Rotary airlock device and system for moving and placing granulate material

Abstract

A system for moving and placing granulate is provided together with a rotary airlock device. The system has a housing mountable to a trailer with cabinet located on a side of the housing with a compressor, at least one back compartment located on a back side of the housing. The compartment has a rotary airlock device in communication with the compressor. The compressor feeds air to the rotary airlock device under pressure, and an actuatable feeder located on the back side of the housing receives granulate and feeds the granulate to the rotary airlock device.

Claims

1. A system for moving and placing granulate, the system comprising: a housing mountable to a vehicle, trailer or both; at least one cabinet located on a side or back side of the housing, wherein the at least one cabinet comprises a compressor; at least one rotary airlock device located at a back end of the housing, wherein the at least one rotary airlock is in communication with the compressor, and wherein the compressor feeds air under pressure to the at least one rotary airlock device; an actuatable feeder located on the back side of the housing, wherein the feeder, when in an open position, is configured to receive granulate and feed the granulate to the at least one rotary airlock device, and wherein the feeder is actuatable downwardly to the open position, and is actuatable upwardly to a closed position when not in use; a hose mount located on the housing and in communication with a bottom portion of the at least one rotary airlock device, wherein when the compressor is actuated, the granulate is fed from the actuatable feeder, through the at least one rotary airlock device and out through the hose mount into a hose to place the granulate in a predetermined place.

2. The system of claim 1, wherein the at least one rotary airlock device comprises two rotary airlock devices in parallel and in communication with each other to an increase in pressure in the system.

3. The system of claim 1, wherein the at least one cabinet comprises: a motor to power the at least one rotary airlock device to rotate; a programmable logic controller (PLC); and multiple sensor arrays coupled to the PLC to sense an amount of the granulate the system is moving.

4. The system of claim 1, further comprising at least one back compartment located on the back side or a side of the housing, wherein the at least one back compartment comprises the at least one rotary airlock device.

5. A rotary airlock device attachable to a housing, the rotary airlock device comprising: a wear plate assembly comprising a bottom wear plate and a top wear plate; a rotor component comprising a rotary airlock chamber, wherein the rotor component is coupled to a motor and when actuated, rotates to provide a first airflow and a silo to increase a pressure in the rotary airlock chamber, wherein the rotor component is configured to move the granulate through the rotary airlock chamber; a housing bowl positioned below the rotary component, wherein the housing bowl comprises a ring extending from an exterior side of the housing bowl providing a mating surface for the bottom wear plate; an outlet assembly coupled to the housing bowl, wherein the outlet assembly comprises: an air and granulate outlet; an air pipe coupled to the air and granulate outlet wherein the air pipe is configured to provide a second airflow to move the granulate out of the outlet assembly.

6. The device of claim 5, wherein the bottom wear plate is configured to protect the housing bowl, and wherein the top wear plate is configured to protect the rotor component, wherein each of the bottom wear plate and the top wear plate further comprises an aperture to allow granulate to pass therethrough.

7. The device of claim 6, further comprising a rotor set plate to couple the rotary airlock device thereto.

8. The device of claim 5, wherein the rotary airlock chamber comprises a plurality of chambers in the rotor component, wherein the plurality of rotary airlock chambers are configured move the granulate therethrough based on an increased pressure in the plurality of rotary airlock chambers.

9. The device of claim 5, wherein the wear plate assembly and the housing bowl are congruently arranged.

10. The device of claim 5, wherein the top wear plate comprises an air input line connected to a compressor to pump air into the rotary air lock device to create the pressure to pump the granulate down through the device and out of the air and granulate outlet.

11. The device of claim 10, wherein the air pipe is further coupled to the compressor to provide the second airflow.

12. The device of claim 5, wherein the rotor component is connected to a hydraulic motor.

13. The device of claim 5, wherein the air pipe is coupled to the air and granulate outlet using an elbow connector attached to a second end of the air and granulate outlet channel.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) The foregoing summary, as well as the following detailed description of the invention, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, exemplary constructions of the invention are shown in the drawings. However, the invention is not limited to the specific methods and structures disclosed herein. The description of a method step or a structure referenced by a numeral in a drawing is applicable to the description of that method step or structure shown by that same numeral in any subsequent drawing herein.

