Note: Descriptions are shown in the official language in which they were submitted.
2146~gl
~t~CTTl~TT~ METERING AND CONTROL SYSTEM AND MET}IOD FOR
LIVESTOCR FEEDING OPERATION
Back~round of t h~ TnYeIltiOn
1. Field of the Invention
The present invention relates generally to a system for
accurately metering and controlling the amount of f eed
distributed to feed bunks in a livestock feeding operation such
as a feedlot More particularly, the inventive system allows
precise computer control of a feed distributing vehicle so that
feed is uniformly distributed in bunks of various lengths serving
feedlot pens of varying configurations.
2. De3~riT~ion of the Related 1~r~
A large percentage of production beef cattle and other
livestock are fed by commercial feedlot operators. These
businesses often constitute in~PrPnAPnt operations which accept
cattle from farmers or ranchers at a certain age and size and
feed them until they reach a size at which they are ready for
slaughter. In re~urn, the farmer or rancher pays a rental fee
for space and care in the feedlot pen and for the feeding costs
plus operating profiTt of the feedlot.
In the feedlot, cattle are grouped n pens according to
their feed requirements, e.g. cattle of a like age and size
should be fed the same ration in the same amount. Feeding is
accomplished by driving a feed truck or other feed distributin~
vehicle along feed "bunks" which extend ~-nnt;n~ usly along one or
more sides of eac~ pen. The cattle are generally fed several
times daily and it is very important for uniform growth and
2~1649~
health that each animal receive the a~signed ration each day.
Thi~ not only mean~ that the proper total amount of feed mu~t be
distributed to each pen each day, but that the feed must al~o be
evenly di~tributed throughout the bunk. Thi~ i~ due to the fact
that cattle are creature~ of habit and therefore they have a
~trong tendency to feed from the ~ame place in the bunk each
time. Thuc, each animal must have it~ proportion of the total
bunk feed available to it within it~ immediate feeding area in
order to maximize consumption.
Typically, commercial feedlot~ have distributed feed via
feed truck~ which are driven along each feed bunk. Each truck
ha~ a feed ~3torage hopper mounted on it which is connected to a
feed di3tributing chute via a hydraulically and/or manually
controlled door. Often a feed transfer auger is positioned to
lift feed from the hopper door opening to the di~tributing chute.
The rate at which feed i~ distributed thus depend~ upon the
ground speed of the truck, the speed of the transfer auger and
the po~itioning of the door. The truck driver i~ given a listing
of pen number~3 and feed amounts to be di~tributed to each pen in
20 his route. It i8 Up to the driver, ba~ed upon experience and
"feel", to open the chute door the requi~ite amount and to drive
the truck the correct ~peed to distribute the af~igned feed
amount evenly throughout each ~unk. The rate of ~eed
distribution i~ often displayed to the driver on a di~3play, but
the feed rate i~ u~ually derived via a plurality of load cell~3
placed beneath the feed hopper on the truck. The~e load cell~
convert the weight of the hopper to an electrical ~ignal which i~
sent to a monitoring scale. There are often four load cell~, one
po3itioned at each corner of the hopper, and the ~cale monitor~
30 each load cell and derive~ a total weight for the hopper and feed
214~91
cnnt~;n,-r~ therein by accumulating the weight information
forwarded from each load cell. When the known empty weight of
the hopper is subtracted out, the weight of f eed remainlng ie
displayed to the driver.
The problems inherent in the prior art approach are
numerous. Under ideal conditions, each pen would be identical in
size and shape and each bunk would be identical in length.
However, feedlots are seldom constructed under ideal conditions,
and, furthermore, the original design conditions are subject to
10 constant change. Topography often dictates that pens will vary
in size and shape, and, therefore, the lengths of bunks will
vary. The positioning of gates and other pen construction
considerations often shorten the length of a bunk serving a
particular pen relative to even other pens of identical
construction. It is difficult or impossible for a typical feed =
truck driver, even if he is aware of these bunk length
variations, to properly compensate for them by adjusting the feed
rate and/or vehicle ground speed. This inability to properly
adapt feed rate to bunk length often results in a driver
20 dispensing the total feed amount over less than the total bunk
length. Alternatively, a driver will often reach the end of the
bunk without having distributed the requisite feed amount. This
means that he will need to shut off the feed door, back up the
truck, reopen the feed door and distribute the r~=in~ r of the
bunk allotment over a small portion of the bunk. Furthermore,
this requirement to back up and retrace a portion of the bunk,
when repeated many times per day, greatly adds to the time and
expense of feed distribution. It has been estimated by some
feedlot operators that fully 509~ of a driver's feeding time is
30 spent backing up and covering bunk lengths twice. This situation
21~91
also increases fuel consumption and adds to vehicle maintenance
expense by causing increased wear on brakes, transmissions,
tires, etc.
