U.S. patent number RE34,776 [Application Number 07/721,685] was granted by the patent office on 1994-11-08 for programmable apparatus and method for delivering microingredient feed additives to animals by weight.
Invention is credited to William C. Pratt.
United States Patent |
RE34,776 |
Pratt |
November 8, 1994 |
Programmable apparatus and method for delivering microingredient
feed additives to animals by weight
Abstract
A method and apparatus whereby livestock and poultry are
administered feed additives in their feed ration. The apparatus
stores additive concentrates separately until just prior to use,
then on demand dispenses the additive concentrates into one or more
weigh hoppers for weighing therein. The weighed contents of the
weigh hoppers are discharged into a liquid carrier within a mixing
vessel where the dispensed additives are diluted, suspended, and
dispersed by mixing. The resulting carrier-and-additive slurry is
pumped to a receiving station for mixing with a feed ration. The
weighing components are isolated from movements that would affect
additive weight determinations during the weighing process so that
accurate measurements of additive weights are obtained. Dispensing
and weighing of multiple additives within a single weigh hopper are
sequential. Each additive may be weighed and discharged from the
hopper individually or cumulatively with other additives. With
multiple weigh hoppers, dispensing, weighing and discharge of
additives from the different hoppers can occur simultaneously or
independently. A programmable control can program the apparatuses
for dispensing either entirely on a weight basis, partly on a
weight basis and partly on a metering basis, on a
weight-compensated metering basis, or entirely on a metering basis
if the weighing means malfunctions.
Inventors: |
Pratt; William C. (Canyon,
TX) |
Family
ID: |
27167840 |
Appl.
No.: |
07/721,685 |
Filed: |
June 26, 1991 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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833904 |
Feb 26, 1986 |
4733971 |
|
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Reissue of: |
137501 |
Dec 22, 1987 |
04815042 |
Mar 21, 1989 |
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Current U.S.
Class: |
366/141; 141/104;
141/83; 222/57; 366/152.2; 366/153.1; 366/154.2; 366/156.2;
366/168.1; 366/181.8; 366/320; 414/21; 414/294 |
Current CPC
Class: |
A01K
5/0216 (20130101); B01F 3/1221 (20130101); B01F
3/18 (20130101); B01F 5/265 (20130101); B01F
15/0201 (20130101); B01F 15/0234 (20130101); B01F
15/0445 (20130101); G01G 15/001 (20130101); G01G
19/24 (20130101); G01G 19/382 (20130101); G01G
23/06 (20130101); G05D 11/001 (20130101); G05D
11/134 (20130101); B01F 2003/125 (20130101); B01F
2215/0008 (20130101); Y10S 366/603 (20130101) |
Current International
Class: |
A01K
5/00 (20060101); A01K 5/02 (20060101); B01F
3/12 (20060101); B01F 15/04 (20060101); B01F
3/00 (20060101); B01F 3/18 (20060101); B01F
15/02 (20060101); B01F 5/00 (20060101); B01F
5/26 (20060101); G01G 23/06 (20060101); G01G
19/38 (20060101); G01G 19/00 (20060101); G01G
23/00 (20060101); G01G 15/00 (20060101); G01G
19/24 (20060101); G05D 11/00 (20060101); G05D
11/13 (20060101); B01F 015/04 () |
Field of
Search: |
;366/141,150,151,152,154,160,161,162,16,17,18,19,20,21
;111/57,77,58,59 ;364/502,567 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
"The Great Plains Chemical Co" Exhibit A (undated). .
"The Brewster Weigh Machine" Exhibit B, pp. 1-11 (undated). .
Feed Management Magazine vol. 36, No. 3 pp. 54-58, "Micro-Systems"
(Mar. 1985). .
"The Hough Microwang System", Brochure of Hoe Kenebec
International, West Hartford, Conn. (undated). .
"The Hickman Micro-System", 4-Page Brochure of Hickman's
Micro-System, Inc. of Gordo, Ala. (undated). .
"Automated Pre-Mixed System", 1-Page Advertisement of Agra Products
International, Inc. (undated). .
"All-Digital Loss-in-Weight Feeding", pp. 4-5 From a K-Tron
Corporation Publication (undated). .
"System Responsibility . . . From Bulk Storage to the Precision
Metering of Dry Materials", 5 pp., Acrison, Inc. (undated). .
"Prater Blue Streak Feed Processor, The Accurate One", 2-Page
Advertisement (undated). .
"Weight Weigh-Tronix's Revolutionary SFM-200 Radiation Master
Stationary Feed Mixer", 2-Page Advertisement (undated). .
Feed Management Magazine, vol. 37, No. 7, pp. 20, 22, 24,
"Micro-Ingredient Control"(Jul. 1986)..
|
Primary Examiner: Jenkins; Robert W.
Attorney, Agent or Firm: Klarquist, Sparkman, Campbell,
Leigh & Whinston
Parent Case Text
RELATED APPLICATIONS
This application is a continuation-in-part of my prior copending
application Ser. No. 833,904 filed Feb. 26, 1986, now U.S. Pat. No.
.[.4,733,471,.]. .Iadd.4,733,971 .Iaddend.and entitled
"Programmable Weight Sensitive Microingredient Feed Additive
Delivery System and Method. "
Claims
I claim: .[.1. An apparatus for measuring, dispensing, and
delivering microingredients in small but accurate proportions in a
liquid carrier slurry into a livestock or poultry feed ration
shortly before the delivery of said feed ration to the animals for
consumption, said apparatus comprising:
multiple storage means for storing separately a plurality of
different microingredient feed additive concentrates;
a plurality of separate dispensing means, one for each said storage
means, for dispensing separately and without intermingling additive
concentrates from said multiple storage means;
multiple weigh hopper means in additive-receiving relationship to
said plural dispensing means for receiving additives dispensed from
said multiple storage means by said plural dispensing means, each
said hopper means including hopper discharge means for discharging
additives therefrom;
a mixing vessel in additive-receiving relationship to said multiple
hopper means for receiving additive concentrates from said multiple
hopper means upon operation of said hopper discharge means and for
receiving liquid carrier from a remote source;
flow inducing means for inducing a flow of liquid within said
mixing vessel;
delivery means for delivering a slurry of liquid carrier and
additive concentrates from said mixing vessel to a receiving
station for mixing with a feed ration at a location remote from
said mixing vessel;
separate weigh means for each said weigh hopper means, said weigh
means being operable to determine predetermined weights of
additives received in said weigh hopper means delivered to said
weigh hopper means by said dispensing means when said predetermined
weight of additives have been added to said weigh hopper means..].
.[.2. An apparatus according to claim 1 wherein said dispensing
means and weigh means associated with each of the multiple weigh
hopper means are operable simultaneously such that different
additives can be dispensed from said storage means and weighed in
said multiple weigh hopper means simultaneously..]. .[.3. An
apparatus according to claim 2 wherein said discharge means for the
multiple weigh hopper means are operable simultaneously to
discharge the weighed additives from the multiple weigh hopper
means simultaneously into said mixing vessel..]. .[.4. An apparatus
according to claim 1 wherein said multiple weigh hopper means are
mounted on a common support frame means..]. .[.5. An apparatus
according to claim 4 including isolation means for isolating said
support frame means from external vibration inducing forces such
that accurate weight determinations can be made within said weigh
hopper means..]. .[.6. An apparatus according to claim 4 wherein
said weigh means for each said weigh hopper means comprises a load
cell means suspending said weigh hopper means from said support
frame..]. .[.7. An apparatus according to claim 6 including
isolation means isolating each said load cell means from said
support frame means such that the dispensing and weighing of
additives within each weigh hopper means is not affected by the
dispensing and weighing of additives within the other weigh hopper
means during the simultaneous dispensing and weighing of additives
within said multiple weigh hopper means..]. .[.8. Apparatus
according to claim 4 wherein the discharge means for each weigh
hopper means includes an electric motor means on said hopper means
and said weigh means includes load cell means mounting said weigh
hopper means including said electric motor means to said support
frame means..]. .[.9. Apparatus according to claim 8 including
isolator means mounting said load cell means to said support frame
means..]. .[.10. Apparatus according to claim 9 including panel
means enclosing said support frame means to isolate said support
frame means and its supported component from external
motion-inducing influences..]. .[.11. An apparatus according to
claim 1 wherein said dispensing means and weigh means associated
with a weigh hopper means are operable to dispense and weigh
multiple microingredients sequentially within each said weigh
hopper means..]. .[.12. An apparatus according to claim 11 wherein
said dispensing means and weigh means operable to sequentially
weigh multiple microingredients within each weigh hopper means are
operable simultaneously such that weighing of multiple
microingredients within different said weigh hopper means can occur
simultaneously..]. .[.13. An apparatus according to claim 1 wherein
the discharge means for each weigh hopper means is operable
independently of the discharge means for the other weigh hopper
means such that the multiple hopper means can be discharged
simultaneously or at different times..]. .[.14. An apparatus
according to claim 1 wherein said dispensing means and weigh means
for each weigh hopper means are operable to weigh multiple
microingredients within the associated weigh hopper means, and said
discharge means for each weigh hopper means is operable selectively
to either discharge each ingredient from its weigh hopper means
before the dispensing of the next microingredient into the same
said weigh hopper means or discharge only after an accumulation
predetermined weights of at least two microingredients within the
same said weigh hopper means..]. .[.15. Apparatus according to
claim 1 including programmable control means for controlling the
operation of said dispensing means, weigh means, flow-inducing
means and delivery means, said weigh means including a scale head
means operable to receive multiple weight readings within a given
time span, average said readings, and transmit said average to said
programmable control means within the same said time span and
thereby
dampen the effects of any erroneous weight readings..]. 16.
