Abstract
A vehicle contains multiple cargo hoppers. A system opens the first hopper, which discharges its cargo into a chute. After discharge completes, a driver moves the vehicle forward, and the system opens the second hopper, which discharges into the chute. After the discharge is completed, the driver moves the vehicle forward, and the system opens the third hopper, which discharges into the chute, and so on. The process and system repeat for as many hoppers need to be unloaded.
Claims
1. An apparatus for use in a vehicle containing multiple hoppers, each having a discharge gate comprising: a) a plurality of actuators, each for opening a respective discharge gate; and b) a control system which induces the actuators to open the gates in sequence.
2. The apparatus according to claim 1, in which the control system opens each gate after its preceding gate has fully discharged its hopper.
3. The apparatus according to claim 2, in which each gate is opened at a predetermined time after its preceding gate has opened.
4. The apparatus according to claim 1, in which timing of the sequence of gate openings is adjustable by a human.
5. The apparatus according to claim 4, in which the timing is adjusted by a human to suit said vehicle.
6. The apparatus according to claim 1, in which a human initiates operation of the control system, which operates without human intervention after initiation.
7. The apparatus according to claim 1, wherein the vehicle comprises a) hopper H1 having a leading gate G1, b) hopper H2, having a gate G2 which is adjacent gate G1, c) hopper H3 having a gate G3 which is adjacent gate G2, d) hopper H4, having a gate G4 which is adjacent gate G3, wherein the control system e) opens gate G1 at time T1 in response to a start signal issued by a human, f) opens gate G2 after a time delay following opening of gate G1, g) opens gate G3 after a time delay following opening of gate G2, h) opens gate G4 after a time delay following opening of gate G3.
8. The apparatus according to claim 7, in which the time delays are programmable by said human.
9. The apparatus according to claim 1, in which the sequence begins with a leading gate.
10. The apparatus according to claim 1, in which the vehicle contains a source of compressed air, and a) the vehicle contains an input for receiving a start signal; b) the control system, in response to the start signal, delivers compressed air which (i) opens a first discharge gate and then (ii) opens a second discharge gate.
11. The apparatus according to claim 10, in which, during operation, the control system opens a gate only when the gate is engaged with a discharge chute.
12. The apparatus according to claim 10, in which, during operation, the control system opens a gate only when the gate is positioned above a grate which leads to a collection pit at a grain elevator.
13. A method of operating a vehicle containing multiple cargo hoppers, each having a gate, comprising: a) initiating a control which opens the gates, one-at-a-time, at predetermined intervals, and b) moving the vehicle so that every gate discharges its cargo into a stationary chute located below the vehicle.
14. The method according to claim 13 in which the vehicle does not change direction during said intervals.
15. The method according to claim 13, in which the vehicle changes direction during said intervals.
16. The apparatus according to claim 1, in which each hopper has a respective gate, the hoppers being numbered 1 through N, in which: a) the actuators comprise i) a plurality of pneumatic valves, numbered 1 through N, ii) a plurality of pneumatic pistons, numbered 1 through N, each 1) actuated by a respective valve, and 2) connected to a respective gate; b) the control system comprises a group of time-delay relays, numbered 1 through N, each associated with a respective valve, wherein i) relay 1 closes in response to a signal from a human, and actuates valve 1, to thereby actuate piston 1, to thereby open the gate of hopper 1; ii) in response to the closure of relay 1, a time delay occurs, after which relay 2 closes and actuates valve 2 to thereby actuate piston 2, to thereby open the gate of hopper 2; and iii) in response to the closure of relay 2, a time delay occurs, after which relay 3 closes and actuates valve 3 to thereby actuate piston 3, to thereby open the gate of hopper 3.
17. The apparatus according to claim 1, in which a) the plurality of actuators comprising i) a first pneumatic piston which opens a first gate; ii) a second pneumatic piston which opens a second gate; b) the control system induces i) a first actuator to actuate the first piston after it receives a start signal; and ii) a second actuator to actuate the second piston at a predetermined time after the start signal.
18. The apparatus according to claim 17, and further comprising: d) a third pneumatic piston, which opens a third gate; e) a third actuator which actuates the third piston at a predetermined time after actuation of the second piston.
19. The apparatus according to claim 1, in which the vehicle empties the hoppers into a stationary chute, and a) the discharge gates are manually operable by a person, and b) the control system responds to a start signal issued by a person by (i) opening a first discharge chute when it is engaged with a stationary chute, and (ii) opening a second discharge chute when it is engaged with the stationary chute.
20. The apparatus according to claim 19, in which each gate is held open for a sufficient time to allow discharge of the contents of its hopper.
21. The apparatus according to claim 20, in which the controller is of the Programmable Digital Logic type, PDL.
22. The apparatus according to claim 1, further comprising: a) a start switch; and b) the control system comprises a Programmable Digital Controller, PDL, which responds to the start switch by opening gates in sequence.
23. The apparatus according to claim 22, in which the PDL receives no input signals other than the start signal and possibly a termination signal.
24. The apparatus according to claim 23, in which the PDL (i) opens a first discharge gate when it is engaged with a stationary chute, and (ii) opens a second discharge gate when it is engaged with the stationary chute.
25. The apparatus according to claim 24, in which c) the vehicle occupies a first position when the first discharge gate is engaged with the stationary chute, d) the vehicle occupies a second position when the second discharge gate is engaged with the stationary chute, and e) the PDL imposes a time delay between opening of the first discharge gate and opening of the second discharge gate, and that delay is selectable by a human operator.