Another problem with prior art distribution systems is the
imprecision with which feed rates and vehicle speeds are
monitored. Load cells positioned beneath a hopper give a fairly
accurate reading of the total feed amount in the hopper when the
feed truck is not in motion. ~Iowever, when the truck is in
motion, particularly on the rutted and/or muddy road conditions
10 which often occur in feedlots, the inertial effects of constant
swaying and jolting, starting and 8topping, and acceleration and
deceleration of the truck causes the load cells to be constantly
differentially loaded and unloaded. The result is that the
amount of feed sensed by a connected scale can vary
instantaneously by several hundred pounds. It is readily
apparent that a feed rate derived from such an inaccurate
weighing system will itself be subject to large inaccuracies.
One approach of past distributing systems has been to provide
limitæ to the feed rate ~wings sensed by load cells by providing
20 synthesized high and low rate change limits. One example of such
a system is taught in U.S. Patent No. 4,762,252 to EIyer et al.
In this patent, the synthesized rate change is m~;nt~in~r~ until
the sensed feed rate returns to a normal range. Unfortunately,
with rough road conditions, this can take several seconds during
which the truck driver is being fed erroneous rate information.
For truck speed sensing, feedlot operators often simply use
the standard truck speedometer or tachometer. ~owever, feed
truckf~ during a bunk distribution run usually travel at speeds
better measured in feet per minute, i.e. speeds which may not
30 even register on a standard speedometer and engine speed
~ 2~64~1
variations which may not be accurately reflected on a tachometer.
This requires a driver to establish and vary his truck speed by
feel and experience. This is not only an extremely inaccurate
method of speed regulation, but also requires unacceptable
training times for feed truck drivers, otherwise relatively low
skill and low pay positions with consequent high turnover rates.
It has been estimated that a typical driver can be trained to
~know" the feedlot, bunk routing etc. within a week, but that it
takes upwards of three months to train a driver to obtain the
feel of a vehicle to a point where he can adequately distribute
feed to the various bunks on his route. Furthermore, there are a
large number of different manufacturers of feed trucks, with some
manufacturers making several different models. Consequently, a
single feedlot often operates two or more different types of feed
trucks. Often the trucks are different enough that a driver must
be virtually totally retrained on each truck model. These
extensive training times and costs and the inconsistent feeding
during training, exact an intolerable cost from the average
f eedlot .
It i8 clear then that a need e~i~3ts for a system which i8
capable of reliably and effectively monitoring the feed rate and
feed vehicle speed for a cattle feeding operation. Such a system
should provide for the input of custom feedlng instructions to
accommodate varying pen configurations and bunk lengths and
should reliably provide for consistent control of the feed rate
and vehicle speed to allow the allotted feed amount to be evenly
distributed throughout each bunk. Furthermore, in addition to
providing information which allows the driver to precisely
control the vehicle, the system may also provide for real time
~ 2 ~
correction oi vehicle speed and feed rate to adjust for changing
conditions .
Su~arv o~ the Inven~ion
In the practice of the present invention, a compreheneive
accurate feed rate monitoring and control system and method
includee a central ~, ~JyL hle controller mounted in the feed
truck or other vehicle into which is input æpecific information
10 for each pen and associated feed bunk. This information includes
the pen number, the length of the bunk, and any unusual pen
configuration and other data which, in general, doee not change
from day to day. Additional information which is input prior to
each feeding session includes the ration proportions and the
amount of feed to be distributed in each bunk. The amount of
feed to be distributed may depend upon whether any feed remains
in the bunks from prior ieedings. A sensor or a plurality of
sensors can be mounted on the bunks 80 that it can be remotely
det~-rm;nf~-l, via electromagnetic or ultrasonic eenders and
20 receivers or the like, whether feed remains in the bunks, and/or
the quantity of any such r,omF~1n1n~ feed. The computer then
calculatee initial set points for vehicle speed and/or discharge
door openings for each bunk, taking into account the bunk length
and any special pattern feedlng due to pen conf iguration . These
desired set points are displayed to the driver eo that door
position and vehicle speed can be manually set. This system can
be readily installed in exieting vehiclee at relatively low cost.