.[.Apparatus according to claim 1 including.]. .Iadd.An apparatus
for measuring, dispensing, and delivering microingredients in small
but accurate proportions in a liquid carrier slurry into a
livestock or poultry feed ration shortly before the delivery of
said feed ration to the animals for consumption, said apparatus
comprising:
multiple storage means for storing separately a plurality of
different microingredient feed additive concentrates;
a plurality of separate dispensing means, one for each said storage
means, for dispensing separately and without intermingling additive
concentrates from said multiple storage means;
multiple weigh hopper means in additive-receiving relationship to
said plural dispensing means for receiving additives dispensed from
said multiple storage means by said plural dispensing means, each
said hopper means including hopper discharge means for discharging
additives therefrom;
a mixing vessel in additive-receiving relationship to said multiple
hopper means for receiving additive concentrates from said multiple
hopper means upon operation of said hopper discharge means and for
receiving liquid carrier from a remote source;
flow inducing means for inducing a flow of liquid within said
mixing vessel;
delivery means for delivering a slurry of liquid carrier and
additive concentrates from said mixing vessel to a receiving
station for mixing with a feed ration at a location remote from
said mixing vessel;
separate weigh means for each said weigh hopper means, said weigh
means being operable to determine predetermined weights of
additives received in said weigh hopper means delivered to said
weigh hopper means by said dispensing means when said predetermined
weight of additives have been added to said weigh hopper means;
and .Iaddend.programmable control means for controlling the
operation of said dispensing, weigh and discharge means, said
programmable control means including program means for selectively
operating said dispensing means in conjunction with said weigh
means in a weigh mode or independently of said weigh means in a
metering mode to dispense said
microingredients by volume. 17. A method of dispensing and
delivering microingredient feed additives into a livestock feed
ration shortly before delivering the feed ration to the livestock
for consumption, comprising the steps:
storing separately multiple said additives in concentrate form,
including some said additives in solid particulate-concentrate form
and at least .[.one.]. .Iadd.some others .Iaddend.of said multiple
additives in liquid concentrate form;
dispensing predetermined amounts of selected said solid particulate
concentrates by weight into a liquid carrier .Iadd.within a mixing
vessel.Iaddend.;
dispensing predetermined amounts of selected said liquid additive
concentrates .Iadd.by volume .Iaddend.into .[.a.]. .Iadd.the
.Iaddend.liquid carrier .[.by volume.]. .Iadd.within the mixing
vessel.Iaddend.;
intermixing the .Iadd.dispensed .Iaddend.additive concentrates in
the liquid carrier .Iadd.within the mixing vessel.Iaddend.,
including both the solid particulate additive concentrates and the
liquid additive concentrates, to dilute, disperse, and suspend them
and form a liquid carrier-additive slurry .Iadd.within the mixing
vessel.Iaddend.;
.Iadd.after forming the slurry within the mixing vessel,
.Iaddend.directing the slurry to a receiving station while
maintaining the suspension and
dispersion of the additives until delivered into a.[.-.].feed
ration. 18. A method of dispensing and delivering microingredient
feed additives into a livestock feed ration shortly before
delivering the feed ration to the livestock for consumption,
comprising the steps:
storing separately multiple said additives in concentrate form;
dispensing predetermined amounts of selected said additive
concentrates into a liquid carrier with no substantial intermixing
of the additive concentrates before they enter the liquid
carrier;
intermixing the additive concentrates in the liquid carrier to
dilute, disperse, and suspend them and form a liquid
carrier-additive slurry;
directing the slurry to a receiving station while maintaining the
suspension and dispersion of the additives until delivered into a
feed ration;
determining the predetermined amounts of the selected additives by
weighing at least some of the selected additive concentrates
dispensed within weighing container means;
before weighing said some of the selected additive concentrates
within the weighing container means, detecting an overweight or
underweight condition of the weighing container means and (a) if an
overweight condition of the weighing container means is detected
discharging the container means of any residual ingredients from a
preceding dispensing and delivering cycle, and (b) if an
underweight condition of the container means is detected, metering
the predetermined amounts of said some additive concentrates into
the weighing container means on a volumetric basis, and discharging
the predetermined amounts of said some concentrates from the
weighing container means into the liquid carrier.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the administering of feed
additives to livestock, and more particularly to a method and
apparatus for supplementing the diets of livestock and poultry with
feed additives such as nutrients and medicines supplied in a
consumptive fluent carrier such as water.
2. General Discussion of the Background
It has long been a common practice to feed additive supplements to
cattle and other livestock, including poultry. Such supplements
include vitamins, minerals, proteins, enzymes, hormones,
antibiotics, worm medicines, and other nutritional supplements and
medications, which provide a balanced diet, protect the livestock
from disease, and stimulate growth.
An early method of feeding additives to livestock involved the use
of commercially prepared additive premixes. The additives were
premixed together in dry form, with some dry diluting filler
material, and then stored at the feedlot for a period of time until
ready for use. The premix was either mixed with the feed ration
before delivery to the animals or spread on the feed at the feed
trough. Premixes suffer the drawbacks of being costly to buy, store
and administer. They are difficult to mix evenly with the feed, and
additives of different densities tend to segregate in premixes,
increasing the chances that specific animals will receive too much
or too little of a given additive. Too much of especially toxic
additives can have dangerous or even lethal consequences.
Additives also tend to lose their potency in premixes through
physical or chemical breakdown, especially if, stored for a long
period of time under changing environmental conditions in
combination with other additives. Therefore, there is no assurance
that livestock receive their intended dosages of specific additives
when the additives are administered in premixes.
Premixes also limit the choices of additive combinations that
livestock feeders can feed their animals to those combinations
available commercially. They also limit a feedlot's flexibility to
feed different groups of animals different combinations and dosages
of additives to meet their differing needs.
Many of the foregoing problems were solved by the methods and
apparatus of U.S. Pat. Nos. 3,437,075, 3,498,311; 3,822,056;
3,670,923; and 3,806,001, which are commonly assigned to the owner
of the present application. These patents disclose various methods
and apparatus for separately dispensing at the feedlot, separately
stored livestock feed additive concentrates into a flow of fluent
carrier material for dilution, dispersion and suspension, and for
transporting the resulting slurry into livestock drinking water or
feed rations shortly before the time of intended consumption. Each
of these methods and apparatus, however, meter the desired amount
of each feed additive on a volumetric basis. Volumetric metering
can be inaccurate because of changes in the densities of additive
concentrates caused by variations in humidity, particle size,
moisture content, flow characteristics, temperature, oil content
and other factors. Even minor inaccuracies in the amount of
additive concentrates dispensed can cause serious problems, since
some of the additives are very potent, toxic drugs. Typically, only
10 to 100 grams of a given additive concentrate are dispersed in a
ton of feed. Volumetric metering is only accurate to within 1-2%
even under the best of conditions.
Therefore, there is a need for a more accurate method and means for
dispensing additive concentrates in systems for delivering
additives into feed rations at the feedlot, just before the time of
intended consumption of the ration. One potentially more accurate
approach is to dispense additive concentrates by weight rather than
volume. It is believed that at least one weigh-type additive
concentrate delivery system has been tried, but unsuccessfully. It
is believed that such system weighed and then dispensed each
additive separately and sequentially. It is believed that such
system was unsuccessful because it was too slow and too inaccurate
for handling additive concentrates in a feedlot environment.
U.S. Pat. Nos. 2,893,602 and 3,595,328 disclose machines for
weighing batch amounts of aggregate mixtures such as asphalt. Each
of these machines uses a scale or strain gauge to measure the
amount of bulk material dispensed from a storage container. These
systems are only suitable, however, for making the gross kinds of
measurements needed in dispensing and mixing bulk materials such as
aggregates for making asphalt or concrete, and feed grains for
making feeds in commercial feed mills. The weighing components of
these machines, for example, are not able to weigh gram amounts of
materials as would be required for additive concentrate dispensing
in feedlots. Even if they were able to make such fine measurements,
their scales would be affected by environmental conditions commonly
found at feedlots such as wind and movement of machine components
that would adversely affect their accuracy to an unacceptable
extent. Finally, these devices would lose accuracy progressively
because of a buildup of residue of aggregate particles in their
weighing containers during use. They would therefore be unsuitable
for dispensing additive concentrates in a feedlot environment.
Accordingly, a primary object of the present invention is to
provide a new and improved method and means for dispensing and
delivering feed additive concentrates in various combinations and
dosages to livestock using primarily weight-controlled rather than
volumetric dispensing of additive concentrates.
Another primary object is to provide a new and improved method and
apparatus for dispensing and delivering combinations in feed
additive concentrates in a liquid slurry to a livestock feed ration
at feedlots which is more accurate than prior such methods and
apparatus.
Another object is to provide a method and apparatus as aforesaid
which can be operated selectively either on a weight or volumetric
basis.
Another object is to provide a method and apparatus as aforesaid
that can be used effectively in a feedlot environment.
Still another object is to provide such an apparatus and method
with an improved control system that can be controlled by a central
processing unit that can be quickly and conveniently programmed to
meet the varying needs of a given feedlot and different
feedlots.
Another object is to provide a method and apparatus that are
flexible in enabling the dispensing and weighing of two or more
additives either simultaneously or cumulatively, or both, and in
enabling the discharge of each weighed additive into a diluting
liquid carrier either individually before other additives are
weighed or together with other weighed additives.
Finally, it is a specific object of the invention to provide a
method and apparatus as aforesaid which can accurately dispense
gram amounts of potent microingredient additive concentrates to
accuracies within 0.5 grams.
SUMMARY OF THE INVENTION
The aforementioned objects are achieved by providing a method and
apparatus for measuring, dispensing, and delivering different
combinations and proportions of microingredient feed additive
concentrates on primarily a weight basis in small but accurate
amounts, into a liquid carrier. The carrier and concentrates form a
slurry which is delivered into a livestock or poultry feed ration
shortly before the feed ration is delivered to the animals for
consumption. The apparatus includes multiple dry and liquid
additive concentrate storage means for storing the various additive
concentrates separately at the foodlot. A plurality of separate
dispensing means, such as conveyor screws for the dry additives and
pumps for the liquid additives, dispense separately and without
intermingling the additive concentrates from each of the storage
means into a receiving means such as separate compartments of a
hopper or multiple weigh hoppers. Weighing means are provided for
determining the weights of the different additives dispensed and
for stopping the dispensing of each additive when a predetermined
weight of that additive has been dispensed. The weigh means, for
example, may comprise a weigh scale means supporting each weigh
hopper or supporting the storage means.
In a preferred embodiment shown and described, the weigh hopper is
scale-mounted, and the additives are dispensed and weighed
sequentially and cumulatively as they are added to the weigh
hopper. Isolating means isolate the weighing means from movements
affecting its weighing function so that accurate weight
determinations are obtained. A control means, such as a central
processing unit, controls separately the operation of each
dispensing means to dispense a given microingredient additive from
a given storage means until a predetermined weight of that
microingredient has been dispensed and weighed. When all selected
additive concentrates have been dispensed into the weigh hopper and
weighed, the hopper deposits its contents into a liquid carrier
within another portion of the receiving means comprising a mixing
vessel. The liquid carrier and additive concentrates are intermixed
in the mixing vessel to dilute, dispense and suspend the additives
in a liquid slurry. The slurry is then delivered to a receiving
station where it is either sprayed directly into and mixed with a
feed ration or held for subsequent addition to a feed ration.
The control means of the apparatus includes means for operating the
apparatus either in a weigh mode, or, for example, if the weigh
means is inoperative, in a volumetric dispensing mode.
The control means may include a programmable controller,
programmable to cause the apparatus to dispense microingredients
either entirely on a weight basis, partly on a weight basis and
partly on a volumetric (metering) basis, on a weight-compensated
metering basis, or entirely on a metering basis if, for example,
the weighing means malfunctions.
The isolation means may include a separate, independently mounted
and isolated weigh subframe assembly for the weighing components of
the apparatus. Within the subframe assembly, scale components may
be further isolated from other components. Further isolation may be
provided by an independent main frame surrounding the subframe and
protecting it from external forces by protective panels.
The weigh means may include multiple weigh hoppers, each for
weighing one or more different additives. Different additives may
be dispensed into the multiple weigh hoppers and weighed
simultaneously to speed up the makeup of a batch formulation of
additives. Where multiple additives are dispensed into each weigh
hopper, the hopper may be discharged after each additive is weighed
or only after all additives are weighed cumulatively.
Where multiple weigh hoppers are used, each includes its own
independent weighing means to enable weighing of multiple additives
to occur simultaneously. Each weighing means includes a scale head
that takes a weight reading many times per unit of time, averages
such readings, and then transmits the averaged reading to the
central processing unit only once during the same unit of time,
thereby minimizing the effects of any erroneous weight reading
induced by extraneous or other transient factors.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and advantages of the present invention
will become more apparent from the following detailed description
which proceeds with reference to the accompanying drawings
wherein:
FIG. 1 is a perspective view showing the major components of an
apparatus in accordance with the present invention.
FIG. 2 is a schematic perspective view illustrating the internal
components of the main cabinet shown in FIG. 1.
FIG. 3 is an enlarged, perspective view of a typical foot portion
and isolation pad of a support leg of the apparatus of FIG. 1.
FIG. 4 is an enlarged, front elevational view of the main cabinet
shown in FIG. 1, the cabinet panels having been removed to show the
internal parts of the machine.
FIG. 5 is an enlarged, perspective view of the weigh frame
subassembly of the apparatus shown in FIG. 4.
FIG. 6 is an enlarged, fragmentary, perspective view of a load cell
in a weigh tower of the weigh frame of FIG. 5, the remainder of the
weigh frame being broken away.
