Note: Descriptions are shown in the official language in which they were submitted.
WO 94/15453 , o ~ ~ ~ PCT/US93/12226
FEED CONVEYING APPARATUS
Background of the Invention
This invention relates to animal or poultry feeding systems in which a
. 5 pulverant, fluent feed is conveyed to a series of feeding stations where
it is dispensed for
chickens (or other animals or birds) to eat, and, more particularly, to a feed
intake unit
to which the feedstock is delivered and from which it is conveyed.
Poultry feeding systems are well-known in the art. See, for example, U.S.
Patent Nos. 4,850,307; 4,460,230; 4,003,339; 3,971,340; 3,598,087; 3,415,228;
and
3,230,933. As shown in these representative patents, feedstock from a bulk
feed tank or
the like is delivered to an intake cup or hopper. From the hopper, the feed is
delivered
to a conveyor which services a number of feeding stations. In large poultry
houses, one
of these conveyors may have a length of up to 400 feet and there may be 200-
300 or so
of the feeding stations. The feed is conveyed, usually by means of an auger
received in a
feed conveyor tube extending through each of the feed stations. The auger may
either
be rotary driven or axially propelled within the tube to convey the feed from
the intake
cup and from feeder to feeder. Feed is deposited from the conveyor into feed
pans of the
feeders located at each station for subsequent consumption by the birds.
It is a problem with present feeding systems that they can become
overloaded and jammed up with feed. This situation is likely to occur, for
example,
when the feeders are full. Then a substantial amount of feed is retained in
the conveyor
loop. At the same time, additional feed is being dispensed from the hopper
into the
conveyor. When that happens, the pressures created compact the feed in the
conveyor
loop until all void spaces are filled or packed. The resultant pressures
eventually cause
the auger to jam and stop moving. For example, in certain of the prior art
feeding
systems (such as shown in U.S. Patent 4,850,307), it is a feature of these
systems that
voids are intentionally formed between the flights of the auger within the
conveyor tube
through the use of bailles within the intake cup so as to restrict the flow of
feed to the
auger. However, it has been found that if no feed is being dispensed to the
feed stations
and as the conveyor is run continuously, these voids tend to become overfilled
as more
feed is delivered to the auger. The feed at the inlet to the conveyor is also
compacted,
as is the feed above it. In this latter regard, even if the feed at the inlet
to the conveyor
is broken up, the compacted feed above it may create a solid bridge preventing
any feed
from reaching the conveyor from the hopper.
If the further delivery of feed to the conveyor system ultimately jams the
auger, the conveyor feed tube must be disassembled, the compacted feed cleaned
out,
CA 02150221 2004-08-16
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and everything then reassembled. The feed intake to the conveyor must also be
cleaned out
to break up deposits of compacted feed. This is not only a time consuming and
expensive
process, but it means the poultry is either not fed, or must be fed by hand or
in some other
manner during the down time.
Summary of the Invention
In one aspect, the invention provides a feed intake apparatus for a poultry or
livestock
feeding system, the apparatus comprising at least one housing having a feed
inlet which
receives feed from a feed supply and a feed outlet, a feed conveyor extending
from the
housing in an endless loop and returning to the housing, a plurality of
feeders spaced along
the endless loop, the feed conveyor comprising a conveyor tube and a conveyor
element
disposed within the tube, the conveyor element having a multiplicity of
conveying elements
spaced therealong, the conveyor element being axially driven within the
conveyor tube
around the endless loop for picking up feed from the housing and for conveying
it through the
conveyor tube to each of the feeders along the conveyor path and for returning
any excess
feed to the housing, and a regulating tube within the feed outlet receiving an
auger, the
regulating tube including a regulating section having a diameter only somewhat
greater than
the diameter of the auger thereby to regulate the amount of feed carned by the
auger and to
insure that a partial void is provided in the conveyor tube downstream from
the feed intake
apparatus thereby positively preventing over compaction of feed in the
conveyor tube. The
regulating tube may further comprise a striping section upstream from the
regulating section
having a diameter only somewhat larger than the diameter of the auger for
stripping excess
feed carned by the auger. The regulating tube may have a discharge outlet
upstream from the
feed striping section for the discharge of the excess feed striped from the
auger by the striping
section. Suitably, the tube has a feed inlet opening intermediate the striping
section and the
regulating section for directing feed into the auger upstream of the
regulating section thereby
to insure the supply of fresh feed to the conveyor. Preferably, the conveyor
element is an
auger housed within the conveyor tube, the feed auger having a multiplicity of
substantially
equally spaced flights with at least some of the auger flights within the feed
intake apparatus
being open from above, the apparatus further comprising an agitator member
engageable with
the auger flights as the latter move through the housing so as to effect
intermittent movement
CA 02150221 2001-O1-17
3
of the agitator member relative to the auger. Preferably, the agitator member
has an elongate
member extending therefrom into the housing for agitating feed within the
housing so as to
insure that the feed flows to the regulating tube for being picked up by the
auger and
conveyed by the feed conveyor.