Alternatively, in addition to displaying the set points to
the driver, the system can be enhanced such that controller
3 0 generated set points can be used to directly control a vehicle
2~
speed governor, and/or a discharge door actuator. In such an
- enhanced system, the feed vehicle can include an accurate ground
speed sensor or other vehicle position sensor, which can be, for
example, a magnetic sensor sensing front axle revolutions, and an
accurate feed rate sensor, which can be a load cell sensor
mounted on the feed chute it8elf. Alternatively, a sensor, such
as a radar emitter or the like, can be mounted on the f eed bunk
to determine the distance of the vehicle f rom the end of the
bunk. This distance can be sent to the vehicle via radio or
10 ultrasonic transmitters, etc.
Once a feed run is c. -n~ rl along a specific bunk, the
computer provides repetitive or real time monitoring of vehicle
speed and/or position as well as feed rate, constantly
recalculating the amount r~m~ n; n~ to be f ed and the length
rPm~1n;n~ to the end of the bunk. These parameters, which can be
updated as often as 20 times per second, are then used to update
and adjust the set points for vehicle speed and/or discharge door
opening. The result is an even distribution of the assigned pen
f eed amount throughout the length of each bunk but compensated
20 for variations in pen configuration and bunk length. The
~nhi~nt~rl gystem virtually eliminates the need for specialized
driver training, permitting an inexperienced driver to distribute
feed virtually as uniformly as one with years of experience.
In accordance with the present invention there is provided
a material monitoring and control system for evenly distributing
material along a path from a moving vehicle, the system
comprising means for storing the length of the path remaining to
be traveled; means for storing the amount of the material
L. ;nln~ to be distributed along the path; a programmable
30 controller means for calculating desired set points for one or
2~ ~4~1
more distribution rate parameters based upon the r~mi~;n;nrj path
length and the r~ ;n;n~ material amount and also outputting the
desired set points wherein the vehicle can be configured thereby,
the proyL hl e controller means being connected to the means
for storing path length rr-~;n;n~ and the means for storing
material Ll ;n;nrg; flow rate sensing mean~ for detecting the
flow rate of the material from the vehicle; vehicle position
detecting means for detecting the position of the vehicle along
the path; and the ~LUyL hle controller mean~ is connected to
10 the flow rate sensing means and the position detecting means, the
programmable controller means providing a repetitive indication
of a distribution rate determining parameter based upon feedback
from the flow rate sensing means and the position detecting
means .
Also in accordance with the present invention there is
provided a feed monitoring and control ~ystem for evenly
distributing livestock feed along an elongate feed bunk from a
moving feed distributing vehicle, the sy~tem comprising
proyL hl e means for repeatedly calculating and for storing the
20 length of the feed bunk r~m~;n;nj to be traveled by the vehicle
as the vehicle traverses the bunk; means for repeatedly
calculating and storing the amount of feed remaining to be
distributed to the bunk; and the programmable means is programmed
to repeatedly calculate de~ired set point~ for one or more
di~tribution rate parameters ba~ed upon the 1~ 1n;n~ path length
and the r~m~;n;n~ material amount and to output each desired set
point [~] wherein the vehicle can be repeatedly configured
thereby .
Further in accordance with the pre~ent invention there is
30 provided a feed monitoring and control sy~tem for evenly
2~4~4~1
di~tributing livestock feed along an elongate feed bunk from a
moving feed distributing vehicle, the F~ystem compri~ing means for
ctoring the length of the feed bunk rPm~n;n~ to be traveled by
the vehicle; mean~ for storing the amount of feed r~m~;n;nr, to be ~-
di~tributed to the bunk; flow rate sen~ing mean~ for detecting
the flow rate of the feed from the vehicle; vehicle po~ition
detecting mean~ for detecting the po~ition of the vehicle along
the bunk; and programmable controller mean3 for calculating
desired ~et points for one or more di~tribution rate parameter~3
based upon the r~m:~;n;nr, path length and the remalning material
amount and for outputting the de~ired ~et points wherein the
vehicle can be configured thereby, the programmable controller
means being cnnnrrtf~ to the mean~ for storing bunk length
remaining, the mean~ for storing feed rr~-~nin,r, the flow rate
~ensing means and the vehicle position detecting means, the
programmable controller means providing a repetitive indication
of a distribution rate determining parameter based upon f eedback
from the flow rate ~en~ing mean~ and the po~ition detecting
mean~ .
