Note: Descriptions are shown in the official language in which they were submitted.
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FEED BIN MONITORING SYSTEM AND METHOD
[0001]
TECHNICAL BACKGROUND
[0002] The disclosure relates generally to feed bin monitors or the like
and
methods of installing feed bin monitors. More particularly, the disclosure
relates to feed bin monitors having a load cell that is positioned above a
bottom of a bin leg.
BACKGROUND
[0003] Many animal finishing facilities have bulk bins and automated feed
delivery systems. In theory, these bins and delivery systems are intended to
assure an uninterrupted flow of feed to the feeder. In reality, however,
various
known delivery systems result in varying disruptions of feed availability,
which
may have very serious consequences. For example, out-of-feed events can
cause animal health problems, such as ulcers, particularly in pigs. Other
potential health problems include, for example, cannibalistic tail biting and
Hemorrhagic Bowel Syndrome, which is often fatal to the animal. Moreover, it
is believed that even one out-of-feed event can have a prolonged negative
effect on weight gain. Paid dividends can be directly affected as a result.
[0004] Out-of-feed events can be caused by a variety of causes. One notable
cause is human error. Human errors are generally associated with empty
bins, which occur when feed is not ordered, prepared, and delivered in a
timely manner. Other causes of out-of-feed events include, for example,
bridging and rat-holing of the feed. In these cases, the feed still remains in
the bin, but does not flow to the delivery or auger system. As a result, even
though feed is present in the bin, it is not delivered to the animals. When
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occurs, the feed delivery system may shut down due to its extended run
timers. No feed is then delivered until the feed delivery system is manually
reset. If producers are not closely monitoring the feed delivery system,
animals can be without feed for extended periods of time. While out-of-feed
events can be prevented, in practice, they occur quite often.
[0005] One method of preventing out-of-feed events involves personally
checking each bin by climbing up a ladder to the top of the bin and visually
noting and monitoring the level of the bin. This method is labor-intensive and
can be quite dangerous, especially in frigid, icy, or wet weather. To save
time
and avoid safety risks associated with climbing to the top of the bin, some
workers have resorted to physically hitting the bin to estimate the level of
the
feed by listening to the sound reverberation. This method, however, does not
provide the producer with very accurate information. It is also still labor-
intensive because the worker has to personally check each individual bin.
Further, as compared to the past, it is now more common for farms to be
isolated from the workers. As a result, it takes more effort to check and
monitor the feed systems. Therefore, the feed bins often are not checked
frequently enough to prevent out-of-feed events because it takes too much
time to check the bins, and, additionally, rush orders are often not fulfilled
quickly enough.
[0006] Accordingly, electronic monitors have been devised to monitor feed
levels. These known electronic monitors are equipped with compression load
cells positioned on a concrete slab underneath the bin legs. The load cells
measure the amount of the feed in the bin and are able to track the level and
the changes in the feed weight, for example, from deliveries and consumption.
Some of these known electronic monitors can make feed level data available
to producers by telephone. Many producers choose not to implement these
known systems, however, because they are costly and are difficult to retrofit
to existing bins. Separate jacks or cranes are required so that the bin legs
can be raised approximately 3-4 inches off of the concrete slab. Raising the
bin disrupts the connections between the bins and the conveyor pipes that
carry the feed from the bin to the feeding point. Known electronic feed bin
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monitors can also be unreliable because they are often susceptible to adverse
affects on the accuracy of their measurements due to ice and foreign material
under the supporting mechanisms. These supporting mechanisms include
foot pads that are bolted to the concrete slab beneath the bin. Bolting the
foot
pads to the concrete slab introduces torques that can twist the load cell
system enough to produce false readings at times.
[0007] Some other known systems are sonar or ultrasound based. One
drawback of such systems is that they only report a feed level, not weight. As
a result, these systems have difficulty maintaining accuracy when, for
example, there is bridging or rat-holing of feed, there are significant
changes
in feed density, or there are temperature variations. All of these events can
alter the correlation between feed level and the true amount or weight of
feed.
Known sonar or ultrasound based systems can also only provide level
monitoring. Thus, they cannot accurately measure feed delivered or
consumed by weight. The present invention addresses problems associated
with the related art.
SUMMARY OF THE DISCLOSURE
[0008] According to various example embodiments, a bin monitoring system
functions both as a device for lifting the bin and as a weighing system for
monitoring or measuring the level of feed in a feed bin. Various embodiments
having a load cell and methods of retrofitting the bin monitoring system to
existing bins are provided. Further, the accuracy provided by various
embodiments enables one to accurately predict when the feed bin will be
empty. Thus, the feed mill can be aware of anticipated needs days in
advance, allowing the feed mill to better optimize its scheduling and
deliveries.
[0009] One embodiment is directed to a feed bin monitoring system that has
a
suspended load cell in tension that accurately measures the amount of feed
going into and out of a feed bin having bin legs that support the bin above a
foundation. The feed bin monitoring system of this embodiment can quickly
detect if no feed is being consumed by the animals due to, for example,
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bridging of the feed in the bin. The feed bin monitoring system includes a
frame configured to be securable to the foundation. A load cell is joined to
the
frame and is configured to measure a weight of the bin. Various preferred
embodiments include a lifting mechanism arranged to selectively lift the bin
leg, thus applying the load to the load cell. Another aspect of the invention
is
directed to a method of monitoring an amount of feed in a feed bin having a
plurality of bin legs by operatively connecting at least one feed bin monitor
to
each of the bin legs and transmitting data collected from the load cell to a
display device.
[0010] Further preferred embodiments for measuring the weight of a bin
include a frame securable to the foundation adjacent one bin leg; a load cell
connected to the frame and operatively positioned to have the weight of the
bin applied to the load cell; and a mechanical connector attached to the load
cell and attachable to the adjacent bin leg and constructed and arranged to
suspend the bottom of the bin leg at an elevation below the load cell; and a
first plate or bracket secured between the mechanical connector and the bin
leg.
[0011] Alternate preferred embodiments include a set of bin monitoring
systems, the set of bin monitoring systems comprising a first frame securable
to the foundation adjacent a bin leg; a first load cell carried by the first
frame
and operatively positioned to have the weight of the bin applied to the first
load cell; a first mechanical connector secured to the load cell; a first
bracket
secured to the mechanical connector and the bin leg; a second frame
securable to the foundation adjacent a bin leg; proximate the first frame; a
second load cell carried by the second frame and operatively positioned to
have the weight of the bin applied to the second load cell; and a second
mechanical connector secured to the second load cell; a second bracket
secured to the second mechanical connector and the bin leg, the second
bracket being constructed and arranged be securable to the first bracket and
to suspend the bottom of the bin leg at an elevation below the load cell.