In a further aspect, the invention provides a method of conveying feed from a
bulk
supply of the feed to a plurality of feeders by means of a feed conveying
system, the feed
conveying system comprising a housing for receiving a supply of feed, a
conveyor tube
extending along a feed conveyor path from the housing to a multiplicity of
feeders spaced
along the conveyor tube with each of the feeders receiving feed from the feed
conveying
system, the feed conveyor path extending in an endless loop and returning to
the housing, a
feed conveying element disposed within the feed conveyor tube and being
axially propelled
therewithin around the endless loop, wherein the method comprises the steps
of:
(a) axially propelling the feed conveying element through the feed conveying
tube
and around the endless loop to pick up feed from the housing and for
delivering feed to each
of the feeders around the endless loop and thence returning any excess feed to
the housing;
(b) regulating the amount of :feed carried by the feed conveying element
downstream
from the housing to an amount less than will fill the feed conveyor tube so as
to form a partial
void within the feed conveyor tube; and
(c) continuously driving the feed conveying element through the feed conveyor
tube
after all of the feeders have been filled with feed so as to replenish feed
within the feeders as
such feed is consumed without jamming the feed conveying element within the
feed conveyor
tube.
Brief Description of the Drawings
Fig. 1 is a representation of a portion of a poultry feed delivery system with
which the intake
cup of the present invention is used;
Fig. 2 is a top plan view of the cup with a paddle or stirring assembly used
in the first
embodiment of the invention;
Fig. 3A is a sectional view of the cup taken along line 3-3 in Fig. 2;
Fig. 3B is a sectional view of another embodiment of the cup of Fig. 3;
Fig. 3C is a view (see sheet 7) on, an enlarged scale taken along line 3C - -
3C of Fig. 3B
illustrating a gear having teeth bent out of the plane of the gear with the
gear driven by the
CA 02150221 2001-O1-17
3a
conveyor auger;
Fig. 3D is a view similar to Fig. 3C wherein the gear teeth have enlarged end
portions
interengageable with the flights of the anger so as to aid in the breaking up
of compacted feed
between the flights;
Fig. 3E is a view taken along line 3E - - 3E of Fig. 3C illustrating in plan
manner in which
the bent gear teeth mesh with the auger to dislodge compacted feed and to
regulate the amount of
feed;
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Fig. 4 is a top plan view of the cup with a ball installed in the cup and used
in a second embodiment of the invention;
Fig. SA is a sectional view of the cup taken along line S-5 in Fig. 4;
Figs. SB and SC illustrate additional ball configurations for the second
embodiment;
Figs. 6A and 6B are, respectively, a perspective view of the ball (Fig. 6A)
and a combined ball and agitator rod (Fig. 6B);
Fig. 7 is a plan view of the cup of Fig. 4 with portions of the ball broken
away a frame installed in the housing of the
cup for holding the ball agitator in a desired position with respect to the
auger;
Fig. 8 is a side elevational view of one side member of the frame;
Fig. 9 is a plan view of the cup housing with a multiple diameter regulator
tube of the invention installed;
Fig. 10 is a side view of the tube;
Fig. 11 is a top view of the tube; and
Fig. 12 is a side view of a second embodiment of the tube;
Fig. 13 is a side elevational view of the lower portion of an intake feed cup
of the present invention incorporating the regulator tube of Figs. 9-12
illustrating the
conveyor tube having a flared bell end adapted to be received on an inlet tube
and on an
outlet tube of the intake housing;
Fig. 13A-13F illustrate the various diameters of the agitator tube and their
relation to the diameter of the conveyor tube and the auger so as to loosen
compacted
feed, to supply fresh feed, and to form a void (regulate) in the conveyor tube
to prevent
over filling;
Fig. 14 is a semi-diagrammatic view of a feed delivery and feeder system
using multiple conveyor drives and multiple feed intake cups of the present
invention;
Fig. 15 is a view of a bulk feed tank which supplies feed to the intake feed
cup of Fig. 1 with the bulk feed tank
having an outlet boot at the bottom thereof with a rotary driven auger within
the boot
and with an agitator in the boot similar to the agitator disclosed above in
regard to Figs.
4-8; and
Fig 16 is an enlarged view taken on line 16--16 of Fig. 15 illustrating a ball
agitator/rod for breaking up compacted feed within the outlet or boot portions
of the
bulk feed tank.
Corresponding reference characters indicate corresponding parts
throughout the drawings.
~WO 94/15453 ~ ~ PCTIUS93/12226
Description of Preferred Embodiments
Referring to the drawings, a poultry feeding system is indicated generally
in Figs. 1 and 14. System 10 includes a hopper 12 into which feed is received
from a
bulk feed tank BFT or the like (see Fig. 15). From hopper 12, the feed
gravitates (falls)
5 into an intake or hopper unloader cup 14 which comprises the present
invention and
which is described in detail hereinafter. From cup 14, the feed enters a
conveyor 16.
The latter includes a conveyor tube 17 in which an auger 18 is located.
Preferably,
auger 18 is a centerless auger having the appearance of a stretched out coil
spring.
Auger 18 driven by a drive mechanism 20 to cause the feed to be transferred by
10 conveyor 16 to one or more feed stations 22. Auger 18 may be rotatably or
linearly
driven by the drive mechanism. Auger 18 may be linearly propelled through tube
17 by
means of a drive gear having gear teeth in mesh with the flight of the auger.
Such a drive
is described in U.S. Patent 4,460,230.
Alternatively, the auger maybe rotary driven within the conveyor tube such
that the auger acts like a screw to convey the feed through the conveyor tube.
Still
other well-known feed conveyors (e.g., a chain conveyor) may be used. As shown
in
Fig. 14, when auger 19 is linearly propelled, conveyor 16 may be an endless
closed track
system in which the conveyor 16 is arranged in a closed loop configuration
around the
poultry house. As shown in Fig. 14, additional drive mechanisms 20 and
additional
intake feed cups 14 may be located along the loop to facilitate movement of
feed to the
various feeders 22.