Still further in accordance with the present invention there
is provided a method of di~tributing material from a moving
vehicle evenly along a path to be traveled by the vehicle, the
method comprising the ~teps of storing the path length r~--;n;nr,;
ctoring the amount of material rr-~n;nrJ to be di3tributed along
the path; and controlling at lea~t one material distributing rate
parameter based upon the path length remaining to be traveled and
the amount of material ~ ln;nr, to be di~tributed; accurately
monitoring the flow rate of material from the vehicle and
repeatedly calculating the amount of material ~. ;n;nrJ to
di~tribute ba~ed upon the flow rate over time; accurately
21~64~
monitoring the position of the vehicle along the path; repeatedly
calculating the distance L~ ;n;ng to be traveled along the path
based upon the vehicle position; and repeatedly changing at least
one material distributing rate parameter each time the path
length L~ ;n;ng to be traveled and the amount of material
remaining to be distributed are recalculated.
Also in accordance with the present invention there iæ
provided a method of evenly distributing feed from a feed
distributing vehicle along a feed bunk ~xtPn-l;n~ a certain length
10 alongside and adjacent to a feeding pen rrnti~;n;ng a number of
livestock to be fed, the method comprising the steps of storing
the bunk length; storing the total amount of feed to be
distributed along the bunk; calculating the position of the
vehicle along the bunk and calc~ t;n~ the bunk length rr-~;n;n~
to be traveled from the vehicle position; sensing the amount of
feed distributed and calculating the amount of feed rl~m~;n;n~ to
be distributed along the bunk; and controlling at least one feed
distributing rate parameter based upon the bunk length r~mi~;n;n~
to be traveled and the amount of f eed remaining to be
20 distributed.
Further in accordance with the present invention there is
provided a method of evenly distributing feed from a feed
distributing vehicle along a feed bunk Pxtf~n(1;n~ a certain length
alongside and adjacent to a feeding pen rnnti~;n;n~ a number of
livestock to be fed, the method comprising the steps of storing
the bunk length; storing the total amount of feed to be
distributed along the bunk; and controlling at least one feed
distributing rate parameter based upon the path length :L~ ;n;n~
to be traveled and the amount of feed rr~;n;ng to be
30 distributed; accurately - ;trr;n~ the flow rate of feed from the
` 21~
vehicle and repeatedly calculating the amount of feed rrm;~;n;nr~
to distribute based upon the flow rate over time; accurately
monitoring the position of the vehicle; repeatedly calculating
the distance L. ; n; nr, to be traveled along the bunk based upon
the vehicle position; and repeatedly changing at least one feed
distributing rate parameter each time the path length L~ ;n;nr~
to be traveled and the amount of feed r~m~;n;ng to be distributed
are recalculated.
Still further in accordance with the present invention there
10 is provided a feed monitoring and control system for evenly
distributing livestock feed along an elongate feed bunk from a
moving feed distributing vehicle, the system comprising
programmable means for computing and storing pattern feeding
criteria for altering the distribution of feed along the feed
bunk to compensate for irregularities in pen shape or
configuration or cattle feeding habits and for storing the
position of the vehicle along the feed bunk; controllable
distribution means on the vehicle for selectively controlling the
rate of distribution of feed, the distribution means being
connected to the programmable means, the programmable means being
programmed to selectively cau~e the distribution means to alter
the even distribution of feed along the bunk based upon the
position of the vehicle along the bunk and the pattern feeding
criteria .
Also in accordance with the present invention there is
provided a method of distributing feed from a feed distributing
vehicle along a feed bunk extending a certain length alongside
and adjacent to a feeding pen rrn~3;n;ng a number of livestock to
be fed, the method compri~ing the ~teps of ~toring the bunk
30 length; computing pattern feeding criteria for altering the
11
~ 4~1
distribution of feed along the feed bunk to compensate for
irregularities in pen shape or conf iguration or cattle eating
habits; storing the po3ition of the vehicle along the feed bunk;
selectively altering the distribution of feed along the bunk
based upon the position of the vehicle along the bunk and the
pattern feeding criteria.
