the container
may also have a second sensor therein that is configure to measure
the ambient air pressure outside the drum; however, the location of
the second sensor may be any one of on the first end, between the
seal and the first end, in a compartment attached to the tube, and
spaced from the sensor apparatus without departing from the scope
of the invention; preferably, the second sensor is located on a
micro board, a printed circuit board, or the like; the first and
second sensors may be connected by a wire to a processor, that is
shown labeled in the Figures as a control box; the processor
preferably includes a mini SD disk or the like, a battery backup or
the like, and a cellular board; the processor may be configured to
compute a volume of the liquid in the drum based on the
measurements of the first sensor and the second sensor, and, also
using a plurality of inputs representing at least one of a
dimension of the drum, a dimension of the sensor apparatus, and a
specific gravity of the liquid; the processor may be configured for
entry of the plurality of inputs via a remote electronic device;
the processor may be configured to automatically determine the
depth of the liquid in the drum, according to:
H=(P.sub.b-P.sub.a)/(PPIC*SG.sub.liquid), where P.sub.b is the
pressure in the drum at the opening of the tube as measured by the
first sensor, P.sub.a is the atmospheric pressure outside the drum
as measured by the second sensor, SG.sub.liquid is the specific
gravity of the liquid inside the drum, H is the depth, or height,
of the liquid inside the drum generally above the opening in the
tube, PPIC is determined by ((H-TUBE.sub.liquidinches)*249.17)/H),
where TUBE.sub.liquidinches is the height of liquid in the tube
above the opening, and 249.17 is the standard pressure exerted by a
one inch column of water; the processor may be further configured
to automatically determine the volume of the liquid in the drum and
take into account any adjustment needed due to the presence of the
sensor apparatus therein by using the depth of the liquid in the
drum and dimensions of the drum to determine an initial volume of
liquid in the drum, then the processor automatically adjusts the
initial volume of liquid in the drum to get a final volume of
liquid in the drum that takes into account the sensor apparatus,
according to: Vdrum-final=Vdrum-initial-((H-Dliquid-in-sensor)*A),
wherein H is the depth of liquid in the drum generally above the
opening in the tube, Vdrum-final is the final volume of liquid in
the drum, Vdrum-initial is the initial volume of liquid in the
drum, A is a cross sectional area of the tube, Dliquid-in-sensor is
the depth of the liquid in the tube determined as follows:
Dliquid-in-sensor=(L-(((Pi*Vi/Ti)*(Tf/Pf))/A)), wherein L is a
length of the tube, Pi is the initial pressure in the tube prior to
insertion of the tube in the liquid, Vi is the initial volume of
the tube that is calculated by the dimensions of the tube, Ti is
the initial temperature of air in the tube, Pf is a pressure in the
tube when the tube is submerged in the liquid as calculated by the
first sensor, and Tf is the final temperature of the air inside the
tube when the tube is submerged; the processor may be configured to
collect a plurality of usage data comprising at least one of a time
and a temperature of liquid withdrawn from the drum; the processor
may be configured to compare the plurality of usage data against a
plurality of predetermined data and issue an alert when a
discrepancy occurs; a hose that is connected to a pump may also be
placed within the drum to withdrawal liquid from the drum; the
processor may be configured to determine whether a pressure drop as
measured by one of the first sensor and the first and second
sensors is a withdrawal of liquid or a non withdrawal event; the
processor may further be configured to send an alert by text
message if the volume of liquid withdrawn is less than a
predetermined amount, thereby warning the owner or a third party
that there is a problem with the liquid withdrawal setup;
[0032] FIG. 3 is a front view of the sensor apparatus of FIG. 2
including the outer tube; the tube may have an outer tube disposed
over the tube; the outer tube having third and fourth ends and
configured to withdraw the liquid from the drum when the sensor
apparatus is inserted into the hole in the top of the drum; at
least a portion of the tube may protrude from the fourth end of the
outer tube so that withdrawal of the liquid from the drum via the
outer tube does not create suction that seals the outer tube to a
bottom of the drum; instead of a hose being inserted into the drum,
the hose may be located on the outer tube and in fluid
communication therewith such that liquid withdrawn from the drum
via the outer tube then traverses the hose; having the hose on the
outer tube reduces the number of steps needed to transfer the
sensor apparatus and hose to another drum since the hose and the
sensor apparatus are connected; the container that holds the second
sensor and that is located on the first end of the tube may also
form a second seal between the outer tube and the tube, and, the
third end of the outer tube and the atmosphere; a first area
defined by an axial cross section of the fourth end of the outer
tube may be greater than a second area defined by an axial cross
section of the third end of the outer tube; at least one device may
be located within the fourth end and is configured to prevent the
liquid in the outer tube from exiting the sensor apparatus between
the tube and the outer tube via the fourth end when the sensor
apparatus is withdrawn from the liquid in the drum; the at least
one device may not prevent liquid from entering the outer tube
through the fourth end; the second end of the tube may be located
off-center in the fourth end of the outer tube in order to provide
additional room for the operation of the at least one device; the
at least one device may be a duck bill valve, although, those of
ordinary skill in the art will recognize that the at least one
device may be any other suitable device without departing from the
scope of the invention;
[0033] FIG. 4 is a cross sectional view of FIG. 3 taken along the
line 4-4; the cross section of the second end of the tube and the
at least one device can be seen within the fourth end of the sensor
apparatus;
[0034] FIG. 5 is a second preferred embodiment of the sensor
apparatus; in this embodiment, the seal may be located in the tube
between the first and second ends; the seal may be a printed
circuit board and the first sensor may be located on the seal
between the seal and the second end; however, the first sensor may
be located anywhere that is in fluid communication with the inside
of the drum without departing from the scope of the invention; the
second sensor may be located between the seal and the first end of
the tube; a portion of the tube between the seal and the first end
may have an opening therein such that the sensor is in fluid
communication with ambient pressure outside the drum; however,
those of ordinary skill in the art will recognize that the second
sensor may be located anywhere that allows the second sensor to be
in fluid communication with ambient pressure outside the drum, or,
fluid communication with air inside the drum without departing from
the scope of the present invention; the first and second sensors
may generate first and second signals that correspond to the
pressure of the liquid at the bottom of the drum and the ambient
pressure outside the drum, respectively; the first sensor may have
wires that extend therefrom that extend through the seal, the
second seal, and run to the top of the container; the second sensor
may wire that extend therefrom and extend through the second seal
and run to the top of the container; the top of the container may
have a main wire that transfers the first and second signals from
the first and second sensors to the processor; however, the first
and second signals may be transferred in any suitable way without
departing from the scope of the invention;
[0035] FIG. 6 is a third preferred embodiment of the sensor
apparatus; in this embodiment, the second sensor may be located
spaced from the sensor apparatus and may be located on the
processor;
[0036] FIGS. 7A and 7B are a flow chart showing a preferred method
used by the processor for an equipment wash on a dairy farm;
however, those of ordinary skill in the art will recognize that the
method may be used for any agricultural, equipment wash, or animal
husbandry system without departing from the preferred embodiment;
the processor is preferably configured to determine when a washing
cycle has started and ended by first determining if the temperature
recorded by a temperature sensor on a milk line has risen a
predetermined number of degrees in a predetermined time period,
therefore, meaning that the milking of cows is over; if the
processor has determined that the temperature of the milk line has
risen a predetermined number of degrees within a predetermined time
period, the processor is preferably configured to start storing
readings of the pressure measured by at least one sensor apparatus;
preferably, the processor is further configured to start compiling
reports for each sensor apparatus; preferably, the processor is
preferably configured to store the newest of at least two reports
for every liquid used in the washing cycle; more preferably, the
processor is configured to store the newest of at least three
reports for every liquid used in the washing cycle; more preferably
still, the processor is configured to store the newest five reports
for every liquid used in the washing cycle; preferably, the
processor is further configured to analyze the stored reports for
each liquid; preferably, the processor determines whether a liquid
withdrawal has started in any of the liquids used in the washing
cycle; if so, the processor is preferably configured to determine
that a withdrawal of the respective liquid has just started; if
not, the processor preferably starts the determination again when a
new report is compiled; preferably, the processor is configured to
determine a wash cycle has begun when the processor determines that
the first withdrawal of any of the liquids; preferably, the
processor preferably records the time that the processor determined
a washing cycle has started, and, the number of washing cycles
performed each day; after a liquid withdrawal has occurred for any
of the liquids, the processor preferably is configured to determine
when the liquid withdrawal has ended for the same liquid; after
determining a liquid withdrawal for a particular liquid has ended,
the processor is preferably configured to immediately determine the
pressure drop of the liquid at the bottom of the drum;
subsequently, the processor is preferably configured to determine
the order that each liquid's withdrawal ended; after the processor
determines that a withdrawal has started on at least one liquid,
the processor may be configured to start a timer such that if the
processor fails to determine that the liquid withdrawal has ended
for all liquids within a predetermined length of time, the
processor may reverse its determination that a withdrawal has taken
place; after a liquid withdrawal for each liquid has ended, and,
the order in which the liquids were withdrawn has been determined,
the processor is preferably configured to perform another check to