In delivering feed to feeders 22, one problem which is encountered is feed
compaction. Compaction is usually caused by an over abundance of feed being
conveyed through the system. If, for example, feed currently in the conveyor
is not
deposited at a station because the feed already there has not been consumed,
excess feed
in the conveyor will be circulated back to cup 14. At the same time,
additional feed
flows from hopper 12 into cup 14 for entry into the conveyor. Since the flow
of feed
through the cup is by gravity, the feed will exert a substantial amount of
"hydrostatic"
pressure on the feed so as to pack even more feed into the feed conveyor. And,
since
the excess feed in the conveyor is being constantly recirculated throughout
the feed
loop, rather than deposited at the stations, it often becomes more and more
compacted
until jamming occurs. If the conveying system gets jammed, it must be
disassembled by
removing the auger from the conveyor tube, the compacted feed cleaned out, and
the
system then reassembled. This creates a time consuming and expensive delay
especially
considering the number of birds fed by the system, and the amount of wasted
feed which
WO 94/15453 . PCTJUS93/12226
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6
is created by the jam. Intake cup 14 of the present invention alleviates feed
compaction,
and thus eliminates the attendant time delay and cost.
In Figs. 2 and 3A, a first embodiment of the intake cup is shown to include
a housing 24. The housing has a generally rectangular upper end 26 the side
walls 28 of
which define a feed inlet I. Respective flanges 30 are formed at the upper end
of each
side wall for attachment of the intake to the bottom or outlet end of hopper
12. It will
be appreciated that feed may be supplied to cup 14 by means other than hopper
14. For
example, feed may be supplied by means of a suitable drop tube (not shown).
Side walls
28 of housing 24 also have a lower tapered section 32 for the lower end of the
housing
to define an outlet O into which feed flows from the intake cup 14 into
conveyor 16.
Feed conveyor 16 is connected to housing outlet O for the feed flowing
through the housing to flow into the conveyor. The conveyor includes conveyor
tube 17
having an inlet end at the outlet of the housing and a series of spaced
outlets 36, one at
each feed station 22. The lower end of section 32 of housing 24 has a rounded
semi-cylindrical base portion, as indicated at 38 in Fig. 3A. In addition to
helping to
define outlet O of the intake cup, base portion 38 also provides a housing for
auger 18.
The auger moves rotatably in or linearly through housing section 38 for
conveying feed
falling from the hopper to be delivered to the conveyor and to be distributed
to the
outlets 36. Alternately, and as described hereinafter, a multiple diameter
tube 40, see
Figs. 9-11, may be installed through openings 42 in the lower sidewall of the
housing,
and auger 18 is movable axially through this tube. The multiple diameter tube
40 serves
to permit more feed from within housing 24 to enter the conveyor and also
serves to
prevent over filling and/or over compaction of the feed in a manner as will
appear.
Referring to Fig. 3A, an optional baffle 44 within housing 24 has one end
attached to a side wall 28 of the housing at the upper end of the housing.
Baffle 44
angles downwardly into the housing to form a chute for the feed F delivered to
cup 14
from the hopper. In addition to baffle 44, a support plate 46 is also attached
to a side
wall 28 of the cup housing. The upper end of plate 46 is, as shown in Fig. 3A,
attached
to the same side wall 28 as is the upper end of baffle 44, so the baffle and
plate depend
- 30 from the same side of the housing. Baffle 44 overhangs plate 46 minimize
the effect of
"hydrostatic" pressure of the feed in the intake cup and hopper 12 from over
compacting
the feed. Or, as shown in Fig. 2, baffle 44 does not have to be used.
An agitator 48 is positioned in the tapered lower end of housing 24 so as
to agitate the feed falling into the outlet of the intake cup. By churning or
stirring the
feed within housing 24, it will not be easily compacted and therefore will not
bridge
within the housing and will thus flow continuously down toward the conveyor.
Agitator
WO 94115453 ~ PCTIUS93/12226
:a
..,, :f. , .. .
48 first includes a pair of rotatable blades 50 and 52, respectively, commonly
mounted
for rotation on a shaft 54. The stirring blades are mounted on the shaft so
they are at a
90_ angle to each other as shown in Fig. 2. Shaft 54 extends through support
plate 46
and is rotatably supported on the plate 46 and on housing 24 by bearings 56. A
gear 58
is fixedly mounted on shaft 54. The gear is located such that its teeth 60
extend into the
outlet portion 38 of the housing. The teeth mesh with flights 62 of auger 18
(see Fig.
3C). Consequently, movement (either axially or rotary) of the auger turns the
gear, and
rotation of the gear causes rotation of the agitator blades 50, 52. This
produces the
stirring action discussed above. In operation, upper blade 50 of the blade
assembly
promotes flowability of feed from the hopper, and the lower blade 52 provides
agitation
of the feed to keep it flowing into the outlet. As gear teeth 60 move in and
out of mesh
with the flights 62 of auger 18, the gear teeth move in toward the center of
the auger
and thus physically break up compacted feed carried by the auger. Thus, the
gear teeth
tend to prevent over compaction, over filling, and jamming of the conveyor.
Further, as
~ excess, compacted feed is dislodged from the auger by the gear teeth, fresh
feed is
re-mixed therewith such that fresh, loose feed is conveyed from the feed cup
to feeders
22.
It will be appreciated that teeth 60 of gear 58 may be enlarged and may be
of a bulbous shape so as to fit more closely between the flights 62 of auger
18 thereby
to aid in breaking out compacted feed within the auger and to insure proper
conveyor
filling and to reduce or nunimize the possibility of jamming the conveyor.