(2) FIG. 1a illustrates an exemplary side view of a containerized system for moving and placing granulate material according to an embodiment of the present system.

(3) FIG. 1b illustrates an exemplary back view of a containerized system for moving and placing granulate material according to an embodiment of the present system.

(4) FIG. 2 illustrates an exemplary exploded view of a rotary air lock mechanism, according to an embodiment of the present system.

(5) FIG. 3 illustrates an exemplary air outlet channel coupled to a pumping device, according to an embodiment of the present system.

(6) FIG. 4 illustrates an exemplary inlet assembly and motor arrangement, according to an embodiment of the present system.

(7) FIG. 5 illustrates an exemplary top view of a housing bowl, according to an embodiment of the present invention.

(8) FIG. 6 illustrates an exemplary top perspective view of a lid, according to an embodiment of the present invention.

(9) FIG. 7 illustrates an exemplary a rear view of the lid, according to an embodiment of the present invention.

(10) FIG. 8 illustrates an exemplary top perspective view of a rotor component or feed bowl, according to an embodiment of the present invention.

(11) FIG. 9 illustrates an exemplary bottom portion of the rotor component, according to an embodiment of the present invention.

(12) FIG. 10 illustrates an exemplary rear view of the container according to an embodiment of the present invention.

(13) Other features, advantages, and aspects of the present system will become more apparent and be more readily understood from the following detailed description, which should be read in conjunction with the accompanying drawings.

DETAILED DESCRIPTION OF THE INVENTION

(14) The present invention is best understood by referencing the detailed figures and description set forth herein.

(15) It is expected that the present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.

(16) Embodiments of the invention are discussed below with reference to the examples. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these examples is for explanatory purposes as the invention extends beyond these limited embodiments. For example, it should be appreciated that those skilled in the art will, in light of the teachings of the present invention, recognize a multiplicity of alternate and suitable approaches, depending upon the needs of the particular application, to implement the functionality of any given detail described herein, beyond the particular implementation choices in the following embodiments described and shown. That is, there are numerous modifications and variations of the invention that are too numerous to be listed but that all fit within the scope of the invention. Also, singular words should be read as plural and vice versa and masculine as feminine and vice versa, where appropriate, and alternative embodiments do not necessarily imply that the two are mutually exclusive.

(17) It is to be further understood that the present invention is not limited to the particular methodology, compounds, materials, manufacturing techniques, uses, and applications, described herein, as these may vary. It is also to be understood that the terminology used herein is used for the purpose of describing particular embodiments only and is not intended to limit the scope of the present invention. It must be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include the plural reference unless the context clearly dictates otherwise. Thus, for example, a reference to “an element” is a reference to one or more elements and includes equivalents thereof known to those skilled in the art. Similarly, for another example, a reference to “a step” or “a means” is a reference to one or more steps or means and may include sub-steps and subservient means. All conjunctions used are to be understood in the most inclusive sense possible. Thus, the word “or” should be understood as having the definition of a logical “or” rather than that of a logical “exclusive or” unless the context clearly necessitates otherwise. Structures described herein are to be understood also to refer to functional equivalents of such structures. Language that may be construed to express approximation should be so understood unless the context clearly dictates otherwise.

(18) For purposes of illustrating features of the embodiments, a simple example will now be introduced and referenced throughout the disclosure. Those skilled in the art will recognize that this example is illustrative and not limiting and is provided purely for explanatory purposes. An example of a computing system environment is disclosed. Any computing system environment is not intended to suggest any limitation as to the scope of use or functionality of the system and method described herein. Neither should the computing environment be interpreted as having any dependency or requirement relating to any one or combination of components illustrated in the exemplary operating environment.