26. The apparatus according to claim 25, in which a transit time occurs while the vehicle moves from the first position to the second position, and the time delay is greater than the transit time.
27. The apparatus according to claim 26, in which f) the vehicle spends a first dwell time D1 at the first position, g) the PDL holds the first discharge gate open for at least a first open time T1, and h) the first dwell time D1 is greater than first open time T1.
28. The apparatus according to claim 27, in which f) the vehicle spends a second dwell time D2 at the second position, g) the PDL holds the second discharge gate open for at least a second open time T2, and h) the second dwell time D2 is greater than second open time T2.
29. A control system for opening gates of hoppers in a vehicle, which: a) applies a first voltage to a first solenoid which opens a first valve which delivers air pressure to a first piston which opens a first gate; and b) detects the first voltage and, in response, pauses for a delay and then applies a second voltage to a second solenoid which opens a second valve which delivers air pressure to a second piston which opens a second gate.
30. A kit for modifying a vehicle which contains a number N hoppers, each having a gate, comprising: a) N pneumatic actuators; b) N brackets, each for connecting an actuator to a respective gate, to allow an actuator to open its gate; and c) a control which actuates a first actuator, and then actuates the remaining actuators, one-at-a-time, at predetermined intervals.
31. An apparatus for controlling discharge doors of hoppers in a vehicle, comprising: a) a first pneumatic piston, which opens a first door of a first hopper; b) a second pneumatic piston, which opens a second door of a second hopper; c) a programmable logic controller, which contains program code, which receives a start signal and, in response, i) actuates the first piston to open the first door, in accordance with the program code, and ii) actuates the second piston to open the second door, after the first hopper has discharged fully, in accordance with the program code.
Description
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0102] FIG. 1 illustrates a hopper trailer of the prior art;
[0103] FIG. 2 is a bottom view of one type of gate in a prior art hopper trailer;
[0104] FIG. 3 shows a prior art mechanism for opening a gate of the type shown in FIG. 2;
[0105] FIGS. 4 and 4A illustrate how a spool valve operates a pneumatic piston;
[0106] FIG. 5 illustrates one form of the invention;
[0107] FIGS. 6 and 6A illustrate operation of the piston/valve combination in response to the signal online in FIG. 5;
[0108] FIG. 7 illustrates potentiometers P1-P8, which deliver voltages to the controller 50 of FIG. 5, to thereby define times T1-T4 and D1-D4;
[0109] FIG. 7A illustrates a trailer having four hoppers, with respective gates 30, 32, 34 and 36;
[0110] FIG. 8 illustrates another form of the invention;
[0111] FIGS. 8A-8C show how timer TR1T and relay TR1 can be incorporated into modular housings 90;
[0112] FIGS. 9A, 9B, 9C, and 9D illustrate symbolically the operation of a timer TR1T and its associated relay TR1;
[0113] FIG. 10 illustrates sequences of events implemented by one form of the invention;
[0114] FIGS. 11A-11F illustrate programmable logic controllers (PLCs) used by one form of the invention;
[0115] FIG. 12 defines time intervals;
[0116] FIG. 13A illustrates the functioning of one type of Programmable Digital Logic controller, PDL;
[0117] FIG. 13B illustrates a digital logic circuit which can deliver the signals indicated onto lines 101-104 in FIG. 13A;
[0118] FIG. 13C illustrates a fuse, which can replace switches shown in FIG. 13A;
[0119] FIGS. 14A, 14B, 14C and 14D illustrate how switches can act as memory within a PDL;
[0120] FIG. 15A shows a protective container which contains a panel which supports the solenoid valves and the timers; and
[0121] FIG. 15B shows the container mounted on the trailer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0122] Referring now to FIGS. 4-15B, a system 100 and method for automatically controlling flow of materials M (FIGS. 10 and 12), such as sand, gravel, agricultural corn, beans, grain or the like (collectively referred to as materials) out of a plurality of hoppers H1-H5 and through a plurality of slide doors or gates 30, 32, 34, 36 and 38, respectively. FIGS. 4 and 5 illustrate an embodiment with only four controlled slide doors or gates 30-36 with four associated hoppers H1-H4, while the embodiments of FIGS. 10 and 12 show five slide doors or gates 30-38 with five associated hoppers H1-H5, respectively. Thus, it should be understood that the invention may be applied to any multi-door, multi-hopper vehicle and is not limited to any specific number of slide doors or gates or hoppers. In one embodiment, the system 100 and method control the opening and closing of the plurality of slide doors or gates 30-38 in a predetermined sequence or manner as described herein. In one form of the invention, each of the plurality of slide doors or gates 30-38 are equipped with at least one driver 39 (FIGS. 4-6) coupled to each slide door or gate 30-38. In the illustration, the at least one driver 39 drives its associated slide door or gate 30-38 between open and closed positions and may comprise a controlled electrical solenoid, a hydraulic solenoid, a pneumatic solenoid or a piston, such as a piston 40 shown in FIG. 6. For ease of illustration and description, the at least one driver 39 associated with slide door or gate 30 will now be described, with it being understood that the other slide doors or gates 32-38 have the same or similar at least one driver 39.
