Note: Descriptions are shown in the official language in which they were submitted.
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INFRARED FEEDER CONTROLLER
BACKGROUND OF THE INVENTION
[0001] This application relates to controllers for feed delivery systems,
and in
particular to a controller which utilizes infrared sensors to determine when
feed
has stopped flowing through a feed delivery system.
[0002] Infrared sensors for use in feed delivery systems are known. For
example, Controltech Corporation of Bondurant, Iowa sells a feed controller
which
utilized infrared sensors under the name HALOTM. However, in controllers such
as
the Halo controller the infrared light transmitter (i.e., an LED) and the
infrared light
sensor or receiver are in the tube through which the feed passes, and are thus
directly exposed to, and in contact with, the feed. Thus, the sensor
components
can become covered in feed dust. Further, the feed dust could infiltrate the
electronics of the controller, and affect the operation of the controller.
[0003] Additionally, feed controllers are placed directly in the drop tube
of a
feed system, and define or form part of the drop tube. Should the controller
become inoperable for some reason, the drop tube must be disassembled to
remove the controller.
[0004] It would be desirable to provide a controller which utilizes
infrared
sensing technology, but in which the emitter and receiver are protected from
the
dust of the feed environment. It would also be desirable to provide a
controller can
be easily repaired or replaced without the need to disassemble the drop tube
in
which the controller is positioned.
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BRIEF SUMMARY OF THE INVENTION
[0005] A control assembly for use in a feed delivery assembly comprises a
housing having an inlet, an outlet, and a chamber between said inlet and
outlet.
The chamber is opened in a plane parallel, but radially offset from, an axis
of the
inlet and outlet. A tube member is removably receivable in the chamber. The
removable tube member includes a tube having a length sufficient to span a
distance between the inlet and outlet tubes. At least one infrared emitter and
at
least one infrared receiver are mounted on the tube member tube and are
positioned to be opposed to each other such that the receiver will receive and
detect light from the emitter. The emitter and receiver are operatively
connected
to a controller. The controller emits a signal when it is determined that the
light
from the emitter to the receiver is interrupted.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0006] FIG. 1 is a schematic of a feed system incorporating a feed
controller;
[0007] FIGS. 2A and B are perspective and exploded views, respectively, of
an
illustrative infrared controller assembly as described herein;
[0008] FIGS. 3A and B are top plan and top perspective views, respectively,
of
a housing of the assembly;
[0009] FIGS. 4A-D are perspective, side elevational, top plan, and bottom
plan
views, respectively of a tube member of the assembly;
[0010] FIGS. 5A-B are perspective and front elevational views, respectively
of a
flexible control board of the controller in a curved condition;
[0011] FIG. 5C is a plan view of the flexible control board in a flat
condition;
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[0012] FIG. 6 is a top perspective view of the assembly with a cover
removed
showing the tube member with the control board positioned in the housing; and
[0013] FIG. 7 is a top perspective view of the assembly with the cover and
control board removed showing the tube member in the housing.
[0014] Corresponding reference numerals will be used throughout the several
figures of the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The following detailed description illustrates the invention by way
of
example and not by way of limitation. This description will clearly enable one
skilled in the art to make and use the invention, and describes several
embodiments, adaptations, variations, alternatives and uses of the invention,
including what I presently believe is the best mode of carrying out the
invention.
Additionally, it is to be understood that the invention is not limited in its
application
to the details of construction and the arrangements of components set forth in
the
following description or illustrated in the drawings. The invention is capable
of
other embodiments and of being practiced or being carried out in various ways.
Also, it is to be understood that the phraseology and terminology used herein
is for
the purpose of description and should not be regarded as limiting.