(19) Referring now to FIG. 1a, a side view of a system 100 for moving and placing granulate is shown. The disclosed system 100 is a portable, self-contained system capable of discharging granulate into hard-to-reach areas, as well as providing assistance in covering vast open areas with granulate in a short time. In embodiments, the system is containerized so that it can be coupled to a trailer. Furthermore, the system 100 and method described herein permit the application of granulate into areas that are normally inaccessible and would require many hours of human labor, thereby potentially avoiding damage to the site that might be incurred if employing a prior method, system or device. Still further, the present system and apparatus serve to provide discharge of granulate near or adjacent to retaining walls and underneath concrete flatwork.

(20) The system 100 may be coupled to a trailer 102 having a truss 104 upon which the housing 106 is mounted. The housing 106 comprises components including but not limited to a high-capacity air compressor, a motor (e.g., hydraulic motor), and a programmable logic controller (PLC) 124 together with multiple sensor arrays 128 and manual override components. The system further comprises an openable feeder/hopper 122, and at least one rotary airlock device 210 (shown in FIG. 2) and a hose mount 120 in which output air flows and a hose is mountable to. The hose outputs granulate to the desired area. The system further comprises multiple cabinets 112 and 114 in which electronics such as the PLC 124 and manual overrides are disposed. A hitch 110 is also provided in case multiple systems are required.

(21) In operation, the feeder/hopper 122 may be actuated downwardly according to arrow 130 to open and receive loads of granulate via the PLC 124. The granulate is filtered by size and is then output into the rotary airlock device 210 for pneumatic compression and output via house mount 120 for output of particulate. In embodiments, the feeder/hopper 122 may be attached to the back of the housing at an upper end above the rotary airlocks outside of any compartments.

(22) With reference to FIG. 1b a back view of the containerized system in a “closed” configuration is shown. The system comprises back compartments 116 and 118. The compartments may comprise the rotary airlock devices 210. The compartment 116 may comprise room for parts such as hoses. The compartment 116 comprises the airlock devices and feeder mechanisms to feed granulate the rotary device 210. In other embodiments, the rotary airlocks are located outside of the cabinet and are attached to the housing on the outside toward a back lower end as shown in FIG. 10.

(23) FIG. 2 illustrates an exploded view of the rotary airlock devices that is housed in the compartments of the system 100. The rotary airlock 210 is a pumping device. The rotary airlock device 210 comprises a rotary air lock chamber 252 (or plurality of chambers) to move aggregates such as sand, rock, soil, through a hose and discharge at the end users point of placement. In operation, the rotary airlock mechanism 210 is configured to increase production rates and maximum aggregate size able to be pumped through hose and reduce clogging. The rotary airlock mechanism 210 is configured to increase production rates in cubic yards, or tons per hour, whilst increasing maximum aggregate size able to be pumped through hose, that is larger than ⅜″ or approximately one centimeter.

(24) The functional components of the rotary airlock system 210 comprise a wear plate assembly (222 and 224), a rotor component 242. The rotor component 242 is configured as a material input or intake and rotates to silo the material until it rotates over the outlet chamber (shown in FIG. 3) for output. The wear plate assembly comprises a bottom wear plate 222, and a top wear plate 224. The bottom wear plate 222 is positioned at a lower portion of the rotary airlock 210, and may be manufactured from, for example, a duplex material composed of a chromium-tungsten carbide, austenitic alloy. However, other materials that are suitable may be used as well. The bottom wear plate 222 is configured to protect the lower rotary plate 230 and the housing bowl 234. The bottom wear plate 222 comprises an aperture 254 to allow material flow and to protect the rotor assembly itself.

(25) The top wear plate 224 is positioned at a top portion of the rotary airlock 210, and like the bottom wear plate 222, may be manufactured from, for example, a duplex material composed of a chromium-tungsten carbide, austenitic alloy. However, other materials that are suitable may be used as well. The top wear plate 224 is configured to protect the upper rotary plate 232.

(26) Still with reference to FIG. 2, the rotor 242 comprises a plurality of chambers 252 disposed therewith to eject the aggregate material deposited in the chambers. The chambers 252 in this embodiment are sized with an increase in volume compared to traditional assemblies. The rotor has an airlock seal, and is configured to lock air in as the air is discharged therethrough. In this way, the functional components of the rotary airlock system 210 are congruently arranged and keep materials and air in the form of a vacuum, until the rotor spins and aligns with an exhaust (shown in FIG. 4).