[0123] The piston 40 of the at least one driver 39 is connected to slide door or gates 30-38 by a bracket 131. The energization or actuation of each piston 40 opens its respective slide door or gate 30-38. For example, an illustrative trailer TK is shown in FIGS. 10 and 12 and it contains five hoppers H1, H2, H3, H4 and H5, and the invention opens the slide doors or gates 30-38 associated with the hoppers H1-H5, respectively, in a predetermined or desired order. In one embodiment, the slide doors or gates 30-38 are opened in a serial order so that slide door or gate 30 for hopper H1 opens first, then slide door or gate 32 for hopper H2 is opened, then slide door or gate 34 for hopper H3, then slide door or gate 36 for hopper H4 and then finally slide door or gate 38 for hopper H5. After all slide doors or gates 30-38 are opened, all hoppers H1-H5 are cleared of their contents and the system 100 causes all slide doors or gates 30-38 to close so the hoppers H1-H5 can be refilled. It should be understood that during unloading of the hoppers H1-H5, an operator, such as a truck driver, advances the trailer TK after each hopper H1-H5 is emptied so that the next unemptied hopper H2-H5 becomes aligned over a grate and storage area 47 (FIG. 10), which is usually located in the ground.
[0124] In another embodiment, some trailers TK, such as the six-door trailer hopper offered by Hensley Fabricating & Equipment Co., Inc. located in Tippecanoe, Indiana, may be positioned and remain stationary during the unloading of the contents of the hoppers H1-H5. In this type of embodiment, the conventionally known trailer TK comprises an auger that transports the contents in the hoppers H1-H5 to the chute, pit, conveyor or storage area 47. In this embodiment, the trailer TK remains stationary over the storage area 47 and the auger delivers the contents from each of the hoppers H1-H5 to the storage area 47 in a manner conventionally known. FIGS. 15A and 15B illustrate such an embodiment.
[0125] In one embodiment, the sequential opening is induced automatically, without human intervention, once a human operator initiates the sequence, as will now be explained.
[0126] FIG. 4 shows a spool valve 41 connected to a solenoid 42. Pressurized air through a line 44 is supplied by a compressor (not shown) enters the spool valve 41 as shown and is diverted into line 44 at this time causing the piston 40 to move rightward (as viewed in FIG. 4), thereby causing air in a chamber 46 to be expelled through line 48 and exit from the spool valve 41 to the atmosphere as indicated. A spring 37 biases a spool 51 in the spool valve 41 into the condition shown, which will be called a rest position for illustration.
[0127] FIGS. 4-4A illustrate a general operation of the at least one driver 39. In FIG. 4A, solenoid 42, when energized, overcomes the bias of the spring 37 and pulls the spool 51 of the spool valve 41 leftward (as viewed in FIG. 4A) into the position shown in FIG. 4A. This causes compressed air to enter through line 48, thereby causing the piston 40 to extend leftward into an actuated position and to displace air from the solenoid 42 through line 48. The piston 40 of the at least one driver 39 is coupled to a bracket 131 (FIG. 6) which is coupled to at least one slide door or gate 30-38 shown and the at least one driver 39 drives at least one slide door or gate 30-38 between open and closed positions and in a predetermined order or in sequence as controlled by a controller 50.
[0128] FIG. 5 shows the controller 50 for controlling an operation of the system 100 and the at least one driver 39 which is implemented in a software computer (not shown) which may comprise one or more non-transient computer programs or instructions resident in a performance database or a memory and utilize a processor algorithm or procedure resident in the memory. The controller 50 can take the form of a PIC microcontroller available from Microchip Corporation, or a Basic Stamp, available from Parallax Inc. The controller 50 has four output lines 52-58 in the illustration of FIG. 5, one for each of the at least one driver 39. When the controller 50 receives a start signal 60, which is initiated by the operator, it issues the sequence of pulses shown on the output lines 52-58.
[0129] FIG. 10 illustrates a plurality of slide doors or gates 30-38. For ease of description, FIG. 5 shows only four drivers 39 and four slide doors or gates 30-36. Thus, the embodiments being described can be used with as few as one door, such as slide door or gate 30, or multiple slide doors or gates such as gates 30-38 in FIGS. 10 and 12. The first pulse begins at time T1 and has a duration of D1. The second pulse begins at T2 and has a duration of D2. The third pulse begins at T3 with duration of D3. The fourth pulse begins at T4 with a duration of D4. At least one buffer or amplifier 62 may optionally be provided to supply a sufficient current level to the solenoids 42. The events induced by the pulse will now be explained.
[0130] Prior to time T1 in FIG. 5, the spring 37 in FIGS. 4, 4A and 5 biases the spool valve 41 (as viewed to the right in FIG. 5) into a rest position. The piston 40 is also in its rest position. When time T1 arrives in FIG. 5, a voltage on line 52 goes high, initiating the pulse of duration D1 and delivering current to the solenoid 42, thereby causing it to pull spool 51 to the left, as shown in FIG. 6. The spool 51 drives air or causes air to pass through line 48, thereby causing or urging the piston 40 to move leftward (as viewed in FIG. 5) thereby driving the at least one slide door or gate 30 (FIG. 10) associated with the slide door or gate 30 (FIG. 7A) of the first hopper H1 to an open position. FIG. 7A illustrates the four hoppers H1-H4 and then the associated slide doors or gates 30-36. This results in any materials M in hopper H1 (FIG. 10) being unloaded or dumped into the grate and storage area 47.
[0131] The piston 40 remains in the left most position (as in FIG. 4A) for the duration D1 in FIG. 5. In one embodiment, all slide doors or gates 30-38 remain open until all hoppers H1-H5 are unloaded and all solenoids 42 are de-energized at the same time. When D1 in FIG. 5 terminates, the voltage on line 52 terminates, thereby de-energizing solenoid 42, thereby allowing spring 37 in FIG. 4 to push the spool valve 41 to the right, thereby applying compressed air to line 44, which drives the piston 40 to the right to its rest position, as in FIGS. 4 and 5.