[0016] A feed delivery system 10 typically includes a hopper 12 containing
feed, a plurality of feed bins 14, and a feed delivery tube 16 which delivers
the
feed from the hopper to the bins. Typically, an auger (not shown) extends
through
the delivery tube 16 and is driven by a motor 18 to carry the feed from the
hopper
12 through the tube 16 to the bins 14. Additionally, the system 10 has drop
tubes
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20 which extend downwardly from the delivery tube 16 to the bins 14, there
being
at least one drop tube per bin. As can be appreciated, when the respective
bins
are full of feed, their respective drop tubes fill with feed. As the bins are
filled, their
drop tubes will fill with feed in a consecutive manner. When the drop tube of
the
last bin in the system fills with feed, all the bins have been filled with
feed.
Typically, a controller 22 is provided in the last drop tube. The controller
22
includes a sensor to determine when the drop tube fills with feed. Upon
sensing
this condition, the controller sends a signal which deactivates the motor 18
to stop
delivery of feed through the system 10.
[0017] The controller 22 can comprise a control assembly 30, such as shown
generally in FIGS. 2A and 2B. The control assembly 30 comprises a housing 32
having an inlet tube 34, an outlet tube 36, and a chamber 38 positioned
between
and in line with the inlet and outlet tubes. The inlet and outlet tubes are
sized to
be connected to the tubing which comprises the drop tube 20 in which the
control
assembly is positioned. As shown, the inlet tube 34 is larger than the outlet
tube
36. Hence, with the configuration shown, the outlet tube is received in a
lower
portion of the drop tube and the inlet tube 34 receives an upper portion of
the drop
tube. However, both the inlet and outlet tubes could receive, or be received
by,
their respective portions of the drop tube. Alternatively, the inlet tube
could be
received by the upper portion of the drop tube and the outlet tube could
receive
the upper portion of the drop tube. In a further alternative, a coupler could
be used
to connect the inlet and outlet tubes to the drop tube. As can be appreciated,
the
housing 32 (and hence the control assembly 30) can be placed in the drop tube
20
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by most any acceptable method which will allow feed to pass through the
housing
(as will be described below).
[0018]
Turning to FIGS. 3A and 3B, the housing chamber 38 is defined by front
and back walls 40a,b, side walls 42 and a bottom 44. The inner surfaces of the
front and back walls 40a,b slope downwardly and inwardly, such that the
bottoms
of the walls 40a,b are closer together than the tops of the walls 40a,b. The
side
walls 42 include an upper section 42a, a mid-section 42b, and a lower inwardly
inclined section 42c (Fig. 3B). A step 46 is formed between the upper and mid-
sections 42a and 42b, such that the mid-section 42b of the side walls 42 is
positioned inwardly relative to the upper section 42a. The lower inclined
section
42c merges or joins with the chamber bottom 44 which is curved. Positioning
posts 48 are positioned on the step 46. Two positioning posts are shown in
each
step, but more (or fewer) could be provided if desired. As seen in FIG. 3B,
the inlet
and outlet tubes 34 and 36 intersect the front and back walls 40a,b such that
the
bottoms of the tubes are spaced slightly from the bottom 44 of the chamber.
Lastly, the chamber 38 is provided with a pair of wire connectors 50 which are
positioned on the housing chamber front wall 40a. The wire connectors 50 are
comprised of metal and define a bore which extends through the connectors 50.
The connectors 50 can each include a main portion having a stem which extends
through a hole in the wall 40a and a securing member which holds the connector
main portion in place. For example, the stem can be threaded, and the securing
member can be a nut-like member.
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[0019] A tube member 52 (FIGS. 4A-D) is received in the chamber 38. The
tube member comprises a tube 54 of a diameter substantially equal to the
diameter of the junctions of the inlet and outlet tubes 34, 36 with the
chamber 38.