ensure a washing cycle, and liquid withdrawals, have indeed taken
place; the check preferably includes the processor configured to
determine if at least four of following have occurred: the
processor has determined a wash cycle has started, the order in
which the processor determined the liquid withdrawals occurred
matches the order in which the liquids are to be withdrawn that was
entered into the processor, if the pressure at the bottom of each
drum has dropped by thirty or more Pascal's, if the temperature
recorded by a temperature sensor on the milk line has risen or
dropped a predetermined number of degrees in a predetermined time
period, and if the temperature sensors on each hose are consistent
with predetermined temperatures; if at least four have occurred,
the processor is preferably configured to confirm the washing
cycle; subsequently, the processor is preferably configured to send
an alert if any data collected by the processor, such as
temperature of the liquids flowing through the hose, the time of a
washing cycle, or a pressure differential at the bottom of the
drums after a liquid withdrawal has occurred, is inconsistent with
a plurality of predetermined data; if less than four have occurred,
the processor preferably reverses its determination that the
washing cycle has started; subsequently, the processor preferably
begins analyzing the stored reports again;
[0037] FIG. 8 is a flow chart showing a second preferred method for
providing a system for measuring a depth of a liquid in a drum;
[0038] FIG. 9 is a flow chart showing a third preferred method for
providing a system for measuring a depth of a liquid in a drum;
[0039] FIGS. 10A and 10B are a flow chart showing a fourth
preferred method for providing a system for measuring a depth of a
liquid in a drum;
[0040] FIG. 11 is a flow chart showing a fifth preferred method for
measuring a depth of a liquid in a drum used as part of a system
for use in at least one of agricultural, equipment cleaning, and
animal husbandry;
[0041] FIG. 12 is a flow chart showing a sixth preferred method for
measuring a depth of a liquid in a drum used as part of a system
for use in at least one of agricultural, equipment cleaning, and
animal husbandry;
[0042] FIGS. 13A and 13B are a flow chart showing a seventh
preferred method for measuring a depth of a liquid in a drum used
as part of a system for use in at least one of agricultural,
equipment cleaning, and animal husbandry;
[0043] FIG. 14 is a flow chart showing an eighth preferred method
for providing a system for measuring a depth of a liquid in a
drum;
[0044] FIG. 15 is a flow chart showing a ninth preferred method for
providing a system for measuring a depth of a liquid in a drum;
and
[0045] FIGS. 16A and 16B are a flow chart showing a tenth preferred
method for providing a system for measuring a depth of a liquid in
a drum;
[0046] FIG. 17 is a fourth preferred embodiment of the sensor
apparatus; the sensor apparatus, similar to that shown in FIG. 5,
may be spaced from the drum with a portion of the tube fixed to the
drum; the second end of the tube may be disposed on the sidewall of
the drum such that the tube and an inside of the drum are in fluid
communication; preferably, the second end of the tube is on a
portion of the tube that is perpendicular to a vertical sidewall;
those of ordinary skill in the art will appreciate that the portion
of the tube may be at any angle with respect to the vertical
sidewall without departing from the scope of the present invention;
the processor may be able to calculate the height of the liquid in
the drum above the opening; preferably, the height of the liquid in
the drum is from an effective location to the surface of the liquid
in the drum; while the effective location of the embodiment
disclosed in FIG. 17 is located at a maximum height of the opening
with respect to the bottom of the drum, those of ordinary skill in
the art will appreciate that the effective location may be at a
different location and may be changed due to a change of the angle
of the portion of the tube with respect to a vertical sidewall
and/or the shape of the opening without departing from the scope of
the present invention; the processor may use the height of liquid
in the drum along with the dimensions of the drum to determine an
initial volume of liquid in the drum above effective location;
preferably, the processor takes into account the vertical distance
between the effective location and the bottom of the drum in order
to calculate a finial height of the liquid in the drum that can be
used to calculate the total volume of liquid in the drum, or, the
processor may determine the volume of liquid below the effective
location of the drum based on the drums dimensions and add this
volume to the initial volume in the drum to calculate the total
volume of liquid in the drum; preferably, the processor is
configured to determine the volume of liquid in the tube so that
the processor may determine a final volume of liquid by adding the
volume of liquid in the tube to the total volume of liquid in the
drum; the drum may have a hose connected to the bottom of the drum;
however, those of ordinary skill in the art will appreciate that
the hose may be located at any point on the drum without departing
from the scope of the present invention; the hose may be connected
to a pump and configured to withdrawal liquid from the drum;
however, more sophisticated systems, such as some advanced hoofbath
systems, may operate without any pump or electronics and instead
operate based on fluid pressures and vacuums in a generally closed
circuit type of arrangement; the drum may be located on a stand to
give the drum more stability, especially if the drum 24 does not
have a flat bottom;
[0047] FIG. 18 is view of the graphic user interface (GUI) of the
processor; the GUI may be located on the processor or may be
accessible online or by the use of an electronic device; the GUI
preferably has the name of the dairy farm, or other business, at
the top; under the name, the GUI may have the current date and
time; below the date and time, the GUI may have pictures of drums
showing the depth of the liquid in the drum; underneath the
pictures of the drums, the GUI preferably lists the liquid in each
drum along with the volume of the liquid in the drum, the pump
status, and the weeks until pump failure; the GUI may indicate that
the pump has not reached its minimum volume threshold level for a
wash by showing an "X" next to pump status; if the pump has met the
minimum volume threshold, the GUI may indicate the pump is okay by
showing a checkmark next to pump status; to the left of the
pictures of the drums, the GUI may have a contact dealer button and
a contact service provider button that, when pressed, automatically
contact the dealer and service provider, respectively, either by a
call, text, email, or the like; the GUI may also have a contacts
button that allows a user to view and contact all stored contacts;
at the bottom of the GUI may be a bunch of buttons such as buttons
that may allow a user to view valve status, view current alerts,
view wash history, view alert and reply history, maintenance log,
and a button to stop wash immediately; however those of ordinary
skill in the art will recognize that the GUI may include any
suitable data, information, artwork, phrases, numbers, words,
letters, or the like, in any arrangement without departing from the
scope of the invention;
[0048] FIGS. 19A1-19A3, 19B-190, 19P1-19P4, and 19Q are a preferred
schematic for the processor;
[0049] FIGS. 19AA1-19AA3, 19BB-19OO, 19PP1-19PP4, and 19QQ are a
second preferred schematic for the processor;
[0050] FIG. 20 is a preferred schematic for the first sensor;
[0051] FIGS. 21A-21N are a preferred schematic for the second
sensor or microprocessor that the second sensor is located on;
[0052] FIG. 22 is a flowchart illustrating one preferred method for
providing a sensor apparatus for measuring a depth of a liquid in a
drum above an initial drum liquid height.
[0053] FIG. 23 is a screenshot of a sample GUI showing text
messages between the processor and a person; a person may ask the
processor a text inquiry and the processor may send a text inquiry
reply answering the text inquiry; a person may ask the processor to
send a text inquiry reply related to certain information pertaining
to the liquid in the drum, such as, the volume of liquid in each
drum, the temperature of the liquids in each drum, etc.; also shown
is a text alert from the processor; shown is a text alert informing
at least one predetermined person that a liquid did not dispense
during a wash. Those of ordinary skill in the art will appreciate
from this disclosure that similar error, inquiry, reply, and
reminder messages or the like can be communicated via voice
simulation and voice recognition or any other suitable
communications means without departing from the scope of the
present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0054] Certain terminology is used in the following description for
convenience only and is not limiting. The term "fluid communication
between A and B" means that A and B are located such that a fluid,
such as air or liquid, may flow from A to B. For example, A and B
are in fluid communication if A and B are sitting on an empty desk
since air may freely flow from A to B. As another example, A and B
may be in fluid communication with each other if A is sitting on a
desk and B is located in a box containing a hole on the desk since
air can still flow from A into the box, via the hole, to B. As yet
another example, A and B may not be in fluid communication if A is
sitting on a desk and B is located in an airtight box on the desk
since air may not be able to flow from A into the box. The term
"electronic device" refers to any device that manipulates electron
flow for its operation, such as, a cell phone, tablet, device
connected via the Internet, smart phone, keypad, computer, or the
like. The word "drum" as used in the claims and in associated
portions of the specification, means "any object configured to hold
liquid therein such as a drum, barrel, tote, tub, tank, bath,
holding tank, container, vat, and/or the like". The language "at
least one of `A`, `B`, and `C`," as used in the claims and/or in
corresponding portions of the specification, means "any group
having at least one `A`; or any group having at least one `B`; or
any group having at least one `C`; --and does require that a group
have at least one of each of `A`, `B`, and `C`." Additionally, the
words "a" and "one" are defined as including one or more of the
referenced item unless specifically stated otherwise. The
terminology includes the words above specifically mentioned,
derivatives thereof, and words of similar import.
[0055] Referring to FIGS. 2-4, wherein like numerals indicate like
elements throughout, there is shown a preferred embodiment of a
sensor apparatus 20 for measuring a depth of a liquid 22 in a drum
24. The sensor apparatus 20 preferably includes a tube 26 that has
first and second ends 28A, 28B wherein the second end 28B may be
configured for placement within the liquid 22. While the tube 26
preferably has a circular cross-section when taken generally
perpendicular to a longitudinal axis thereof, Those of ordinary
skill in the art will appreciate from this disclosure that the tube
cross section can be triangular, square, polygonal, irregular, or
the like without departing from the scope of the present
invention.