FIG. 7 is an enlarged, fragmentary perspective view of a portion of
the weigh hopper subassembly of the weigh frame shown in FIG.
5.
FIG. 8 is a fragmentary top perspective view of a dry additive
dispensing means portion of the apparatus of FIG. 4, shown mounted
on the main frame assembly of FIG. 4;
FIG. 9 is a fragmentary top perspective view of the mixing vessel
and associated components of the main frame assembly shown in FIG.
4;
FIG. 10 is a plumbing diagram for the fluid components of the
apparatus of the preceding figures;
FIG. 11 is a schematic view of the air flush system for the weigh
hopper portion of the apparatus;
FIG. 12 is a flow diagram illustrating the logic of a computer
program which controls the weigh means of the present
apparatus.
FIG. 13 is a flow diagram illustrating the logic of a computer
program which controls all machine operating sequences and
functions other than the weigh functions illustrated in FIG.
12.
FIG. 14 is an electrical control schematic diagram for the
illustrated apparatus.
FIG. 15 is a flow diagram illustrating the logic of a computer
program which controls alternative volumetric metering and
dispensing functions of the illustrated apparatus;
FIG. 16 is a schematic view illustrating a first alternative
embodiment of the invention in which microingredient additive
concentrates are dispensed directly into a mixing vessel from
individually weighed storage containers.
FIG. 17 is a schematic view illustrating a second alternative
embodiment of the invention in which dry additive concentrates are
dispensed by weight into a weigh hopper while liquid additive
concentrates are metered by volume directly into the mixing
vessel.
FIG. 18 is a schematic view showing a third alternative embodiment
of the invention in which different additive concentrates can be
dispensed into different weigh hoppers simultaneously and the
different weigh hoppers discharged either independently or
simultaneously and either after the weighing of each additive or
cumulatively after the cumulative weighing of multiple additives in
each hopper.
FIG. 19 is a flow diagram illustrating the logic of a modification
of the computer program of FIG. 15 which controls a hybrid
volumetric-weight system of measuring the amounts of
microingredients dispensed using apparatus of the general type
shown in FIG. 16.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Introduction
The microingredient feed additive concentrates of the present
invention include such potent substances as hormones, antibiotics,
and vitamins that are typically administered to cattle and poultry
at feeding operations, such as cattle feedlots, in gram amounts or
less. It is often essential that a prescribed amount of a
microingredient be delivered to an animal, and no more. Too little
of a microingredient has no effect, while too much of it may be
toxic or fatal. The range between too much or too little of some
additives is often no more than 0.5 gram. The apparatus and method
disclosed in this detailed description is intended to accurately
dispense dry and liquid additive concentrates within this range of
accuracy.
General Assembly
With reference to the drawings, FIG. 1 illustrates an apparatus
shown generally at 10 for measuring, dispensing, and delivering
microingredient feed additive concentrates in small but accurate
proportions in a liquid carrier slurry to livestock shortly before
delivery of the feed ration to the animals for consumption. The
apparatus 10 includes several separate components including a main
cabinet 11, and a remote control unit 20, shown for convenience
near cabinet 11 but normally located at a remote control station
such as at a feed truck filling station in a feedlot.Iadd..
.Iaddend.Additional separate components include multiple liquid
additive concentrate storage containers 76, 78 (only one being
shown in FIG. 1) supported on a stand 79, and their dispensing
pumps 79 (see FIG. 2). Typically, a separate water supply tank 195
(FIG. 14) supplies the necessary carrier and flush water to the
cabinet through fill and flush conduits (FIG. 10), via a booster
pump 193 (FIG. 14).
Another separate cabinet (not shown) houses a weigh micro computer,
or central processing unit, shown schematically at 424 in FIG. 14.
A second microcomputer, or central processing unit, shown
schematically at 430 in FIG. 14, for controlling the machine
sequencing and volumetric metering functions, is housed within one
end portion 13 of cabinet 11. Various speed controls and electrical
relay interfaces and circuitry of the control system shown in FIG.
14 are also housed within cabinet end portion 13. Such end portion
is a separate compartment of cabinet 11 that can be swung open
about a hinged vertical axis for access.
Cabinet 11 houses the major mechanical components of the apparatus.
The exterior of the cabinet, with its protective panels 12,
completely encloses and shields such components from external dust,
dirt and other contaminants common in a feedlot environment. The
panels also protect the internal components, especially the
weight-sensitive ones, from external forces such as wind, jarring
contact, and the like, that would otherwise affect the accuracy of
weight measurements.
Referring to FIG. 4 showing the major components inside the cabinet
11, such components include a main frame 46 and an entirely
separate and independently mounted subframe 34, each mounting
certain components. Access to the components mounted on these
frames is gained through access doors 15, 17, 19 in a front wall of
the cabinet 11, and through hinged lids 16, 18 on a top wall of the
cabinet.
In general, weigh subframe 34 mounted those components which are
necessary to the weighing function of the apparatus, and main frame
46 mounted the remaining components that could, during their
operation, induce undesirable movements in the weigh components to
adversely affect the weighing function. Accordingly, the weigh
subframe serves as a means for isolating the weigh components from
internal machine movements induced through operation of components
on the main frame.
The main frame components include storage bins 68, 70, 72, 74 for
storing different dry additive concentrates, dry additive
dispensing means 80 for dispensing additives from the storage bins,
and an additive-receiving means comprising a mixing vessel or tank
170. Other main frame-mounted components include a discharge pump
244 for pumping slurry from mixing vessel 170, slurry mixers 180,
and various plumbing components for supplying carrier and flush
water to the mixing vessel and discharging slurry liquid from the
vessel. Cabinet lids 16, 18 provide access to the storage bins for
refilling them.
The subframe 34 includes an entire subassembly of weigh components,
including a weigh hopper means comprising the compartmented weigh
hopper 122, and a suspension means for suspending the weigh hopper
from a weighing means 250. The suspension means includes a pair of
suspension frames 123, one at either end of the weigh hopper. Each
such frame rotatably supports weigh hopper 122. Each suspension
frame 123 includes a suspension arm 270 suspending the suspension
frame from the weigh means 250. The weigh means includes, at each
end of the subframe 34, a weigh tower 252 projecting upwardly from
the subframe and suspending therein a load cell 264. The load cell
in turn suspends the weigh hopper through an appropriate connection
to suspension arm 270 of suspension frame 123.
Remote control unit 20 includes a computer terminal 22 supported on
a stand 30 having a base plate 32. Terminal 22 includes a primary
keyboard 24, a primary display screen 26, a small, secondary
keyboard 27 and a small, secondary display screen 79. Various
control switches and indicators are provided on a control switch
box 28 mounted on a shelf 31 of the stand below the terminal
22.
Weigh Frame Subassembly
Apparatus 10 is seen therein and in FIG. 5 to comprise a weigh
frame 34 having four uprights 36 and two each of parallel
crossbeams 38, 40 and longitudinal beams 37, 39 rigidly
interconnecting the four uprights 36. A vertical slat 41, 43 is
carried between each pair of beams 37, 39. Each of uprights 36 has
an enlarged foot 42 to enhance the stability of weigh frame 34.
Each foot 42 is mounted on an elastomeric isolation pad 44 (FIG. 3)
which absorbs vibrations or other environmental influences that may
affect the accuracy of the functions performed by weigh frame 34.
Each pad 44 includes a square upper plate 45 to which foot 42 is
secured, the upper plate having a peripheral, downwardly depending
flange which forms an enclosure. A square lower plate 47 is
attached to a floor with bolts below plate 45 and has a peripheral,
upwardly extending flange that forms an enclosure. A rubber cushion
48 is placed between plates 45, 47 within the enclosures formed by
the flanges on the plates. Cushion 48 is thick enough to maintain
the upwardly and downwardly extending flanges in spaced
relationship so that vibrations are not communicated between plates
45, 57.
Main Frame Subassembly
Separate mounting or main frame 46 substantially surrounds weigh
frame 34, the mounting frame 46 comprising four uprights 49
interconnected by four top support beams 50 and four bottom support
beams 52. Two intermediate parallel support beams 51, 53 extend
across opposing parallel faces of frame 46, and two parallel
support beams 54, 55 extend across the middle of frame 46 parallel
to beams 51, 53. A pair of parallel, U-shaped brackets 56, 57 are
fixed to and suspend from beams 51, 54 (FIG. 8), and a pair of
similar U-shaped brackets are fixed to and suspend from beams 53,
55. Only one U-shaped bracket 59 is shown in FIG. 4, although it
will be understood that a second, parallel U-shaped bracket extends
between beams 53, 55 in an arrangement similar to that shown in
FIG. 8 for U-shaped brackets 56, 57.
Mounting frame 46 is supported by casters 58 each having a roller
60 that is received within a cup 62 that is attached to an
isolation pad 64 which is similar in structure to pad 44 shown in
FIG. 3. Pad 64 comprises a top plate 65 having a peripheral,
downwardly depending flange and a bottom plate 66 bolted to the
floor and having a peripheral, upwardly extending flange. A rubber
cushion 67 is positioned between plates 65, 66 within the
enclosures formed by their peripheral flanges, the width of cushion
67 being great enough to keep the peripheral flanges in spaced
relationship to one another and avoid metal to metal contact which
might transfer vibrations.
FIGS. 2 and 4 show multiple storage means such as dry additive
concentrate storage bins 68, 70, 72, and 74 for storing separately
a plurality of different dry microingredient feed additive
concentrates. Each of the bins has a square top opening and square
bottom opening, the bottom opening having a smaller area than the
top opening such that the cross-sectional area of each bin
diminishes in the direction of the bottom opening. A pair of
vibrator motors 75, 77 (FIG. 4) are placed on each bin 68-72 to
assist in moving dry microingredient concentrates out of the bins
during dispensing.
A plurality of liquid containers 76. 78 are also shown in FIG. 2
for storing separately different liquid microingredient feed
additive concentrates. The liquid containers are supported on a
table 79 (FIG. 1) adjacent cabinet 11 and connected to the
apparatus through flexible tubes described later.
A separate dry dispensing means 80 is provided for each dry bin
68-74. A separate liquid dispensing means 120 is provided for each
liquid container 76-78. Each liquid and dry dispensing means is
independently operated and controlled for dispensing separately
several selected additive concentrates from their respective bins
and liquid containers in predetermined weights during a machine
operating cycle.
One of the dry dispensing means 80 for a dry microingredient is
shown best in FIGS. 4 and 8. It includes an annular collar 82
having a square cross section. The collar fits closely about the
open bottom of a bin 68-74 and extends partially up its sidewalls.
Collar 82 has a square frusto-pyramidal configuration which defines
a flow passageway of progressively decreasing cross section from
the bottom bin opening to a top opening into a coreless metering
screw assembly 84 within a rectangular lower extension section 86
of collar 82 having a curved bottom. Screw assembly 84 includes a
rotatable core 88 which carries a helical metal screw 90 and
rectangular screw agitator 92 with a circular band 94 around one
end thereof. A stationary rear one-half tube extension 96 of a
conveyor tube 108 projects into the interior of agitator 92 to
start the conveyance of material that is moved by the screw 90 into
conveyor tube 108. Agitator 92 helps maintain a uniform
microingredient density around rotating screw 90.
Agitator 92 is rotated by a shaft 100 which is driven through a
right-angle gear box 104 by a variable-speed motor 102, with three
pre-set speeds. Core 88 and screw 90 project through opening 106
and into conveyor tube 108 having an open end that terminates
adjacent a deflection plate 110 above the top opening of weigh
hopper 122. Thus the metering screw assembly conveys additive from
the supply bin into a compartment of the weigh hopper.