Figs. 3B and 3C illustrate an alternate embodiment of agitator means 48
from that shown in Fig. 3A. In Fig. 3B, a gear 58" (a third rotatable stirring
blade)
mounted on shaft 54. The teeth 66 of gear 58" are angled or bent with respect
to the
body of the gear for contact with flights 62 of auger 18. Now, as the auger is
moved,
the bent gear teeth 66 are engaged by the moving auger 18 thus causing gear
58" to be
rotated in the appropriate direction producing, in turn, rotation of blades 50
and 52.
Blades 50 and 52 function as previously described. Bent gear 58" provides the
additional feature of regulating feed level. This is important when, for
example, the
auger is completely filled with feed. Through use of bent gear 58", as the
bent gear
teeth 66 move down into, across, and up out of the space between the flights
62 of
conveyor 18, so as to dig out compacted feed thus resulting in a positive
displacement
of excess feed. In Fig. 3C, the bent gear 58" is shown in side elevation and
it can be seen
that bent gear teeth 66 move down and into the auger below the centerline
thereof.
Simultaneously, as shown in Fig. 3F, the teeth sweep horizontally across the
auger. In
this manner, compacted feed within the auger is positively broken up,
dislodged and is
WO 94/15453 ' y : . : PCTIUS93112226
8
physically discharged from the auger. This then allows the auger to move
through the
unloader cup and into conveyor tube 17 not completely filled thereby
minimizing the
tendency to jam. As discussed above, it is when the auger is filled that
jamming of the
system is likely to occur. Also, fresh feed within the intake cup may be mixed
with the
dislodged jammed feed.
As shown in FIG. 3b, a plate 47 is cantilevered from sheet 46 so as to
extend above and along side a portion of auger 18 so as to prevent feed
dislodged from
the auger by gear teeth 66 from falling back into the auger. This aids in
preventing
jamming of the auger.
It will be understood that if gear 58" is moved toward or away from the
center line of auger 18, the amount of feed positively dislodged from the
auger may be
regulated. More specifically, if gear 58" is moved in toward the centerline of
the auger,
teeth 66 will penetrate the auger to a greater extent and more feed will be
displaced
from between the flights.
It will be understood that while gear 58 is shown to be formed of relatively
heavy sheet metal with gear teeth 66 bent therefrom, gear 58" may be molded
from a
suitable plastic. If
gear 58" is molded of plastic, it may be desirable that the planar body of the
gear be of a
thickness corresponding generally to the thickness that its gear teeth 66 are
"bent" out
of the plane of the gear body. In other words, if the bent teeth 66 are bent
out of the
plane of the gear body 5/8 inch, the molded gear may have a thickness of 5/8
inches.
It will be appreciated that with the gear agitators 58 and 58" described
above in regard to Figs. 3A and 3B, auger 18 may either be linearly driven in
tube 17 by
a gear drive system as described in the above-noted U.S. Patent 4,460,230, or
may be
rotary driven.
It will be appreciated that due to the construction of the intake cup 14 of
the present invention and the operation of gears 58 or 58", the feed conveyor
may be
operated without jamming after all of the feed stations 22 have been
completely filled.
This insures that conveyor tube 17 is charged with feed between each of the
feeders 22.
Thus, upon startup of the conveyor system, feed is delivered simultaneously to
all of the
feeders thereby preventing the birds in a poultry house from being attracted
to only a
few of the first feeding stations to receive fresh feed. .
Referring now to Figs. 4-6, a second and gearless embodiment of the feed
intake cup and agitator is indicated generally 114. As before, cup 114
transfers or
unloads feed from hopper 12 to conveyor 16 so the feed can be delivered to the
feed
stations 22. Cup 114 includes a housing 124 having an inlet I' which is
connected to the
-WO 94/15453 'r' PCTIUS93/12226
9
outlet of hopper 12 for feed to flow into the housing through the inlet.
Housing 124 has
an upper rectangular shaped section '126 comprised of side walls 128. The
upper end of
the side walls define housing intake I'. The lower reaches of the side walls
are angled to
form a second and generally tapered section 132 for flowing the feed into
housing outlet
O'. As shown in Figs. 4 and 5, bolts (or rods) B 1 and B2 extend transversely
of the
centerline of the outlet across the housing. The bolts are located adjacent
the respective
end walls of the housing. The bolts are secured to the housing by nuts N. It
will be
noted that the bolts also act to stir the feed since the feed flowing into the
outlet end of
the housing must divert itself around the bolts, and then recombine.
The feed conveyor is connected to outlet O' for feed flowing through the
housing to flow into the conveyor. The conveyor includes a hollow tube defined
by a
rounded section 13 8 of the housing walls formed at the lower end of the
housing. Auger
18 is located in this tube for movement as previously described. Like cup 14,
cup 114
includes an agitation means 140 positioned in the housing and movable by auger
18. As
with the agitator paddles or blades 50, 52, means 140 agitates the feed to
prevent the
aforementioned compaction problem within housing 124. Agitation means 140
includes
an agitator weight, preferably a ball 144, installed in the housing. The ball
is sized to fit
in outlet O', and as best seen in Figs. SA-SC, rests upon the upper portion of
auger
flights 62. The diameter of the ball is greater than the spacing of the
flights of the auger.