[0056] The sensor apparatus 20 may be configured for insertion into
the liquid 22 via a hole 42 in a top 40 of the drum 24. It is
preferable, although not required, that the second end 28B be
configured to rest against the bottom of the drum 24. The second
end 28B may have an opening 36 therein to let liquid 22 in the drum
24 partially fill the tube 26 when the second end 28B is placed
within the liquid 22 in the drum 24. To assure flow of liquid 22
into the tube 26 through the opening 36 in the second end 28B, the
second end 28B may be irregular in shape such that positioning of
the second end 28B on a flat bottom of the drum 24 will not prevent
flow of liquid 22 into the tube 26. Said another way, the surface
of the second end 28B of the tube 26 may have a different contour
than the bottom of the bottom of the drum 24 such that when the
second end 28B is resting on the bottom of the drum 24, at least a
portion of the second end 28B is not in contact with the bottom of
the drum 24. While the opening 36 in the preferred embodiment has
an area similar to the area of the second end 28B, those of
ordinary skill in the art will appreciate from this disclosure that
the area of the opening 36 may be any value smaller than the area
of the second end 28B without departing from the scope of the
present invention. Those of ordinary skill in the art will also
appreciate from this disclosure that the second end 28B may have
multiple openings therein without departing from the scope of the
present invention. Those of ordinary skill in the art will also
appreciate from this disclosure that the opening 36 may not be in
the second end 28B, but may be located on a portion of the tube 26
spaced from the second end 28B without departing from the scope of
the present invention.
[0057] Referring to FIGS. 2 and 3, a seal 30 may be positioned in
the tube 26 and spaced from the second end 28B. The seal 30
preferably is an air-tight seal. Preferably, the seal 30 is located
on the first end 28A of the tube 26. However, as seen in FIG. 5,
the seal 30 may be positioned between the first and second ends
28A, 28B of the tube 26. In the preferred embodiment, the seal 30
is a printed circuit board that forms an air-tight seal, however,
the seal 30 may be any suitable material without departing from the
scope of the invention.
[0058] The sensor apparatus 20 preferably includes a first sensor
32A located between the second end 28B and the seal 30 to measure
the air pressure of the tube 26 between the seal 30 and the second
end 28B. While the preferred embodiment has the first sensor 32A
connected to the seal 30, the first sensor 32A may be located at
any location such that the first sensor 32A is in fluid
communication with the air in the tube 26 between the seal 30 and
the second end 28B. Referring to FIG. 20, a preferred schematic of
the first sensor 500 is shown. The illustrated schematic for the
first sensor 500 is exemplary only. Those of ordinary skill in the
art will appreciate from this disclosure that any suitable
circuit(s) can be used without departing from the scope of the
present invention.
[0059] Still referring to FIGS. 2 and 3, the sensor apparatus 20
may include a shield 38 located between the second end 28B and the
seal 30. The shield 38 is preferably configured to form a barrier
between the first sensor 32A and an inner surface of the tube 26
such that, when the sensor apparatus 20 is laid on its side or
transported to another location, a drop of liquid 22 is less likely
to flow along the inner surface of the tube 26 and contact the
first sensor 32A. While the preferred embodiment of the sensor
apparatus 20 has a conically shaped shield 38 extending from the
first end 28A of the tube 26, those of ordinary skill in the art
will recognize that the shield 38 can have any suitable shape that
impedes the flow of liquid 22 down the inner surface of the tube 26
without departing from the scope of the invention. Preferably, but
not necessarily, the shield 38 is configured to leave at least one
air passageway 52 between the first sensor 32A and the second end
28B so that the air pressure measurements of the first sensor 32A
are not altered by the shield 38.
[0060] The sensor apparatus 20 may also include, but is not
required to include, a second sensor 32B that is configured to
measure atmospheric pressure outside the drum 24 or the pressure of
the air inside the drum 24 and above the liquid 22. While the
preferred embodiment shows the second sensor 32B located in
container 50 attached to the first end 28A of the tube 26, the
second sensor 32B may be located at any one of on the first end
28A, between the seal 30 and the first end 28A, in a compartment
attached to the tube 26, and spaced from the sensor apparatus 20
without departing from the scope of the invention. The second
sensor is preferably located on a microprocessor that is in
electronic communication with the second sensor and the first
sensor. Those of ordinary skill in the art will appreciate from
this disclosure that instead of the second sensor, an assumed
atmospheric pressure value can be used, a general pressure reading
provided by an online, cellular, televised, or physical paper news
source can be used without departing from the scope of the present
invention. Referring to FIGS. 21A-21N, a preferred schematic of the
second sensor or the microprocessor that the second sensor is
located on 600A, 600B, and 600C is shown. The illustrated schematic
for the second circuit 600A, 600B, 600C is exemplary only. Those of
ordinary skill in the art will appreciate from this disclosure that
any suitable circuit(s) can be used without departing from the
scope of the present invention.
[0061] As best seen in FIG. 3, the sensor apparatus 20 may include
an outer tube 44 disposed over the tube 26 wherein the outer tube
44 has third and fourth ends 46A, 46B and may be configured to
withdraw liquid 22 from the drum 24 when the sensor apparatus 20 is
inserted into the hole 42 in the top 40 of the drum 24. The outer
tube 44 may be, but need not be, sealed to the tube 26 at a
location on the tube 26 spaced from the second end 28B. At least a
portion of the tube 26 may protrude from the fourth end 46B of the
outer tube 44 so that withdrawal of the liquid 22 from the drum 24
via the outer tube 44 does not create suction that seals the outer
tube 44 to a bottom of the drum 24. A hose 48 may be located on, or
connected to, the outer tube 44 and in fluid communication
therewith such that liquid 22 withdrawn from the drum 24 via the
outer tube 44 then traverses the hose 48. The hose 48 may be
connected to a pump 54 in order to create the pressure differential
needed for the outer tube 44 to withdrawal liquid 22 from the drum
24. The outer tube 44 may have a protrusion extending therefrom
that the outer tube 44 may be located on, or connected to. However,
those of ordinary skill in the art will recognize from this
disclosure that the hose 48 may be connected to the outer tube 44
in any suitable way, or at any location on the outer tube 44,
location without departing from the scope of the invention. A first
area defined by an axial cross section of the fourth end 46B of the
outer tube 44 may be greater than a second area defined by an axial
cross section of the third end 46A of the outer tube 44. At least
one device 68 may be located within the fourth end 46B and
configured to prevent the liquid 22 in the outer tube 44 from
exiting the sensor apparatus 20 between the tube 26 and the outer
tube 44 via the fourth end 46B when the sensor apparatus 20 is
withdrawn from the liquid 22 in the drum 24. The at least one
device 68 allows the sensor apparatus 20 to be withdrawn from the
drum 24 and placed back in the liquid 22 in the drum 24, or another
drum, without having to re-prime the outer tube 44 in order for the
pump 54 to function properly. The at least one device 68 preferably
allows the liquid 22 to entering the outer tube 44 through the
fourth end 46B. The at least one device 68 may be a duck bill
valve. However, those of ordinary skill in the art will recognize
that the one device 68 may be any suitable device without departing
from the scope of the invention. As best shown in FIGS. 3 and 4,
the second end 28B of the tube 26 may located off-center in the
fourth end 46B of the outer tube 44 in order to provide additional
room for the operation of the at least one device 68. Duck bill
valves, and other similar devices, may not work properly if they
contact other instruments or parts. Therefore, the additional room
created by locating the second end 28B off-center in the fourth end
46B of the outer tube 44 may allow the at least one device 68 to
function unimpeded. The use of the at least one device 68 provides
the advantage of preventing liquid from draining out of the sensor
apparatus and connected hose when the sensor apparatus is removed
from the drum. This facilitates use of the sensor apparatus with
pumps that are not self priming.
[0062] A container 50 is preferably, but not necessarily,
positioned on the first end 28A of the tube 26. As described above,
the container 50 preferably, but not necessarily, contains the
second sensor 32B. The container 50 may have a second opening 64
therein in to allow the second sensor 32B to be in fluid
communication with the ambient air outside the drum 24. The second
opening 64 may be relatively small compared to a side of the
container 50, however, those of ordinary skill in the art will
recognize that there may be one or more openings that may be any
size in relation to the container 50 without departing from the
scope of the invention. As seen in FIGS. 5 and 6, if the second
sensor 32B is in a location other than the container 50, or there
is no second sensor in the sensor apparatus 20, the container 50
need not have an opening thereon. As best seen in FIG. 5, if the
second sensor 32B is located in the tube 26 between the first end
28A and the seal 30, the tube 26 may have a third opening 66
therein such that the second sensor 32B is in fluid communication
with the ambient air outside the drum 24, or, the air inside the
drum 24. The container 50 on the first end 28A of the tube 26 may
form a second seal 62 between the outer tube 44 and the tube 26,
and, the third end 46A of the outer tube 44 and the atmosphere. It
is preferable that that the third end 46A of the outer tube 44 be
sealed off from the atmosphere so that the pump 54 may function
properly.