The tube 54 has a length substantially equal to the distance between the front
and
back chamber walls 40a,b. Further, the opposite ends of the tube have a slope
or
incline corresponding to the slope or incline of the chamber walls. Hence,
when
the tube member 52 is received in the chamber, the tube 54 will define a
passage
between the inlet and outlet tubes 34, 36 to form a substantially continuous
flow
passage through the control assembly 30. The tube 54 includes
circumferentially
extending slots 56a,b. Two slots 56a are formed on opposing sides of the tube
54
and two slots 56b are formed on the top and bottom of the tube 54. As best
seen
in FIGS. 4A-D, the slots 56a are aligned with and face each other and the
slots
56b are aligned with and face each other. However, the slots 56a and 56b are
axially offset from each other. Additionally, an axially extending slot 58 is
positioned between the top circumferentially extending slot 56b and one of the
side circumferentially extending slots 56a. The axially extending slot is
shown to
have a length such that one end of the slot is approximately aligned with the
side
slot 56a and the other end is approximately aligned with the side slot 56b, as
best
seen in Fig. 4B.
[0020] Front
and back walls 60 extend outwardly from opposite ends of the
tube 54. The walls 60 are sized and shaped to correspond to the size and shape
of the chamber 38, such that the walls 60 can be received in the chamber 38.
As
best seen in FIG. 4B, the walls 60 are not perpendicular to the axis of the
tube 54.
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Rather, the walls 60 slope downwardly and inwardly, such that the bottom of
the
opposed walls 60 are closer together than the top of the opposed walls 60. A
groove 62 (Fig. 4A) can be formed in the walls 60 around the tube 54. The
grooves 62 can receive sealing elements, such as 0-rings, to form a seal
between
the tube member 52 and the inlet and outlet tubes 34, 36 of the housing 32. A
connector 64 extends between the front and back walls 60, preferably at the
top
thereof; and mounting members or flanges 66 extend outwardly from the
connectors 64. The mounting members or flanges 66 are sized to be received on
top of the step 46 in the housing chamber 38. The mounting flanges 66 each
have
a pair of positioning openings 68 which are sized and positioned to fit over
the
positioning posts 48 of the chamber step 46. The sides of the tube member 52
are
opened to allow access to the tube 54. That is, the tube 54 is not fully
enclosed.
Preferably, at least the tube 54 of the tube member 52 is made from a material
through which infrared light can pass. Hence, the tube 54 is at least
translucent,
and preferably transparent, to infrared light, such that infrared light can
pass
through the wall defining the tube 54.
[0021] The tube 54 and the walls 60 of the tube member 52 are sized and
shaped such that when the tube member 52 is received in the chamber 38, the
tube 54 will be coaxially aligned with the inlet and outlet tubes 34, 36 of
the
housing 32. Thus, the housing inlet tube 34, the tube member tube 54, and the
housing outlet tube 36 define a portion of the drop tube of the feeding
system.
[0022] A
flexible circuit board 70 (FIGS. 5A-C) is wrapped about the tube 54 of
the tube member 52. The flexible circuit board 70 includes a microprocessor or
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controller 72 on one surface of the board 70 and a plurality of infrared
emitters 74
and infrared receivers 76 on an opposite surface of the board. The infrared
emitters and receivers are electrically connected to the controller, for
example, by
printed circuits in the flexible circuit board 70. The flexible circuit board
70 is
shown in a flat ¨ unrolled ¨ condition in FIG. 50. As seen therein, the
infrared
receivers 76 and the infrared emitters 74 are formed in groups of three.
Further,
there are two groups of receivers 76 and two groups of emitters 74, the two
groups
being offset from each other. The infrared receivers and the infrared emitters
are
positioned on the circuit board, and the circuit board is sized, such that
when the
board is wrapped about the tube 34, the infrared emitters 74 will be opposed
to the
infrared receivers 76, as can be seen in FIG. 5B. Further, as seen, the
infrared
receivers and emitters are on an inner surface of the circle defined by the
circuit
board, and the controller 72 is on an outer surface of the circle defined by
the
circuit board 70. This provides for two sets of emitters/receivers which emit
infrared light at approximately right angles to each other and axially off set
from
each other. As is known, the receivers detect the light from the emitters.
When
the light beam is cut, the controller will detect such, and issue a signal
indicative of
the fact that the light beam has been cut.