[0132] In FIG. 5, the pulses on lines 52, 54 and 56 and opening of the slide doors or gates 32-36 perform similarly with respect to the pistons 40 and spool valves 41 and are controlled by those lines 52, 54 and 56.
[0133] After the duration D1, the controller 50 generates another pulse at T2 for duration D2 which energizes solenoid 42 via line 52. The general process repeats at each time T1-T4 to separately and independently open each one of the plurality of slide doors or gates 30-38. The apparatus of FIG. 5 can be used to control the plurality of slide doors or gates 30-38 on a bulk materials trailer TK, such as trailers TK1-TK10 shown in FIGS. 10 and 12. It should be understood that the trailer TK could have more or fewer slide doors or gates 30-38 and associated hoppers H1-H5 associated at least one driver 39. Some significant features of the operation are the following.
[0134] First, the slide doors or gates 30-38 open in sequence. The slide door or gate 30 is opened, then slide door or gate 32, then slide door or gate 34, then slide door or gate 36, then slide door or gate 38. That is, the opening of slide door or gate 30 precedes the opening of slide doors or gates 32-38 in FIGS. 10 and 12. The opening of slide door or gate 32 precedes the opening of slide door or gate 34. The opening of slide door or gate 34 precedes opening of slide door or gate 36 and so on.
[0135] Second, a time duration is assigned to each pulse, namely, D1 through D4 in FIG. 5. Each duration D1-D4 includes a minimum duration expected and generally corresponds to the time required by its respective hopper H1-H4 in the example of FIG. 5 to fully discharge its materials M or cargo. For example, D1 may be sixty (60) seconds, but the time for the discharge of the corresponding hopper H1 may be only twenty (20) seconds. The unloading time for each hopper H1-H4 in FIG. 5 or H1-H5 in FIGS. 10 and 12 may change, depending on the type of materials M carried in hoppers H1-H5. In this example, D1 is longer than the discharge time in order to provide a generalized margin for error.
[0136] Third, a more specific reason for D1 being much longer than the discharge time of twenty (20) seconds can exist. The remaining forty (40) seconds above can be used by the driver of the trailer TK to move the trailer TK into the correct position to accommodate the opening of the next slide door or gate 30-38. This is explained more fully below.
[0137] Four times T1, T2, T3, and T4 in FIG. 5 can be called initiation times for slide door or gate 30-36 openings. No initiation of a slide door or gate 30-36 (FIG. 5 or slide doors or gates 30-38 in FIGS. 10 and 12) opening can occur before full discharge of a prior slide door or gate 30-36. For example, if hopper H1 takes fifteen (15) seconds to discharge, then the next slide door or gate 32 in the sequence cannot be initiated earlier than fifteen (15) seconds after the initiation of the prior slide door or gate 30. Stated in other words, no slide door or gate 30-38 can be opened while another slide door or gate 30-38 is open and still discharging its associated hopper H1-H5.
Setting Delay Times T and Durations D
[0138] FIG. 7 illustrates how the times T1-T4 and the durations D1-D4 can be established or programmed into the controller 50. Potentiometers P1-P4 are connected to individual input pins of the processor. In the case of a Basic Stamp, the processor measures the voltage of the potentiometer by measuring the RC time constant of a resistorcapacitor pair (capacitor is not shown). The processor then computes the effective resistance of the potentiometer based on RC and thus ascertains the voltage of the potentiometer tap. That is, the potentiometer in effect delivers a number (a voltage) to the processor, which is interpreted as a time, such as T1.
[0139] Potentiometers P5-P8 deliver voltages in the same way to indicate the time delays D1-D4. In practice, each potentiometer will be actuated by the switch 70 (FIG. 9B) which is labeled with the parameter which it controls, namely T1 or D2, for example. The potentiometers P1-P8 eliminate any need to establish the times T1-T4 and the delays D1-D4 by declaring variables within the code (not shown) running on the controller 50. Initially establishing the variables and also changing the variables at a later time to suit different materials M, different hoppers H1-H5 and different cargos, for example, would require the ability to write computer code, but simply adjusting the potentiometers P1-P8 in FIG. 7 does not and can be performed by the operator. Nevertheless, establishing the variables as parameters in code is possible.
[0140] FIG. 8 illustrates another control circuit. Resistors SOL1-SOL6 represent individual solenoids 42, like those shown in FIG. 4 (although FIGS. 4 and 4A show only two solenoids 42 by comparison). In this illustration, six solenoids SOL1-SOL6 driving at least one slide door or gate, such as slide doors or gates 30-38 (FIGS. 10 and 12), respectively, are shown. In FIG. 8, items TR1-TR6 are relays, which are controlled by corresponding timers TR1T-TR6T which energize them. Relay TR1 is physically contained within a single housing with its timer TR1T, as illustrated in FIG. 8A and both together form a time-delay relay, although they are shown as separate units TR1T and TR1 in FIG. 8 for ease of illustration. This comment on pairing applies to the other relays TR2-TR6 and timers TR2T-TR6T, respectively, in FIG. 8.