[0063] Referring to FIGS. 2 and 3, the first and second sensors
32A, 32B may be in electronic communication with a processor 34.
The first and second sensors 32A, 32B may be electrically connected
to a cable 56 located on top of the container 50. As seen in FIG.
5, the first sensor 32A may have at least one wire 58 extending
therefrom that extends through the seal 30, through the first end
28A, and connected to the second sensor 32B, or alternatively, the
microprocessor. The second sensor 32B may have at least one wire 60
that extends to the top of the container 50. Referring to FIGS. 2,
3, and 5, the top of the container 50 may be configured for the
installation of an Ethernet jack, or the like, therein that may be
configured for insertion of an Ethernet cable 56, or the like. The
cable 56 may extend from the top of the container 50 may
electrically connect the first and second sensors 32A, 32B to the
processor 34. Alternatively, communications via the first or second
sensor and a processor can be accomplished wirelessly or by any
other suitable method. In some instances the processor referred to
in the drawings may actually be a user's cell phone or computer
that is connected via the Internet, wirelessly, or via a wifi
network to the sensors. Alternatively, data can be stored on the
sensor apparatus and manually withdrawn for analysis. At least one
of the cable 56 and the container 50 may have a predetermined color
such that if multiple sensor apparatus's are being used and
connected to the same processor 34, it would be easy for a user to
determine the cable 56 connected to a specific sensor apparatus 20.
Although, those of ordinary skill in the art will recognize from
this disclosure that the first and second sensors 32A, 32B may be
electrically connected to the processor 34 in any suitable way
without departing from the scope of the invention. Referring to
FIGS. 19A1-19A3, 19B-190, 19P1-19P4, and 19Q, a preferred schematic
of the processor 300A, 300B is shown. The preferred schematic of
the processor 300A, 300B discloses a four channel controller.
Referring to FIGS. 19AA1-19AA3, 19BB-19OO, 19PP1-19PP4, and 19QQ, a
second preferred schematic of the processor 400A, 400B is shown.
The second preferred schematic of the processor 400A, 400B
discloses a six channel controller. The illustrated schematics for
the processor 300A, 300B, 300C, 300D are exemplary only. Those of
ordinary skill in the art will appreciate from this disclosure that
any suitable circuit(s) can be used without departing from the
scope of the present invention.
[0064] The processor 34 may be configured to compute a volume of
the liquid 22 in the drum 24 based on the measurements of the first
sensor 32A and the second sensor 32B, and, also using a plurality
of inputs representing at least one of a dimension of the drum 24,
a dimension of the sensor apparatus 20, and a specific gravity of
the liquid 22. The processor 34 may be configured for entry of the
plurality of inputs via a remote electronic device. The remote
electronic device may be a cell phone, a computer, a tablet, a
website, or any other suitable way. The processor 34 may be
configured to automatically determine the depth of the liquid 22 in
the drum 24, according to:
H=(P.sub.b-P.sub.a)/(PPIC*SG.sub.liquid), wherein P.sub.b is the
pressure in the drum 24 at the opening 36 of the tube 26 as
measured by the first sensor 32A, P.sub.a is the atmospheric
pressure outside the drum 24 as measured by the second sensor 32B,
SG.sub.liquid is the specific gravity of the liquid inside the drum
24, H is the depth, or height, of the liquid inside the drum 24
above the opening 36, PPIC is determined by
((H-TUBE.sub.liquidinches)*249.17)/H), TUBE.sub.liquidinches, or TL
in the Figures, is the height of liquid 22 in the tube above the
opening 36, and 249.17 Pascals is the standard pressure exerted by
a one inch column of water. however Those of ordinary skill in the
art will appreciate from this disclosure that the precise pressure
of one inch of water may vary due to circumstance without departing
from the scope of the present invention. The processor 34 may be
further configured to automatically determine the volume of the
liquid 22 in the drum 24 and take into account any adjustment
needed due to the presence of the sensor apparatus 20 therein. By
using the depth of the liquid 22 in the drum 24 and the dimensions
of the drum 24 to determine an initial volume of liquid 22 in the
drum 24, the processor 34 may automatically adjust the initial
volume of liquid 22 in the drum 24 to get a final volume of liquid
22 in the drum 24 that takes into account the sensor apparatus 20,
according to: Vdrum-final=Vdrum-initial-((H-Dliquid-in-sensor)*A),
wherein H is the depth of liquid in the drum 24; Vdrum-final is the
final volume of liquid in the drum; Vdrum-initial is the initial
volume of liquid in the drum 24; A is a cross sectional area of the
tube 26; Dliquid-in-sensor is the depth of the liquid in the tube
26 generally above the opening in the tube determined as follows:
Dliquid-in-sensor=(L-(((Pi*Vi/Ti)*(Tf/Pf))/A)), wherein L is a
length of the tube 26; Pi is the initial pressure in the tube 26
prior to insertion of the tube 26 in the liquid; Vi is the initial
volume of the tube 26 that is calculated by the dimensions of the
tube 26; Ti is the initial temperature of air in the tube 26; Pf is
a pressure in the tube 26 when the tube 26 is submerged in the
liquid as calculated by the first sensor 32A; and Tf is the final
temperature of the air inside the tube 26 when the tube 26 is
submerged.
[0065] While a preferred method of calculating liquid volumes and
heights is disclosed above, those of ordinary skill in the art will
appreciate from this disclosure that any other suitable calculation
method or system can be used without departing from the scope of
the present invention.
[0066] The processor 34 may be configured to collect a plurality of
usage data comprising at least one of a time and a temperature of
liquid 22 withdrawn from the drum 24. However other usage data may
be collected such as duration of the withdrawal of liquid 22 from
the drum 24, and, total volume of liquid 22 withdrawn from the drum
24 without departing from the scope of the invention. The processor
34 may further be configured to compare the plurality of usage data
against a plurality of predetermined data and issue an alert when a
discrepancy occurs. The alert may be issued by any electronic
means, such as a text, a phone call, an email, an alarm or any
audible sound, a flashing light or any visual alert, or any other
suitable way.
[0067] FIG. 17 shows an alternative embodiment of the sensor
apparatus 20. The sensor apparatus 20, similar to that shown in
FIG. 5, may be spaced from the drum 24 with the second end 28B of
the tube 26 preferably disposed on the sidewall 24A of the drum 24
such that the tube 26 and an inside of the drum are in fluid
communication. Said another way, the tube 26 is not located in, or
configured for placement in, the drum 24. Instead, the tube 26 may
be attached, or detachably connected, to a sidewall 24A of the drum
24. Preferably, the second end of the tube is on a portion 28D of
the tube 26 that is perpendicular to a vertical sidewall 24A. Those
of ordinary skill in the art will appreciate that the portion 28D
of the tube 26 may be at any angle with respect to the vertical
sidewall 24A without departing from the scope of the present
invention.
[0068] The processor 34 may be able to calculate the height H of
the liquid 22 in the drum above the opening 36. Preferably, the
height H of the liquid 22 in the drum 24 is from an effective
location 28C to the surface of the liquid 22 in the drum 24. While
the effective location 28C of the embodiment disclosed in FIG. 17
is located at a maximum height of the opening 36 with respect to
the bottom of the drum 40A, those of ordinary skill in the art will
appreciate that the effective location 28C may be at a different
location and may be changed due to a change of the angle of the
portion 28D of the tube 26 with respect to a vertical sidewall 24A
and/or the shape of the opening 36 without departing from the scope
of the present invention. The processor 34 may use the height H of
liquid 22 in the drum 24 along with the dimensions of the drum 24
to determine an initial volume of liquid in the drum above the
opening 36. Preferably, the processor 34 takes into account the
initial liquid height ILH, which is the vertical distance between
the effective height 28C and the bottom of the drum 40A in order to
calculate a finial height of the liquid 22 in the drum 24 that can
be used to calculate the total volume of liquid 22 in the drum 24.
Alternatively, the processor 34 may determine, or the information
be inputted, the volume of liquid 22 below the effective height
28C, and, add this volume to the initial volume in the drum 24 to
calculate the total volume of liquid 22 in the drum 24. Preferably,
the processor 34 is configured to determine the volume of liquid in
the tube to further determine a final volume of liquid by adding
the volume of liquid in the tube to the total volume of liquid in
the drum.
[0069] The drum 24 may be located on a stand 24B to give the drum
more stability, especially if the drum 24 does not have a flat
bottom 40A. The drum 24 may have a hose 48 connected to the bottom
of the drum 24 that may pass through the stand 24B. However, those
of ordinary skill in the art will appreciate that the hose 48 may
be located at any point on the drum 24 without departing from the
scope of the present invention. The hose 48 may be connected to a
pump 54 and configured to withdrawal liquid 22 from the drum 24.
However, more sophisticated systems, such as some advanced hoofbath
systems, may operate without any pump 54 or electronics and instead
operate based on fluid pressures and vacuums in a generally closed
circuit type of arrangement. This type of advanced hoofbath system
is detailed in U.S. Pat. No. 8,347,821 which is hereby incorporated
by reference in its entirety as if fully set forth herein.