Consequently, ball 144 is caused to rotate and to move up and down (bounce) by
movement of the flights 62 as auger 18 is propelled either linearly or
rotatably. It will
be understood that while linear movement of auger 18 is preferred, agitator
140 will
work with rotary driven augers as well. Ball 144 is a relatively heavy metal
ball so that
it will bear against the flights of the auger and to be bounced up and down as
the auger
moves. As shown in Fig. 6A, the ball may be hollow and has an opening 146
formed in
it. A hollow ball imposes less weight on the housing than a solid ball so the
housing
walls do not have to be reinforced and prevents undue compaction of the feed
due to the
weight of the ball.
Referring to Figs. 7 and 8, cup 114 further includes a frame 148 mountable
in housing 124 for limiting movement of the ball so that the ball does not
become
dislodged from the auger. Frame 148 includes side pieces 150 which are
connected
together by bolts 152. The bolts are inserted through openings 154 in the side
pieces
and the bolts are secured to the side pieces by nuts 156 attached to each end
of the
bolts. As seen in Fig. 7, frame 148, when installed in the housing is
positioned such that
the spacing between the bolts somewhat greater than the diameter of the ball.
This
holds the ball captive and keeps the ball generally in register with the auger
flights, and
WO 94/I5453 PCTIUS93/12226
.. . ~ . . .. .
2Z~~2~.~
allows the ball to freely contact the auger flights. As shown in Fig. 8, the
side pieces
150 each have an upper main body portion 158 in which the spaced openings 154
are
formed. A pair of legs 160 depend from the sides of the main body. The legs
are
spaced apart such that when the frame is positioned in the housing, the base
of the legs
S rest upon the transversely extending bolts B 1, B2. The main body portion of
the side
pieces then keep the ball from being rolled up the tapering side walls of the
housing.
Finally, sleeves 162 can be fitted over the bolts 152 as shown for the left-
hand bolt in
Fig. 7. Each sleeve is of a plastic material which not only protects the bolts
from
damage by contact with the ball; but also, prevents any moisture in the feed
from
10 contacting the bolt and causing it to rust and prevent the feed from
sticking to the bolts.
Referring to Fig. SB, agitation means 140 is shown to include a ball 144a.
Unlike the ball 144 shown in Fig. 6A, ball 144a has an elongate rod 164 fixed
to the ball
and extending upwardly therefrom into the upper reaches of the intake cup 114
above
auger 18. As the ball moves up and down due to movement of auger 18, the ball
and
the rod are repeatedly move (oscillate) about and churn the feed falling into
the outlet
portion of the cup. In addition, the upper end of the rod may be flattened, as
indicated
at 166. A chain may be attached to this flattened end of the rod. The outer
end of the
chain is connected to a sidewall of the housing, at the upper end of the
housing by a
crossbar 170. Since the chain is connected to the free end of the rod, the
chain tethers
the rod in a generally desired vertical position, but allows the ball and the
rod to be
moved freely by the auger. Further, the chain provides a flailing action as
this upper end
of the rod moves around in the housing. This provides a further stirring
action to the
feed. In addition, if the feed were to bridge over any portion of hopper 14 or
intake cup
12 so that feed could not flow down into the outlet O, the flailing action of
the rod or
chain would readily breakup any such bridging of the feed to reestablish the
flow of
feed.
While rod 164 is shown in FIG. SB as being supported by a single chain
168, it will be understood that multiple chains may be used or even preferred
to maintain
the rod in its desired upright position and to further agitate the feed.
As shown in Fig. SC, the length of the rod can be longer than that shown
in Fig. SB. Here, a rod 164a is attached to ball 144a so as to extend well up
into hopper
114. A guide ring 172 is centrally positioned in this upper end of the
housing. The ring
is located in place by respective arms 174a, 174b. The upper end of rod 164a
extends
through the guide ring. Now, as ball 144a moves about, the upper end of the
rod
executes a swirling motion which is generally circular. The extent of this
motion defined
by the extent to which the upper end of the rod extends through the guide ring
and the
~WO 94/15453 ~ ~ PCT/US93/12226
diameter of the guide ring. In any event, the result is to provide a stirring
motion for the
feed flowing through the cup.
With the above described embodiments using the ball 144 or 144a (as
shown in Figs. 4-7), it will be understood that the ball could be of different
diameters.
The constraint is that the diameter be large enough that the ball not slip
between
adjacent flights 62 of auger 18 and block its operation. On the other hand,
the diameter
cannot be so great that an adequate continuous flow of feed into the outlet of
the cup is
prevented. Similarly, the length of rod 164 can be of any of a range of
lengths. The
constraint is that it cannot be so short as to allow itself to fall between
adjacent flights of
the auger. Again, this would jam the auger.
While the balls 144, 144a are shown to be positioned above the centerline
of auger 18, it will be appreciated that in certain designs of the intake cup
114, the balls
may be located off the vertical centerline of the auger between about
approximately the
10 O'clock or 2 O'clock positions. It will be understood that if ball 144 is
located off
the centerline of auger 18, the auger will impart not only vertical movement
to the ball,
but the ball will also be rotated.
Referring now to Fig. 15, a bulk feed tank BFT is shown located
proximate a poultry hose H in which feeding system 10 is installed. Typically,
such bulk
feed tanks (or other storage silos or bins) are used in conjunction with
feeding system 10
to store large quantities of feed and to supply the intake feed cups 14 and
114
previously described. As shown, the bulk feed tank has a raised tank body 201
with a
downwardly converging outlet section 203. At the bottom end of the outlet
section, an
outlet boot 205 is provided for directing feed from within the tank into a
feed supply
auger conveyor 207.
The feed supply auger conveyor 207 has a conveyor tube 209 in which a
rotary driven auger 211 is driven by a motor 213. The auger conveyor supplies
feed by
means of drop tubes 215 to the intake cups 14 and 114 located within the
poultry house.