[0141] FIGS. 9A, 9C, and 9D generally and schematically illustrate an operation of the components within the dashed box B of FIG. 9B. FIG. 9B illustrates a section of FIG. 8, namely, that above arrows A-A in FIG. 8. In FIG. 9A, a timer TR1T is represented as a clock face CF. A contact C rides in a circular track 55, and an operator selects a position for the contact C to thereby select a time delay. The hollow circles C1, C2 in FIGS. 9B and 9C represent other possible positions. When the timer TR1T is initiated, a hand H rotates clockwise and eventually reaches contact C (as shown in phantom).
[0142] FIG. 9C generally and schematically illustrates timer TR1T and relay TR1 connected together to further illustrate and simplify the description. In FIG. 9C, a timer TR1T is labeled for ease of illustration and description and is coupled to the relay TR1. FIG. 9C shows that hand H has reached contact C, which connects V+ across the coil of relay TR1, which creates a MAGNETIC FIELD MF, which draws iron bar 67 upward (as viewed in FIG. 9C) which connects SOL1 to 12 volts, thereby creating CURRENT through SOL1 as shown. SOL1 represents one of the solenoids 42 in FIG. 5 described earlier and is also shown in FIG. 8. To repeat, in FIG. 9B, element TR1T is a timer and when TR1T is actuated, it counts down from a predetermined value selected or predetermined by the operator. One such value corresponds to the time delay T1 in FIG. 5. When the count of TR1T reaches zero, relay TR1 closes, thereby driving current through solenoid SOL 1.
[0143] This countdown is initiated by momentary closure of a start switch 70 in FIGS. 9B and 9C. Timer TR1T introduces a delay in closure of timed relay TR1 after the momentary closure of switch 70, which is analogous to delay T1 in FIG. 5. In practice, the time delay of TR1T may be short because timed relay TR1 controls the first slide door or gate 30 and there may be no reason for a significant delay in opening that first slide door or gate 30.
[0144] The opening of one of the slide doors or gates 30-36 in FIG. 5 or 30-38 in FIGS. 10 and 12 in a series was just described. FIG. 8 shows apparatus which continues with the opening of subsequent slide doors or gates 30-36. The Inventor repeats that (1) elements TR1T through TR6T are, in concept, countdown timers which are triggered by incoming voltages, as at points 92-100 in FIG. 8. These timers TR1T to TR6T close their corresponding relays TR1-TR6, respectively, when they time out. That is, TR2T closes TR2, TR3T closes TR3, and so on, as indicated by arrows A1-A6. It should be understood that these timers TR1T to TR6T are not individual, discrete parts (although they could be). Instead, they are physically parts of overall time-delay relay apparatus or module 102, as indicated in FIG. 8A. Each such module 102 includes (1) a timer such as TR1T, and (2) the relay itself, such as TR1. The use of modules 102 provides various benefits, as this discussion will later be explained, in connection with FIGS. 11A-11D.
[0145] In FIGS. 8-8C, when TR1 closes and solenoid SOL1 (FIG. 8) is actuated, 12 volts is applied to line 92 as mentioned earlier. This triggers timer TR2T into beginning counting down. When it times out, it closes relay TR2, as indicated by arrow A2. When TR2 closes, solenoid SOL2 is actuated, and at that moment, 12 volts is applied to point 94, which triggers timer TR3T into counting down. When it times out, it closes relay TR3, as indicated by arrow A3.
[0146] When TR3 closes, solenoid SOL3 is actuated and 12 volts is applied at that moment to point or line 96, which triggers timer TR4T into counting down. When it times out, it closes relay TR4, as indicated by arrow A4.
[0147] When TR4 closes and solenoid SOL4 is actuated 12 volts is applied at that moment to point 98. That triggers timer TR5T into counting down. When it times out, it closes relay TR5, as indicated by arrow A5.
[0148] When TR5 closes, and solenoid SOL5 is actuated, 12 volts is applied at that moment to point 101, which triggers timer TR6T into counting down. When it times out, it closes relay TR6, as indicated by arrow A6, which actuates solenoid SOL6.
[0149] The inventors repeat that when TRT1 times out, it closes relay TR1. Closure of TR1 triggers TR2T, which closes relay TR2 when TR2T times out. Closure of TR2 triggers TR3T, which closes relay TR3 when TR3T times out. Closure of TR3 triggers TR4T, which closes relay TR4 when TR4T times out, and so on.
[0150] In general, the slide doors or gates 30-36 in FIG. 5 or 30-38 in FIGS. 10 and 12 form a sequence and associated solenoids form a parallel sequence, together with their associated relays, such as solenoids SOL1-SOL4 and relays TR1-TR4 in FIG. 8. The following TABLE I shows several illustrative parallel sequences:
TABLE-US-00001 TABLE I Gate Sequence Relay/Solenoid Sequence 30 TR1/SOL1 32 TR2/SOL2 34 TR3/SOL3 36 TR4/SOL4
[0151] Thus, when one relay closes, such as TR1 in FIG. 8, it does two things. It (1) immediately actuates its own solenoid, such as SOL1 in this example, and (2) causes actuation of the next solenoid in the sequence, SOL2, but after a predetermined time delay D1, which will be determined by timer TR2T in the illustration being described.
[0152] This process repeats until all slide doors or gates 30-38 are opened and their associated hoppers H1-H5, respectively, are emptied and unloaded in sequence as described earlier with respect to FIGS. 8-8C.