[0012] Further alternate embodiments include a cross-bar suspended from
two load cells. Such preferred embodiments include a set of frames, each
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frame having an opening; a cross bar at least partially positioned within the
openings; wherein the cross bar is arranged and configured such that a bin
leg can be positioned on the cross bar in between the frames. Each frame
includes a load cell having a top and a bottom; the top connected to the
respective frame and one end of the respective cross bar is interconnected to
the bottom. The cross bar can be raised to subsequently raise the bin leg and
thus, apply a load to the set of load cells proximate the respective bottoms
of
the load cells. The invention further includes methods of installing and using
such bin monitoring systems, wherein a bin leg is positioned on top of the
cross bar, between two frames.
[0013] Another aspect of this invention is directed to methods of
installing a
bin monitoring system, such as that described, to a leg of a feed bin. The
method generally includes the steps of securing at least one bin monitoring
system to one or more of the bin legs and using the bin monitoring system to
support the bin legs preferably no more than approximately 0.5 inches above
the ground, thus facilitating retrofitting of existing bins.
[0014] One preferred method of securing a bin monitoring system to a bin
includes the steps of providing a set of bin monitoring systems, each bin
monitoring system having a frame; a load cell carried by the respective frame
and operatively positioned to have the weight of the bin applied to the load
cells; a mechanical connector secured to one respective load cell; and a
bracket. Then, the first frame is secured to the foundation adjacent a bin
leg,
the first bracket is secured to the mechanical connector and the bin leg, the
second bracket is secured to the first bracket. Then, the bin leg is lifted by
raising the position of the mechanical connector with respect to the frame.
Preferably, the bin leg is positioned below the load cell.
[0015] Various embodiments may provide certain advantages. For instance,
feed levels can be monitored easily and accurately so that out-of-feed events
can be significantly reduced. Also, feeding animals with feed bins equipped
with automatic bin monitoring systems reduces the need for expedited orders
and allows feed producers to predict production needs in advance. Feed
throughput may be improved, and feed transportation costs may be reduced.
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Further, the bin monitoring systems described herein can be retrofitted to
existing bins easily and inexpensively, thereby reducing implementation costs.
[0016] Additional objects, advantages, and features will become apparent
from the following description and the claims that follow, considered in
conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] In the drawings, in which corresponding reference numerals and
letters
indicate corresponding parts of the various embodiments throughout the
several views, and in which the various embodiments generally differ only in
the manner described and/or shown, but otherwise include corresponding
parts;
[0018] Figure 1A is a front plan view of an embodiment of a bin monitoring
system 10.
[0019] Figure 1B is a front view of the bin monitoring system 10 of Figure
1A,
wherein the bin monitoring system 10 is operatively attached to a bin leg L.
[0020] Figure 1C is an enlarged, partial, perspective view of the bin
monitoring
system 10 illustrated in Figures 1A-1B.
[0021] Figure 1D is a rear view of the bin monitoring system 10 of Figures
1A-
1C operatively connected to the bin leg L.
[0022] Figure 2A is a side view of the bin monitoring system 10of Figure
1A-
1 D.
[0023] Figure 2B is another side view of the bin monitoring system 10 of
Figures 1A-1D, wherein the bin monitoring system 10 is operatively attached
to the bin leg L.
[0024] Figure 3A is a front view of a frame of the bin monitoring system
10 of
Figure lA illustrating preferred fold lines of the preferred frame 12.
[0025] Figure 3B is a plan view of the folded frame 12 of Figure 3A.
[0026] Figure 3C is a side view of the frame 12 of Figures 3A-3B.
[0027] Figure 4A is a plan view of a channel bracket 60 of the bin
monitoring
system 10 of Figure 1A.
[0028] Figure 4B is front view of the channel bracket 60 of Figure 4A
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illustrating preferred fold lines.
[0029] Figure 40 is a side view of the folded channel bracket 60 of
Figure 4A-
4B.
[0030] Figure 5A is a top view of a load block 70 of the bin monitoring
system
of Figure 1A.
[0031] Figure 5B is a cross-sectional, side view of the load block 70 of
Figure
5A.
[0032] Figure 6 is a view of a bin monitoring system 10 attached to each
leg L
of two adjacent bins B according to an alternate embodiment.
[0033] Figure 7 illustrates an alternate embodiment of a bin monitoring
system
10' in which the channel bracket 60 of Figure lA is replaced with a chain link
suspension or mechanical connector 80 attached to a clevis 82.
[0034] Figure 8A is an alternate bin monitoring system 110 having a
channel
block 160 to which the bin leg L1 is secured.
[0035] Figure 8B is a perspective view of the bin monitoring system 110
of
Figure 8A, the bin monitoring system secured to bin leg L1.
[0036] Figure 9A is an exploded view of an alternate bin monitoring
system
210.
[0037] Figure 9B is a rear view of bin monitoring system 210 of Figure 9A
operatively secured to bin leg L2.
[0038] Figure 10A is an exploded view of a further alternative bin
monitoring
system 310.
[0039] Figure 10B is a perspective view of the bin monitoring system 301
of
Figure 10A operatively secured to a bin leg L3.
[0040] Figure 11A is partially exploded, perspective view of a set of bin
monitoring systems 410, 410'.
[0041] Figure 11B is a partially exploded, perspective view of the set of
bin
monitoring systems 410, 410' of Figure 11A operatively secured to each
other.
[0042] Figure 110 is a perspective view of the set of bin monitoring
systems
410, 410' of Figures 11A-11B operatively secured to a bin leg L4.
[0043] Figure 12A is an exploded view of a set of bin monitoring systems
510
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interconnected by a cross bar 560.
[0044] Figure 12B is a perspective view of the set of bin monitoring
systems
510 of Figure 12A interconnected by the cross bar 560 on which an I-Beam
shaped bin leg or the like (not shown) can be positioned.
[0045] Figure 13A is a partially exploded view of a set of bin monitoring
systems 610.
[0046] Figure 13B is a perspective view of the set of bin monitoring
systems
610 of Figure 13A operatively secured to a bin leg L6.
[0047] Figure 14A is a partially exploded view of a set of bin monitoring
systems 710.
[0048] Figure 14B is a perspective view of the set of bin monitoring
systems
710 of Figure 14A operatively secured to a bin leg L7.
[0049] Figure 15A is a perspective view of the mechanical connector or
channel block 160, which is the same as preferred channel blocks 260, 360,
460, 660, 760 and 860.
[0050] Figure 15B is a rear view of the channel block 160 of Figure 15A.
[0051] Figure 150 is a side view of the channel block 160 of Figures 15A-
15B.