A portion of the auger within boot 205 is open to feed in the lower reaches of
the outlet
section 203.
As best shown in Fig. 16, a ball agitator 217 (similar to agitators 140
previously described in regard to Figs. 4 - 8) is provided within boot 205 and
outlet
section 203 so as to agitate the feed therein and to insure the free flow of
feed to auger
211. More particularly, ball agitator 217 comprises a ball weight 219
positioned within
outlet boot 205 in position to bear on the exposed section of auger 211 such
that the
ball weight will be bounced up and down and in other manners upon rotation of
the
auger by drive motor 2I3. The ball weight may be provided with a rod agitator
221
WO 94/15453 PCT/US93112226
similar to rods 164 or 164a previously described, except the agitator rod for
a bulk feed
tank may be considerably Longer than the rods used in an intake cup
application. For
example, an agitator rod for a bulk feed tank my be 6 - 10 feet long. Of
course, the
agitator sod 221 may be guided by either a fixed ring collar 223 (similar to
collar 172)
supported within outlet section 203 by arms 225, or by a tether chain (not
shown in Fig.
16) similar to chain 168 in the manner heretofore described in regard to Figs
SB and SC.
Further, the agitator rod 221 may optionally be provided with arms or pegs 227
which
extend out from the rod at various positions therealong so as to engage and to
stir more
feed than an agitator rod without the arms could contact upon the ball weight
being
moved (oscillated) by the auger.
As previously noted, rod 221 may be several feet long so as to extend a
considerable distance above auger 211. As the rod 221 oscillates up and down,
compacted feed within outlet 203 is caused to fall downward around rod 221
toward the
auger thus forming an inverted cone-shaped area of loosened feed or, in some
instances,
an inverted cone-shaped opening. Continued up and down movement of rod 221
loosens the compacted feed alt along the length of the rod.
It will be appreciated that by using the ball agitator 217 and rod 221 within
a bulk feed tank, cumbersome unloading flails and other unloaders previously
used with
bulk feed tanks may be eliminated. Upon start up of the auger drive motor 213,
ball
agitator will automatically be operated. Alternatively, it will be appreciated
that in some
bulk feed tank applications or the like, the ball agitator above described may
employ
drive other than an auger. For example, the ball agitator may be bounced up
and down
or otherwise oscillated by means of a rotary driven cam or other oscillatory
drive.
In conjunction with or separate from the use of ball agitator 217 in boot
205, a bent gear agitator (not shown in Figs. 15 or 16) similar to gear 58"
described in
conjunction with Figs. 3B and 3C above may be employed. More specifically, the
bent
gear teeth 66 of gear 58" are engaged by auger 211 such that rotation of the
auger by
drive motor 213 causes the gear 58" to rotate. Thus the bent gear teeth 66
positively
draw feed from boot 205 into the auger, and, if such auger becomes filled with
compacted feed, tends to dig out the compacted feed.
In addition to use of the gear driven agitators 48 in cup 14, or the agitator
142 of cup 114, the present invention may further be constituted by multiple
diameter
agitator or regulator tube 300 (see Figs. 9-13) which is insertable through
the outlet
portion of housing 24 or 124. Auger 18 extends through tube 300 and is movable
therein, reciprocally or rotatably, to transport feed through conveyor 16. As
seen best
in Figs. 10 and 11, tube 300 has three sections, as indicated at 302, 304, and
306,
WO 94!15453 ~ ~ ~ ~ ~ PCT/US93/12226
13
respectively, with a narrow cutout 308 being made between sections 302 and
304, and a
substantially longer cutout 310 between sections 304 and 306. As indicated in
Fig. 10,
tube 300 the auger enters the tube at its left hand end and exits from the
right hand end.
Auger 18 may, for example, have an outer diameter of about 1.438 inches (3.65
cm).
Tube 300 has a uniform outer diameter A along its length. This diameter may,
for
example, be 1.75 in. (4.45 cm.) and the radius 0.875 in. (2.22 cm). The wall
thickness
at the inlet end 302 of the tube is indicated B and is (for example) 0.035 in.
(0.089 cm).
This means the inside diameter of the pipe, at its inlet end 302 is 1.68 in.
(4.27 cm)
which is considerably larger than the outer diameter of auger 18. In addition,
the
distance from the lower outer wall of the tube to the upper inner wall
thereof, dimension
C in Fig. 10, is 1.715 in. (4.36 cm). As can be seen in Fig. 13, the inner
diameter of the
inlet section 302 of tube 300 is approximately the same as the inner diameter
of
conveyor tube 17. The later has a flared, bell end 1T sized to be received on
the end of
section 302 to connect the conveyor tube to tube 300.
Tube 300 may, for example, have a length of about 12 in. (30.5 cm).
Section 302 is 2.625 in. (6.67 cm) in length. Cut out section 308 is, for
example, 1 in.
(2.54 cm) in length. Approximately half way along the length of section 308,
or 3.125
in. (7.94 cm) from the inlet end of the tube, the wall thickness of the tube
changes from
the dimension B value to the thicker wall thickness as indicated by dimension
D. This
transition in thickness is indicated at 312. The new wall thickness of the
tube is, for
example, 0.113 in. (0.29 cm), and is uniform throughout the remaining length
of the
tube.
Tube section 304 is also 1 in. (2.54 cm) in length and has the thicker wall.