Obiect~ An~l AdvAn~A~re~ of the prP~Pn~ Invention
The objects and advantages of the present invention include:
providing an accurate livestock f eed rate monitoring and control
system and method; providing such a system which compensates for
pen configurations and varying feed bunk lengths; providing such
a system which provides accurate set point data to a vehicle
driver based upon length of f eed bunk, pen conf iguration and
amount of feed to distribute in that bunk; to provide an PnhAnc
system which includes monitoring of feed rate and feed vehicle
speed or position, updated several times per second; providing
such an enhanced system which provides repetitive or real time
20 monitoring of the amount of feed left to feed to the current bunk
and the r~~~;n~n~ distance to the end of that bunk; providing
such a system which repeatedly calculates a desired feed rate
based upon the amount of feed r(~ ning to ~eed and the bunk
length rPrnAinln~; providing such a system which automatically
displays and/or controls desired vehicle speed and/or f eed rates;
providing such a method for displaying set points which will
allow for uniformly and consistently distributing an assigned
feed ration throughout each bunk of a feedlot, while compensating
for pen configuration and bunk length; providing such a method
30 for directly and repetitively controlling one or more feed
12
~ ~ 2 1 ~
distributing rate parameters, such as vehicle speed or feed flow,
based upon repetitive or real time monitoring of feed amount
remaining and ve~icle position; to provide such a method which
will insure the uniform and consistent distribution of an
assigned feed ration throughout each bunk of a feedlot, while
compen~ating for pen configuration and bunk length; and providing
~uch a ~ystem and method which is economical to manufacture,
efficient in operation, capable of a long operating life and
particularly well adapted for theproposed usage thereof
10 Other obj ects and advantages of this invention will become
apparent from the following description taken in conjunction with
the accompanying drawings wherein are set f orth, by way of
illu~tration and example, certain embodiments of this invention.
The drawings constitute a part of this specif ication and
include exemplary embodiments of the present invention and
illustrate various objects and features thereof.
srie~ D~cri~tio~ Q~ ~he Drawi n~Ts
Fig. 1 is a per~pective view of a feed di3tributing truck
equipped with an accurate monitoring and control sy3tem and
method for a livestock feeding operation in accordance with the
present invention.
Fig. 2 is an enlarged per3pective view of a feed chute and
feeder in the tr~ck of Fig 1, with portions broken away to
illu~trate the feed augers and hydraulically operated chute door
Fig. 3 is a schematic block diagram of the accurate feed
monitoring and control system.
13
~1~64~
Fig. 4 is an illustration of a computer screen upon which
are displayed system parameters to a vehicle driver during a feed
run .
Fig. 5 is a logical flow chart illustrating the initial
setup of the control system prior to the vehicle making a f eed
run .
Fig. ~ is a logical 10w chart illustrating the active
monitoring and feed control algorithm of the system while the
vehicle is making a feed run.
Detailçs~ DescriDtion o~ ~-h~ Pre~erred r ~ I; tR
I . IntrQduc~;ioD ~n~ nv; t
As required, detailed embodiments of the present invention
are disclosed herein; however, it is to be understood that the
disclosed embodiments are merely exemplary of the invention,
which may be embodied in various forms. Therefore, specific
structural and functions details disclosed herein are not to be
interpreted as limiting, but merely as a basis for the claims and
20 as a representative basis for teaching one skilled in the art to
variously employ the present invention in virtually any
dLl~)LU~I)l lately detailed structure.
Certain terminology will be used ln the f ollowing
description for convenience and reerence only and will not be
limiting. For example, the words "upwardly", "downwardly~,
"rightwardly" and "leftwardly" will refer to directions in the
drawings to which re~erence is made. ~he words ~inwardly~ and
"outwardly" will refer to directions toward and away rom,
respectively, the geometric center of the structure being
30 referred to. Said terminology will include the words
14
21~6~QI
specifically mf~nt;o~ derivatives thereof and words of similar
import .