[0070] Preferred implementations of preferred methods of the
present invention will be described below (alone or in combination
with various embodiments of the sensor apparatus 20). The steps of
the method of the present invention can be performed in any order,
omitted, or combined without departing from the scope of the
present invention. As such, optional or required steps described in
conjunction with one implementation of the method can also be used
with another implementation or omitted altogether. Additionally,
unless otherwise stated, similar structure or functions described
in conjunction with the below method preferably, but not
necessarily, operate in a generally similar manner to that
described elsewhere in this application.
[0071] Referring to FIGS. 8-10, one method according to the present
invention is directed to a method of providing a system for
measuring a depth of a liquid 22 in a drum 24. The method
preferably includes providing a first sensor 32A configured to be
located in fluid communication with an inside of the drum 24. The
first sensor 32A preferably is an air pressure sensor that
generates a first signal corresponding to the pressure of the
liquid 22 at a bottom of the drum 24. The method preferably
includes the step of providing a second sensor 32B that is
configured to be in fluid communication with ambient atmosphere
outside of the drum 24. Wherein the second sensor 32B may be an air
pressure sensor that generates a second signal corresponding to
ambient pressure outside the drum 24. The method may include the
step of providing a tube 26 having a first end and a second end
28A, 28B, wherein the second end 28B is configured for placement
within the liquid 22. The tube 26 may include a seal 30 positioned
in the tube 26 and spaced from the second end 28B, wherein the
first sensor 32A is configured to be located between the seal 30
and the second end 28B. The method may include the step of
configuring the second sensor 32B to be located at any one of on
the first end 28A of the tube 26, between the seal 30 and the first
end, in a compartment attached to the tube 26, and spaced from the
system. The method may include the step of providing an opening 36
located in the second end 28B of the tube 26 and configured to let
the liquid 22 in the drum 24 partially fill the tube 26 between the
second end 28B and the seal 30. The method may include the step of
providing a shield 38 configured to be located between the second
end 28B and the seal 30, wherein the is preferably configured to
form a barrier between the first sensor 32A and an inner surface of
the tube 26 such that a drop of the liquid 22 is less likely to
flow down the inner surface of the tube 26 and contact the first
sensor 32A. The method may further comprise an outer tube 44 having
third and fourth ends 46A, 46B disposed over the tube 26 and
configured to withdraw the liquid 22 from the drum 24 when the
system is inserted into a hole 42 in a top 40 of the drum 24. The
third end 46A of the outer tube 44 may be sealed to the tube 26 at
a location on the tube 26 spaced from the second end 28B. The
method may include a container 50 positioned on the first end 28A
of the tube 26, wherein, the container 50 houses the second sensor
32B therein and forms a second seal 62 between the outer tube 44
and the tube 26, and, the third end 46A of the outer tube 44 and
the atmosphere. The method may comprise placing at least one device
68 within the fourth end 46B such that the at least one device 68
preferably is designed to prevent the liquid 22 in the outer tube
44 from exiting the system between the tube 26 and the outer tube
44 via the fourth end 46B when the sensor apparatus 20 is withdrawn
from the liquid 22 in the drum 24. Preferably, the at least one
device 68 is configured to allow the liquid 22 to enter the outer
tube 44 through the fourth end 46B. The method may comprise of
configuring at least a portion of the tube 26 to protrude from the
fourth end 46B of the outer tube 44 so that withdrawal of the
liquid 22 from the drum 24 via the outer tube 44 does not create
suction that seals the outer tube 44 to a bottom of the drum 24.
The method preferably includes the step of providing a at least one
software module stored on a non-transitory computer readable
storage medium, the software module being configured such that when
operating on a processor 34, the processor 34 is configured to
automatically determine the depth of the liquid 22 in the drum 24
based on at least one of the first signal and the second signal.
The module may be provided via dvd, on a processor, or via
electronic download or the like. The method may provide the step of
providing a processor 34 including the at least one software module
thereon, wherein the processor 34 is configured to automatically
determine at least the depth of the liquid 22 in the drum 24 based
on at least one of the first signal and the second signal. The
provided processor may be that already owned by a user of the
invention. This would enable a first sensor to be properly
positioned in the drum and have electronic signals transferred to a
computer on which the requisite software module is downloaded
without departing from the scope of the present invention.
[0072] Referring to FIG. 18, a view of the graphic user interface
(GUI) 200 of the processor 34 is shown. The GUI 200 may be located
on the processor 34 or may be accessible online or by the use of an
electronic device. The GUI 200 preferably has the name of the dairy
farm 202, or other business, at the top. Under the name 202, the
GUI 200 may have the current date 204 and the current time 206.
Below the date and time 204, 206, the GUI 200 may have pictures of
drums 208 showing the depth of the liquid 210 in the drum 208.
Underneath the pictures of the drums 208, the GUI 200 preferably
lists the type of liquid 212 in each drum, the volume of the liquid
214 in the drum, the pump status 216, and the weeks until pump
failure 222. The GUI 200 may indicate that the pump has not reached
its minimum volume threshold level for a wash by showing an "X" 220
next to pump status 216. If the pump has met the minimum volume
threshold, the GUI 200 may indicate the pump is okay by showing a
checkmark 218 next to pump status 216. To the left of the pictures
of the drums 208, the GUI 200 may have a contact dealer 224 button
and a contact service provider button 226 that, when pressed,
automatically contact the dealer and service provider,
respectively, either by a call, text, email, or the like. The GUI
200 may also have a contacts button 228 that allows a user to view
and contact all stored contacts. At the bottom of the GUI 200 may
be a bunch of buttons such as buttons that may allow a user to view
valve status 230, view current alerts 236, view wash history 230,
view alert and reply history 238, maintenance log 240, and a button
to stop wash immediately 234. However those of ordinary skill in
the art will recognize that the GUI 200 may include any suitable
data, information, artwork, phrases, numbers, words, letters, or
the like, in any arrangement without departing from the scope of
the invention.
[0073] The method may include the step of configuring the processor
34 to receive a plurality of inputs representing at least one of a
dimension of the drum 24, a dimension of the sensor apparatus 20,
and a specific gravity of the liquid 22 for use in computing a
volume of the liquid 22 in the drum 24. The method may include the
step of configuring the processor 34 to subtract the ambient
pressure outside the drum 24 from the pressure of the liquid 22 at
a bottom of the drum 24. The method may include the step of
configuring the processor 34 such that the plurality of inputs may
be entered via a remote electronic device. The method may include
the step of configuring the processor 34 to automatically determine
the depth of the liquid 22 in the drum 24 according to:
H=(P.sub.b-P.sub.a)/(PPIC*SG.sub.liquid), wherein P.sub.b is the
pressure in the drum 24 at the opening 36 of the tube 26 as
measured by the first sensor 32A, P.sub.a is the atmospheric
pressure outside the drum 24 as measured by the second sensor 32B,
SG.sub.liquid is the specific gravity of the liquid inside the drum
24, H is the depth, or height, of the liquid inside the drum 24 and
above the opening 36, PPIC is determined by
((H-TUBE.sub.liquidinches)*249.17)/H), where TUBE.sub.liquidinches
is the height of liquid in the tube above the opening 36, and
249.17 is the standard pressure exerted by a one inch column of
water. The method may include the step of configuring the processor
34 to automatically determining the volume of the liquid in the
drum 24 and taking into account any adjustment needed due to the
presence of the tube 26 therein by using the depth of the liquid in
the drum 24 and dimensions of the drum 24 to determine an initial
volume of liquid 22 in the drum 24, then the processor 34
automatically adjusts the initial volume of liquid 22 in the drum
24 to get a final volume of liquid 22 in the drum 24 that takes
into account the tube 26, according to:
Vdrum-final=Vdrum-initial-((H-Dliquid-in-sensor)*A), wherein H is
the depth of liquid in the drum 24; Vdrum-final is the final volume
of liquid in the drum 24; Vdrum-initial is the initial volume of
liquid in the drum 24; A is a cross sectional area of the tube 26;
Dliquid-in-sensor is the depth of the liquid in the tube 26
determined as follows:
Dliquid-in-sensor=(L-(((Pi*Vi/Ti)*(Tf/Pf))/A)), wherein L is a
length of the tube 26; Pi is the initial pressure in the tube 26
prior to insertion of the tube 26 in the liquid; Vi is the initial
volume of the tube 26 that is calculated by the dimensions of the
tube 26; Ti is the initial temperature of air in the tube 26; Pf is
a pressure in the tube 26 when the tube 26 is submerged in the
liquid as calculated by the first sensor 32A; and Tf is the final
temperature of the air inside the tube 26 when the tube 26 is
submerged. Those of ordinary skill in the art will recognize that
the above formulas may be modified, or other formulas used in
replace, without departing from the scope of the invention. The
method may include the step of configuring the processor 34 to
collect a plurality of usage data comprising at least one of a
time, a temperature of liquid, and a volume of liquid withdrawn
from the drum 24. The method may include the step of configuring
the processor 34 to compare the plurality of usage data against a
plurality of predetermined data and issue an alert when a
discrepancy occurs. Although the first and second sensors are
preferably air pressure sensors, one ordinary skill in the art will
appreciate from this disclosure that any other suitable sensor may
be used without departing from the scope of the present
invention.
