MULTIPLE SENSOR RESIN DELIVERY OPTIMIZING VACUUM PUMP OPERATION

Abstract

Method and apparatus for pneumatically conveying granular resin material and controlling such conveyance includes a sensor associated with granular plastic resin material receiver with the sensing vacuum level thereat and a microprocessor adjusting vacuum pump speed based on vacuum level sensed at the receiver.

Claims

1. A method for a pneumatically conveying plastic resin material from a resin supply using a vacuum pump having a suction intake, comprising: a) providing a plurality of receivers for temporarily storing resin material until needed by an associated process machine; b) providing a conduit for conveying granular resin material from the resin supply to the receivers in response to vacuum drawn through the conduit by a vacuum pump; c) sensing vacuum level at at least one receiver; d) sensing vacuum level at the suction intake; e) actuating the vacuum pump; f) adjusting vacuum pump speed based on vacuum level sensed at the receiver.

2. The method of claim 1 further comprising adjusting vacuum pump speed based on vacuum level sensed at the receiver at the vacuum pump.

3. A method for a pneumatically conveying plastic resin material from a resin supply using a resin pump having a suction intake, comprising: a) providing a plurality of receivers for temporarily storing resin material until needed by an associated process machine; b) providing a conduit for conveying granular resin material from the resin supply to the receivers in response to vacuum drawn through the conduit by a vacuum pump; c) periodically sensing vacuum level at at least some of the receivers; d) storing the sensed vacuum levels; e) actuating the vacuum pump; f) adjusting vacuum pump speed based on the stored vacuum levels.

4. The method of claim 3 further comprising serially sensing vacuum levels at the receivers.

5. The method of claim 4 further comprising adjusting pump speed based on multiple collections of serially sensed vacuum levels.

6. The method of claim 3 further comprising periodically sensing vacuum level at the vacuum pump.

7. The method of claim 6 further comprising sensing vacuum level serially.

8. The method of claim 7 further comprising adjusting pump speed based on multiple collections of serially sensed vacuum levels.

9. A method for conveying granular plastic resin material from a supply thereof to at least one receiver, for temporary storage of the granular plastic resin material in the receiver until the material is needed by a process machine associated with the receiver, comprising: a) positioning a first conduit with an open end in the supply; b) drawing vacuum through the first conduit, thereby conveying granular plastic resin material out of the supply and along the conduit; c) providing a receiver connected with the conduit for receipt of granular resin material from the conduit; d) providing a second conduit connecting the receiver to a vacuum source providing the drawn vacuum via the receiver to the first conduit e) providing at least one vacuum sensor on the first conduit; f) regulating operation of the vacuum source according to sensed vacuum level at the vacuum sensor.

10. The method of claim 9 further comprising: a) providing a vacuum sensor on the second conduit; and b) regulating operation of the vacuum source according to vacuum levels sensed at the vacuum sensors.

11. The method of claim 10 further comprising: a) providing a vacuum sensor at the receiver; and b) regulating vacuum draw by the vacuum source according to vacuum levels sensed at the vacuum sensors.

12. The method of claim 10 further comprising: a) providing a computing device; b) regulating vacuum drawing according to an algorithm executed by the computing device based on input signals received from the vacuum sensors.

13. A method for conveying granular plastic resin material from a supply thereof to at least one receiver, for temporary storage of the granular plastic resin material in the receiver until the material is needed by a process machine associated with the receiver, comprising: a) positioning a first conduit with an open end in the supply; b) drawing vacuum through the first conduit, thereby conveying granular plastic resin material out of the supply and along the conduit; c) providing a receiver connected with the conduit for receipt of granular resin material from the conduit; d) providing a second conduit connecting the receiver to a vacuum source providing the drawn vacuum via the receiver to the first conduit; e) providing at least one vacuum sensor on the first conduit; f) recording vacuum levels provided by the sensor; g) correlating recorded vacuum levels with observed conveyance of granular resin material from the supply to the receiver in a computing device to create an executable algorithm for optimized conveyance of the granular resin material; and h) executing the algorithm in the computing device to regulate the vacuum source.

14. The method of claim 13 wherein the computing device is a microprocessor.

15. The method of claim 14 further comprising recording physical parameter data including at least one of ambient temperature, atmospheric pressure, relative humidity, and available line voltage and using data reflecting at least one of these physical parameters in creating the executable algorithm.

16. A method for conveying granular plastic resin material from a supply thereof to at least one receiver, for temporary storage of the granular plastic resin material in the receiver until the material is needed by a process machine associated with the receiver, consisting of: a) positioning a first conduit with an open end in the supply; b) drawing vacuum through the first conduit, thereby conveying granular plastic resin material out of the supply and along the conduit; c) providing a receiver connected with the conduit for receipt of granular resin material from the conduit; d) providing a second conduit connecting the receiver to a vacuum source providing the drawn vacuum via the receiver to the first conduit; e) providing at least one vacuum sensor on the first conduit; f) recording vacuum levels provided by the sensor; g) correlating recorded vacuum levels and recorded physical parameter data including at least one of ambient temperature, atmospheric pressure, relative humidity, and available line voltage, with observed conveyance of granular resin material from the supply to the receiver in a microprocessor to create an executable algorithm for optimized conveyance of the granular resin material; and h) executing the algorithm in the microprocessor device to regulate the vacuum source.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0080] FIG. 1 is a schematic representation of a resin delivery system in accordance with aspects of the invention.

