Note: Descriptions are shown in the official language in which they were submitted.
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133620~
PROGRAMMABLE WEIGHT SENSITIVE MICROINGREDIENT
FEED ADDITIVE DELIVERY SYSTEM
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
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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. Patents 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.
13362~0
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. Patent No. 2,893,602 and U.S. 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.
133623~
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 of 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.
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
133~20~
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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 feedlot. 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. 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 the 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
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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 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.
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
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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
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weigh hopper while liquid additive concentrates are
metered by volume directly into the mixing vessel.
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
~ith 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. 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
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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
5 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
10 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 mounts those
components which are necessary to the weighing function
of the apparatus, and main frame 46 mounts the remaining
components that could, during their operation, induce
undesirable movements in the weigh components to
1~36200
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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
35 primary display screen 26, a small, secondary keyboard
27 and a small, secondary display screen 29. Various
control switches and indicators are provided on a
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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
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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
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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
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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 contents, 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 semicircular 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
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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
rotates 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.
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- 16 -
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
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- 17 -
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
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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 weigh 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 ad]acent 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
13362~0
-- 19 --
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. The 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
35 capacity has not been exceeded, the machine is ready to
batch at 290.
133620Q
- 20 -
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 acutally 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 begin 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
l3362~a
- 21 -
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, personnel 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
microingredients 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 dispenses 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
1336200
- 22 -
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
- 23 - 1336200
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 that component has been completed,
the computer determines if the just dispensed
concentrate was the 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. 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
35 predetermined weight of additive from each of bins 72,
74 is similarly dispensed into compartments 115, 116.
Liquid microingredient additive concentrates from
- 24 - 1336200
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 acceptance of the measured
weight by the control means following operation of
dispensing means 80 until motion of hopper means 122
1336200
- 25 -
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 to
subside. Alternately, 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 and 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 pmup 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
- 26 - 1336200
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 determned 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
35 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
1336200
- 27 -
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
alternately 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 activiated 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
- 28 - 13362~0
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 it be supplied with electrical power of a
- 29 - 1336200
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
~ 30 - 1336200
connected through line 422 with a weigh microcomputer
424 tRCA 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 beween 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
438.
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
20 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
30 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
35 control 444 determines whether screw 90 rotates at a
fast speed during the initial weighing period of a given
1336200
- 31 -
concentrate, or at a slow 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 440 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
30 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
35 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
1336200
- 32 -
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 interconnected 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
30 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
35 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
- 33 - 1336200
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 supplied 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
30 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.
35 Dispensing means 120 for liquid additive concentrates in
containers 76, 78 also operate simultaneously with
dispensing means 80 to volumetrically deliver
- 34 - 133620
predetermined amounts 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 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 193 is actuated
13362~
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 510. 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.
Other Embodiments
Fig. 16 shows a second embodiment of apparatus
10 in which hopper means 122 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 weight 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 deliver dry
microingredients separately from bins 600-606 into
1336200
- 36 -
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 be 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 accurately 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 volumetric 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
~ 37 - 1336200
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 batch 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.
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 microingredients. 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 simultaneously empty
the dry microingredient contents of hopper means 712
- 38 - 1336200
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 addditive 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.
30 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
- 39 - 1336200
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 switched 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 a final 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.
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 detail
without departing from such principles. I claim all
modifications coming within the spirit and scope of the
following claims.