Referring to the drawings in more detail, reference numeral
1 in Fig. l generally designates a typical feed truck equipped
with a feed monitoring and control system in accordance with the
present invention. The feed truck 1 includee a cab 2 within
which is a system CPU 3, display 4 and control keyboard or other
input device 5 (Fig. 3) mounted ~or use by a driver. Referring
to Figs. 1 and 2, the truck 1 is shown distributing feed 6 to a
feed bunk 7. The truck 1 includes a hopper 11 with side walls 12
attached to a truck body 13. A hopper door 14 covering an
opening 15 is selectively opened and closed via a hydraulic
cylinder 20 and attached piston rod 21. A three sided feed box
22 surrounds the opening 15 and includes a pair of feed augers 23
which draw feed from the opening 15 up to and out of the top of
the box 22. A drop chute 25 is pivotably attached to the top of
the box 22 via hinges 31, with the drop chute 25 being
selectively raised and lowered hydraulically via cylinder 32 and
pieton rod 33.
To implement a repetitive or real time monitoring of feed
flow rate, a pair o~ weight sensing elements 34 can be attached
to the chute 25, with one shown in Figs. 1 and 2. The sensing
elemente 34 are attached between the bottom of the chute 25 and a
load sensing plate 35 which is attached at one end to the piston
rod 33 and pivotally attached to the feed box 22, with the chute
25 also being pivotable relative to the plate 35. The sensing
elements 34 can be load cell sensors constrained to detect
additional weight in the chute 25 via a pressure differential
between the chute 25 and the load seneing plate 35 caused by the
weight of feed 6 on the chute 25. The sensors 34 then output an
electric signal proportional to the weight, which signals are
analog to digital converted via A/D convertor 41 and they are
input to the CPU 3. In addition, a number of load cells 42, of
which one is ~hown in Fig. 1, are positioned at the corners of
the hopper 11 in known fashion to give a static readout of the
hopper weight and thus the amount of feed ration L~ ;n;n~. The
output of the load cells 42 i9 also output to the CPU 3 via an
A/D convertor 43. The CPU 3 thus has two aources of information
regarding feed amount ~ ;n;n~ and feed flow rate, which can be
10 cross-checked for enhanced reliability. For more precise control,
the truck 1 can also be equipped with a ground 3peed sensor or
vehicle position sensor 44, which is shown as a magnet 45
attached to the inside of the right front wheel 46, with a
magnetic sensor element 51 attached beneath the front a~le 52 and
in close proximity to the magnet 44. The magnetic sensor element
51 thus senses the magnet 45 once per wheel revolution and
outputs a signal to the CPU 3 with each revolution, which signals
are accumulated and multiplied by the outside tire diameter to
determine the distance traversed and differentiated to determine
20 the truck ground speed. A8 an alternative to, or in addition to
sensing vehicle speed and deriving vehicle position therefrom, a
sensor, such as the radar detector 53 shown in Fig. l, can be
mounted at the end of the bunk 7 to directly sense the presence
and the position of the truck 1. This position can be re~otely
sent to the CPU 3 via radio wave~ or the like. Other alternative
position or speed sensors include GPS or l~oran sensors mounted on
the truck 1 which can directly detect vehicle position.
Referring to Fig. 3, the feed monitoring and control system
i~ illustrated in block diagram form. The CPU 3, display 4, and
0 keyboard or other input device 5 are conventional components
16
~4~9 1. ~
which are usually mounted in the cab 2 of the truck l. A memory
54 is assoclated with the CPU 3, and can include conv~n~ n;31
memory elements ;nc111fling hard wired memory chips, hard disc
drives and/or floppy disc drives. The CPU 3 can be connected to
the hopper load cells 42 via the A/D convertor 43, and to the
feed chute load cell sensors 34 via the A/D convertor 41. The
CPU 3 is programmed to calculate both a current feed rate and an
amount remaining to feed from each of these inputs. The feed
chute load cell~ 34 are relied upon primarily a~ a feed rate
lO monitor, with a feed rate differe~tiated from the hopper load
cell readoutF~ used merely as a re~11ln~1~n~-y check. For example,
the CPU 3 can be ~1~UyL ^d to compare the feed amount remaining,
as calculated by integrating the outputs from the feed chute load
cells 34, with the feed amount rc~-1n~ng as indicated directly by
the hopper load cell readouts. In the event that the two values
differ by more than a set amount, a system alarm is visually or
aurally provided to the driver. The truck speed or position
sensor 44 is connected to the CPU 3 to provide a signal from
which the vehicle distance traveled and ground ~peed can be
20 calculated. A digitally controlled truck speed governor 61 is
connected to the CPU 3 to directly control the speed of the truck
l fûr precise feeding operations. The hopper door hydraulic
double acting cylinder actuator 20 is connected to the CPU 3 via
a door position sensor and solenoid control circuit 62. For
example, the sensor within the circuit 62 can constitute a
rheostat within the hydraulic double acting cylinder 20 which
senE~es the position of the piston 21 therein and provides an
electrical resistance readout indicative of the position of the
hopper door 14 within the hopper opening 15 to the CPU 3. The
30 control of the hydraulic cylinder 20 can be accomplished by the
17
~146~i
CPU 3 via conventional solenoids in the circuit 62 which are
opened or closed via electrical signals to supply hydraulic fluid
to either side of the double acting cylinder 20. A pair of
variable speed auger motors 64 are connected to the CPU 3 via a
motor drive control circuit 65. The drive control circuit 65 can
constitute a variable amplifier which i8 controllable to vary the
speed of the auger motors 64, and thus the f eed rate of f eed out
of the feed box 22.