The inner diameter of the tube at intermediate uniform section 304 is now
reduced to
1.524 in. (3.87 cm), which is only somewhat greater than the 1.438 in. (3.65
cm)
diameter of auger 18. It will be appreciated as auger 18 enters section 304,
any excess
compacted feed carried on the outside of the auger 18 is physically stripped
from the
auger. In addition, the relatively close tolerance between the inner diameter
of stripping
section 304 and auger 18 tends to guide the auger as the later passes through
tube 300.
Cut out 310 extends for 4.75 in. (12.07 cm), for example. The wall
thickness throughout this section is the thicker wall section. Lastly, section
306 is the
same length as section 302. The wall thickness at this outlet end of the pipe
is the
thicker wall thickness. Now, the distance from the lower outer wall of the
tube to the
upper inner wall, dimension E in Fig. 10, is 1.638 in. (4.16 cm). These
dimensions and
the corresponding cross sectional areas of the tube, the auger, and the amount
of feed in
the auger at various locations are shown in Fig. 13.
WO 94/15453 _ , PCT/US93/12226
21~~0221~
The construction of regulator tube 300, as above described, is designed to
prevent feed compaction in auger 18. It will be noted that the transition in
the tube at
312 from a larger inner diameter to a smaller diameter is located in the
cutout section
308 of the tube. Since larger diameter section 302 is at the inlet end of the
tube, excess
feed which has traveled around the conveyor loop with the auger is subject to
a
stripping or scraping action as the auger enters intermediate section 304
which is of the
smaller diameter so as to scrape the excess feed off the auger. The scraped
off feed
flows via discharge opening 308 back into the cup. Fresh feed delivered
through the
cup to the outlet now enters the tube through inlet cutout 310. The scraped
off feed is
stirred in the with new feed by either gear agitator 48 or by a ball agitator
140, as
previously described. As the auger, with the excess feed scraped off and with
a full
charge of loose, fresh feed from inlet opening 310, enters the smaller
diameter scraper
section 306 and as the auger moves with the conveyor tube, the feed level
within the
conveyor tube and excess feed is removed from the auger so as to regulate or
meter the
amount of feed carried by the auger to a predetermined amount. As the auger
enters the
full diameter of the conveyor tube 17 which is of a larger cross section than
regulator
section 306, a void V (see Fig. 13F) is formed in conveyor tube 17 thus
insuring that the
feed in the conveyor is not jammed and is free to flow into each of the
feeding stations
22.
As a result, dual diameter regulator tube 300 performs the feed regulation
and compacted feed dislodgment functions earlier described and performed by
the gear
teeth 60 or 60' of gears 58, 58". Because compacted feed is scrapped from the
auger by
small diameter section 304, and because the scrapped off excess feed is
returned to the
interior of the intake cup, the regulator tube 300 functions like a stationary
agitator thus
eliminating for the need for rotary gears and other moving parts. It will be
understood
that while discharge opening 308 and inlet opening 310 are shown to be
separate from
one another, it has been found that a single opening may function as both the
discharge
and inlet opening.
It will be appreciated that by changing the inner diameter of sections 302
and 304 relative to the diameter of the auger 18, the amount of feed
regulation effected
by tube 300 may be varied.
With respect to Fig. 12, a tube 300x, is shown to be comprised of two
tubes 314 and 316, respectively. Both tubes have identical outer diameters
corresponding to the diameter values noted above. Tube 314 has a different
inner
diameter from that of tube 316. Again, these diameter values correspond with
those
discussed for tube 300. The length of the tubes correspond to the respective
lengths of
WO 94/15453 ~ ~ ~ ~ PCT/US93112226
the larger and smaller diameter sections of the tube 300. Tubes 314 and 316
are
connected together, for example, by welding as indicated at 318. While tubes
314 and
316 could be joined together to form the tube, a single tube may be preferable
for use in
the conveying system. This is because a single tube is easier to align during
installation,
5 and does not require as many welds to connect to the housing of cup 14 or
114, and the
conveyor tube 17.
Referring now to Fig. 13 and to Figs. 13A - 13F, multiple diameter
agitator tube 300 is shown installed in an intake cup 114 (as illustrated in
Figs. 4 - 9).
As shown, the ends 302 and 306 of the agitator tube extend from the outlet
portion O'
10 of the intake feed cup. These ends have an outer diameter somewhat less
than the inner
diameter of a flared bell end 1T of a conventional conveyor tube 17 such that
with a
flared end on the conveyor tube, the flared ends of the conveyor tube may
readily be
installed on the protruding ends 302 and 306. It will be noted in Fig. 13 that
the inner
diameter of conveyor tube 17 and the inner diameter of the ends 302 and 306
are
15 approximately the same. As shown, auger 18 extends through the multiple
diameter
agitator tube 300 and the auger is preferably linearly driven in the direction
shown by
the arrow in Fig. 13 such that end 302 constitutes and inlet end and such that
end 306
constitutes an outlet end.
Referring to Fig. 14, a typical feed conveyor 16 is illustrated having a
linearly propelled feed conveyor auger 18 driven by drive motors 20A or 20B.
The
latter drive a coarse pitch gear which has teeth in mesh with the flights 62
of auger 18 so
as to linearly (axially) drive the auger through the conveyor tube 17. As
shown, feed
conveyor 16 is an endless loop conveyor. In such conveyor systems, it is
necessary to
join the ends of auger 18 together, as by brazing or by using a connector.