[0052] Figure 15D is a top view of the channel block 160 of Figures 15A-
15C.
[0053] Figure 15E is a bottom view of the channel block 160 of Figures
15A-
15D.
[0054] Figure 16A is a perspective, partially-exploded view of an
alternative
preferred bin monitoring system 812 having first and second brackets 862,
862' for securing a bin leg L8 to mechanical connector 860.
[0055] Figure 16B is a perspective view of the bin monitoring system 810
of
Fig. 16A partially secured to bin leg L8 (with bolts secured within apertures
864" and A removed for clarity).
[0056] Figure 160 is a perspective view of preferred second bracket 862'
of
the bin monitoring system 810 of Figs. 16A-16B.
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DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0057] The following description of various embodiments implemented in the
context of monitoring the volume or weight of feed bins and installing such
monitoring systems is to be construed by way of illustration rather than
limitation. This description is not intended to limit the invention or its
applications or uses. For example, while various embodiments are described
as being implemented in this context, it will be appreciated that the
principles
of the disclosure are applicable to other environments, as will be apparent to
one of ordinary skill in the art.
[0058] In the following description, numerous specific details are set
forth in
order to provide a thorough understanding of various embodiments. It will be
apparent to one skilled in the art that some embodiments may be practiced
without some or all of these specific details. In other instances, well known
components and process steps have not been described in detail.
[0059] Various embodiments of the bin monitoring system are illustrated in
Figures 1A-16C. Referring now in particular to Figures 1A-3C and 6, a bin
monitoring system 10 includes a frame 12. In various preferred embodiments,
the frame 12 is A-shaped and has an aperture or opening 13, a top 14 and
two legs or supports 20a and 20b extending diagonally downward from the
top 14. In the illustrated embodiments, each support 20a and 20b has a
respective base or flange 24a and 24b with at least one respective flange
aperture 28a and 28b for anchoring the frame 12 to a foundation such as a
concrete slab C, as most bins are installed on concrete slabs. The top 14
includes a bolt aperture 16 that receives a bolt 18 for securing the frame 12
to
the top of a load cell 50. In preferred embodiments, the frame 12 can be
constructed of fabricated iron. Alternatively, the frame can be constructed of
fabricated channel iron or the like.
[0060] In some embodiments, the load cell 50 is implemented as an S-type
load cell for measuring the tension or changing weight of a bin B. The bin
monitoring system 10 incorporates the load cell 50 to measure the weight and
changes of weight of the bin B. An example implementation of the load cell
50 is disclosed in U.S. Patent Application Serial No. 11/422,910 of Jaeger et
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al., the teachings of which are herein incorporated by reference in their
entirety. In some embodiments, the load cell 50 includes an electrical
connection 52 having a wire cord that passes through an aperture 22 in one of
the supports 20a and 20b to a transmitter (not shown) such that data collected
from the load cell 50 can be accessed via a remote location such as, for
example, by a wired, wireless, or mobile telephone or using a network such as
the Internet.
[0061] It is further contemplated that the bin monitoring systems
described
herein may be an element of a larger system in which the data transmitted
may be compiled with other data, such as animal weights, so that multiple
variables can be monitored and tracked in one central location. Such a larger
system can also include, for example, a component for generating reports,
such as a bin status report, a configuration report, an alarm settings report,
a
feed usage report, and a bin summary report. The bin status report may
illustrate an image of a feed bin showing the current weight, alarm settings,
and alarm conditions. The configuration report may list the configuration for
the setup menu, interface menu, and computer port. The alarm settings
report may list the alarm settings for each indicator. The feed usage report
may list daily feed usage sorted by date and the total feed delivered for a
selected date range. The bin summary report may list the current bin weights
and any alarm conditions for the feed bins.
[0062] Now also referring to Figures 4A-C, the bin monitoring system 10
additionally includes a mechanical connector, in this case a channel bracket
60, that is used to connect the bin monitoring system 10 to a leg L of the bin
B. The channel bracket 60 may be generally U-shaped, being deeper at the
top than at the bottom, to correspond to the shape of the bin leg L. In some
embodiments, the bin monitoring system 10 includes a limiting mechanism 66
to restrict the upward movement of the channel bracket 60. The limiting
mechanism 66 prevents the bin B from lifting and blowing over when, for
example, there is a gust of wind and the bin B is empty. As shown, the
limiting mechanism 66 may be a stop strap having bolt apertures 68 for use
with a bolt 69 to secure the strap to the frame 12 as shown in Figures 1A-1C.
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The channel bracket 60 further includes a slot 62 for receiving and in some
instances, supporting a load block 70 and is deep enough such that when the
channel bracket 60 is bolted to the bin leg L and the frame 12 is secured to
the concrete slab C, the channel bracket 60 extends beyond the stop strap
66, allowing it to contact and be restricted by the stop strap 66 when the bin
B
is lifted too high. This configuration is also illustrated in Figure 2A. In
alternative embodiments, the channel bracket 60 may be replaced with a
alternate mechanical connector, such as a chain link suspension 80 attached
to a clevis 82, as shown in Figure 7. It will be understood that other
mechanical connectors can be used.
[0063] Now further referring to Figures 5A-5B, as previously mentioned,
the
bin monitoring system 10 preferably further includes the load block 70, which
is received within the slot 62 of the channel bracket 60 and is supported by
the channel bracket 60 until the bracket 60 is elevated with respect to the
frame. The load block 70 is illustrated in Figures 5A-5B as having a bolt
aperture 72. The load block 70 is placed in the slot 62 of the channel bracket
60. A threaded bolt 65 is then placed through a bolt aperture 72 of the load
block 70 and threaded into the load cell 50. The load block 70 can move
within the slot 62. This configuration allows for some misalignment of the
channel bracket 60.
[0064] A typical feed bin has 4, 6, or 8 generally U-shaped legs. The bin
monitoring system 10 may be placed alongside each leg L and bolted to the
concrete slab C with an anchor bolt 30 through two of the flange apertures
28a and 28b. Two more bolts 65 may be pressed through the bolt holes 64 of
the channel bracket 60 to connect the bin monitoring system 10 to the bin leg
L.
[0065] As described above, the bin monitoring system 10 includes the
threaded bolt 18 or the like, which secures the load cell 50 to the frame 12.
According to various embodiments, the bolt 18 also serves as a jack to lift
and
support the load cell 50 when the load cell 50 is suspended off of the
concrete
slab C. In some embodiments, the bin monitoring system 10 supports the bin
B no higher than about 0.75 inches above the foundation, preferably no higher
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than about 0.5 inches above the concrete slab C. Because installing the bin
monitoring system 10 does not require the bin B to be significantly lifted,
existing bins may be retrofitted without having to empty the bin or disconnect
flex augers and associated piping.