[0074] Referring to FIGS. 11-13, one method according to the
present invention is directed to a method for measuring a depth of
a liquid 22 in a drum 24 used as part of a system for use in at
least one of agricultural, equipment cleaning, and animal
husbandry. The method preferably includes providing the drum 24
configured to contain the liquid 22 used in the system. Preferably,
the drum 24 is cylindrically shaped, however, the drum 24 may be of
any shape or dimensions without departing from the scope of the
invention. The method preferably includes providing a first sensor
32A located in fluid communication with an inside of the drum 24,
the first sensor 32A being an air pressure sensor generating a
first signal corresponding to the pressure of the liquid 22 at a
bottom of the drum 24. Those of ordinary skill in the art will
recognize that the first sensor 32A may generate a first signal
corresponding to the pressure of the liquid 22 at any predetermined
or known distance from the bottom of the drum 24 without departing
from the scope of the invention. The method preferable includes
providing a second sensor 32B in fluid communication with ambient
atmosphere outside of the drum 24, the second sensor 32B being an
air pressure sensor generating a second signal corresponding to
ambient pressure outside the drum 24. Those of ordinary skill in
the art will appreciate from this disclosure that any type of
sensor can or other suitable device can be used as the first or
second sensor without departing from the scope of the present
invention. Similarly, the second sensor can be omitted entirely
without departing from the scope of the present invention.
Alternatively, the second sensor 32B may be in fluid communication
with air inside the drum 24. As previously discussed, the second
sensor 32B may be provided in order to obtain more accurate
calculations of the depth of the liquid 22 in the drum 24 by
accounting for changes in pressure due to changes the atmospheric
pressure or by wind gusts, etc. As such, those of ordinary skill in
the art will recognize that the method does not need to provide a
second sensor or second signal. The method may include the step of
providing a tube 26 having a first end and a second end 28A, 28B,
wherein the second end 28B may be configured for placement within
the liquid 22. The method may include an outer tube 44 having third
and fourth ends 46A, 46B disposed over the tube 26, wherein the
outer tube 44 is configured to withdraw the liquid 22 from the drum
24 when the tube 26 is inserted into a hole 42 in a top 40 of the
drum 24. The method preferably includes the step of determining the
depth of the liquid 22 in the drum 24 based on at least one of the
first signal and the second signal. This step may further comprise
of providing at least one software module stored on a
non-transitory computer readable storage medium, the software
module being configured such that when operating on a processor 34,
the processor 34 is configured to automatically determine the depth
of the liquid 22 in the drum 24 based on at least one of the first
signal and the second signal. The method may include the step of
providing a processor 34 including the at least one software module
thereon, wherein the processor 34 automatically determines the
depth of the liquid 22 in the drum 24 based on at least one of the
first signal and the second signal. This step may further include
the processor 34 being configured to receive a plurality of inputs
representing at least one of a dimension of the drum 24, a
dimension of the sensor apparatus 20, and a specific gravity of the
liquid 22 for use in computing a volume of the liquid 22 in the
drum 24. This step may further include the processor 34 being
configured to subtract the ambient pressure outside the drum 24
from the pressure of the liquid 22 at a bottom of the drum 24. This
step may further include the processor 34 being configured for
entry of the plurality of inputs via a remote electronic device.
This step may further include the processor 34 being configured to
automatically determine the depth of the liquid 22 in the drum 24
according to: H=(P.sub.b-P.sub.a)/(PPIC*SG.sub.liquid), wherein
P.sub.b is the pressure in the drum 24 at the opening 36 of the
tube 26 as measured by the first sensor 32A, P.sub.a is the
atmospheric pressure outside the drum 24 as measured by the second
sensor 32B, SG.sub.liquid is the specific gravity of the liquid
inside the drum 24, H is the depth, or height, of the liquid inside
the drum 24 and above the opening 36, PPIC is determined by
((H-TUBE.sub.liquidinches)*249.17)/H), where TUBE.sub.liquidinches
is the height of liquid in the tube above the opening 36, and
249.17 is the standard pressure exerted by a one inch column of
water. This step may further include the processor 34 automatically
determining a volume of the liquid in the drum 24 and taking into
account any adjustment needed due to the presence of the tube 26
therein by using the depth of the liquid in the drum 24 and
dimensions of the drum 24 to determine an initial volume of liquid
in the drum 24, then the processor 34 automatically adjusts the
initial volume of liquid in the drum 24 to get a final volume of
liquid in the drum 24 that takes into account the tube 26,
according to: Vdrum-final=Vdrum-initial-((H-Dliquid-in-sensor)*A),
wherein H is the depth of liquid in the drum; Vdrum-final is the
final volume of liquid in the drum; Vdrum-initial is the initial
volume of liquid in the drum 24; A is a cross sectional area of the
tube 26; Dliquid-in-sensor is the depth of the liquid in the tube
26 determined as follows:
Dliquid-in-sensor=(L-(((Pi*Vi/Ti)*(Tf/Pf))/A)), wherein L is a
length of the tube 26; Pi is the initial pressure in the tube 26
prior to insertion of the tube 26 in the liquid; Vi is the initial
volume of the tube 26 that is calculated by the dimensions of the
tube 26; Ti is the initial temperature of air in the tube 26; Pf is
a pressure in the tube 26 when the tube 26 is submerged in the
liquid as calculated by the first sensor 32A; and Tf is the final
temperature of the air inside the tube 26 when the tube 26 is
submerged. This step may further include the processor 34 being
configured to collect a plurality of usage data comprising at least
one of a time, a temperature, and the volume of liquid 22 withdrawn
from the drum 24. This step may further include the processor 34
being configured to compare the plurality of usage data against a
plurality of predetermined data and issue an alert when a
discrepancy occurs. The step of providing the drum 24 may include
the system being a dairy wash system that is configured to use the
liquid 22 in the drum 24. The dairy wash system may perform a
predetermined number of washes, wherein the dairy wash system only
withdraws liquid 22 from the drum 24 during a wash. The step of
providing the processor 34 may also include the processor 34 being
configured to determine when the wash is taking place and when the
wash is completed by analyzing the first and second signals. The
step of providing the processor 34 may further include the
processor 34 being configured to determine a volume of liquid 22
used during the wash. The step of providing the processor 34 may
further include the processor 34 being configured to send an alert
if the volume of liquid 22 used during the wash is lower than a
predetermined volume, or, if the volume of liquid 22 in the drum 24
is below a predetermined minimum volume. A person of ordinary skill
in the art will recognize that a wash may use multiple liquids that
are in multiple drums. As such, each liquid, or drum, may include
the aforementioned method. A person of ordinary skill in the art
will recognize that at least one processor 34 may be used to
measure the depth of liquid and/or a volume of liquid 22 in each
drum simultaneously. A person of ordinary skill in the art will
further recognize that a wash may use multiple liquids at the same
time, or at different times, and the processor 34 may be configured
to determine whether a wash has occurred by analyzing at least one
of: a change in depth of at least one liquid, a change in volume of
at least one liquid, an order for which each of the liquids was
withdrawn, a time of withdrawal of at least one liquid, a duration
of withdrawal of at least one liquid, a temperature of at least one
liquid, etc.
[0075] Referring to FIGS. 14-16, one method according to the
present invention is directed to a method for providing a system
for measuring a depth of a liquid 22 in a drum 24. The method
preferably includes the step of providing a first sensor 32A
configured to be located in fluid communication with an inside of
the drum 24, wherein the first sensor 32A may be an air pressure
sensor that generates a first signal corresponding to the pressure
of the liquid 22 at a bottom of the drum 24. The method preferable
includes the step of providing a second sensor 32B configured to be
in fluid communication with ambient atmosphere outside of the drum
24, wherein the second sensor 32B may be an air pressure sensor
that generates a second signal corresponding to ambient pressure
outside the drum 24. The method may include the step of providing a
tube 26 having a first end and a second end 28A, 28B, wherein the
second end 28B may be configured for placement within the liquid
22. The step of providing the tube 26 may further include an outer
tube 44 having third and fourth ends 46A, 46B and configured to be
disposed over the tube 26, wherein the outer tube 44 may be
configured to withdraw the liquid 22 from the drum 24 when the
system is inserted into a hole 42 in a top 40 of the drum 24. The
method preferably includes the step of providing at least one
software module stored on a non-transitory computer readable
storage medium. The software module may be configured such that
when operating on a processor 34, the processor 34 is configured to
automatically determine the depth of the liquid 22 in the drum 24
based on at least one of the first signal and the second signal and
to automatically determine whether a liquid 22 withdrawal has
occurred or whether changes in the first signal represent a
non-withdrawal event. A withdrawal event is when liquid from the
drum is purposefully being withdrawn. A non withdrawal event can be
any event that changes pressure in the drum, but is not actually a
purposeful liquid withdrawal, such as a jostling of the drum,
knocking of the sensor apparatus, a strong wind, sudden change in
temperature from hail or other weather, or the like.