[0153] During operation, the operator aligns one slide door or gate 30-38 over the grate or storage area 47 (FIG. 10). For example, the operator aligns slide door or gate 30 over grate or storage area 47 and unloads the hopper H1 by utilizing the switch 70 (FIG. 8). After the hopper H1 is unloaded, the operator advances or moves the trailer TK to align the second door or gate 32 over the grate or storage area 47, preferably before the start of the next slide door or gate 32-38 opening. That slide door or gate 32 opens in accordance with the procedure described herein to unload the contents of hopper H2, thereafter the operator advances the trailer TK to align the next slide door or gate 34 over the grate or storage area 47 to unload the next hopper H3 and so on. This process repeats until all hoppers H1-H5 are unloaded. Thereafter, the system 100 causes the slide doors or gates 30-38 to close at the same time or after each hopper H1-H5 is unloaded.
[0154] Several variations or alternate embodiments will be described. Different types of timed relays can produce different results. For example, if a time-delay relay merely closes a relay after a delay, then the relay may remain closed thereafter. If such relays were used in the circuit of FIG. 8 (for example, as the combination of timer TR1T and timed relay TR1, as in module 102 in FIG. 8C), then after a hopper H1-H5 had been discharged, its associated slide door or gate 30-38 would remain open. The reason is that the solenoid 42 in FIG. 4A would remain energized because its relay remains actuated, which may be a desirable mode of operation.
[0155] On the other hand, another type of relay may be used, such as time-delayed one-shot. Such a relay (1) waits for an actuation signal, (2) imposes a delay after the signal is received, and then (3) actuates a one-shot relay. A one-shot relay remains closed for a predetermined duration and then opens. Module 102A in FIG. 8B illustrates such a one-shot relay apparatus. For example, in FIG. 5, line 52, nothing happens until time T1. That absence of events prior to T1 represents the delay in a time-delayed one-shot. Then, in FIG. 5, a pulse of duration D1 arises, which is the shot of a one-shot. After delay D1 expires, the pulse terminates, which de-activates solenoid 42. Termination of the signal when duration D1 expires would then remove actuation of the solenoid 42 in FIG. 4, thereby closing its associated slide door or gate 30-38 after its hopper H1-H5 had discharged.
[0156] Another embodiment of the invention comprises a kit 110 (FIG. 11A) of components which are installed or retrofitted on the hopper vehicle, such as a semi-truck, semi-trailer TK, or a railroad car. FIG. 11A shows a flat plate 112 having a top side 112a and a bottom side 112b. The bottom side 112b contains electrical wiring, which may take the form of a printed circuit board in which the wiring corresponds in layout to that of FIG. 8. On the top side 112a, the time-relay and timer modules labeled TR1T/TR1 are the time-delay relays described earlier which implement the functioning described herein and in FIG. 8. This comment applies to the other modules in FIGS. 11A-11D which begin with the symbols TR.
[0157] The modules SOL1-SOL6 (FIG. 8) are solenoid valves, corresponding to solenoids 42 in FIG. 4, and the associated spool valve 41. For example, when module TR1T/TR1 in FIG. 8 or 11A actuates solenoid valve SOL1, the latter delivers pressure to the piston 40 in FIG. 4A through line 48, as described earlier, thereby controlling movement of its associated gate 30-38.
[0158] In FIG. 11B, connectors (not shown) extend through the board or plate 112 to deliver electrical signals and power to the solenoid and relay modules on the top side 112a (FIG. 11A). For example, points P10, P11, P12, and P13 on the bottom side 112b are connected to respective points P10, P11, P12, and P13 on the top side 112a (FIG. 11A). The plate 112 is installed in a weather-tight electrical housing or box 120 (FIG. 11C), which is not drawn to scale which can be mounted or retro-fitted on the vehicle.
[0159] The kit 110 also includes one pneumatic piston or solenoid 42 (FIGS. 4 and 4A) for each slide door or gate 30-38 to be mechanized on the vehicle as explained earlier, plus any necessary conventional plumbing (not shown) for delivering compressed air to the pneumatic piston or solenoid 42. Each solenoid SOL comprises at least one relay TR and one timer TRT. Brackets 131 in FIG. 6 may be included for coupling the solenoid 42 to its associated slide door or gate 30-38.
[0160] It should be understood that the time-delay relays comprising of TR1T and TR1 as in FIG. 8 and represented as module 102 in FIG. 8C are commercially available. The part numbers and availability are listed in the table below.
[0161] The following components are available from Electro Controls of Sidney, Ohio: [0162] CHD2PA6, RELAY, SOCKET 4 POLE RELAYS D2PR2 AND D2PR4 [0163] CHD2RR4R1ICE CUBE RELAY, 4PDT, 6 A, 12 VDC COIL [0164] CHFAZC51SPBREAKER, SUPP 1P C CURVE 5 A (REPLACE WMZS1C05) [0165] CHM22DG PB OPERATOR, NON-ILLUM, GREEN, FLUSH, MOMENTARY, SILVER BEZE [0166] CHM22DR PB OPERATOR, NON-ILLUM, RED, FLUSH, MOMENTARY [0167] CHM22K01 CONTACT BLOCK, N.C., SCREW TERM, REPLACED E22B1 [0168] CHM22K10 CONTACT BLOCK, N.O., SCREW TERM, REPLACED E22B2 [0169] HOFCP1616 PANEL ONLY [0170] HOFCSD16168SS ENCLOSURE, 16168SS [0171] HTMSOCN11808PARL4 18 MM INDUCTIVE PROX, 10-30 VDC M12 QUICK CONNECT [0172] HTMSRFS4TZT665 M12 FEMALE STRAIGHT TPE WELDING CABLE [0173] MMC5679K55 RARE EARTH MAGNET 10-24 THREDED [0174] RSP1026123 MULITFUNCTION TIMING RELAY, 12-230V
[0175] The following components are available from Dickman Industrial & Electrical Supplies of Sidney, Ohio. [0176] CHEASYE4UC12RC1; EASYE4 NPLC 12/24DC, 24AC RLY DISP SCWTRM; Catalog #EASY-E4-UC-1 2RC1; 39 PCS SIDNEY STOCK [0177] CHEASYE4UC16RE1; EASYE4 ACCY DIO 12/24DC, 24AC 8DI 8RO STM; Catalog #EASY-E4-UC-1 6RE1; EXPANDER MODULE; FACTORY STOCK
[0178] A 12 vdc solenoid valve is available from Atlantic Valve & Supply Company of Baltimore, Maryland.