(27) In operation, the bottom wear plate 222 is attached to an upper part of a housing bowl 234. A lower part of the rotor component 242 is attached to the rotor component 242. The bottom wear plate 222 and the top wear plate 224 are attached to the rotor component 242 via fasteners. The fasteners include, but are not limited to, clamp screws, screws, and bolts. The wearing plate assembly 222 and 224 arrangement and configuration are configured to provide mechanical and adhesive bond to the rotor components. In one embodiment, the rotor component 242, the rotor plate assembly (230, 232) and the rotor gasket assembly (shown in FIG. 8) comprise circumferentially arranged plurality of openings 256 which lead to chamber 252. The circumferentially arranged openings 256 of each assembly are congruent to one another. In operation, when granulate is fed into the rotary airlock via hopper, the granulate falls into the chamber of the bowl (to be discussed in more detail with reference to FIG. 6). While granulate is being deposited the rotor component 242 is rotating under power from a hydraulic drive that connects to the bottom of the device. In turn, as the rotor rotates each chamber is presented to a manifold so that high-pressure air from the air compressor via a hose hookup to conduit is introduced into the chamber 252. The high-pressure air is introduced through opening 202 and forces material located in chamber out through material ejection conduit (shown in FIG. 3). During operation, a pump hose, which can be up to several hundred feet long, is attached to the end of a conduit attached to housing bowl 234 and is used to place the stream of granulate generated by rotary air lock mechanism. The clamp screws 236 and 238 are provided to couple the elements together.

(28) Referring now to FIG. 3, an outlet assembly 300 is shown in which there is a second stream of compressed air that facilitates additional pumping force and obviates clogs. The outlet assembly 300 is positioned at a bottom end of the rotary airlock 210 and is in communication with the rotary airlock 210 such that granulate flows from the airlock to the outlet assembly 300. The outlet assembly comprises air and granulate outlet channel 304 coupled to the rotary airlock 210. A seal 302 is located at the end coupling the air and granulate outlet channel 304 and the rotary airlock 210. A coupling 306 (e.g., elbow connector) is located at a second end of the air and granulate outlet channel 304 to attach to hose outlet 1012 (shown in FIG. 10). An air pipe 312 is coupled to the air and granulate outlet channel 304 via an coupling 306 and may be coated with zinc. The air pipe 312 is coupled a compressor at one end and the air and granulate outlet channel 304 on the other end. The air outlet channel and granulate 304 comprises an aperture to which coupling 306 is connected to provide the additional stream of air. In operation, the air hose may be connected to the same compressor or a different compressor to provide power and pressure to the air outlet assembly 300 for discharging of granulate out of an end 314 of the air and granulate outlet channel 304 into hard-to-reach areas, as well as providing assistance in covering vast open areas with granulate in a short time.

(29) Referring to FIG. 4, is a top perspective view of an arrangement 400 of the rotor set plate 402, motor 408 and an air inlet assembly 300 comprising an air inlet 406 is shown. The inlet 406 is configured to push matter downstream. A compressor or motor 408 is disposed at a first end of the air inlet 406. An optional gear box is located downstream. The rotor assembly 210 is coupled to set plate 402 so that matter passes through the rotor through aperture 404, out of inlet 302 via outlet channel 304.

(30) Referring to FIG. 5, a top perspective view of the housing bowl 234 is shown generally at 500. The housing bowl 234 is configured to act as a shield for internal components whilst keeping the granulate in the housing. A ring 508 extends from an exterior side of the housing bowl 234 providing a mating surface for wear plate assembly and connections via the clamp screws 236 and 238. An upper end of the housing includes notches 504 for fixing bottom wear plate 122 in place.

