ROTARY AIRLOCK DEVICE AND SYSTEM FOR MOVING AND PLACING GRANULATE MATERIAL

Abstract

A system for moving and placing granulate is provided. A housing is mountable to a trailer and has at least one cabinet located on a side of the housing with a compressor, at least one back compartment located on a back side of the housing, wherein the at least one back compartment has at least one rotary airlock device in communication with the compressor, wherein the compressor feeds air to the rotary airlock device under pressure, an actuatable feeder located on the back side of the housing, wherein the feeder when in an open position receives granulate and feeds the granulate to the at least one rotary airlock device, and a hose mount located on the housing and in communication with a bottom portion of the at least one rotary airlock, wherein when the compressor is actuated, the granulate is fed from the feeder, through the at least one rotary airlock and out through the house mount into a hose to place the granulate in a predetermined place.

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 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, in communication with the compressor, wherein the compressor feeds air to the rotary airlock device under pressure; an actuatable feeder located on the back side of the housing, wherein the feeder when in an open position receives granulate and feeds the granulate to the at least one rotary airlock device; a hose mount located on the housing and in communication with a bottom portion of the at least one rotary airlock, wherein when the compressor is actuated, the granulate is fed from the feeder, through the at least one rotary airlock and out through the house 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 comprises two rotary airlocks in parallel and in communication with the other to provide increased pressure.

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

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

5. The system of claim 1, wherein the feeder is actuatable downwardly to open upwardly to close when not in use.

6. A rotary airlock feeder device attachable to a housing, the rotary airlock feeder comprising: a wear plate assembly comprising a bottom wear plate and a top wear plate, wherein the bottom wear plate is attached to an upper part of a housing bowl, and wherein the top wear plate has a granulate input aperture; a rotary component comprising a rotary airlock chamber, wherein the rotary component is coupled to a motor and when actuated, rotates to provide a silo to increase pressure and move the granulate through the chamber; a housing bowl positioned below the rotary component; an outlet assembly attached to housing bowl, wherein the outlet assembly comprises: a granulate outlet; and an air pipe coupled to the outlet assembly to provide an airflow to move granulate out of the outlet assembly.

7. The device of claim 5, wherein the bottom and top wear plates protect the lower rotary plate and the housing bowl and further comprises an aperture to allow granulate.

8. The device of claim 5, further comprising a plurality of chambers in the rotor component, wherein the chambers are configured move granulate therethrough based on increased pressure in the chambers.

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

10. The device of claim 7, wherein the first rotor plate and second rotor plate comprise the plurality of chambers disposed therewith to receive and reject, respectively, the aggregate material deposited in the chambers.

11. The device of claim 5, wherein the bottom wear plate is configured to protect the first rotary plate and the housing bowl.

12. The device of claim 5, wherein the first rotor gasket and the second rotor gasket are provided with a radial and circumferentially arrayed plurality of downwardly projecting flange portions.

13. The device of claim 5, 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.

14. 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 to create pressure to pump the granulate down through the device and out of an output line.

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

Description

BRIEF DESCRIPTION OF DRAWINGS

[0021] 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.

[0022] 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.

[0023] 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.

[0024] FIG. 2 illustrates an exemplary exploded view of a rotary air lock mechanism, according to an embodiment of the present system.

[0025] FIG. 3 illustrates an exemplary air outlet channel coupled to a pumping device, according to an embodiment of the present system.

[0026] FIG. 4 illustrates an exemplary inlet assembly and motor arrangement, according to an embodiment of the present system.

[0027] FIG. 5 illustrates an exemplary top view of a housing bowl, according to an embodiment of the present invention.

[0028] FIG. 6 illustrates an exemplary top perspective view of a lid, according to an embodiment of the present invention.

[0029] FIG. 7 illustrates an exemplary a rear view of the lid, according to an embodiment of the present invention.

[0030] FIG. 8 illustrates an exemplary top perspective view of a rotor component or feed bowl, according to an embodiment of the present invention.

[0031] FIG. 9 illustrates an exemplary bottom portion of the rotor component, according to an embodiment of the present invention.

[0032] FIG. 10 illustrates an exemplary rear view of the container according to an embodiment of the present invention.