Each of liquid containers 76, 78 is provided with a separate
dispensing means 120. Each liquid dispensing means is, for example,
a variable-speed or displacement rotary or piston pump 79 (FIG. 2).
The liquid dispensing means pumps liquid additive from a container
76, 78 through a flexible feed conduit which connects to a rigid
dispensing tube end 120 (FIG. 5) on the weigh subframe to deliver
the additive into a liquid compartment 117-118 of weigh hopper
122.
The hopper 122 (FIGS. 2, 4, 5, and 7) is carried by weigh subframe
34 between frame slats 41, 43 below the open end of extension tube
108 of screw conveyor 80. Hopper 122 is an elongated trough having
a substantially semicylindrical cross section and a plurality of
partitions 112 which divide the hopper transversely into several
dry microingredient receiving compartments 113, 114, 115, 116. Each
of the dry compartments 113-116 is provided with a deflector 132 on
its partition wall having a triangular cross section that directs
additive concentrates to the interior of the compartments during
both filling and emptying of the hopper.
Additional partitions 111 of hopper 122 cooperate with some
partitions 112 and upper walls 128 to define liquid
additive-receiving compartments 117, 118 having narrow openings 130
into which liquid dispensing tubes 120 direct liquid additives from
containers 76, 78.
The liquid and dry additive compartments of hopper 122 maintain
dispensed additives separated until the hopper discharges its
content, after weighing, into the diluting liquid carrier within
the mixing vessel 170 positioned vertically below the hopper.
Hopper 122 is supported by weigh frame 34 such that it is free to
rotate about its longitudinal axis. Each semi-circular end plate
134 (one being shown in FIG. 7) of hopper 122 is secured to a shaft
136. The shaft 136 at the hopper end shown in FIG. 7 is drivingly
connected to a motor 138 that is fixed to hopper suspension frame
123 by a mounting bracket 273. The shaft at the opposite end of the
hopper is mounted in a bearing 140 (FIG. 4). Motor 138 operates
first to rotate hopper 122 to an inverted position for emptying
(FIG. 11); then to an upright position (in the same direction) for
the next dispensing and weighing cycle.
An air flush means for compartments 113-116 of hopper 122 is shown
in FIG. 11. The air flush means is carried by the main frame and
comprises a compressor 142 in fluid communication through
passageway 144 with air pressure accumulator tank 146. A solenoid
valve 149 regulates the flow of air through passageway 148 to
header 150. The header in turn fluidly communicates with a
plurality of hoses 152 that project into each compartment 113-116
of hopper 122 when the hopper is inverted. Each of hoses 152 is
positioned to direct a stream of air against far wall 154 of the
hopper. It is not necessary to direct the air stream against near
wall 156 because that wall will have already been scraped
relatively clean by the movement of dry additives against the wall
and out of the hopper as hopper 122 routes to an inverted
position.
A vibrator motor 141 is carried by suspension frame 123 at the end
of hopper 122 opposite hopper rotating motor 138. Vibrator motor
141 operates during inversion of the hopper to promote emptying of
the hopper compartments by vibrating the hopper.
An elongated mixing vessel 170 which serves as a receiving means
for receiving additives from the hopper 122 and also as a mixing
means for mixing such additives with water, is placed below hopper
122. Vessel 170 is an elongated tub that is longer and wider than
hopper 122. Vessel 170 comprises a continuous, annular upright wall
172 around a sloping bottom formed from a plurality of triangular
sections 176 that slope towards a pair of central bottom openings
including an inlet port 177 and discharge port 178.
Variable speed flow inducing means, such as variable two-speed
mixers 180, serve as part of the mixing means and are provided in
mixing vessel 170 for inducing a turbulent flow of liquid within
the mixing vessel. Each mixer 180 is comprised of four angled
mixing blades 182 connected to the end of a rotary mixing shaft 184
that is connected to a gearbox 186 and motor 188 for rotating shaft
184. Each of motors 188 is mounted on a motor mounting frame 190
along an outside face of vessel wall 172. Level sensors 192, 194
are also mounted over the edges of wall 172 and project downwardly
into the tub for determining the level of water contained therein
and shutting off a supply of water to the tub when a predetermined
level is reached. Sensors 192, 194 are, for example, electrodes
through which an electrical circuit is completed or a timing
circuit energized when the water surface in the tub reaches the
predetermined level. Sensor 192 is the primary sensor, while sensor
194 is a backup sensor which detects a near overflow condition,
closes fill solenoid 206, and interrupts the fill cycle.
FIG. 10 shows a plumbing system for apparatus 10 which delivers and
removes carrier and flush water from vessel 170. Water is
introduced from a source 195 by pump 193 through line 194 where its
pressure is detected by pressure gauge 196. Water then continues to
flow through line 198 where it is divided by tee 200 into water
lines 202, 204. The flow of water through fill line 204 is
controlled by solenoid valve 206 which, when open, allows water to
flow through line 208, thence to conduit 210 and into vessel 170
through port 177. When solenoid valve 206 is open, a second
solenoid valve 212 in line 202 remains closed such that all of the
supply of water moves through line 204 to fill vessel 170.
Solenoid valve 212 is interposed between line 202 and flush line
214 that in turn communicates with line 216 to establish fluid
communication with conduit 210. Line 214 also fluidly communicates
with line 218 having branches 220, 222. Branch 220 fluidly
communicates with a pair of nozzles 224, one positioned above
blades 182 of each mixer 180, nozzle 224 directing a flow of water
onto the blades to clean them. Line 222 provides a passageway
through which the water moves to flush ring 226 (FIGS. 9 and 10)
which is positioned around the upper inner periphery of vessel 170
adjacent its top edge. Ring 226 has a number of flush nozzles 228
which direct a flow of water downwardly against wall 172 of vessel
170 to flush it.
Apparatus 10 also has a delivery means for delivering slurry from
vessel 170 to a receiving station for mixing with an animal feed
ration at a location remote from the mixing vessel. This delivery
means includes discharge opening 178 in fluid communication with
conduit 240 that empties into discharge line 242. Discharge pump
244 withdraws slurry through line 242 and sends it through line 246
to receiving station 248 where, typically, it is sprayed into a
livestock feed ration and mixed therewith.
Weigh Means
A weighing means 250 (FIG. 6) is provided on weigh frame 34 for
weighing predetermined weights of the different additive
concentrates dispensed from bins 68-74 and containers 76, 78.
Weighing means 250 includes a weigh tower 252 extending vertically
upward from a crossbeam 40 of weigh frame 34 midway between
uprights 36 at each end of frame 34. Each tower 252 has a flat top
plate 254 with a central opening through which the threaded shank
of an eye member 256 is placed and secured with a nut. A rubber pad
258 is placed against the interior face of plate 254 before member
256 is secured to top plate 254 with the nut. A pair of suspension
members 260 pivotally interconnect eye member 256 and a second eye
member 262 from which a load cell 264 is suspended. The amount of
strain on load cell 264 is communicated to a control unit through
line 265. The load cell 264 in the preferred embodiment is capable
of weighing to an accuracy of 0.5 grams.
A rubber isolator pad 266 is pivotally suspended beneath load cell
264 by suspension members 268. A suspension arm 270 of the hopper
suspension frame 123 is in turn suspended from isolation pad 266 by
hook 272 and eye 274 secured to arm 270. Arms 270 of suspension
frames 123 thus suspend hopper 122 such that the entire weight of
the hopper is freely suspended from load cells 264. Arms 270 are
braced by gussets 271 to their rectangular weight frames 123.
Hopper 122 is suspended interior to frames 123 between slats 41, 43
of frame 34 by suspending shafts 136, one of which is driven (FIG.
7) and the other of which is mounted in a bearing 140 (FIG. 4). The
hopper is therefore free to rotate between frames 123 to an
inverted position. This arrangement allows the weight of the hopper
to be transferred through frames 123 to arms 270 for acting on load
cells 264. The weight of additive concentrates in hopper means 122
can therefore be accurately determined.
As best shown in FIG. 7, a transverse vibration and sway dampening
rod 276 extends between a bracket 278 carried by an upright of
hopper suspension frame 123 and a bracket 279 carried by two
longitudinal beams 37, 39 of weigh frame 34. Such a rod 276 is
provided at each end of weigh frame 34 adjacent face 134 of hopper
122 for preventing or damping transverse movements of the hopper. A
similar longitudinal rod (not shown) extends along one longitudinal
side of hopper 122 to prevent or dampen longitudinal vibratory or
swaying movements of hopper 122, one end of the longitudinal rod
being fixed to longitudinal beam 39 and the other end being fixed
to weigh frame 34. Such sway dampening rods provide part of the
means isolating the weight-sensitive components of the apparatus
from movements that could affect accurate weight measurements.
Control Means
Apparatus 10 is provided with a control means, such as a central
processing unit, for controlling the operation of apparatus 10. In
the preferred embodiment, two-programmed central processing units
are used, one for operating the weighing functions of apparatus 10
and the other for operating all other machine functions.
Weighing Program
The logic of the program for operating the weighing functions of
the machine is shown in FIG. 12. The weighing CPU is activated by
starting the menu at 280 and then entering ration data with
keyboard 24 for a particular feedlot or data for one of a series of
desired batches at a feedlot. This formulation of each desired
batch has been preprogrammed into the computer such that a batch
formulation can be chosen by entering a code number at 282. The
computer then searches at 284 for a match to this encoded
formulation until the match is found and the machine is ready to
batch. If a match is not found, the program at 285 returns to step
280 and a prompt is sent to screen 26 to enter ration data.
Once a match is found at 284, a program prompt at 286 appears on
screen 26 requesting the size of the batch to be prepared. After
this information is entered, the program prompt at 287 requests the
number of batches to be prepared, and if the batch size exceeds the
capacity of the preprogrammed limit for the feed lot ration mixer
or the compartments 113-118 of hopper 122, this is computed at 288.
If capacity has been exceeded, a prompt is sent to screen 26 at box
289, and the program will request that new data concerning batch
size and number be entered by returning to step 286. If capacity
has not been exceeded, the machine is ready to batch at 290.
The weighing computer first checks to determine if a weigh switch
is on at 292, and if the weigh switch is off, an alarm is sounded
at step 293 and the program returns to ready at 290. The alarm will
alert an operator that the weighing switch must be turned on in
order for batching to continue.
The program next calculates metering ration data at 294 and sends
it to the machine operating program at 295 as indicated by A in
FIGS. 12 and 13. The metering data is calculated for any additives
that have been selected for dispensing in the metering mode during
the weigh cycle. Dispensing a portion of the additives by volume is
more fully set forth in connection with steps 361-363 of FIG. 13
below.
The program then sets an output for the water level at 296, the
level of the water determining how much fluid carrier will be
present in the slurry which is ultimately delivered to receiving
station 248. Water level information is sent to the machine
operating program at 297, as indicated by B in FIGS. 12 and 13. The
program next waits at 298 for a start signal which the operator
gives by activating start switch 299 on switch panel 28. The
weighing cycle is then started at 300 by sending a start signal at
301 to the machine operating program as indicated by C in FIGS. 12
and 13. Even though the weighing cycle has started, no weighing of
microingredients actually commences until a signal is received back
from the machine operating program at 302 as indicated by D in
FIGS. 12 and 13 that indicates weighing should begin at 304. This
communication between the programs at D enables the machine
operating program to being its initial checks while
microingredients are being dispensed and weighed.
Once the signal to begin weighing is received at 304, the weighing
sequence begins at 306. It is first determined at 308 whether a
motion sensor is detecting movement of hopper means 122.