[0076] The method may comprise the step of providing a processor 34
that includes the at least one software module thereon, wherein the
processor 34 receives the first and second signals and
automatically determines the depth of the liquid 22 in the drum 24
and automatically determines whether a liquid 22 withdrawal has
occurred or whether changes in the first signal represent a
non-withdrawal event. This step may further include the processor
34 being configured to receive a plurality of inputs representing
at least one of a dimension of the drum 24, a dimension of the
sensor apparatus 20, and a specific gravity of the liquid 22 for
use in computing a volume of the liquid 22 in the drum 24. This
step may further include the processor 34 being configured to
subtract the ambient pressure outside the drum 24 from the pressure
of the liquid 22 at a bottom of the drum 24. This step may further
include the processor 34 being configured for entry of the
plurality of inputs via a remote electronic device. This step may
further include the processor 34 being configured to automatically
determine the depth of the liquid 22 in the drum 24 according to:
H=(P.sub.b-P.sub.a)/(PPIC*SG.sub.liquid), wherein P.sub.b is the
pressure in the drum 24 at the opening 36 of the tube 26 as
measured by the first sensor 32A, P.sub.a is the atmospheric
pressure outside the drum 24 as measured by the second sensor 32B,
SG.sub.liquid is the specific gravity of the liquid inside the drum
24, H is the depth, or height, of the liquid inside the drum 24 and
above the opening 36, PPIC is determined by
((H-TUBE.sub.liquidinches)*249.17)/H), where TUBE.sub.liquidinches
is the height of liquid in the tube above the opening 36, and
249.17 is the standard pressure exerted by a one inch column of
water. This step may further include the processor 34 automatically
determining a volume of the liquid 22 in the drum 24 and taking
into account any adjustment needed due to the presence of the tube
26 therein by using the depth of the liquid 22 in the drum 24 and
dimensions of the drum 24 to determine an initial volume of liquid
22 in the drum 24, then the processor 34 automatically adjusts the
initial volume of liquid 22 in the drum 24 to get a final volume of
liquid 22 in the drum 24 that takes into account the tube 26,
according to: Vdrum-final=Vdrum-initial-((H-Dliquid-in-sensor)*A),
wherein H is the depth of liquid 22 in the drum 24; Vdrum-final is
the final volume of liquid 22 in the drum; Vdrum-initial is the
initial volume of liquid 22 in the drum; A is a cross sectional
area of the tube 26; Dliquid-in-sensor is the depth of the liquid
in the tube 26 determined as follows:
Dliquid-in-sensor=(L-(((Pi*Vi/Ti)*(Tf/Pf))/A)), wherein L is a
length of the tube 26; Pi is the initial pressure in the tube 26
prior to insertion of the tube 26 in the liquid; Vi is the initial
volume of the tube 26 that is calculated by the dimensions of the
tube 26; Ti is the initial temperature of air in the tube 26; Pf is
a pressure in the tube 26 when the tube 26 is submerged in the
liquid 22 as calculated by the first sensor 32A; and Tf is the
final temperature of the air inside the tube 26 when the tube 26 is
submerged. This step may further include the processor 34 being
configured to collect a plurality of usage data comprising at least
one of a time, a temperature, and the volume of liquid 22 withdrawn
from the drum 24.
[0077] The step of determining whether the liquid 22 withdrawal has
occurred may further include the first sensor 32A generating the
first signal at a predetermined interval and the second sensor 32B
generating the second signal at the predetermined interval. The
step of providing the processor 34 may include the processor 34
being configured to store a plurality of readings, wherein the
plurality of readings may be any one of the first signal and the
first signal minus the second signal. Said another way, the
plurality of readings may be any one of a pressure of the liquid 22
at a certain depth, or, a pressure of the liquid 22 at a certain
depth minus the pressure of the air outside or inside the drum 24.
The step of providing the processor 34 may include the processor 34
being configured to compile a report, wherein the report may be an
average of the plurality of readings over a predetermined time. For
example, if the first and second sensors 32A, 32B generate first
and second signals every second, and, a report was compiled by the
processor 34 every minute, then, the report would be the average of
sixty readings. The step of providing the processor 34 may further
include the processor 34 being configured to store at least two of
the reports. Preferably, the processor 34 stores the newest at
least two reports compiled. More preferably, the processor 34
stores the newest at least three reports compiled. More preferably
still, the processor 34 stores the newest at least five reports
compiled. The step of providing the processor 34 may further
include the processor 34 being configured to determine a pressure
difference between at least two of the reports. The step of
providing the processor 34 may further include the processor 34
being configured to recognize the liquid withdrawal when the
pressure difference between at least two of the reports is greater
than a predetermined pressure. The step of providing the processor
34 may further include the processor 34 being configured to
determine a total pressure difference when the liquid withdrawal
has ended between the pressure of the liquid 22 at the bottom of
the drum 24 before the liquid withdrawal started and the pressure
of the liquid 22 at the bottom of the drum 24 after the liquid
withdrawal ended. The step of providing the processor 34 may
further include the processor 34 being configured to determine a
volume of the liquid withdrawn in the liquid withdrawal by
analyzing the total pressure difference.
[0078] A preferred method of determining whether a liquid
withdrawal has occurred or whether changes in the first signal
represent a non-withdrawal event operates as follows. The preferred
method is not limiting, but is solely meant to provide an example.
The liquid 22 in a drum 24 may be used for the purpose of washing
dairy equipment. Preferably, the washing cycle for the dairy
equipment withdrawals liquid 22 from the drum 24 for a
predetermined amount of time. The first and second sensors 32A, 32B
may generate first and second signals, respectively, every 512
milliseconds. Preferably, but not necessarily, the processor 34
stores a plurality of readings wherein each reading is the pressure
at the bottom of the drum 24 as measured by the first sensor 32A
and carried in the first signal minus the pressure of ambient air
outside the drum 24 as measured by the second sensor 32B and
carried in the second signal. Preferably, but not necessarily, the
processor 34 compiles a report that averages a plurality of
readings over a time period that is equal to or greater than the
predetermined amount of time the washing cycle withdrawals liquid
22 from the drum 24. More preferably, the processor 34 compiles a
report that averages a plurality of readings over a time period
that is equal to the predetermined amount of time the washing cycle
withdrawals liquid 22 from the drum 24. Preferably, but not
required, the processor 34 stores the five newest reports compiled.
For simplicity, assume that the reports are numbered 1-5 where 1 is
the newest report compiled and 5 is the 5.sup.th newest report
compiled such that as soon as a report is compiled it becomes
number one and the other reports move down a number as follows: 1
becomes 2, 2 becomes 3, 3 becomes 4, 4 becomes 5, and 5 gets
deleted. Since the length of time the washing cycle withdrawals
liquid 22 is preferably equal to the length of time to generate a
new report, a withdrawal by the washing cycle may only occur during
a single report or two consecutive reports. Said another way, if a
liquid withdrawal started at some point within the readings
averaged by the third report, the liquid withdrawal would have
ended at some point within the readings averaged by the second
report. Preferably, the processor 34 compares the average pressures
taken in the fifth report and the third report. Preferably, if the
average pressure taken in the fifth report minus the average
pressure taken in the third report is greater than twenty Pascal's,
the processor 34 determines a withdrawal has taken place.
Preferably, the processor 34 uses the average pressure taken in the
first report as the post-withdrawal pressure at the bottom of the
drum 24 after determining a liquid withdrawal has taken place.
Preferably, the processor 34 determines the pressure drop caused by
a liquid withdrawal by taking the fifth report minus the first
report instantaneously after the processor 34 determines a
withdrawal has occurred. The processor 34 may use the pressure drop
to determine the depth of liquid 22 used in the liquid withdrawal
and/or to determine the volume of liquid 22 used in the washing
cycle. Preferably, if the volume of liquid 22 used in the washing
cycle is lower than a predetermined volume, the processor 34 is
configured to send an alert. Preferably, the alert re-sends after a
pre-determined amount of time in perpetuity until an
acknowledgement, such as a text reply, is received by the
processor. However, the acknowledgment may be any other suitable
acknowledgment of the alert without departing from the scope of the
invention.
[0079] Referring to FIGS. 1, 3, 4, 7A, and 7B, one embodiment of at
least one sensor apparatus 20 for use in a dairy wash system
operates as follows. Preferably, but not necessarily, the dairy
wash system includes a washing cycle for dairy equipment.
Preferably, the washing cycle commences after milking of cows.
Preferably, the washing cycle withdrawals three different kinds of
liquids that are located in separate drums. The liquids are
preferably withdrawn by hoses 48 attached to pumps 54. The hoses 48
may have a temperature sensor thereon to measure the temperature of
liquid 22 flowing through the hose 48. However, the washing cycle
may withdrawal any number of liquids from any number of drums
without departing from the scope of the invention. Preferably, the
three liquids used are a detergent, an acid, and a sanitizer.
Preferably, each of the liquids are in their own drum, wherein each
drum 24 includes a sensor apparatus 20 therein. Preferably, the
first and second sensors 32A, 32B in each sensor apparatus 20 are
electronically connected to a single processor 34. However, any
number of processors may be used without departing from the scope
of the invention. Preferably, the processor 34 is configured for
entry of a plurality of inputs via a text from a cell phone.