This creates a
double thickness of the auger in the location of the joint. It has been found
that as such
continuous loop augers circulate feed in the conveyor after the feeders 22
have been
filled, a so-called back lagging effect may be encountered. Back lagging is a
condition
in which feed conveyed with the auger between adjacent flights is spilled over
the
trailing flight into the space behind and in which feed from the space between
a pair of
flights moves rearwardly through the center opening of the auger toward the
trailing
flights. Generally, such back lagging is uniform from flight to flight and
does not present
a problem (except that the efficiency of the conveyor is diminished).
However,. in the
area of the joint between ends of the conveyor, a more serious problem is
encountered.
More particularly, the double thickness of the joint between the ends of
auger 18 effectively prevents feed from flowing in a backward movement past
the joint.
Further, the double thickness of the joint partially blocks the flow of feed
through the
WO 94/15453 PCTIUS93/12226
_~~~~2~1 '
center of the auger. As such, a void will form behind the joint and a solid
slug of feed
will buildup in front of the joint. With continued operation of the conveyor
after the
feeders have been filled, and with additional feed being supplied to the auger
from feed
cups 14, the slug of compacted feed carried along with the joint will grow
(increase in
length). Of course, the more compact the feed becomes in this slug and the
longer the
slug becomes, the more friction it creates as it moves through conveyor tube
17 thus
increasing the amount of power required to drive the auger around the conveyor
loop.
Referring to Fig. 14, a test conveyor loop CL is shown having a test length
of about 70 feet and a width of about 10 feet. The test loop has two auger
drive
motors, as shown at 20A and 20B, and a pair of intake feed cups 14 of the
present
invention installed in the conveyor loop. The turns of the conveyor are shown
to be 90
degree corners and are indicated at C. The conveyor loop CL has a conveyor
tube 16
and an auger 18, as previously described.
In a first test, the conveyor was driven only by drive motor 20A and was
1 S operated for about 15 minutes to with no feed in conveyor tube 17 and with
no feed in
the feed cups 14 so as to establish a steady state no load condition. The
current
supplied to drive motor 20A was measured to be 4.3 amps. Feed was then
supplied to
intake cups 14 so as to fill the conveyor and an excess supply of feed was
maintained in
each of the feed cups so as to continue to add feed to the conveyor. As the
feed was
added, the current required by drive motor 20A increased to 5.3 amps. As the
filled
conveyor continued to circulate for about 15 minutes, the current required by
the drive
motor increased to 7.1 amps at which point the conveyor would jam and the
drive motor
would be unable to continue to drive the auger in the conveyor tube. Under
such high
load conditions, even if the auger did not jam in the conveyor tube, if the
drive motor
would be shut off, the auger could not be re-started. In accordance with this
invention,
a re-leveling box 401 was placed in conveyor tube 17 upstream from drive motor
20A
so as to breakup the slug of feed in the conveyor and to prevent jamming. More
specifically, re-leveling box 401 comprises either a dual diameter metering
tube 300 or a
gear 58 or 58" agitator and an accumulator supply hopper 403 with the metering
tube or
- 30 the gear agitator positioned so as to positively break up the slug of
feed in the conveyor,
to strip excess feed from the auger as the later passes through the re-
leveling box, and to
resupply the stripped feed to feed voids in the auger as they present
themselves while
moving through the re-leveling box. More particularly, if metering tube 300 is
used, as
the slug of compacted feed moves therethrough, excess feed is stripped from
the auger
by the stripping section 304 and the stripped feed is directed into the hopper
403 via
discharge passage 308 to await the passage of a void in the auger. The feed in
the
CA 02150221 2001-O1-17
WO 9.iI15453 PCTlUS93112226
17
hopper 403 with then flow into the void via passage 310 In this manner, the
compacted
slug of feed is broken up each time it passes through the re-leveling box and
the trailing
void is refilled. In tests with the test loop CL as above described, it has
been found that
with the conveyor filled with feed and with the intake cups constantly
supplying
additional feed to the conveyor, the conveyor would reach a steady state
conditions in
which the drive motor 20A would draw only about 5.3 amps and would maintain
this
even when the auger was continued to be driven for up to four hours with no
increase in
current to drive motor 20A.
If a bent gear _'i8" is. used in place of the dual diameter tube 300 in
re-leveling box 401, it will be understood that the gear is mounted in the re-
leveling box
such that the gear is free to rotate with gear teeth in mesh with the auger as
it passes
therethrough. Thus, teeth 66 tend to dislodge compacted feed from between the
flights
62 of the auger and to form a void in which fresh feed or dislodged feed may
flow so as
to prevent the buildup of a slug of feed which will result in jamming of the
conveyor.
What has been described is an improved feed intake cup for use in a
poultry feeder system by which feed is delivered from a hopper to a feed
conveyor by
which the feed is conveyed to a plurality of feeding sites. The conveyor
system uses an
auger for moving the feed and improved intake cup prevents the auger being
jammed.
The intake cup, as described above, simply and easily prevents compaction of
feed
which would otherwise cause the jamming. It does this by jolting the auger as
it moves
through the cup, or by turning a pair of paddles to agitate, by vibration of
the auger or
stirring of the feed, the feed delivered to the auger. An important feature of
the cup is
the dual diameter tube in which the feed drive auger is positioned. By
installing the tube
so the auger is driven from the larger into the smaller diameter portion of
the tube,
excess feed can be removed from the conveyor rather than being constantly
recirculated.
This also helps prevent compaction of the feed and potential jamming.
Additionally, the
dual diameter regulating tube has no moving parts and thus is simple to
construct and to
operate.
As various changes could be made in the above constructions without
departing from the scope of the invention, it is intended that all matter
contained in the
above description or shown in the accompanying drawings shall be interpreted
as
illustrative and not in a limiting sense.