Information is received from the motion sensor on the hopper at
309, as indicated by E in FIGS. 12 and 13. The program will not
progress beyond 308 until the motion sensor indicates that hopper
means 122 is not moving, since movement of the hopper means will
adversely affect weight determinations of load cell 264. Hopper
means 122 can be put in motion by a variety of influences, such as
wind gusts, floor vibration, personal contact, or movement of
machine parts. Although the effect of these movements on load cell
264 may not be great, the extreme accuracy required in dispensing
microingredient feed additive concentrates makes absence of
movement desirable.
It is next determined at 310 whether the scale reading is less than
1000 grams. If the reading is greater than 1000 grams, it is
probably because the hopper means is not empty, as indicated at
311, and a signal is sent at 312, 313 to dump hopper means 122 so
that weighing of a new lot of microingredients can begin. The
signal to dump is sent to the machine operating program as
indicated at step 314 and F in FIGS. 12 and 13. The mixers 182 are
also started at 315 as indicated by G in FIGS. 12 and 13 so that
the microingredient dumped from hopper means 122 will be mixed into
a slurry and discharged to receiving station 248 in accordance with
normal operation of the machine operating program described in
connection with FIG. 13 below.
If the scale reading is less than 1000 grams, it is determined at
316 if the scale reads below zero. If that is the case, a message
is given to the operator by 317 on screen 26 that the scale has
failed and the supervisor should be called. Then at 318 the program
prompts the operator to switch to a backup metering mode system
which disperses additive concentrates by volume instead of by
weight, and a prompt is sent at 319 to screen 26 directing that the
weigh switch 321 at panel 28 be turned off. The operator then
performs as outlined in FIG. 15 by turning the meter switch on at
step 500 and entering ration data at 502. Volumetric metering of
additive concentrates is performed by activating motor 102 of each
bin 68-74 to rotate screw 90 for a predetermined period of time.
Since screw 90 will dispense an approximate known amount of
concentrate per unit of time, a volumetric approximation of the
desired amount of concentrate can be dispensed without
weighing.
If the scale reads above zero at 316, the weighing mode of the
program is instead used. Ingredient flow is started at 320 by
activating motor 102 for screw 90 below bin 68. Motor 102 has at
least two speeds so that it initially operates at a higher speed
during the initial phase of dispensing additive concentrates from
bin 68 into a first compartment 113 of hopper means 122. The weight
of concentrate introduced into compartment 113 is sensed by load
cell 264 and that information is continually fed back to the
computer through line 265. As the weight of concentrate dispensed
from bin 68 approaches the predetermined amount of that concentrate
for the batch formulation chosen at 282, motor 122 is switched to a
lower speed at 322 and 324 that more slowly dispenses the
concentrate from bin 68 during a final phase of dispensing. In this
manner, a more accurate weight of microingredient can be dispensed
from bin 68 into compartment 113 since the dispensing of additive
will have slowed before it is finally stopped when the correct
weight of this first concentrate is sensed at 326.
The program contains a weight compensation step at 328. It
sometimes happens that the actual weight of additive concentrate
dispensed by dispensing means 80 into compartment 113 will be
slightly greater or less than the desired weight set by the ration
data at 282. The program compensates for such inaccuracies by
adding or subtracting a weight compensation factor to the ration
amount set for the additive concentrate at 282. In this manner, the
weight inaccuracy will be corrected the next time a microingredient
additive is dispensed from bin 68 into compartment 113.
When the predetermined weight of microingredient additive
concentrate is sensed at 326 and the weighing of the component has
been completed, the computer determines if the just dispensed
concentrate was the last microingredient dispensed at 330. Assuming
the microingredient concentrate in bin 68 was not the only
concentrate to be dispensed in this formulation, the program then
returns to box 320, and the flow of ingredients from bin 70 is
initiated by activating motor 102 beneath bin 70 to turn screw 90
at a fast speed and begin moving microingredient additive from bin
70 into compartment 114 of hopper means 122. Load cell 264
continues to sense the weight of concentrate added to hopper means
122 from bin 70 until that weight begins to approach the final
predetermined weight desired of the second concentrate. This
predetermined weight will be the total actual net weights of the
first additive concentrate plus the predetermined weight of the
second additive concentrate since hopper means 122 has not yet
inverted and the first additive concentrate still remains in
compartment 113.Iadd.. .Iaddend.As the total combined actual weight
of additive concentrate in compartments 113, 114 approaches the
predetermined amount, motor 102 is switched to a slower speed, and
additive concentrate is continued to be slowly dispensed with screw
90 from bin 70 until the total combined weight of additive
concentrate is reached, and motor 120 is shut off.
This same procedure is repeated until the predetermined weight of
additive from each of bins 72, 74 is similarly dispensed into
compartments 115, 116. Liquid microingredient additive concentrates
from containers 76 and 78 are dispensed by activation of a liquid
pump which sequentially dispenses liquid additive from containers
76, 78 into liquid receiving compartments 117, 118 of hopper means
122 until a predetermined amount of each liquid additive has been
dispensed.
Once the last additive has been dispensed, as determined at 330,
the computer determines that weighing has been completed at 332,
which sends at 334 a signal to the machine sequence program as
indicated by H in FIGS. 12 and 13. The computer pauses at 336 to
wait on discharge of hopper means 122. Once dumping of hopper means
122 has been completed by inversion of the hopper and its return to
an upright position, this information is sent from the machine
operating program of FIG. 13 to the weighing program of FIG. 12 as
shown at I and 338. It is then determined at 340 whether another
batch of microingredient is required. If not, the program returns
from 342 to its starting point at 280. If another batch is
required, the program returns to box 292 and the sequence repeats
itself as described above.
Although not shown in FIG. 12, the weigh program can be modified to
keep a running inventory of additive concentrates. This can be
accomplished by entering into the weigh computer the weight of
additive concentrate placed in each of bins 68-74 and containers
76, 78. The weight of each concentrate actually dispensed and
sensed by load cells 264 is then subtracted from the original
weight of concentrate to determine the inventory of concentrate
remaining.
The control means can also be programmed to perform other functions
that enhance the accuracy of weight determinations by the weighing
means. For example, the isolating means can include programming the
control means to prevent acceptable of the measured weight by the
control means following operation of dispensing means 80 until
motion of hopper means 122 sensed by motion sensors has subsided to
a level that will not affect load cells 264. The same result can be
achieved by programming the control means to delay operation of all
other movable machine components (such as dispensing means 80, 120
or mixers 182) for a predetermined period of time sufficient for
hopper 122 to settle or until any oscillatory movements subside.
Alternatively, the isolating means can include programming the
control means to prevent operation of moving components (such as
dispensing means 80, 120 or mixers 182) while weight determinations
are being made by the load cells 264.
Machine Sequence Program
FIG. 13 schematically illustrates the logic of a program for
actuating the sequence of operations of apparatus 10. The program
begins by determining at 344 if the weigh switch on switch panel 28
has been turned on. Once the weigh switch is on, the program is
ready for a metering data signal at 345. It waits at 346 until the
metering ration data is received at 346 from steps 347 and 295 as
indicated by A.
Once the metering data is received, the program is ready to batch
at 348. It receives water level data at 349 from 350 and 297 as
indicated by B. The start signal from 301 is then relayed via C to
351 to 352. The machine cycle is then started at 353, and
initiation of the cycle is signaled to the weighing program from
354 through D to 302.
Boost pump 193 is then turned on at 355 for introducing water
through line 194 in FIG. 10 with solenoid 206 open and solenoid 212
closed. It is determined at step 355 if the boost pump is on, and
if it is not, an alarm is sounded at 356 that the pump is switched
off. Boost pump 193 introduces water through line 208, conduit 210,
and port 177 until a predetermined water level set at 294 is sensed
by level probe 192. If the predetermined water level is not reached
within a set period of time as indicated by 357, an alarm sounds at
358 to indicate that an error has occurred. Otherwise, if mixing
vessel 170 fills within the set time, this condition is detected by
level probe 192 and mixing blade motors 188 are activated at 359 on
a slow speed to cause the water in mixing vessel 170 to flow. If
the motors 188 do not turn on, an alarm is given at 360 to alert
the operator of this malfunction.
It is possible to accurately dispense some liquid microingredient
additives such as those in containers 74, 76 by volumetric metering
instead of weighing. Such accurate volumetric metering is possible
since the density of most liquids is quite constant over the range
of environmental conditions in which apparatus 10 is used.
Volumetric metering of liquid additives selected by the metering
ration data is achieved at 361 by activating the piston pump in
dispensing means 120 for a period of time determined by 362, 363.
Once the metering step is completed, the dumping mechanism is
enabled at 364 for proceeding to weigh complete step 365 before
inverting hopper 122.
The program waits at step 365 for the weighing sequence shown in
FIG. 12 step 320 through step 334 to be complete. Once the weighing
sequence is completed at step 334, a signal is sent to 365 through
366 at H from the weigh program, and the sequence program
progresses to 367 where a signal is given at 368 from 314 via F to
actuate motor 138 and invert hopper means 122 to dispense the
additive concentrates contained in compartments 113-118 separately
but simultaneously into the flowing water of vessel 170. The
dumping mechanism is disabled at 369 once the hopper leaves its
upright position. Once hopper means 122 is inverted at 370,
vibrators on the hopper are activated at step 372 to promote
complete removal of all microingredient particles from bins
113-118. Compressor 142 is next actuated at 373 to compress air in
air tank 146, and a solenoid to header 150 is opened which moves a
flow of air through hoses 152 and toward wall 154 of each of
compartments 113-116 to remove any traces of solid additive
concentrates from the compartments. Air flushing continues for a
predetermined period of time at step 373.
Hopper means 122 is then sent to its home position at step 374 by
activating hopper motor 138 to continue to turn shaft 136 in the
same direction it turned to invert the hopper. When the hopper
returns to its upright position, this is sensed by a switch as
indicated by step 375, and a signal is sent at 376, 377 to 338
through I that the contents of hopper means 122 have been dumped,
and another weigh cycle (FIG. 12) can begin. Meanwhile the machine
operating program of FIG. 13 progresses to step 378 which switches
motors 188 of mixers 180 to a higher speed. The lower motor speed
is used until hopper means 122 leaves its inverted position since
high speed mixing while the hopper is inverted could cause water
drops to be splashed into containers 113-116. Step 378 also begins
to measure a predetermined mixing time. When the period for the
preselected mixing time expires, as determined at 380, the mixing
motors 188 are switched back to their lower speed. Once the
weighing program receives a discharge signal at 381 from step 315
through G and 382, or alternatively from actuation of a discharge
switch 383 on switch panel 28, a discharge signal is sent by the
program at 384 to discharge the slurry in vessel 170. A solenoid
valve in line 240 then opens, and pump 244 (FIG. 10) is activated
to remove the slurry through outlet 178 in vessel 170. Mixer blades
182 continue turning at a slow speed until a predetermined period
of time expires, as set by step 385. Pump 244 continues operating
as the water level lowers and finally clears the bottom of probe
192, as illustrated by step 386. If the level probe is not cleared
within a predetermined period of time, an alarm is given at 387 to
indicate a pumping malfunction.
After the water level clears the bottom of probe 192, pump 244
continues operating and a timed flush cycle begins at 388. Boost
pump 193 is activated at 389 for introducing water through line 194
as solenoid 206 is closed and solenoid 212 is opened. In this
manner, flush water is introduced through line 214 so that it
enters vessel 170 through nozzles 228 of flush ring 226, blade
flush nozzles 224, and port 177. The interior of vessel 170 and the
surfaces of blades 182 are thereby flushed, completely removing any
residue of microingredient additives from the vessel through inlet
179. The boost pump continues introducing a water flush into vessel
170 until the flush time period expires at 390, and the flush is
terminated at 391. Discharge pump 244 continues pumping for a delay
period following the end of the flush cycle, as shown at 392; then
discharge pump 244 is turned off at 393.