[0179] A 12 vdc 5 position air valve 6 bank is available from Baomain Electric located in Wenzhou City, Zhejiang Province, China
[0180] In one form of the invention, only air lines 122 in FIG. 11D will run to the solenoids 42 when installed or retrofitted on the vehicle or trailer TK. No electrical lines 124 will run to the solenoids 42. Electrical lines 124 (FIG. 11D) such as power lines and those running from the start switch 70 and stop switch 70a in FIG. 8 do enter the box 120 as shown. These switches 70 and 70a are preferably located on the exterior of the box 120 itself or nearby for easy access.
ADDITIONAL CONSIDERATIONS AND FURTHER EMBODIMENTS
[0181] 1. One definition of a predetermined time. In FIG. 8, current will reach SOL2 when the timed relay TR2 closes. TR2 will close when timer TR2T times out after counting down. The countdown of timer TR2T begins when timer TR1T times out and closes relay TR1. That is, application of a voltage at line or point 92 (FIG. 8) acts as a trigger signal for timer TR2T. Therefore, once the START signal is given in FIG. 8, the current will reach SOL2 after both timers TR2T and TR1T time out. TR1T is required to time out in order for current to reach SOL1 because TR1 is open prior to that time out. TR2T is required to time out for current to reach SOL2 because TR2 is open prior to that time out.
[0182] The total time for both those timers TR1T and TR2T to count down and thus close relay TR2 is considered to be a predetermined time. One reason is that both times are selected by the user. Another reason is that the count down time of TR1T may be some nominal value, a short time, or even zero. However, a sum of that time, whatever it is, plus TR2T time, will still be a predetermined time.
[0183] 2. In FIG. 8, timer TR2T begins counting down when solenoid SOL1 begins passing current, but that timer finishes counting down based on the position of its own contact C in FIG. 9A (FIG. 9A shows the contact C for timer TR1T). That is, the countdown interval of timer TR2T, as well as of all the other timers TRXT, is determined or programmed by the operator. Similarly, the times T1-T4 and D1-D4 in FIG. 5 are also determined and set by the operator.
[0184] It should be understood that these times T1-T4 and associated durations D1-D4, respectively, are selected by (a) experiment, (b) observation or experience, (c) calculation, or by a combination of (a), (b), and (c). Once the times and intervals have been successfully ascertained, the invention will operate with the following characteristics.
[0185] Case 1. A first slide door or gate 30 associated with the first hopper H1 will open. The next or adjacent slide door or gate 32 associated with the next hopper H2, does not open until the first hopper H1 has fully discharged its contents to a predetermined location, such as the grate and storage area 47. All later slide doors or gates 32-38 in the sequence do not open until all preceding hoppers have fully discharged their contents to a predetermined location such as a grain or bulk material storage area 47 (FIG. 10). These features are a result of the selection of the times T1-T4 and delays D1-D4.
[0186] Case 2. In another form of the invention, at least one multi-hopper trailer TK1-TK5 (FIG. 12) and TK1-TK10 (FIG. 10) delivers materials, such as gravel, grain or corn, to the chute, pit, conveyor or a storage area 47 which leads to the grate and collection or storage area 47a at a grain elevator, for example, as shown in FIG. 7A. Typically, the collection or storage area 47a is below road level and has an inlet 47a1 (FIG. 10) positioned at road level, through which grain passes en route to the grate and collection or storage area 47a. A conventional conveyor 130 conveys the unloaded materials to a desired location (not shown).
[0187] In this embodiment of the invention, the slide doors or gates 30-38 in FIGS. 10 and 12 of each hopper H1-H6 open after their selected time delay, as in Case 1, above. Specifically, for the multi-hopper trailer TK in FIGS. 10 and 12, having hoppers H1, H2, H3, and H4, slide door or gate 30 opens first, then slide door or gate 32, then slide door or gate 34, and finally slide door or gate 36. The first slide door or gate 30 is ordinarily the most forward slide door or gate, although it is possible to begin with the rearmost slide door or gate or even a middle slide door or gate if desired.
[0188] After slide door or gate 30 discharges hopper H1, the delay of opening slide door or gate 32 allows the truck driver sufficient time to move slide door or gate 32 over the area 47 (FIGS. 10 and 12) or over another grate and storage area 47. Similarly, sufficient time is allowed to move the trailer TK until slide door or gate 34 opens to the area 47 after hopper H2 has discharged its load, and so on.
[0189] 3. These embodiments may be used with trailers TK that have one or more hoppers H1-H5. FIGS. 10 and 12 show a hopper trailer TK1 through TK10 with five hoppers H1-H5. They are all the same trailer TK, but at different positions or in different conditions or both. Time runs vertically, as indicated by the arrow labeled TIME in FIG. 10.