[0066] To install the bin monitoring system 10 according to one example
method, the load cell 50, frame 12, and limiting mechanism 66 are operatively
assembled. The footpads are then disconnected from the bin legs L. Next,
two 0.5 inch holes are drilled into the bin legs L for the channel bracket 60.
In
the next step, the channel bracket 60 is first mounted adjacent the side of
the
leg L such that any space in between the channel bracket 60 and the leg L is
reduced. Once the channel bracket 60 is attached adjacent the leg L, the
frame 12 is aligned to the bin leg L and is secured with concrete anchor bolts
30. The channel bracket 60 is connected to a threaded load cell 50 by a
threaded bolt 40 that can also function as a mechanism to lift and support the
bin leg L. As the bolt 40 is rotated, e.g., seven times, the load cell 50 is
moved upwards and correspondingly moves the bin leg L upwards. In the
next step, a summing box or the transmitter (not shown) is mounted to the bin
B and is operatively connected to the load cell(s) 50. Next, the summing box
can be wired to the bin monitoring system 10. Next, wiring to the load cell 50
is secured to the bin support frame, e.g., using one or more cable ties. The
bin monitoring system 10 is then preferably connected to the on-site network
to enable communication with a remote monitoring system. Next, preferably
three of the bin legs L are preferably electrically grounded above each frame
using the anchor bolts.
[0067] Now also referring to an alternate bin monitoring system 110. Bin
monitoring system 110 is preferred for bin legs L1 that are generally shaped
as illustrated in Fig 8B. Preferably, one bin monitoring system 110 is secured
to each bin leg L1. Bin monitoring system 110 preferably includes a generally
A-shaped frame 112, similar to previous embodiments discussed herein. The
preferred frame 112 includes a centrally located opening or aperture 113, a
top 114 having an aperture 116 and two supports 120a, 120b extending
downwardly and outwardly from the top 114. The frame 112 further includes
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a base consisting of flanges 124a, 124b, each flange 124a, 124b having at
least one aperture 128 for receiving an anchor bolt 130 for securing the frame
112 to a concrete slab C or other foundation.
[0068] The bin monitoring system 110 further includes a load cell 150,
preferably an S-type load cell, but it will be understood that other types of
load
cells can be used and are within the spirit and scope of the invention. The
load cell 150 includes a first or top end 152 having a top threaded aperture
154 and a bottom or second end 156 having a bottom threaded aperture 158.
To secure the load cell 150 to the frame 112, a bolt 118 can be inserted
through the aperture 116 in the top 114 of the frame 112 and through the top
threaded aperture 154 of the load cell 150. As desired, a washer 119 or the
like can be provided to reinforce the top aperture 116 of the frame 112. Each
support preferably includes an aperture 122 for optionally threading
electrical
wiring for the load cell 150 (see also, Fig. 10 and related disclosure).
[0069] Within the aperture 113, a mechanical connector or channel block
160
can be positioned. The channel block 160 illustrated is configured and
arranged similarly to mechanical connectors 260, 360, 460, 460', 660, 760
and 860, disclosed herein. The preferred channel block includes an extension
161 that generally limits the upward movement of the channel block 160
within the frame aperture 113. The preferred channel block includes at least
one side aperture 168a extending through the channel block 160 and a top
aperture 168b. The channel block 160 is preferably suspended from the
bottom 156 of the load cell 150 with a bolt 166 secured within the bottom
threaded aperture 158 of the load cell 150 and a top aperture 168b of the
channel block 160. Therefore, when bolts 165 are secured through bin leg L1
apertures and into the corresponding bolt apertures 168a of the channel block
160, the load of the bin leg L1, is transferred to the load cell 150 proximate
the
bottom 156. Similarly to previously discuss embodiments, the channel block
160 and the bin leg L1 can be raised or lowered by rotating bolts 118 or 166.
[0070] Now also referring to Figs. 9A-9B, which illustrate another
preferred bin
monitoring system 210 of the present invention. Bin monitoring system 220 is
preferred for bins having rectangular tubular legs L2, as generally
illustrated.
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Preferably, one bin monitoring system 210 is secured to each bin leg L2.The
bin monitoring system 220 preferably includes a generally A-shaped frame
212, as in previous embodiments. The preferred frame 212 includes a
centrally located aperture 213, a top 214 having an aperture 216 and two
supports 220a, 220b extending downwardly and outwardly from the top 214.
The frame 212 further preferably includes a base consisting of flanges 224a,
224b, each flange 224a, 224b having at least one aperture 228 for receiving
an anchor bolt 230 or the like for securing the frame 212 to a concrete slab C
or other foundation.
[0071] The bin monitoring system 210 further includes a load cell 250,
preferably an S-type load cell, but it will be understood that other types of
load
cells can be used and are within the spirit and scope of the invention. The
load cell 250 includes a first or top end 252 having a top threaded aperture
254 and a bottom or second end 256 having a bottom threaded aperture 258.
To secure the load cell 250 to the frame 212, a bolt 218 can be inserted
through the aperture 216 in the top 214 of the frame 212 and through the top
threaded aperture 254 of the load cell 250. As desired, a washer 219 or the
like can be provided to reinforce the top aperture 216 of the frame 212. Each
support preferably includes an aperture 222 for threading electrical wiring
for
the load cell 250 as desired.
[0072] Within the aperture 213, a mechanical connector or channel block
260
can be positioned. The channel block 260 illustrated is configured and
arranged similarly to mechanical connectors 160, 360, 460, 460', 660, 760
and 860, disclosed herein. The preferred channel block 260 includes at least
one side aperture 268a extending through the channel block 260 and a top
aperture 268b. The channel block 260 is preferably suspended, in tension,
from the bottom 256 of the load cell 250 with a bolt 266 secured within the
bottom threaded aperture 258 of the load cell 250 and a top threaded aperture
268b of the channel block 260. Therefore, when bolts 265 are secured
through bin leg L2 apertures and into the corresponding bolt apertures 268a
of the channel block 260, the load of the bin leg L2, is transferred to the
load
cell 250 proximate the bottom 256. Similarly to previously discussed
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embodiments, the channel block 260 and the bin leg L2 can be raised or
lowered by rotating bolts 218 or 266.
[0073] To support and reinforce the bin leg L2, two plates or brackets 262
are
preferably provided. Each plate 262 has a plurality of apertures 264 that can
be aligned with the side apertures 268a of the channel block 260 so that bolts
265 may pass through the apertures 268a, 264 and be secured within the
apertures with nuts 272. Preferably, one plate 262 is positioned on each side
of the bin leg L2, as is illustrated.