The program then determines if the weigh switch is still on at 394
and if it is, the program returns to step 344 to repeat the
sequence described in steps 344-393. If the weigh switch has been
turned off, the apparatus 10 is turned off at 395 and an alarm is
given at 396 to indicate that a mode change has been made.
The control means includes means for operating mixers 180 and
discharge pump 244 at the same time as dispensing means 80 such
that a first batch of additive concentrate slurry can be mixed and
delivered to a receiving station while a second batch of additive
concentrates are dispensed and weighed prior to their deposit into
the mixing vessel.
Electrical Schematic
A schematic diagram of the electrical connections for apparatus 10
is shown in FIG. 14.
It is important to the proper operation of a computer that is be
supplied with electrical power of a constant and consistent
quality. This is a serious drawback in rural areas where the
electrical power being supplied is often at the end of a long
supply line into which fluctuations are introduced by intervening
power users. Most cattle yards and other users of apparatus 10 are
located in rural areas where variations in power would adversely
affect operation of the computers which control weighing and
sequencing of machine function. For that reason, the present
invention employs a series of transformers to selectively filter
the electrical energy, isolate the power source, and damp
variations in the power before it is supplied to the computers.
Four hundred eighty volts of power are supplied at 400 by a rural
electrical utility, and that power first passes through 10 kw
isolation transformer 402 where it is transformed into 240 V power,
illustrated by 404 in FIG. 14. This initially filtered 240 V power
is supplied to electrical connection line 405 through relay 406 to
booster pump 193 that introduces water into mixing tank 170 during
the filling and flushing cycles. The 240 V power is also supplied
through relay 407 to pump 244 that helps drain the mixing tank.
This relatively unfiltered power can be supplied to pumps 193, 244
since they are not as sensitive to power variations as the
computers.
The 240 V power is also sent to a sola-regulating transformer 408
where it is transformed to 120 V power, as illustrated at 409. This
filtered, 120 V power is used to provide electrical energy to all
components of apparatus 10 other than pumps 195, 244. If electrical
energy is interrupted, three 12 V batteries 410 connected in series
are provided as an uninterruptable power supply through triple
power supply 412.
Remote control unit 20 has monitor screens 26, 29 and keyboards 24,
27 for weighing and metering functions. Remote control unit 20 is
electrically connected through line 422 with a weigh microcomputer
424 .[.(RA.]. .Iadd.(RCA .Iaddend.1800 Micro System Z80
Microprocessor) having a 120 V optically isolated input/output
relay board 426. Remote control unit 20 is also connected through
line 428 with machine sequencing microcomputer 430 (RCA 1800 Micro
System Z80 Microprocessor) having an optically isolated
input/output relay board 432 (Opto PB 24Q). Computer interface 434
provides a data bus between weigh microcomputer 24 and machine
sequencing computer 430.
Machine sequencing computer 430 and weigh computer 434 are supplied
with 5 V power from triple power supply 412 through line 411. Both
I/O boards 426, 432 are supplied with 120 V power through line 436
at .Iadd.438. .Iaddend.
Weigh computer 424 contains an eight slot card cage with three 662
RAM memory cards that contain the programs for operation of the
weighing functions and monitoring of microingredient additive
inventory. Weigh computer 424 also contains a service box 641 card
to connect the service box to the computer, a printer 641 output
card, a 600 system operating program card, and a 6264 memory
card.
The machine computer 430 has a six slot card cage, including two
662 RAM memory cards, as well as a 659, 650, 641 and 600 CPU card.
When apparatus 10 is functioning in the metering mode, it uses only
machine computer 430. A complete set of ration data is stored on
the machine computer's ROM memory separate from the ration data
stored on the RAM memory cards of weigh computer 424.
I/O board 426 is connected through line 448 with a speed control
444 for controlling the speed of dispensing means 80 in the weigh
mode during a weigh cycle. For additives dispensed in weigh mode,
speed control 444 determines whether screw 90 rotates at a fast
speed during the initial weighing period of a given concentrate, or
at a low speed during the terminal phase of weighing as the weight
of the concentrate approaches its predetermined amount. Since it is
necessary to sense the weight of each concentrate that has been
dispensed before the speed of dispensing means 80 can be reduced
and then stopped, load cells 264 are electronically connected
through scale head 418 to the weigh microcomputer 424. Weight
determinations of the weighing means can therefore be sensed and
sent to speed control 444. For additives dispensed by volume during
a weigh cycle, speed control 444 determines that screw 90 rotates
at the preset third speed during the predetermined time of
volumetric dispensing controlled by micro computer 430.
I/O board 432 is connected through line 446 with speed control 444
for controlling the speed of dispensing means 80. Speed control 444
determines that screw 90 rotates at the preset metering speed on
the third speed of speed control 444 for a predetermined amount of
time of volumetric dispensing controlled by microcomputer 430.
Input/output board 432 is connected through line 400 with
ingredient level controls 442 in each of bins 68-74 and containers
76, 78. These level controls are conventional switches located
within the bins and containers for sensing when the level of
additive concentrate in each bin has reached a predetermined low
level. When the low level of additive concentrate is sensed by low
level control 42, a signal is sent to the operator indicating that
more concentrate should be added.
I/O board 432 of machine sequencing microcomputer 430 is connected
through line 450 and relay 452 with hopper rotation motor 138 that
inverts hopper means 122. Line 456 connects I/O board 432 through
relay 458 with vibrator 141 on hopper means 122. A switch 462 is
also provided on hopper means 122 for sensing whether the hopper is
in an upright or inverted position, switch 462 being connected to
I/O board 432 through line 464. Finally, hopper means 122 is
provided with hopper air flush solenoid valve 466 in header 150 for
controlling the introduction of air flush into compartments 113-116
of the hopper after it reaches its inverted position. Solenoid
valve 466 is connected to I/O board 432 through line 468.
Mixer motors 188 on mixing vessel 170 are connected through relay
470 and line 472 with I/O board 432. Level control 192 of the
mixing vessel is connected with I/O board 432 through line 474.
Solenoid valve 212 in flush line 202 is connected to I/O board 432
through line 476, and solenoid 206 in fill line 204 is connected to
I/O board 432 through line 478. Booster pump 195 for pumping water
into vessel 170 is connected through relay 406 and line 480 with
I/O board 432, while pump 244 for withdrawing slurry and flush
water from vessel 170 is connected through relay 407 and line 482
with I/O board 432. Low water control 484 for the water supply is
connected through line 485 with the I/O board. Motion and panel
control sensors 486, which detect any oscillatory movements of
hopper means 122 and determine if any of the panels 12 have been
removed from apparatus 10, are interconnect with I/O board 432
through line 490.
Metering Mode Program
As earlier described in connection with FIG. 12, in the event of
scale failure at step 317, apparatus 10 switches to a meter mode at
318 and the weigh switch is turned off at 319. The off position of
the weigh switch at 319 is sensed as the meter switch being on at
step 500 in FIG. 15. The numeral 1 is entered at keyboard 24 at
step 502 to begin batching in the metering mode, and a ration code
name is entered at 504. The metering mode program of FIG. 15
searches at 506 for a ration corresponding to the code entered at
504. If the corresponding ration is not found at 506, the program
returns at 508 to step 504 so that another ration name can be
entered.
Once the entered code has been matched with a ration at 506, the
program prompts for entry of information concerning batch size,
which is entered at 509. The program next prompts for entry of
information concerning the number of batches to be processed, which
is entered at 510. The machine is then ready to batch at 512 by
volumetric metering instead of by weighing.
The program waits at step 514 for a start signal 516, which is
applied by a start switch 299 on control panel 28. It is then
determined at 518 if boost pump 193 is on, and if it is not, an
alarm is given at 520 to indicate that the pump is off. Boost pump
193 fills mixing vessel 170 during a predetermined amount of time
at step 522. If the water level in mixing vessel 170, as detected
by water level sensor 192, does not reach a predetermined level
within a set period of time, an alarm sounds at 524 to indicate a
filling error.
Once level sensor 192 determines that the water level in mixing
vessel 170 has reached a predetermined level, mixing motors 188 are
activated at 526 to rotate mixing blades 182 at a slow speed. An
alarm sounds at step 528 if the mixers are not on. While mixer
blades 182 induce a turbulent flow of water in mixing vessel 170,
motor 102 for screw 90 below bin 68 is activated at 530. The
metering speed of motor 102 is a third speed, intermediate the fast
and slow speeds used in dispensing additive concentrates by weight.
Screw 90 turns for a predetermined period of time sufficient to
dispense a required volume of additive concentrate. The screw of
each dispensing means 80 below the bins containing desired additive
concentrates turn simultaneously. Dispensing means 120 for liquid
additive concentrates in containers 76, 78 also operate
simultaneously with dispensing means 80 to volumetrically deliver
predetermined amount of liquid concentrate to compartments 117,
118.
When metering is complete at 532, a signal is sent to motor 138 at
step 534 to invert hopper means 122 and dump its contents into the
flowing water of vessel 170. A switch determines at 536 whether the
hopper is inverted, and if it is not, an alarm is given at 538 to
indicate a dump failure. Hopper vibrators are then actuated at 540
while hopper means 122 is inverted to remove, by vibration,
additive concentrate particles that remain stuck to the walls or
bottom of containers 113-116. The air flush (FIG. 11) is actuated
at 542, and the program sends a signal at 544 to send the hopper to
its home, upright position by actuating motor 138 to continue
rotation of shaft 136. If hopper means 122 does not reach its home,
upright position within a predetermined period of time set by 546,
an alarm sounds at 548 to indicate that a malfunction has occurred
and the hopper is still inverted.
When hopper means 122 leaves its inverted position, mixing motors
188 are switched to their second, higher speed at 548. High speed
mixing continues for a predetermined amount of time and then
returns to low speed at step 550 until a discharge signal 554 is
received at 552 from a discharge switch 383 on panel 28 to turn on
discharge pump 244. It is determined at 556 whether discharge pump
244 is on, and if it is not, an alarm is given at 558 to indicate a
pump malfunction.
A predetermined, mix delay the time period is initiated at 558
during which period motors 188 continue to move mixing blades 182
at low speed. If the bottom of level probe 192 is not cleared at
560 within the predetermined period of time set in step 558, an
alarm is given at 562 to indicate pumping problems. Once probe 192
has been cleared, a predetermined flush cycle time is initiated at
564, and boost pump 192 is actuated at 566 to move water through
flush line 214 while solenoid 212 is open and solenoid 206 is
closed. Boost pump 193 continues introducing water through line 214
and into flush ring 226, blade cleaning nozzles 224, and port 177
until a flush period has expired at 568 and pump 193 is turned off
at 570. Discharge pump 244 continues operating for a period of time
set by 572 until all of the flush water residue has been removed
through drain 178 and sent to receiving station 248. Discharge pump
244 is then turned off at 574 when the delay period set at step 572
expires.
The metering mode program then determines whether another batch is
needed at 576, the need for another batch having been determined by
the number of batches entered at 310. If another batch is not
needed, the program returns to step 502 which prompts the operator
to enter the code for another batch. If, on the other hand, another
batch is required at 576, the program checks at 578 to determine if
the meter switch is still on. If the metering switch is on (and
conversely the weigh switch is off), the program returns to step
512 where it repeats steps 512-576. If it is determined at 578 that
the meter switch is off, apparatus 10 is turned off at 580 and an
alarm is given at 582 indicating a mode change.