(31) FIG. 6 illustrates an exemplary top perspective view of a top wear plate 224 (hereinafter referred to as lid 602 for purposes of this figure). An air input line 606 is connected to a compressor to pump air into the rotary air lock 210 to create pressure to pump the gravel down through the device and out of the hose output 1012 (shown in FIG. 10). A compressor is provided on the system 100 together with electronic components to operate the motor of the compressor. The lid further comprises a gravel drop aperture 612 configured to receive granulate dropped down from the hopper. The lid further comprises a connector output 608 to connect the lid to the inlet hosing. An aperture 610 is further provided exhaust during rotation of the rotor assembly. A bolt hole 604 is provided for mating components together.

(32) With reference now to FIG. 7 an underneath view of the lid 602 according to an embodiment of the present invention is shown. The lid 602 is coupled to the wear plate 228 at the bottom side 702 of the lid 602 via a connector 704 to keep the wear plate 228 and lid 602 stationary. The gravel drop 612 and exhaust 610, are shown as well. The lid 602 further comprises additional exhaust conduit 612 to retrieve air pressure when the rotor 242 spins, air conduct 614 acts as a seal for a shot period as rotor 242 spins around spindle 710. Aperture 706 mates the lid 602 with the feed line 708 for air supply downward flange 718 is shown.

(33) FIG. 8 illustrates a top perspective view of the rotor component 242 or feed bowl according to an embodiment of the present invention. In operations, the rotor component 242 rotates generate sifting and a pressure variant. A hydraulic motor the in housing 114 on the truck 102 provides power to rotate the rotor component 242. The rotor component 242 comprises gravel ducts 802 (or chambers 232 or openings 256 with reference to FIG. 2) to allow granulate to flow therethrough. The rotor component further comprises spindles 804 for support and a rubber gasket 806 for further protection and sealing. The ducts, because they allow for direct granulate feed and thus do not clog in a fashion that a U-shape duct would. In operation, the hydraulic motor rotates the feed bowl and is driven by hydraulic fluid from the truck to connect to the hydraulic power unit. Only one gear and bearing are required for rotation of the system and that can be sealed within the hydraulic system. Use of the hydraulic drive also eliminates most of the noise and the speed of rotation can be easily controlled by the flow of hydraulic fluid eliminating the need for gears of various ratios. Use of hydraulic motors, pumps and valves to control and power of most if not all of the systems results in costs savings and a significant reduction in noise and dust created by conventional systems that use noisy air driven motors, chains and gear drives.

(34) Referring now to FIG. 9 an exemplary bottom portion of the rotor component 242 according to an embodiment of the present invention is shown. As shown, the device comprises bearing 906, bottom casing 902, hollow interior 904, attachment fixture 908, and interior bore 910. The bearing 906 is configured to attach the rotor component 238 to the bottom assembly and casing and allows for rotation of the rotor component connection to hydraulic motor. The hollow interior 904 provides a space for connection of the hydraulic motor to provide power to the device. The attachment fixture 908 is provided for attaching device to the trailer (or truck).

(35) FIG. 10 illustrates an exemplary rear view of the system 100 having back compartment open to expose the rotary airlocks according to an embodiment of the present invention.

(36) In embodiments, system comprises two rotary airlock mechanisms including a first rotary airlock 210, a second rotary airlock 1002. FIG. 10 illustrates exemplary hose outlets (1012, 1014) of trailer 102 of FIG. 10, according to an embodiment of the present invention. The rotary mechanisms (1006, 1008) attached to a rear side of the trailer 102. A hollow interior 1004 provides a space for connection of the hydraulic motor to provide power to the device.

(37) Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. It should be understood that the illustrated embodiments are exemplary only and should not be taken as limiting the scope of the invention.

(38) Although specific features of various embodiments of the invention may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the invention, the feature(s) of one drawing may be combined with any or all of the features in any of the other drawings. The words “including,” “comprising,” “having,” and “with” as used herein are to be interpreted broadly and comprehensively, and are not limited to any physical interconnection. Moreover, any embodiments disclosed herein are not to be interpreted as the only possible embodiments. Rather, modifications and other embodiments are intended to be included within the scope of the appended claims.