[0023]
Returning to FIG. 2B, the control assembly 30 lastly includes a gasket
80 which is sized to fit on top of the chamber 38 and a cover 82 which is
secured
to the chamber 80, for example, by means of screws 84. The cover 82 thus
closes
the chamber 38.
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[0024] To
assemble the control assembly 30, initially the flexible circuit board
70 is wrapped about the tube member tube 54. The circumferential slots 56a,b
of
the tube 54 are positioned such that the emitters 74 (which can be LEDs) and
receivers 76 of the circuit board 70 will align with the slots 56a,b. The tube
member 52 with the circuit board 70 is then placed in the chamber 38. When
placed in the chamber 38, the mounting flanges 66 of the tube member 52 rest
on
the chamber step 42c with the mounting holes 68 of the flanges 66 receiving
the
step positioning posts 48. As noted above, the tube member tube 54 connects
the
inlet and outlet tubes 34, 36 of the housing to define a flow passage through
the
assembly 30. The fit between the tube member and chamber is preferably a tight
fit so that the tube member will not be easily dislodged from the chamber, and
to
help form the seal between the tube member and the chamber around the junction
between the tube 54 and the inlet and outlet tubes 34,36, so as to reduce the
possibility of particulate matter from exiting the flow path. However, if
desired, the
tube member 52 can be secured in place by screws which extend through the
mounting flanges 66 into the housing step 46. Leads
from the
controller/microprocessor 72 are connected to the wire connectors 50 of the
housing. The gasket 80 and cover 82 are then positioned over the chamber to
close the chamber. The control assembly 30 can then be placed in line in a
drop
tube 20. The control assembly can be placed in electrical communication with
the
controller for the system (which activates and deactivates the motor 18) by
means
of wires (not shown) which are connected at one end to the wire connectors 50
on
the control assembly 30 (and thus are in communication with the circuit board
70)
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and are connected at the other end to the system controller. If desired, a
wireless
communication could be provided for, in lieu of the wired connection between
the
circuit board 70 and the system controller.
[0025] In operation, feed will flow through the drop tube 20, as generally
described above. When the feed fills up the drop tube 20 containing the
control
assembly 30, the feed will fill the control assembly tube 54 and the light
beam
(from the emitters 74 to the receivers 76) will be interrupted. This will
cause the
circuit board controller 72 to send a signal to the system controller, and,
the
system controller will deactivate the auger motor 18 to stop the flow of feed
through the feed system 10.
[0026] As can be appreciated, the infrared emitters and receivers are
recessed
relative to the inner surface of the tube member tube 54 (through which grain
flows). Thus, the infrared emitters and receivers are protected from direct
contact
with the feed. This will help keep the emitters and receivers clean. Further,
because the tube 34 is made from infrared translucent or transparent material,
the
slots 56a,b need not extend all the way through the tube wall or can even be
omitted. In the former case, the slots would be formed in the outer surface of
the
tube wall. In either event, this will totally isolate the emitters and
receivers from
the feed flowing through the tube 54, thereby preventing feed dust and
particles
from contacting the electronic components of the sensor assembly 30. The
provision of the slots places the emitters and receivers closer to the flowing
feed,
and limits the amount of tubing material through which the infrared light must
pass.
The slots can be formed as grooves in the outer surface or the slots can pass
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through the tube 34, in which case the emitters and receivers are recessed
from
the flowing feed. In the former case, the emitters and receivers remain
totally
isolated from the flowing feed; and in the latter case the emitters and
receivers are
protected from the flowing feed by their being recessed relative to the inner
surface of the tube.
[0027]
Additionally, the tube assembly 52 is not permanently fixed in place. It
can be removed for cleaning, repair or replacement without the need to
disconnect
the housing 32 from the drop tube. As can be appreciated, the fact that the
housing does not need to be removed in order to repair or replace the sensor
assembly greatly eases the ability to repair or replace the sensor assembly.
[0028] 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. For example, if the slots extend
through
the tube member tube 54, the tube member tube could be made from material
which is opaque to infrared light. This example is merely illustrative.
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