Fig. 4 is a frontal view of the display 4 with a number of
10 variable system parameters displayed and a sample keyboard
selection chart 70. The parameters displayed include the lot
number in window 71, for identification purposes, and, in window
72, the pen number, which is a reference for t~e particular pen
currently being serviced. In window 73, the ration number is
indicated, which number indicates the appropriate feed mix for
the pen being serviced. In window 74, the L- ;nln~ amount to
feed i8 an indication of the feed amount, in lbs., which remains
to be fed in the current bunk 7 Below, in window 75, the
distance to end of bunk 7, in feet, i3 displayed, while the
20 current vehicle ~peed, in feet per minute, is indicated in window
81. The current feed rate, in lbs. per second, is indicated in
window 82, while the feed amount rf~m~;n;n~, which represents the
total feed ~ inin~ on the truck in lbs., ig displayed in window
83 .
18
II.Opera~ n and Loq~-~Al Flow DiacrrAlr~q
Figs . 5 and 6 are logical f low diagrams indicating the =--
monitoring and control algorithms accompli3hed by the CPU 3 with
each feed cycle.
Referring to Fig. 5, an initialization routine is
implemented prior to feeding each pen. At block 91, the CPU and
each peripheral device is initialized upon startup. At block 92,
the pen number is read into the CPU memory along with the length
of the feed bunk associated with that pen. Typical feed bunk
lengths range from 60 to 200 feet. At block 93, the ration type
and amount is input into CPU resident memory. Ration types and
pen feed amounts are generally updated on a daily basis when a
supervisor makes the rounds of the pens and notes growth progress
and any changes in the numbers or make-up of the animals in each
pen. This process is often called "calling the bunks~', and the
data generated thereby is stored on a floppy disc or other
portable storage device and then loaded into each truck CPU 3.
Thus block 94 represents the input of relatively constant
information such a~ pen number and bunk length, which may be
20 stored in a hard drive, and information such as ration and feed
amount, which can chanse daily, from a floppy disc or other
portable storage device, into reqident memory of the CPU 3.
At block 95, any pattern feeding information is calculated
by the CPU and ~qtored . This calculation is perf ormed when a pen
is irregular in shape, such a~ a rlght triangle, for example. In
such a pen, although the feed bunk extends along one side of the
triangle, cattle will be more numerous at one end of the bunk
than at the other, ln general proportion to the depth of the pen
at each section of the bunk. Thus, feed mu~3t be concentrated
30 toward the deep end of the bunk, with the amount of feed tapering
19
21~64~1
of f toward the narrow end . In these instances, the CPU 3 takes
the total feed amount allocated to the pen and calculates a
proportional distribution to accommodate the irregular pen shape,
with more feed distributed at the deeper eection3 of the pen.
At block 101, initial set points are calculated for truck
speed, discharge rate, e.g. speed of the auger motors 64, and the
position of the hopper door 14. In order to simplify the
calculation, truck speed and discharge rate can be set at
constant valuee for certain feed rate ranges, with the door
10 opening poeition being calculated based upon those preset values
and the specific desired feed rate. Of course, any two of the
three variables can be preset for a given feed rate range, with
the third variable calculated.