[0033] 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

[0034] The present invention is best understood by referencing the detailed figures and description set forth herein.

[0035] 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.

[0036] 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.

[0037] 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.

[0038] 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.

[0039] Referring now to FIG. 1a a side view of an system 100 for moving and placing granulate is shown. The disclosed apparatus 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, and thereby potentially avoiding damage to the site that might be incurred if employing a prior method and device. Still further, the present invention serves to provide discharge of granulate near or adjacent to retaining walls and underneath concrete flatwork.

[0040] 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 for components including but not limited to a high capacity air compressor, a motor (e.g., hydraulic motor), and a programmable logic controller (PLC) together with multiple sensor arrays 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 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 and manual overrides are disposed. A hitch 110 is also provided in case multiple systems are required.

[0041] In operation, the feeder/hopper 122 may be actuated downwardly to open and receives loads of granulate. 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.

[0042] 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.

[0043] 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 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 or approximately one centimeter.

[0044] 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 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 to allow material flow and to protect the rotate assembly itself.

[0045] 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.

[0046] Still with reference to FIG. 2, the rotor 242 comprises a plurality of chambers disposed therewith to eject the aggregate material deposited in the chambers. The chambers 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).

[0047] In operation, the bottom wear plate 222 attached to an upper part of a housing bowl 234. A lower part of the rotor component 242 attaches 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 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 and the rotor gasket assembly comprise circumferentially arranged plurality of openings. The circumferentially arranged openings 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 barrel is rotating under power from a hydraulic drive that connects to the bottom device. In turn, as the rotor each chamber is presented to a manifold so that high-pressure air from the air compressor by an appropriate hose hookup to conduit is introduced into the chamber. 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 conduit attached to 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.

[0048] Referring now to FIG. 3, an air outlet assembly is shown in which there is a second stream of compressed air facilitates additional pumping force and obviates the clogs. The outlet assembly is positioned at a bottom end of the rotary airlock 210 and is in communication with the rotary airlock 210 such that granulate flow from the airlock to the outlet assembly. The outlet assembly comprises a first end of an air outlet channel 304 coupled to the rotary airlock 210. A seal 302 is located at the end coupling the air outlet channel 304 and the rotary airlock 210. A coupling is located at a second end of the air outlet channel 304 to attach to hose 112. An air pipe 312 is coupled to the air outlet channel 304 via an elbow connector 306 which may be coated with zinc. The air pipe 312 is coupled a compressor one end and the air outlet channel on the other end. The air outlet channel 304 comprises an aperture to which an elbow connector 306 is connected to provide the additional stream of air. In operation, the air hose may be connected to the same compressor a different compressor to provide power and pressure to the air outlet assembly for discharging of granulate into hard-to-reach areas, as well as providing assistance in covering vast open areas with granulate in a short time.

[0049] Referring to FIG. 4, is a top perspective view of an arrangement of the rotor set plate 402, motor 408 and an air inlet assembly 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.

[0050] Referring to FIG. 5, a top perspective view of the housing bowl 234 is shown generally at 502. 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.

[0051] 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 110 to create pressure to pump the gravel down through the device and out of the output line 112. 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.

[0052] 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 60 lid is coupled to the bottom of the lid 702 of the lid 602 via a connector 704 to keep the wear plate 124 and lid 602 stationary. The gravel drops 614 and exhaust 612, are shown as well. The lid 602 further comprises additional exhaust conduit 712 to retrieve air pressure when the rotor 142 spins, air conduct 614 as a seal for a shot period as rotor spins around spindle 710, aperture 706 that mates with the lid 602 and feed line 708 for air and component 718 is shown.

[0053] FIG. 8 illustrates a top perspective view of the rotor component 142 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 120 on the truck 102 provides power to rotate the rotor component 142. The rotor component 242 comprises gravel ducts 802 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.

[0054] 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, and attachment fixture 908 is provided. The bearing 906 is configured to attach the rotor component the bottom assembly and casing and allow 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).

[0055] 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.

[0056] In embodiments, system comprises two rotary airlock mechanisms including a first rotary airlock 201, a second rotary airlock 1002. FIG. 11 illustrates exemplary 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

[0057] 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.

[0058] 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.