FIG. 16 Embodiment
FIG. 16 shows a second embodiment of apparatus 10 in which hopper
means 222 has been eliminated. In this embodiment, the weight of
each microingredient concentrate dispensed is determined on a "loss
of weight" basis. Each of dry concentrate bins 600, 602, 604, 606
is provided with a load cell 608 for determining the weigh of each
container. The program in this embodiment activates a dispensing
means 610 (similar to dispensing means 80 in apparatus 10) to
selectively sequentially or simultaneously delivery dry
microingredients separately from bins 600-606 into mixing vessel
612 having mixers 614, 616. Tank 612 is filled and flushed through
water supply line 618 and emptied through discharge line 620 after
concentrates have been mixed with water in mixing vessel 612.
Liquid microingredient concentrates may also be dispensed on a
"loss of weight" basis by mounting containers of liquid
microingredient on load cells.
The control means for the FIG. 16 embodiment includes a means for
controlling the dispensing rate of each dispensing means 610 in
response to loss of weight sensings of load cell 608 for each bin
600-606. Such a control means is similar to speed control 444 for
dispensing means 80 in FIG. 14.
In a variation of the embodiment of FIG. 16, the control means
includes a means for operating dispensing means 510 for several
cycles in the volumetric metering mode wherein additives are
dispensed using a weight per unit time formula instead of load cell
608. The actual weight of each additive concentrate dispensed will
by determined by the loss of weight measured by each load cell 608.
The actual weight of concentrate lost will be compared by the
computer to the theoretical amount dispensed. The discrepancy
between the actual and theoretical amounts will then be corrected
by adjusting the formula to dispense more accrurately the desired
amount of additive concentrate. Since the remaining concentrate in
each bin has substantially the same density as that already
dispensed, the remaining additive can be dispensed accurately by
volume.
Correction of the weight per unit time formula used for volumeteric
dispensing in the metering mode can be used in connection with any
embodiment employing a weighing means. For example, volumetric
metering into hopper means 122 of FIG. 2 can be adjusted by
comparing actual weights of additive concentrate dispensed into
compartments 113-116 with the desired amounts determined on a
weight per unit time formula. The computer can then correct the
formula to account for the density and other properties of the
particular bath of additive concentrate being dispensed.
Alternatively, dispensing means 80 can be operated in a weigh mode
from the beginning through a major portion of a dispensing cycle
for a particular additive concentrate. The load cell 264 monitors
the weight of concentrate dispensed at a given speed of screw 90.
This information is used by the control means to prepare a weight
per unit time formula for volumetric dispensing of the particular
additive being dispensed. The dispensing means 80 is then operated
in a volumetric metering mode independently of the weighing means
for the final portion of the dispensing cycle.
FIG. 17 Embodiment
Yet another embodiment of the invention is shown in FIG. 17 which
takes advantage of the fact that the density of liquid
microingredient concentrates does not vary as greatly as solid
microingredient. For this reason, it is possible to accurately
meter liquid microingredients by volume while measuring the solid
microingredients by weight. In the embodiment of FIG. 17, four dry
microingredient containing supply means 701, 702, 704, 708 are
shown to each be connected to a dispensing means 710 similar to the
dispensing means 80 of apparatus 10. Each of dispensing means 710
conveys dry additive concentrate to a hopper means 712 similar to
hopper means 122 in FIG. 5, the hopper means 712 being suspended
from a pair of weigh cells. Each additive concentrate is dispensed
sequentially into hopper means 712 from containers 701, 702, 704,
708 using dispensing means 710 until a predetermined weight of each
concentrate has been sensed by a load cell from which hopper means
712 is suspended. Hopper means 712 is then inverted to separately
and simulteously empty the dry microingredient contents of hopper
means 712 into flowing water in mixing vessel 714 which is being
agitated by mixers 716, 718.
In the FIG. 17 embodiment, liquid microingredients are separately
stored in containers 720, 722 which are provided with tubes 724
that empty into vessel 714. Rotary or piston pumps 728 are
interposed in each tube 724 to pump microingredients from
containers 720, 722 directly into mixing vessel 714, thereby
bypassing entirely hopper means 712.
The control means for the FIG. 17 embodiment may, in some
embodiments, include means for selectively operating some
dispensing means simultaneously and others sequentially. Pumps 728
for the liquid additive concentrates in containers 720, 722 may,
for example, be operated simultaneously with each other and with
dispensing means 710. Dispensing means 710 for dry additives
should, however, be operated sequentially in this embodiment since
the overall weight of hopper means 712 is sensed by the load cells
from which the hopper is suspended. If the dry additives were
dispensed simultaneously into hopper means 712, it would not be
possible to weigh accurately the amount of each additive dispensed.
It is through cumulative weight determinations of sequentially
dispensed additives that accurate weight determinations are made in
the compartmented hopper. A first additive concentrate is delivered
into a compartment of the hopper until its load cells register a
first predetermined weight, and delivery of the first additive
concentrate is stopped. Delivery of a second additive concentrate
is then started and continued until the load cells register a
second predetermined weight, and so on until predetermined weights
of all selected additives have been delivered into the hopper.
In yet other embodiments which are not shown in the drawings, the
control means is programmed to operate the dispensing means in an
interrupted, on-off-on-off sequence to dispense selected
microingredients into a weighing means such as hopper 122. Weight
determinations sensed by load cells 264 would only be accepted when
the dispensing means is switches off during the interrupted
sequence. In this manner, weighing inaccuracies caused by movement
of the dispensing means or settling of additives would not affect
weight determinations.
In another disclosed embodiment, the isolating means includes
programming the control means to prevent operation of any other
moving components of apparatus 10 while weight determinations are
being made by the weighing means. The operation of dispensing means
80 and mixer blades 182 would, for example, be prevented by the
control means while weight determinations were being made by load
cell 264.
FIG. 18 Embodiment
FIG. 18 shows an apparatus indicated generally at 800 in accordance
with the invention and somewhat similar to the embodiment of FIGS.
1`15 but having two separate weigh hoppers 802, 803 for weighing
the multiple additive concentrates dispensed from additive
concentrate storage means 805, 806 by dispenser means 808. The
weigh means of the apparatus 800 includes separate weigh means for
each weigh hopper 802, 803, thereby giving the apparatus the
capability of weighing multiple additives simultaneously in
different weigh hoppers. This capability gives the apparatus 800 an
advantage over the apparatus of FIG. 1 in being able to dispense,
weigh and discharge all of the multiple microingredients of a given
formulation into the mixing vessel 810 and thereby complete the
batching of a formulation, more quickly than the apparatus of FIG.
1.
The apparatus 800 also includes a support frame means 812 which may
include either separate support and weigh frames as in the
apparatus of FIG. 1 of a common support frame for all of the major
mechanical components of the apparatus as depicted schematically in
FIG. 18. Support frame 812 rigidly supports the multiple
microingredient concentrate storage containers 805, 806 and their
associated dispensers or metering devices 808, 809. The support
frame means 812 also rigidly supports the mixing vessel 810 which
is shown as a mixing vessel common to both weigh hopper 802 and
weigh hopper 803.
Other major components of the system of FIG. 18 include control and
other components which would normally be mounted apart from support
frame means 812, including a pair of scale heads 814, 815, one for
each weigh hopper, a weigh computer or central processing unit 817
with its associated input/output board 818, and a remote control
unit or terminal 820 for controlling the operation of the computer
817. A separate machine computer or central processing unit 822 has
an associated input/output board 823. An interface 824 enables
communication between the machine computer 822 and the weigh
computer 817. Scale heads 814, 815 transmit weight determination
data through line 826 to the input/output board of the weigh
computer 817. There is also a printer 828 connected to the
input/output board of weigh computer 817 through line 830 for
printing desired output data from the weigh computer 817.
In the apparatus 800 there are four microingredient additive
concentrate storage containers 805 associated with weigh hopper 802
and another four such storage containers 806 associated with the
other weigh hopper 803, thereby giving each weigh hopper the
capability of weighing and discharging four different additives
into the mixing vessel 810. The dispenser 808 associated with the
different additive storage containers 805 are capable of operating
independently of one another upon an appropriate command signal
from a weigh computer 817 transmitted from the input/output board
818 through line 832. Similarly, each of the dispensers 809 for the
four other storage containers 806 are capable of operating
independently of one another to dispense additives into the weigh
hopper 803 upon a suitable command signal from weigh hopper 817
transmitted from input/output board 818 through line 834.
Weigh hopper 802 is mounted at its opposite ends on a pair of load
cells 836, 837 connected by suspension members 838, 839 and a pair
of resilient isolator members 840, 841 to support frame 812.
Weigh hopper 803 is mounted in a similar manner by load cells 842,
843 to support frame 812. Thus, each weigh hopper is independently
mounted by separate weigh means to the frame 812 for independent
weighing of ingredients. The two load cells 836, 837 for weigh
hopper 802 are operatively connected by a line 845 to scale head
815. Weigh hopper 803 is separately connected by a line 846 to a
separate scale head 814. Both of the scale heads in turn are
connected to the input/output board 818 of weigh computer 817
through line 826. Thus each weigh hopper and its contents can be
weighed separately and its contents cumulatively through its
associated scale head simultaneously with the other weigh hopper.
That is, both weigh hoppers can carry out their weighing functions
at the same time and independently of one another.
Each weigh hopper 802, 803 is preferably similar in construction to
the weigh hopper disclosed in FIGS. 2, 3, 5, 6 and 7. That is, each
weigh hopper is mounted in a manner shown in such prior figures for
rotation from its normal additive receiving upright position to an
inverted discharge position by discharge means including an
electric motor 848 in the case of weigh hopper 802 and electric
motor 849 in the case of weigh hopper 803. Each is connected
independently to the input/output board 823 of the machine computer
822 through suitable electrical conductors 850 and 851,
respectively.
Each weigh hopper, 802, 803 also is provided with a motion sensor
853, 854, respectively, connected to the
input.Iadd./.Iaddend.output board 818 of weigh computer 817 through
line 856 for detecting any motion in either weigh hooper during the
weighing process. The software for the weigh computer 817 prevents
a final weight determination from being made for a given weigh
hopper whenever the motion sensor for that hopper senses motion
that might hive a false or highly inaccurate reading.
The support frame means 812 for the weighing and delivery
components of the apparatus is preferably enclosed by housing
panels (not shown) in a manner similar to that shown in FIG. 1 to
shield and isolate the weighing components of the apparatus from
external ambient forces that could cause undesirable motion and
thus inaccurate weight readings. Such forces typically might
include the effects of wind or jarring of the components by direct
contact of personnel. The support frame means 812 is provided with
a sensor 858 which is also connected by line 856 to the
input/output board of weigh computer 817. Sensor 858 is operable to
prevent a weight determination from being made whenever a panel is
removed from the support frame 812. Thus the motion sensors 853,
854 for the weigh hoppers and the panel sensor 858 for support
frame 812 provide additional means for isolating the weighing
components of the apparatus from influences that could affect
weight determinations and the accuracies of such
determinations.
A further means of enhancing the accuracy of the weight
determinations of the apparatus disclosed in FIG. 18 is the
mounting of the discharge motors 848 and 849 in conjunction with
their respective weigh hoppers 802, 803 so that such motors become
part of the tare weight of the hoppers in making additive weight
determinations. Because very lightweight, flexible electrical
conductors can connect such electric motors to the operable control
components of the apparatus, such conductors will have no
appreciable effect on the weight determinations of the weigh means.
This should be contrasted with the hydraulically actuated discharge
means in conjunction with the weigh hoppers of prior apparatus.
With a prior hydraulically actuated discharge means, relatively
stiff hydraulic conduit must connect the hydraulic motor associated
with the hopper to the source of hydraulic fluid remote from the
hopper. Typically such hydraulic conduit affects weight
determinations of the hopper in such instances because it
inherently provides some structural support for the hopper, thereby
influencing load cell weight sensings as ingredients are added to
the hopper because the conduit is partially supporting some of the
load of the added weight.