[0081] FIG. 2 is a schematic representation of an alternate embodiment of a resin delivery system in accordance with aspects of this invention.

[0082] In reference to the drawings, where reference numbers are identical to those used in the description to designate like or similar elements throughout the various views, illustrative implementations of the invention are described. The figures are schematic and therefore not to scale. In some instances the drawings have been exaggerated and/or simplified for illustrative purposes. One of skill in the art will appreciate the many possible applications and variations of the invention that are possible based on the following description of this invention.

DETAILED DESCRIPTION OF THE INVENTION

[0083] In this application, unless otherwise apparent from the context, it is to be understood that the use of the term vacuum means air at slightly below atmospheric pressure. The vacuum (meaning air slightly below atmospheric pressure) provides a suction effect that is used to draw granular plastic resin material out of a supply and to convey that granular plastic resin material through various conduits to receivers where the granular resin material can be temporarily stored before being molded or extruded. Hence, in this application it is useful for the reader mentally to equate the term vacuum with the term suction.

[0084] Referring to the drawings in general and to FIG. 1 in particular, apparatus for conveying granular plastic resin material from the supply to receivers that retain and dispense the resin material when needed by a process machine is illustrated in FIG. 1. The apparatus, which is designated generally 88 in FIG. 1, preferably includes a vacuum pump designated generally 92 and shown schematically in FIG. 1. Vacuum pump 92 preferably includes a vacuum pump suction head 93 also shown schematically in FIG. 1. Connected to the vacuum pump suction head 93 may be an optional airflow limiter 30 shown only in schematic form in FIG. 1. Optional airflow limiter 30 receives vacuum drawn by vacuum pump 92 through vacuum drawing conduit 100.

[0085] The optional air flow limiter 30 is preferably one of the types of air flow limiters disclosed in the United States patents listed above under the heading Cross Reference to Related Patents and Patent Applications. All of these air flow limiters, which are the preferable type of flow limiters for use in the instant invention, must be vertical or essentially vertical in order to function properly. In the drawings, all of flow limiters 30 have been illustrated in a vertical orientation. However, it is to be understood that other kinds and styles of flow limiters may be used in the course of practice of the invention.

[0086] Vacuum drawing conduit 100 is connected to a plurality of receivers 16, each of which receives, retains and dispenses, as needed, granular plastic resin material to a process machine, such as a gravimetric blender, or an extruder, or a molding press as located preferably below a receiver 16. The process machines are not illustrated in FIG. 1 to enhance the clarity of the drawing.

[0087] Further illustrated in FIG. 1 is a hopper 18 for storage of granular plastic resin material therein and a resin conveying conduit 98, which serves to draw resin from hopper 18 and to deliver the resin through resin conveying conduit 98 to the respective receivers 16 as vacuum is drawn by the vacuum pump 92, with vacuum propagating through optional air flow limiter 30, vacuum drawing conduit 100, the various receivers 16, and resin conveying conduit 98, to hopper 18. Receivers 16 are preferably of the type disclosed and claimed in U.S. Pat. No. 8,753,432.

[0088] Still referring to FIG. 1, a plurality of vacuum sensors are illustrated. Vacuum sensors 130 are provided associated with each receiver and located upstream of each receiver to sense the vacuum in resin conveying conduit 98 as that resin conveying conduit conveys resin into a receiver 16. Vacuum sensors 132 are positioned downstream of each receiver to sense vacuum at a position proximate to each receiver in vacuum drawing conduit 100. A vacuum sensor 134 is provided to sense the vacuum being drawn by vacuum pump 92 at a position proximate to vacuum pump suction head 93.

[0089] While the resin conveying system 88 illustrated in FIG. 1 has been depicted with vacuum sensors 130 upstream of each receiver, vacuum sensors 132 downstream of each receiver, and a vacuum sensor 134 at vacuum pump 92, in some implementations of the invention, only vacuum sensors upstream of receiver 16, or vacuum sensors downstream of receiver 16 may be used. Moreover, it is within the scope of the invention to provide a vacuum sensor within one or more of the receivers 16 as indicated by vacuum sensors 136 illustrated in FIG. 1. It is further within the scope of the invention to provide only a few vacuum sensors 130 or 132 or 136, located at strategic positions upstream of a receiver, downstream of a selected receiver, or within a selected receiver. Optionally but desirably a vacuum sensor 138 may also be provided at resin supply 18 to sense the level of vacuum being drawn by vacuum pump 92 through resin conveying conduit 98 proximate resin supply 18.