[0074] Preferred use of bin monitoring systems 110 and 210 are generally
as
follows. First, holes (not shown) are drilled in the leg, proximate the bottom
of
the leg (see generally (Figs. 8B, 9B). One bin monitoring system 110, 210,
310 is preferably secured to each leg L1, L2 of a bin, proximate the
respective
leg such that the holes in the bin leg are aligned with the apertures 168a,
268a in the channel block 160, 260. Then, the bin monitoring system 110,
210 can be secured to the respective bin leg L1, L2 by inserting bolts 165,
265 through the channel block apertures 168a, 268a and into the respective
bin leg for securing with nuts 172, 272. In various preferred embodiments, a
plate 262 or washers 170 are secured on either side of the bin leg L1, L2
before the bolts 165, 265 are inserted to reinforce the leg apertures. Next,
the
channel block 160, 260 is raised, either by rotating the bolt 118, 218 or 166,
266 such that the leg is subsequently lifted. As the bin leg L1, L2 is lifted,
the
load of the bin is transferred to the load cell 150, 250. Preferably, the
steps
disclosed in this paragraph are repeated until each bin leg has a bin
monitoring system operatively connected thereto. The frame 121, 212 flanges
124a, 124b, 224a, 224b can be secured to the foundation with respective
anchor bolts 130, 230. The load cell 150, 250 of each bin monitoring system
110, 210 can then be connected to a transmitter to transmit the load data for
analysis.
[0075] Yet another preferred bin monitoring system 310 is illustrated in
Figs.
10A-10B. The bin monitoring system 310 of Figs. 10A-10B is preferred for
bins having bin legs that are generally rectangular and tubular. Preferably,
one bin monitoring system 310 is secured to each bin leg L3. Bin monitoring
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system 310 preferably includes a generally A-shaped frame 312, similar to
previous embodiments. The preferred frame 312 includes a centrally located
aperture 313, a top 314 having an aperture 316 and two supports 320a, 320b
extending downwardly and outwardly from the top 314. The frame 312
further includes a base consisting of flanges 324a, 324b, each flange 324a,
324b having at least one aperture 328 for receiving an anchor 330 bolt or the
like for securing the frame 312 to a concrete slab C or other foundation.
[0076] The bin monitoring system 310 further includes a load cell 350,
preferably an S-type load cell, but it will be understood that other types of
load
cells can be used and are within the spirit and scope of the invention. The
load cell 350 includes a first or top end 352 having a top threaded aperture
354 and a bottom or second end 356 having a bottom threaded aperture 358.
To secure the load cell 350 to the frame 312, a bolt 318 can be inserted
through the aperture 316 in the top 314 of the frame 312 and through the top
threaded aperture 354 of the load cell 350. As desired, a washer 319 or the
like can be provided to reinforce the top aperture or opening 316 of the frame
312. Each support preferably includes an aperture 322 for threading electrical
wiring for the load cell 350, as desired.
[0077] Within the aperture 313, a mechanical connector or channel block
360
can be positioned. The channel block 360 illustrated is configured and
arranged similarly to channel blocks 160, 260, 460, 460', 660, 760 and 860,
disclosed herein. The preferred channel block 360 includes at least one side
aperture 368a extending through the channel block 360 and a top aperture
368b. The channel block 360 is preferably suspended from the bottom 356 of
the load cell 350 with a bolt 366 secured within the bottom aperture 358 of
the
load cell 350 and a top aperture 368b of the channel block 360. In preferred
embodiments, a bracket or adapter 362 is welded to the bin leg L3 such that a
hook member 367 of the adapter is positioned under the bin leg L3. It is
preferred that the hook member 367 is positioned such that it does not receive
any weight of from the bin leg L3 and that the hook member 367 merely be
positioned under the leg to catch the leg should the weld between the leg L3
and the adapter 362 weaken. In preferred embodiments, bolts 365 are
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secured into the corresponding bolt apertures 368a of the channel block 360,
such that the load of the bin leg L3 is transferred to the load cell 350
proximate the bottom 356. Similarly to previously discuss embodiments, the
channel block 360 and the bin leg L3 can be raised or lowered, for example,
by rotating bolts 318 or 366. The adapter plate 362 can be secured to the
channel block 360 with bolts 365, which extend through apertures 364 and
368a and can be secured with nuts 372.
[0078] The bin monitoring system 310 of Figs. 10A-10B is operated largely
similar to bin monitoring systems 110, 210 with the exception that adapter 362
is preferably welded to the bin leg L3 instead of being bolted on. In
addition,
as discussed above, the hook member 367 of the adapter 362 is positioned
underneath the bin leg L3.
[0079] A set of preferred bin monitoring system 410, 410' are illustrated
in
Figs. 11A-110. The bin monitoring systems 410, 410' of Figs. 11A-110 are
preferred for bins having angle iron legs L4 or the like. Preferably, a set of
bin
monitoring systems 410, 410' is secured to each bin leg L4. Bin monitoring
systems 410, 410' preferably includes two generally A-shaped frames 412,
412'. Each preferred frame 412, 412' includes a centrally located opening or
aperture 413, 413', a top 414, 414' having an aperture 416, 416' and two
supports 420a, 420b, 420a', 420b' extending downwardly and outwardly from
the top 414, 414'. Each frame 412, 414' further includes a base consisting of
flanges 424a, 424b, 424a', 424b', each having at least one aperture 428, 428'
for receiving an anchor 430, 430' bolt or the like for securing the respective
frame 412, 412' to a concrete slab C or other foundation.
[0080] Each bin monitoring system 410 further includes a load cell 450,
450',
preferably an S-type load cell, but it will be understood that other types of
load
cells can be used and are within the spirit and scope of the invention. The
load cells 450, 450' each include a first or top end 452, 452' having a top
threaded aperture 454, 454' and a bottom or second end 456, 456' having a
bottom threaded aperture 458, 458'. To secure one load cell 450, 450', to one
respective frame 412, 412', a bolt 418, 418' can be inserted through the
aperture 416, 416' in the top 414, 414' of the respective frame 412, 412' and
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through the top threaded aperture 454, 454' of the respective load cell 450,
450'. As desired, a washer 419, 419' or the like can be provided to reinforce
the top aperture 416, 416' of the respective frame 412, 412'. Each support
420a, 420b, 420a', 420b' preferably includes an aperture 422, 422' for
threading electrical wiring for the respective load cell 450, 450', as
desired.