The apparatus in FIG. 18 also includes positive mixing means within
the mixing vessel 810 in the form of a pair of mixing blades 860,
861, each driven by an electric motor 862, 863. The mixer motors
are connected by electrical conductor means 864 to the input/output
board 823 of the machine computer 822. A slurry discharge line 866
leads from a bottom opening of mixing vessel 810 to the input side
of a discharge pump 868. The discharge line continues at 870 from
the discharge side of discharge pump 868 to a conventional feed
mixer such as typically the truck-mounted feed mixer 872. A booster
pump 874 pumps a liquid carrier such as water from a source (not
shown) through a fill line 876 into the mixing vessel. A solenoid
operated valve 878 in fill line 876 controls the admission of the
water carrier into the mixing vessel and is operated by the machine
computer 822 through a suitable conductor 878 connected to the
input/output board 823 of such computer.
A flush line 880 branches from fill line 876 downstream of booster
pump 874 and upstream of fill valve 874. Another solenoid actuated
valve 882 in the flush line connected to the input/output board 823
of machine computer 822 through conductor 884, controls the
admission of flush fluid into the mixing vessel.
The hardware components of the control system including the weigh
computer 817, machine computer 823 and their associated
input/output boards, the printer 828, and the remote control unit
820, may be similar to those same units described with respect to
the embodiment of FIG. 1. Similarly, the software controlling the
operation of such computers can be varied to vary the operating
sequence of the machine of FIG. 18.
A typical operating sequence of the machine of the apparatus of
FIG. 18 is as follows:
A driver drives a feedtruck into a feed-receiving station in a
cattle feedlot. The driver departs his vehicle, approaches the
remote control unit 820 and selects the formulation of feed
additive concentrates to be batched and delivered into his truck,
depending on the specific lot of animals to be fed within the
feedlot. The formulation is selected typically by the operator
depressing a key corresponding to the formulation selected on the
computer terminal of the remote control unit.
Assuming that predetermined weights of two additives A1, A2 in
storage containers 805 and two additives A5, A6 from storage
containers 806 are to be included in the formulation, the dispenser
808 for container A1 begins to dispense the additive A1 into weigh
hopper 802. At the same time, the dispenser 809 for container A5
begins to dispense additive A5 into weigh hopper 803. The
dispensing of additive A1 into weigh hopper 802 continues until a
predetermined weigh of such additive has been added to such hopper
as determined by the load cells 836, 837 and the associated scale
head 815, at which point the weigh computer 817 stops the
dispensing of additive A1 from its storage container by stopping
its associated dispensing means 808. At the same time, a weight
determination of the additive A5 added to weigh hopper 803 is
determined in the same manner, but independently of the weight
determination occurring in hopper 802.
When the predetermined weight of additive A1 has been added to
weigh hopper 822, depending on programming, two alternative
functions can occur. Either the weigh hopper 802 can be inverted by
motor 848 to discharge the additive A1 into the mixing vessel 810
and then returned to its upright position to receive the next
additive A2, or the weigh hopper can remain in its upright position
while the dispenser 808 for additive A2 operates to add,
cumulatively, the predetermined weight of additive A2 to weigh
hopper 802. If the latter sequence is used, weigh hopper 802 is
inverted by its discharge motor 848 to discharge the predetermined
weight of additive A1 and additive A2 together into the mixing
vessel 810. The same options are available with respect to the
addition of additives A5 and A6 to weigh hopper 803 and the
discharge of the contents of the weigh hopper 803 into the mixing
vessel 810. It is important to note that both weigh hoppers 802 and
803 can operate entirely independently to weigh and discharge their
preselected additives into the mixing vessel 810, although the
machine and weigh computers could also be programmed to cause both
weigh hoppers 802, 803 to wait until all of the selected additives
have been added and weighed within each weigh hopper and then both
weigh hoppers inverted simultaneously by their respective motors to
discharge all of the weighed additives at once into the mixing
vessel. That is, each additive can be added, weighed and discharged
either separately or cumulatively with other additives, depending
on the programming selected for the control system.
Regardless of which of the above described dispensing, weighing and
discharge options are selected, preferably booster pump 874 pumps
the carrier water through open valve 874 and fill line 876 to fill
the mixing vessel 810 to a predetermined level before any additive
is discharged into the mixing vessel. This will prevent different
and possibly incompatible additives from intermixing in
concentrated form and also prevent additives from sticking to the
inside walls of the vessel, making it difficult to remove such
additives even after carrier water or flush water is added to the
vessel.
Also preferably before the discharge of any additives into the
mixing vessel in making up a batch, mixing blades 860, 861 rotate
to create a turbulent flow within the mixing vessel so that
additives entering the liquid carrier are quickly intermixed with
and dispersed throughout the carrier, thereby diluting the
concentrates.
When the predetermined weights of the selected additives A1, A2,
.[.A3.]. .Iadd.A5 .Iaddend.and A6 all have been weighed in their
respective weigh hoppers 802, 803 and discharged into the water
carrier within mixing vessel 810, mixing blades 860, 861 continue
to rotate for a time to ensure a uniform dispersal of all additives
throughout the carrier liquid slurry thus formed. Of course at this
time, booster pump 874 shuts off and fill line valve 874 closes, as
does flush line valve 882.
When mixing is complete within mixing vessel 810, discharge pump P2
operates to pump the slurry formulation from the mixing vessel
through discharge line 866 and to the waiting feed mixer truck 872
through discharge line 870. When the level of slurry within the
mixing vessel drops below a predetermined level as determined by
level sensors (not shown) within the vessel booster pump 874
restarts and flush line valve 882 opens to pump flush water into
the mixing vessel through its top and along its side walls to flush
all slurry residue from the vessel. Flushing continues as the
discharge of slurry proceeds through the discharge lines 866, 870.
Discharge pump 868 continues to operate during the complete flush
period, pumping the flush liquid with the slurry into the feed
mixer truck 872. After a predetermined length of time sufficient to
enable the complete flushing of the mixing vessel and discharge
lines, and the pumping of all slurry into the feed mixer 872,
booster pump 874 stops and flush valve 882 closes. Pump 868
continues to operate until all of the slurry and most of the flush
liquid is pumped into the feed mixer 872. Thereafter the truck
operator returns to his truck and drives away as the mixing of the
feed and slurry continues. Typically, the driver drives to the feed
bunks of selected pens or lots of animals and delivers the
additive-bearing feed into the bunks immediately upon departure
from the additive receiving station. Thereafter, typically, another
feed mixer truck arrives at the additive receiving station
represented by the position of truck 872 and that operator goes
through the same procedure as just described, selecting the same or
a different formulation depending on the requirements of the
animals within the lot or pens that are to be fed with the feed
ration from such truck.
During the additive formulating process as just described, the
system will not allow a weight determination of a given additive to
be made so long as a panel is removed from the support frame 812 as
detected by sensor 858. Nor will a weight determination be made if
either one of the motion sensors 853, 854 associated with each
weigh hopper detects movement of a weigh hopper that could affect
the weight determination to be made in such weigh hopper.
Typically, scale heads 814, 815 receive weight sensings from their
respective load cells 6 to 8 times per second. The scale heads then
average such readings for that given unit of time and send the
average reading via line 826 to the input/output board 818 of the
weigh computer 817. Computer 817 then records the averaged weight
per unit of time as the weight upon which the computer acts to
control the operation of the additive dispensing means and
discharge means. Because of the large number of readings being
averaged before the average is transmitted to the weigh computer,
any single erroneous reading transmitted to a scale head by the
load cells will have an insignificant effect on the accuracy of the
averaged reading transmitted from the scale head to the weigh
computer for processing. This slow updating of the weigh computer
(about once per second or less) with an average of a large number
of weight sensings received by the scale head is further insurance
against inaccurate weight readings and enhances the accuracy of the
entire system. In the computer updating were faster (such as twice
per second or more), an erroneous reading would have a greater
effect on the accuracy of weights recorded and processed by the
computer.
FIG. 19 Embodiment
FIG. 19 is a flowchart of a computer program applicable to the
computers of FIG. 14 and representing a modification of the program
of FIG. 15 for operating the apparatus of, for example, FIG. 16 on
a weight-compensated metering basis.
The flowchart of FIG. 19 incorporate steps 500-530 of the FIG. 15
program in box 900 and also the completion-of-metering step 532 of
the same program. When all microingredients have been metered into
the mixing vessel 612, the program continues to sequence through
steps 549-582 of the metering program of FIG. 15, skipping steps
534-548 because the apparatus of FIG. 16, unlike the apparatus of
FIGS. 14 and 18, does not use a weigh hopper.
As the program continues to sequence through mixing and discharge
steps 549-582 as indicated at box 902 in FIG. 19, the program also,
at least after so many metering cycles, or if desired after every
metering cycle, reads the weight of each microingredient storage
container 600, 602, 604, 606 as indicated at 904. Thereafter, as
indicated at box 906, the program commands the computer to
calculate the actual loss of weight of the ingredient storage
containers to determine the actual weight of each microingredient
metered, by subtracting the weight of each storage container sensed
after metering at 904 from the initial weight of each storage
container prior to such metering steps.
The program also commands the computer to calculate the theoretical
weight loss of each storage container, which is also the
theoretical weight of each ingredient used, by multiplying the
metering rate of each metering device 610 in, for example, grams
per minute, by the length of time each metering device 610 has
operated, as indicated at box 908. The program then commands the
computer to compare the actual weight of ingredient used as
calculated at 906 with the theoretical or target weight of
ingredient used as calculated at 908, as indicated at box 910. From
this comparison the program commands the computer to adjust either
the time that each metering device 610 operates, or the rate of
speed at which each such device operates, or both, during a
metering cycle so that the actual weight of ingredient used as
determined by weighing equals the desired or theoretical weight of
ingredient used as determined by metering. This adjustment command
occurs at box 912 in the computer program. When the metering speed
or time adjustment is made, the program returns to the start of the
metering cycle as indicated at box 900.
The program also includes a fill mode or routine which is used
whenever a microingredient storage bin 600, 602, 604, 606 is
refilled. In such mode, the program commands a reading of the
initial weight of the storage container being refilled at box 914.
The additional microingredient is then added to the storage
container as indicated in box 916. The program then commands a
reading of the filled weight of the storage container at box 918
and enters such weight in computer memory. At this point the fill
subroutine has been completed and the apparatus is conditioned to
start another metering cycle.
The foregoing described program operates the apparatus of FIG. 16
primarily as a metering apparatus. However, the metering device 610
are adjusted after completion of a predetermined number of metering
cycles based on actual loss-of-weight determinations of each
storage bin as registered by the weighing means 608 for each
storage container. Thus the apparatus of FIG. 16 when operated in
accordance with the program of FIG. 19 is actually a hybrid
weigh-metering system in which the metering components are
periodically readjusted so that the theoretical or target weights
of ingredients metered will closely approximate the actual weights
of ingredients dispensed.
The described weight-compensated metering system can also be used
in a continuous mill application in contrast to the batch mill
application described with respect to FIG. 16. In a continuous mill
system, the metering devices meter the additive concentrates
continuously at predetermined rates from their storage bins into a
liquid carrier, which in turn flows into a feed ration at a
predetermined rate. In such a system, weight losses of the storage
bins can be determined periodically and then used to calculate the
necessary adjustments of metering rates of the metering devices to
bring the actual weights of additives dispensed per unit of time by
metering into line with the theoretical weights desired. This can
be done without interruption of metering, simply by adjusting the
speed controls of the metering devices.
Having illustrated and described the principles of the invention in
several preferred embodiments, it should be apparent to those
skilled in the art that the invention can be modified in
arrangement and detailed without departing from such principles. I
claim all modifications coming within the spirit and scope of the
following claims.
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