However, those of ordinary skill in the art will appreciate that
the plurality of inputs may be entered via any electronic device.
Preferably, the plurality of inputs the processor 34 is configured
to receive is at least one of: number of liquids used in washing
cycle, order in which the liquids are to be withdrawn from their
respective drums during the washing cycle wherein at least two
liquids may be programmed to be withdrawn at the same time, the
specific gravities of the liquids used, the number of washing
cycles expected per day, the number of seconds each pump 54 is
configured to withdrawal each liquid 22 out of their respective
drums, phone numbers to send a text message alert to, and the dairy
name.
[0080] Preferably, as seen in FIGS. 7A and 7B, the processor 34 is
further configured to determine when a washing cycle has begun and
ended. Referring to FIG. 7A, the processor 34 is preferably
configured to determine when a washing cycle has started and ended
by first determining if the temperature recorded by a temperature
sensor on a milk line has risen a predetermined number of degrees
in a predetermined time period 104, therefore, meaning that the
milking of cows is over. If the processor 34 has determined that
the temperature of the milk line has risen a predetermined number
of degrees within a predetermined time period 104, the processor 34
is preferably configured to start storing readings 108 of the
pressure measured by the first sensor 32A minus the pressure
measured by the second sensor 32B for each of the sensor
apparatus's. Preferably, the processor 34 is further configured to
start compiling reports 118 for each sensor apparatus 20, wherein,
preferably, the length of time the processor 34 takes to compile a
new report for any given sensor apparatus 20 is the same amount of
time the liquid 22 the sensor apparatus 20 is placed in is
programmed to be withdrawn from the drum 24 during a wash cycle.
Preferably, the processor 34 is configured to store the newest of
at least two reports for every liquid 22 used in the washing cycle.
More preferably, the processor 34 is configured to store the newest
of at least three reports for every liquid 22 used in the washing
cycle. More preferably still, the processor 34 is configured to
store the newest five reports for every liquid 22 used in the
washing cycle.
[0081] Still referring to FIG. 7A, preferably, the processor 34 is
further configured to analyze 120 the stored reports for each
liquid 22. Preferably, the processor 34 determines whether a liquid
withdrawal has started 122 in any of the liquids used in the
washing cycle. Specifically, the processor 34 preferably determines
whether there is greater than a twenty Pascal pressure difference
in the fifth newest report and first newest report and, whether
there is less than a twenty Pascal pressure difference between the
fifth newest report and the third newest report for all liquids
used. If so, the processor 34 is preferably configured to determine
that a withdrawal of the respective liquid has just started 124. If
not, the processor 34 preferably starts the determination again
when a new report is compiled. Preferably, the processor 34 is
configured to determine a wash cycle has begun 128 when the
processor 34 determines that a withdrawal has started on any of the
liquids. Preferably, the processor 34 records the time the
processor 34 determines a washing cycle has started, and, the
number of washing cycles performed each day 128.
[0082] After a liquid withdrawal has occurred for any of the
liquids, the processor 34 preferably is configured to determine
when the liquid withdrawal has ended 132 by determining whether the
pressure difference between the fifth newest report and the third
newest report is greater than twenty Pascal's. If so the processor
34 is configured to determine that the liquid withdrawal for that
particular liquid has ended. After determining a liquid withdrawal
for a particular liquid 22 has ended, the processor 34 is
preferably configured to immediately determine the pressure drop
134 of the liquid 22 at the bottom of the drum 24 by subtracting
the first newest report from the fifth newest report. Subsequently,
the processor 34 is preferably configured to determine the order
138 that each liquid's withdrawal ended. After the processor 34
determines that a withdrawal has started on at least one liquid,
the processor 34 may be configured to start a timer 130 such that
if the processor 34 fails to determine that the liquid withdrawal
has ended within a predetermined length of time, the processor 34
may reverse its determination that a withdrawal has taken
place.
[0083] After a liquid withdrawal for each liquid has ended, and,
the order in which the liquids were withdrawn has been determined,
the processor 34 is preferably configured to perform another check
142 to ensure a washing cycle, and liquid withdrawals, have indeed
taken place. The check 142 preferably includes the processor 34
configured to determine if at least four of following have
occurred: the processor 34 has determined a wash cycle has started;
the order in which the processor 34 determined the liquid
withdrawals occurred matches the order in which the liquids are to
be withdrawn that was entered into the processor 34; if the
pressure at the bottom of each drum 24 has dropped by thirty or
more Pascal's; if the temperature recorded by a temperature sensor
on the milk line has risen a predetermined number of degrees in a
predetermined time period; and if the temperature sensors on each
hose 48 are consistent with predetermined temperatures. If at least
four have occurred 144, the processor 34 is preferably configured
to confirm the washing cycle 156. Subsequently, the processor 34 is
preferably configured to send an alert 160 if any data collected by
the processor 34, such as temperature of the liquids flowing
through the hose 48, the time of a washing cycle, or a pressure
differential at the bottom of the drums after a liquid withdrawal
has occurred, is inconsistent with a plurality of predetermined
data. If less than four have occurred, the processor 34 preferably
reverses its determination that the washing cycle has started 148.
Subsequently, the processor 34 preferably begins analyzing 120 the
stored reports again. FIGS. 8, 9, 10A-10B, 11, 12, 13A-13B, 14, 15,
and 16A-16B illustrate alternative preferred methods for providing
a system for measuring a depth of a liquid in a drum.
[0084] Referring to FIG. 22, another preferred method of providing
a sensor apparatus for measuring a depth of a liquid in a drum
above an initial drum liquid height is provided. It is preferred
that the drum include a sidewall. The method preferably includes
the step of providing a tube having a first end and a second end.
The second end may be disposed on the sidewall of the drum such
that the tube and an inside of the drum are in fluid communication.
The second end is preferably located on the sidewall proximate the
initial drum liquid height.
[0085] The method may include the step of providing a seal
positioned in the tube and spaced from the second end. The method
may also include the step of providing a first sensor disposed in
the tube between the seal and the second end and configured to
measure air pressure in the tube. The method may further include
the step of providing a processor in electronic communication with
the first sensor, wherein the processor automatically determines
the depth of liquid in the tank not including the initial drum
liquid height.
[0086] Referring to FIG. 23, a sample GUI for a smart phone is
shown. However, those of ordinary skill in the art will recognize
that the smart phone can be a tablet, an internet website, or any
other electronic device without departing from the scope of the
invention. The name of the dairy farm 202 may be the contact name
in the smart phone. In addition to the processor 34 being
configured to send a text alert 256 if any data is inconsistent
with a plurality of predetermined data, the processor 34, as best
seen in FIG. 23, is further preferably configured to send a text
inquiry reply 254, such as the volume of liquid remaining in a
drum, when a text inquiry 252 is asked. However, those of ordinary
skill in the art will recognize that the inquiries may be made by
any other suitable way, such as voice communication or email,
without departing from the scope of the invention. Similarly,
inquiry replies by the processor need not be by text, but may be
made in any other suitable way without departing from the scope of
the invention. Supply companies that supply certain chemicals,
detergent, or other liquids to dairy farms, or other industries,
often find it hard to expand their business past a certain point
due the hassle of having to stop at each dairy farm when on a run
to fill up drums 24 of liquid 22. Allowing the suppliers to ask the
processor 34 the volume of liquids in drums on the dairy farms they
supply may allow the suppliers to skip dairy farms when on a supply
run if the dairy farm does not need their drums re-filled that day,
thereby, allowing the suppliers to expand the number of customers
they may have.
[0087] It is common for pumps 54 to die or stop functioning after a
certain amount of time or use. Usually before a pump 54 stops
functioning, the pump gradually pumps lower and lower volumes of
liquid during a specific time interval. Therefore, it may be
advantageous to configure a processor 34 to determine and store the
volume of liquid each pump pumps during a specific time interval
and compare the results in order to predict when a pump 54 might
fail, or, when the pump 54 may not withdrawal the predetermined
minimum volume of liquid during a wash cycle. The processor 34
preferably is configured to store data comprising at least a volume
of liquid pumped during each wash cycle. This data, and other data,
may be stored on an SD slot card, or the like, and have a backup
system such as a battery backup. The processor 34 is preferably
further configured to compare the stored data of at least a volume
of liquid pumped during each wash cycle in order to create a pump
trend for each pump 54. The processor 34 may be configured to send
a text alert 256 if the volume of liquid pumped during a wash cycle
is lower than a predetermined volume. Further, the processor is
preferably configured to analyze the pump trend in order to
determine how long it will take before the pump 54 fails or cannot
meet the minimum volume threshold for a wash.
[0088] While various shapes, configurations, and features have been
described above and shown in the drawings for the various
embodiments of the present invention, those of ordinary skill in
the art will appreciate from this disclosure that any combination
of the above features can be used without departing from the scope
of the present invention. It is understood, therefore, that this
invention is not limited to the particular embodiments disclosed,
but is intended to cover all modifications which are within the
spirit and scope of the invention as defined by the appended claims
and/or shown in the attached drawings.
* * * * *