[0081] Within the aperture 413, 413' of each frame 412, 412', a mechanical
connector or channel block 460, 460' can be positioned. The channel blocks
460, 460' illustrated are configured and arranged similarly to channel blocks
160, 260, 360, 660, 760 and 860, disclosed herein. The preferred channel
blocks 460, 460' each include an extension 461, 461', at least one side
aperture 468a, 468a' extending through the channel block 460, 460' and a top
aperture 468b, 468b'. The extensions 461, 461' function as a limiting device
to generally limit the upward distance the channel blocks 460, 460' can be
raised with respect to the opening 413, 413'. It will be understood that
channel blocks 160, 260, 360, 460, 460', 660, 760 and 860 and frames 12,
112, 212, 312, 412, 412', 512, 612, 712 and 812 are preferably arranged and
configured to operate in a similar manner.
[0082] Each channel block 460, 460' further includes an adapter 462, 462'.
One channel block 460 includes an outside adapter 462 and the other
channel block 460' includes a corresponding inside adapter 462'. Each
adapter 462, 462' can be secured to the respective channel block 460, 460'
with bolts 467, 467' extending through apertures (see also, apertures 168a of
Figs. 15A-15C illustrating a similar channel block 160) in the adapter 462,
462'. The adapters 462, 462' are arranged and configured to generally mate
with the angled bin leg L4 and include a plurality of apertures 468a, 468a'
that
are aligned such that bolts 465, 465' can be inserted through the apertures
468a, 468a' in the adapters 462, 462' and corresponding apertures to be
drilled in the bin leg (not shown) to secure the bin monitoring system 410 to
the bin leg L4.
[0083] Each channel block 460, 460' is preferably suspended from the
bottom
456, 456' of the respective load cell 450, 450' with a bolt 466, 466' secured
within the bottom aperture 458, 458' of the respective load cell 450, 450' and
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a top aperture 468b, 468b' of the respective channel block 460, 460'.
Therefore, when bolts 465, 465' are secured through bin leg L4 apertures and
into the corresponding bolt apertures 468a, 468a' of the respective adapter
462, 462', the load of the bin leg L4, is transferred to the load cells 450,
450'
proximate the bottom 456, 456' of each load cell 450, 450'. Similarly to
previously discuss embodiments, the channel blocks 460, 460' and the bin leg
L4 can be raised or lowered by rotating bolts 418, 418' or 466, 466'.
[0084] Preferred, use of bin monitoring systems 410, 410' is generally as
follows. First, two sets of holes (not shown) are drilled in the bin leg L4,
proximate the bottom of the angle iron leg (see generally, Fig.110). Two bin
monitoring systems 410, 410' are preferably secured to each leg L4 of a bin,
proximate the respective leg such that the holes in the bin leg are aligned
with
the apertures 468a, 468a' in the respective brackets 462, 462' of each bin
monitoring system 410, 410'. Then, the bin monitoring systems 410, 410' can
be secured to the respective bin leg L4 by positioning each bin monitoring
system such that the adapters 462, 462' are against the bin leg L4. Then,
bolts 465 are inserted into the apertures 468a of the outside adapter 462,
through corresponding holes in the bin leg L4 and then through the aligned
apertures 468a' of the inside adapter 462' to then be secured in place with
nuts 472 and washers 470. Next, the channel blocks 460, 460' are raised,
either by rotating the bolt 418, 418' or 466, 466' such that the leg L4 is
subsequently lifted. As the bin leg L4 is lifted, the load of the bin is
transferred
to the load cells 450, 450'. Preferably, the steps disclosed in this paragraph
are repeated until each bin leg has two corresponding bin monitoring systems
operatively connected thereto. The load cells 450, 450' of each bin
monitoring system 410, 410' can then be connected to a transmitter to
transmit the load data for analysis
[0085] Another alternative set of bin monitoring systems 510 are
illustrated in
Figs. 12A-12B. The set of bin monitoring systems 510 of Figs. 12A-12B are
preferred for use with bins having I-beam shaped legs L5 (shown in phantom)
or the like. Preferably, each bin monitoring system 510 has a frame 512,
which arranged and configured to be secured to each bin leg L5. The frames
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512 are preferably generally A-shaped frames 512, as in previous
embodiments. Each frame 512 is preferably generally identical and includes
a centrally located aperture or opening 513, a top 514 having an aperture 516
and two supports 520a, 520b extending downwardly and outwardly from the
top 514. Each preferred frame 512 further includes a base consisting of
flanges 524a, 524b, each flange 524a, 524b having at least one aperture 528
for receiving an anchor 530 bolt or the like for securing the respective frame
512 to a concrete slab C or other foundation.
[0086] Each bin monitoring system 510 further includes a load cell 550,
preferably an S-type load cell, but it will be understood that other types of
load
cells can be used and are within the spirit and scope of the invention. Each
preferred load cell 550 includes a first or top end 552 having a top threaded
aperture 554 and a bottom or second end 556 having a bottom threaded
aperture 558. To secure one load cell 550 to each frame 512, a bolt 518 can
be inserted through the aperture 516 in the top 514 of the respective frame
512 and through the top threaded aperture 554 of the load cell 550. As
desired, a washer 519 or the like can be provided to reinforce the top
aperture
516 of each frame 512. Each support 520a, 520b preferably includes an
aperture 522 for threading electrical wiring for the load cell 550, as
desired.
[0087] At least partially positioned within each aperture 513, a
mechanical
connector or cross bar 560 can be suspended between the two frames 512.
The preferred cross bar 560 includes two apertures 568 extending through the
cross bar 560 for receiving respective bolts 566 from below. Each bolt 566
extends upwardly through the apertures 568, through mechanical connectors
or spacers 562 and up into the respective threaded bottom apertures 558 of
the respective load cell 550. Therefore, when the bin leg L5 is positioned on
the cross bar 560 between the two frames 512, the load of the bin is applied
jointly to the respective bottoms 556 of the two load cells 550. The bin leg
L5
and the load cells 550 can be raised or lowered by rotating the respective
bolt
518.
[0088] Preferred use of bin monitoring systems 510 is generally as
follows.
First, a bin having an I-beam support base or the like is provided. Then, an I-
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beam L5 is lifted such that the I-beam is positioned on the cross-bar between
two frames 512. As previously discussed, the I-beam L5 and the load cells
550 can be raised or lowered by rotating the respective bolt 518. As the bin
leg L5 is lifted, the load of the bin is transferred to the load cells 550.
Preferably, the steps disclosed in this paragraph are repeated until each bin
leg I-beam has a bin monitoring system operatively connected thereto.
Anchor bolts 530 are then used to secure each frame 512 flange or base 524
to the foundation. The load cells 550 of each bin monitoring system 510 can
then be connected to a transmitter to transmit the load data for analysis, if
desired.