[0090] However many vacuum sensors are used, all of these vacuum sensors provide data, preferably wirelessly, to a controller illustrated only schematically in the drawings, which is desirably in the form of a microprocessor 200. Microprocessor 200 collects data from one or more of the sensors 130,132, 134, 136, 138 preferably sequentially through the sensors in that only a single receiver 16 is usually active at a given time, so desirably the vacuum data relevant to a given receiver 16 is collected only when that receiver 16 is active. (Other data collection schemes, such as serial or random, and algorithmic protocols based on various physical and other parameters such as relative humidity, ambient temperature, atmospheric pressure, available line voltage for the vacuum pump, and the like, are also within the scope of this invention.) This sensed vacuum data and the other physical parameter data are preferably stored and used based preferably on an experientially developed algorithm (developed using such data) which is executed by microprocessor 200 to optimally modulate operation of vacuum pump 92. This data may desirably be correlated with time of day, the type of resin being conveyed, the temperature within the facility, and other physical parameters so as to provide a mathematical algorithm that may be used to optimize the speed of vacuum pump 92.

[0091] Alternatively to wireless communication of the vacuum sensors 130 through 138 with microprocessor 200, wiring can, of course, be used.

[0092] FIG. 2 shows an alternate embodiment of the resin conveying system of the invention where this alternate embodiment of the conveying system has been designated 88A. FIG. 2, as in FIG. 1, depicts a vacuum pump 92 shown in schematic form having a vacuum pump suction head 93 also depicted in schematic form. In the alternate embodiment of the invention illustrated in FIG. 2, vacuum drawing conduit 100 leads directly into and communicates with vacuum pump suction head 93. In the embodiment illustrated in FIG. 2, an optional air flow limiter 30 is shown as being provided for each receiver 16, with the air flow limiter 30 for a respective receiver 16 being located in a portion of a connection conduit 102 that connects a respective receiver 16 to vacuum drawing conduit 100. In FIG. 2, each air flow limiter 30 is depicted in a vertical orientation, just as is airflow limiter 30 depicted in a vertical orientation in FIG. 1. Each receiver 16 is connected by connection conduit 102 to vacuum drawing conduit 100 with optional air flow limiter 30 forming a portion of connection conduit 102. The air flow limiters 30 illustrated in FIG. 2 are desirably one of the type of air flow limiters disclosed above with reference to FIG. 1.

[0093] In FIG. 2, as in FIG. 1, a first conduit 98 serves to convey granular plastic resin from hopper 18 to the respective receivers in response to vacuum drawn by vacuum pump 92 as that vacuum propagates from vacuum pump 92 through second conduit 100, connection conduits 102, receivers 16, and resin conveying conduit 98 to hopper 18. The resin conveying system shown in FIG. 2 is similar to that shown in FIG. 1 in that it includes a variety of vacuum sensors with vacuum sensors 130 being located upstream of associated receivers 16; vacuum sensors 132 being located downstream of respective receivers 16; a vacuum sensor 134 being provided at vacuum pump 92; a plurality of vacuum sensors 136 being provided within receivers 16; and a vacuum sensor 138 desirably being provided at the resin supply to measure the vacuum drawn within resin supply conduit 98 proximate resin supply 18. As with the resin conveying system illustrated in FIG. 1, the vacuum sensors illustrated in FIG. 2 are desirably connected to a microprocessor 200, or other, more powerful computing device, wirelessly. Alternatively, the vacuum sensors can be connected by wires to microprocessor 200 or some other computing device, if necessary. The same approach to optimizing speed and modulation of the vacuum pump 92 as described above with respect to FIG. 1 is applicable to the resin conveying system illustrated in FIG. 2.

[0094] During operation of the resin conveying systems shown schematically in FIGS. 1 and 2, upon actuation of vacuum pump 92, a vacuum is drawn at vacuum pump suction head 93. This vacuum, as it propagates to hopper 18, serves to draw resin out of hopper 18 and into respective receivers 16. In the embodiment illustrated in FIG. 2, optional individual air flow limiters 30 limit the suction or vacuum drawn by vacuum pump 92 through a given associated receiver 16. In the embodiment illustrated in FIG. 1, an optional single air flow limiter 30 limits vacuum drawn through all of receivers 16 forming a portion of the granular resin conveying system illustrated in FIG. 1.

[0095] Although schematic implementations of present invention and at least some of its advantages have been described in detail hereinabove, it should be understood that various changes, substitutions and alterations may be made to the apparatus and methods disclosed herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of this patent application is not intended to be limited to the particular implementations of apparatus and methods described in the specification, nor to any methods that may be described or inferentially understood by those skilled in the art to be present as described in this specification.

[0096] As one of skill in the art will readily appreciate from the disclosure of the invention as set forth hereinabove, apparatus, methods, and steps presently existing or later developed, which perform substantially the same function or achieve substantially the same result as the corresponding embodiments described and disclosed hereinabove, may be utilized according to the description of the invention and the claims appended hereto. Accordingly, the appended claims are intended to include within their scope such apparatus, methods, and processes that provide the same result or which are, as a matter of law, embraced by the doctrine of the equivalents respecting the claims of this application.

[0097] As respecting the claims appended hereto, the term comprising means including but not limited to, whereas the term consisting of means having only and no more, and the term consisting essentially of means having only and no more except for minor additions which would be known to one of skill in the art as possibly needed for operation of the invention.