At block 102, the truck is configured for the calculated set
points as it reaches one end of the bunk 7, as, depending upon
the sophistication of the system, the CPU 3 either directly
controls the speed, auger motor speed and door opening position,
or displays the desired values to the driver via the display 4,
with the driver manually manipulating the controls. In a more
20 basic system, this may end the routine, or a repetitive check can
be accomplished to update the driver' 8 displayed set points one
third or one half of the way down the bunk, for example.
In the optional, f~n~nrt~ system, block 103 represents the
active feed control routine, as shown in Fig. 6. Referring to
Fig. 6, at block 104, the truck 1 begins moving alon 9 the bunk 7,
distributing feed at the initial set point rate, as displayed in
the display window 82. At block 105, the system checks for a
manual override, which the driver would input via the keyboard 5,
for example. I~ the manual override is on, the active feed
3 0 routine is ended. If no manual override is detected, while the
g.~
truck 1 is moving, the CPU 3 constantly samples the truck ground
speed or posltion, via the speed or position sensor 44 at block
105, and recalculates the distance to the end of the bunk 7 based
thereo~, at block 106. Simultaneously, in real time, the CPU 3
senses the feed rate via the feed chute sensors 34 and/or the
hopper load cells 42 at block 111, and calculates both the amount
fed in this bunk at block 112 and the amount rr-~;n;n~ to feed in
the bunk at block 113. The CPU 3 also does a comparison each
time the amount Ll ;n;n~ to be fed is calculated, and, if this
10 is er~ual to 2ero, stops feeding and re8et8, as indicated at block
114, which entails a return to the top of Fig. 5 to initialize
the truck for the next scheduled pen. If the amount rPrn~;nin~ to
be fed is greater than zero, then, at block 115, a new feed rate
is determined by dividing the bunk len~th rf~m~; n; n~ by the amount
of feed rr~n;ng to feed in this bunk, and the vehicle speed,
door opening, and/or auger motor speeds are adjusted to new set
points to ad~ust for the newly calculated feed rate. At block
115, if pattern feeding is needed, the CPU 3 also accommodates
f or stored pattern f eeding criteria by comparing the truck
20 position in the bunk with stored pattern criteria for that
location and ad]usts the feed ra~e accordingly. Depending upon
the computing speed of the C~U 3, this active feed control
algorithm, as represented by Fig. 6, i8 repeated up to 20 times
per second, so that constant ad~ustments are made to accommodate
for variables such as road conditions, moisture in the feed,
driver performance, etc. The total amount of feed rl 1nin~ on
the truck 1, as displayed in the display window 83, also has an
effect upon feed rate due to the lessening effects o~ gravity as
the hopper 11 empties. Each of these variables is automatically
30 accounted for in the active feed control algorithm.
21
~ 21~91
The benefits for a feedlot operation provided by the
inventive system include the provision of an even distribution of
the assigned fe~d amount throughout the length of each bunk 7
while compensating for variations in pen configuration and bunk
length. The system ends the need for the truck drivers to back
up and retrace portions of their feed route, with the consequent
increased time and fuel consumption and the increased maintenance
expenses which this entails. In addition, again, the system
virtually eliminates the need for specialized driver training,
10 permitting an inexperienced driver to distribute feed virtually
a6 unif ormly as one with years of experience .
While the inventive feed monitoring and control system has
been illustrated and described for use in a livestock feeding
operation, it is not 80 limited. The monitoring and control
system is equall~ useful in feeding operations for aquatic fish
hatcheries or farms, where many of the same feeding requirements
apply. Other contemplated uses include t~e distribution of seed
or fertilizer in agricultural operations, salt or other freezing
level reducing agents on roadways, or any other distribution of
20 feed or granular material where an even distribution of material
per given length is desired.
In addition, while specific truck speed and flow rate
sensors have been described, it should be noted that other types
of sensors could be used as well. For example, a global
positioning sensor or a loran based sensor can be used to detect
truck ground speed and position, and an infrared or ultrasonic
based f low rate sensor or other motion detector can be used to
detect the rate of flow of feed from the truck 1. Instead of
feed transfer augers, other feed distribution systems could be
30 used as well. In addition, while the system has been shown
22
~ 214~9~
mounted in a truck 1, it would be equally u~eful in an
agricultural tractor or the like pulling a feed di~tributing
wagon .
It is to be under~3tood that while certain form~ of the
preE3ent invention have been illustrated and de~cribed herein, it
i~ not to be limited to the F~pecific forms or arrangement of
part~ de~cribed and shown.
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