[0089] Yet another preferred bin monitoring system 610 is illustrated in
Figs.
13A-13B. The bin monitoring system 610 of Figs. 13A-13B is preferred for
bins having bin legs L6 that are generally rectangular and tubular.
Preferably,
a set of bin monitoring systems 610 are secured to each bin leg L6. Each
preferred frame 612 includes a centrally located aperture 613, a top 614
having an aperture 616 and two supports 620a, 620b extending downwardly
and outwardly from the top 614. Each frame 612 further includes a base
consisting of flanges 624a, 624b, each flange 624a, 624b having at least one
aperture 628 for receiving an anchor 630 bolt or the like for securing the
frame
612 to a concrete slab C or other foundation.
[0090] Each bin monitoring system 610 includes a load cell 650, preferably
an
S-type load cell, but it will be understood that other types of load cells can
be
used and are within the spirit and scope of the invention. Each preferred load
cell 650 includes a first or top end 652 having a top threaded aperture 654
and a bottom or second end 656 having a bottom threaded aperture 658. To
secure the load cell 650 to the respective frame 612, a bolt 618 can be
inserted through the aperture 616 in the top 614 of the frame 612 and through
the top threaded aperture 654 of the load cell 650. As desired, a washer 619
or the like can be provided to reinforce the top aperture 616 of the
respective
frame 612. Each support preferably includes an aperture 622 for threading
electrical wiring for the load cell 650, as desired.
[0091] Located at least partially within the aperture or opening 613 of
each
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frame, a mechanical connector or channel block 660 can be positioned. Each
channel block 660 illustrated is configured and arranged similarly to channel
blocks 160, 260, 360, 460, 460', 760 and 860, disclosed herein. Each
preferred channel block 660 includes at least one side aperture 668a
extending through the channel block 660 and a top aperture 668b. Each
channel block 660 is preferably suspended from the bottom 656 of one load
cell 650 with a bolt 666 secured within the bottom aperture 658 of the
respective load cell 650 and a top aperture 668b of the channel block 660.
Therefore, when bolts 665 are secured though the first channel block 660,
then through bin leg L6 apertures and into the corresponding bolt apertures
668a of the second channel block 660 and finally secured with nuts 672, the
load of the bin leg L6 is transferred to the load cells 650 proximate the
bottom
656 of the load cells 650. Similarly to previously discussed embodiments, the
channel block 660 and the bin leg L6 can be raised or lowered by rotating
bolts 618 or 666.
[0092] To further secure the bin monitoring system 610 to the bin leg L6,
the
bin monitoring system 610 preferably further includes at least one plate or
bracket 662, preferably two plates 662, each plate 662 having at least one
aperture 664 that can be aligned with the aperture(s) 668a of the channel
blocks 660. The plates 662 can be secure adjacent opposite sides of the bin
leg L6 to reinforce the apertures in the bin leg L6 though which bolts 665 are
inserted.
[0093] Preferred use of bin monitoring system 610 is generally as follows.
First, holes (not shown) are drilled into both sides of a hollow leg,
proximate
the bottom of the leg (see generally, Fig. 13B). Two bin monitoring systems
610 are preferably secured to each leg L6 of a bin, proximate the respective
leg such that the holes in the bin leg are aligned with the apertures 668a in
the channel blocks 660. Then, the bin monitoring systems 610 can be
secured to the respective bin leg L6 by inserting bolts 665 through the
channel block apertures 668a and into the leg for securing with nuts 672. In
various preferred embodiments, plates 664 are secured on opposing sides of
the bin leg L6 before the bolts 665 are inserted to reinforce the leg
apertures.
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Next, the channel blocks 660 are raised, either by rotating the bolt 618 or
666
such that the leg L6 is subsequently lifted. As the bin leg L6 is lifted, the
load
of the bin is transferred to the load cells 650. Preferably, the steps
disclosed
in this paragraph are repeated until each bin leg has a set of bin monitoring
systems 610 operatively connected thereto. The frame 612 flanges 624a,
624b can be secured to the foundation with respective anchor bolts 630. The
load cell 650 of each bin monitoring system 610 can then be connected to a
transmitter to transmit the load data for analysis, as desired.
[0094] A further bin monitoring system 710 is illustrated in Figs. 14A-
14B. The
bin monitoring system 710 of Figs. 14A-14B is preferred for bins having bin
legs L7 that are rectangular and tubular. Bin monitoring system 710
preferably includes two generally A-shaped frames 712, as in various
previously discussed embodiments. Each preferred frame 712 includes a
centrally located aperture or opening 713, a top 714 having an aperture 716
and two supports 720a, 720b extending downwardly and outwardly from the
top 714. Each frame 712 further includes a base comprising two flanges
724a, 724b, each flange 724a, 724b having at least one aperture 728 for
receiving an anchor 730 bolt or the like for securing the respective frame 712
to a concrete slab C or other foundation (see also, Figs. 10 and 6).
[0095] Each bin monitoring system 710 further includes a load cell 750,
preferably an S-type load cell, but it will be understood that other types of
load
cells can be used and are within the spirit and scope of the invention. Each
load cell 750 includes a first or top end 752 having a top threaded aperture
754 and a bottom or second end 756 having a bottom threaded aperture 758.
To secure each load cell 750 to the respective frame 712, a bolt 718 can be
inserted through the aperture 716 in the top 714 of the frame 712 and through
the top threaded aperture 754 of the load cell 750. As desired, a washer 719
or the like can be provided to reinforce the top aperture 716 of the
respective
frame 712. Each support preferably includes an aperture 722 for threading
electrical wiring for the load cell 750, as desired.
[0096] Located at last partially within each aperture 713, a mechanical
connector or channel block 760 is positioned. The channel block 760
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illustrated is configured and arranged similarly to channel blocks 160, 260,
360, 460, 460', 660 and 860, disclosed herein. Each preferred channel block
760 includes at least one side aperture 768a extending through the channel
block 760 and a top aperture 768b. Each channel block 760 is preferably
suspended from the bottom 756 of the respective load cell 750 with a bolt 766
secured within the bottom aperture 758 of the load cell 750 and a top aperture
768b of the channel block 760. To secure each frame 712 to the bin leg L7,
the bin monitoring system 710 preferably further includes adapter plates or
brackets 762 having at least one aperture 764 aligned with the aperture(s)
768a of the respective channel blocks 760 and a hook member 767. As
illustrated, each hook member 767 is preferably slid under and engaged with
the bin leg L7 such that it is proximate the end of the bin leg L7 but is not
supporting the bin leg. The adapter plates 762 can be secured to the
respective channel blocks 760 by with bolts 765 inserted through apertures
764, for example.
[0097] Therefore, when adapter plates 762 are secured to the bin leg L7,
preferably by welding, the load of the bin leg L7, is transferred to the load
cells
750 proximate the bottom 756. Similar to previously discuss embodiments,
the respective channel block 760 and the respective bin leg L7 can be raised
or lowered by rotating bolts 718 or 766.
[0098] Use of bin monitoring systems 710 are generally as follows. First,
one
bin monitoring system 710 is preferably secured to each opposing ends of leg
L7 of a bin, preferably by welding. Then, bolts 765 can be secured within
channel block apertures 768a and secured with washers 770 and nuts 772.
Next, each channel block 760 is raised, either by rotating the bolt 718 or 766
such that the leg is subsequently lifted. As the bin leg L7 is lifted, the
load of
the bin is transferred to the load cells 750. In further preferred
embodiments,
an adapter plate 762 is secured to each channel block 760, either by bolting
or welding, such that when the bin leg L7 is lifted, the hook 767 of the
adapter
plate 762 is below the respective leg L7. In preferred embodiments, the hook
767 is below the leg but does not support the leg L7. The hook 767 is
preferably arranged such that the hook will support the leg only if the weld
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between the adapter plate 762 and the bin leg is weakened or fails.
Preferably, the steps disclosed in this paragraph are repeated until each bin
leg has a set of bin monitoring systems operatively connected thereto. The
frame 712 flanges 724a, 724b can be secured to the foundation with
respective anchor bolts 730. The load cell 750 of each bin monitoring system
710 can then be connected to a transmitter to transmit the load data for
analysis.
[0099] Yet another preferred bin monitoring system 810 having a different
adapter set of plates or brackets 862, 862' is illustrated in Figs. 16A-160.
This
embodiment is largely similar to that of Figs. 9A-9B in that the frame 812,
load
cell 850 and mechanical connector 860, among other identical elements, are
all similarly configured and arranged. For bin legs L8 that are generally
cylindrical, first and second adapter plates or brackets 862, 862' are
preferred.
In this embodiment, the first adapter plate 862 is preferably connected to
mechanical connector 860 with bolts 865 and nuts 872. The adapter plate
862 further includes a plurality of apertures 864 that are aligned with
apertures 864' in the second bracket 862' such that the first bracket and
second brackets 862' can be secured around the bin leg L8 with bolts 867.
To further connect brackets 862, 862' and the mechanical connector to the leg
L8, two additional bolts (not shown) can be secured through apertures 864"
and into corresponding apertures A drilled in the bin leg L8 such that the bin
leg L8 can be raised and lowered by raising or lowering mechanical connector
860 as discussed herein with respect to other similar embodiments.
[00100] Preferred use of bin monitoring system 810 is generally as follows.
First, holes or apertures A are drilled in the leg L8, proximate the bottom of
the leg. One bin monitoring system 810 is preferably secured to each leg L8
of a bin, proximate the respective leg such that the apertures A drilled in
the
bin leg L8 are aligned with the apertures 864" in the adapter plate 862'.
Then,
the bin monitoring system 810 can be secured to the respective bin leg L8 by
securing the channel block 860 to the adapter bracket 862 and the securing
the second adapter bracket 862' to the first adapter bracket 862. The leg L8
is preferably secured to the second adapter bracket 862' by inserting a bolt
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(not shown) into apertures 864" and A. Next, the channel block 860 is raised,
either by rotating bolt 818 or 866 such that the leg is subsequently lifted.
As
the bin leg L8 is lifted, the load of the bin is transferred to the load cell
850.
Preferably, the steps disclosed in this paragraph are repeated until each bin
leg has a bin monitoring system operatively connected thereto and the bin
legs are suspended off of the foundation. The frame 812 can be secured to
the foundation in accordance with methods disclosed herein with respect to
other embodiments. The load cell 850 of each bin monitoring system 810 can
then be connected to a transmitter to transmit the load data for analysis.
[00101] As described above, the bin monitoring system 10, 10', 110, 210,
310,
410, 410', 510, 610, 710 and 810 can be used to determine how much feed
enters and exits a feed bin. In this way, the bin monitoring system 10
facilitates the determination of when more feed should be ordered. In
addition, the bin monitoring system 10 facilitates verifying how much feed is
actually delivered when the bins are refilled and how much is being
consumed. As a result, potential out-of-feed events can be monitored, animal
performance based on feed consumption can be correlated, and future bin
levels can be predicted accurately.
[00102] As demonstrated by the foregoing discussion, various embodiments
may provide certain benefits. For instance, the bin monitoring system 10, 10'
110, 210, 310, 410, 410', 510, 610, 710 and 810 can greatly reduce
monitoring costs. The required labor can be reduced because multiple bin
feed levels can be quickly, simultaneously, and accurately monitored at a
central location, as compared with the conventional approach of visually
inspecting each bin individually. Safety hazards can also be reduced because
workers do not need to climb feed bins to inspect them.
[00103] Additionally, logistical savings can be realized by the bin
monitoring
systems 10, 10', 110, 210, 310, 410, 410', 510, 610, 710 and 810. Typically,
feed mills have large demands on Mondays and Fridays. On these days, the
mills run over capacity and often need to pay overtime to drivers and milling
employees to fill tanks for the weekend or to catch up on empty tanks on
Mondays. On Tuesdays, Wednesdays, and Thursdays, the mills run under
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capacity. Use of the bin monitoring systems 10, 110, 210, 310, 410, 410',
510, 610, 710 and 810 allow the feed mill to level its production flow out
over
the week by delivering feed early to some bins and just-in-time to others.
Accurate monitoring of feed bins allows producers to better predict and
schedule when they will need to replenish the feed bins, which in turn will
reduce the amount of expedited orders and allow the feed mill to plan their
production. By allowing the feed mill to better plan its production, the feed
mill
can schedule the bottlenecks to the maximum increasing throughput.
Overtime is saved in both the feed mill and the trucking, and the incidence of
empty compartments or "air tons" can be reduced. Rush orders can be
eliminated by better planning, thus greatly reducing the frequency of
expedited orders and the associated expense.
[00104] It is further believed that bin monitoring systems utilizing two
frames
412, 412', 512, 612, 712 are preferred as the load is applied more evenly on
the load cell and is not offset as compared to other embodiments. It is
believed that such embodiments, for example, the embodiments of Figs. 11A-
14B provide more accurate measurements.
[00105] It will be understood by those who practice the embodiments
described
herein and those skilled in the art that various modifications and
improvements may be made without departing from the spirit and scope of the
disclosed embodiments. The scope of protection afforded is to be determined
solely by the claims and by the breadth of interpretation allowed by law.
27