[0190] Trailer TK1 is brought to a position shown at a grain elevator (not shown). The slide door or gate 30 now stands over grate and storage area 47 so that when slide door or gate 30 is opened, the contents of the corresponding hopper will fall through the grate and storage area 47 and onto the conveyor 130. The conveyor 130 will then remove the contents to another location.
[0191] Thereafter, slide door or gate 32 is opened, as indicated in TK2, its associated hopper H2, discharges its contents.
[0192] In TK3, the hopper H1 is now empty, so the trailer TK3 is moved to TK4, thereby placing the slide door or gate 32 in proper position over the grate and storage area 47. The slide door or gate 32 is opened in trailer TK5 and its hopper H2 discharges its load. After the discharge, the hoppers H1 and H2 are empty and the trailer TK5 is moved to TK7, thereby positioning slide door or gate 34 over the grate and storage area 47 and then slide door or gate 34 is opened as described herein and its hopper H3 discharges as shown in TK8. When its hopper H3 is empty, as in TK9, the truck or trailer TK is moved so that slide door or gate 36 is moved to the grate and storage area 47, as in TK10, and the process just outlined continues.
[0193] The slide doors or gates 30-36 (FIG. 5) and 30-38 (FIGS. 10 and 12) are opened in the predetermined order or sequence established by the user. The time delay between opening of the slide doors or gates 30-36 is such that the driver of the truck pulling the trailer TK has time to move the trailer TK so that the slide doors or gates 30-36 about to be opened will be stationed above the grate and storage area 47 at the proper time. This reduces or completely eliminates a requirement of manual operation of the gates 30-36, for example. For example, assume in FIG. 10 that the delay between gate-openings is sixty (60) seconds. When slide door or gate 30 is positioned over the grate and storage area 47, the start switch 70 in FIG. 8 may be actuated by an operator. Assume the hopper H1 associated with slide door or gate 30 takes twenty (20) seconds to empty. The driver ascertains the time when the hopper H1 completes its discharge as by (1) detecting the termination of noise from the hopper H1, (2) visually observing a lack of flow, (3) timing twenty (20) seconds using a stopwatch, or (4) some other means.
[0194] Now, after discharge of hopper H1, the driver or operator has forty (40) seconds to move the trailer TK into position TK4 in FIG. 10. The driver does so and awaits slide door or gate 32 to open and unload hopper H2. Thereafter, the driver ascertains the time when discharge of hopper H2 has completed and moves the trailer TK into the next position, such as position TK5-TK10, TK7, and so on.
[0195] In some situations, it may be possible for the driver to move the trailer TK at a continuous slow speed or crawl in order to position each slide door or gate 30-38 over the grate and storage area 47 at the proper time.
[0196] Two types of movement of the trailer TK have just been described. One is interrupted movement, where the trailer TK: [0197] (1) moves to position slide door or gate 30 over the grate and storage area 47 and stops while hopper H1 discharges, then [0198] (2) moves to position slide door or gate 32 over the grate and storage area 47 and stops while hopper H2 discharges, then [0199] (3) moves to position slide door or gate 34 over the grate and storage area 47 and stops while hopper H3 discharges, and so on.
[0200] Another type of movement is a continuous slow crawl of the trailer TK, which keeps the slide doors or gates 30-36 over the grate and storage area 47 for sufficient time to discharge their contents or materials. Both types of movement are considered to follow a predetermined path, whether the movement be interrupted or continuous.
[0201] 4. In another form of the invention, the trailer TK (multi-hopper vehicle, semi-trailer or railroad car, for example) is never moved while a hopper H1-H5 is discharged.
[0202] 5. The time-sequence of opening the slide doors or gates 30-38 in FIGS. 10 and 12 corresponds to the spatial-sequence of the slide doors or gates 30-38. For example, if the spatial sequence is slide door or gate 30, slide door or gate 32, slide door or gate 34, slide door or gate 36, and slide door or gate 38 counting from the front of the trailer TK, the corresponding time-sequence is slide door or gate 30, slide door or gate 32, slide door or gate 34, slide door or gate 36, and slide door or gate 38. Similarly, if the spatial sequence counting from the rear of the trailer is slide door or gate 38, slide door or gate 36, slide door or gate 34, slide door or gate 32, and slide door or gate 30, then the corresponding time-sequence is slide door or gate 38, slide door or gate 36, slide door or gate 34, slide door or gate 32, and slide door or gate 30. This latter sequence would be particularly relevant to a multi-hopper railroad car, which may not have a standardized front and rear, as opposed to the trailer shown, which by convention, does have a forward end.
[0203] 6. It was stated above that one embodiment of the invention schedules opening of the slide door or gate 30-38, such that (1) the first slide door or gate 30-38 to be opened is located at one end of a row of slide door or gate 30-38 and (2) after a discharging hopper H1-H5 finishes discharging, the adjacent slide door or gate 30-38 is opened. This scheduling has implications. One is that, in the example of FIG. 10, the row of gates contains slide door or gate 30, slide door or gate 32, slide door or gate 34, and slide door or gate 36. A second implication is that the first gate to be opened will be either slide door or gate 30 or slide door or gate 36 because these slide doors or gates are the end gates or the first and last slide doors or gates 30-36.
[0204] A third implication is that the next gate to be opened will be (1) slide door or gate 32 if slide door or gate 30 was opened first, or (2) slide door or gate 34 if slide door or gate 36 was opened first.
[0205] A fourth implication is that no slide door or gate 30-38 will be opened while another slide door or gate 30-38 is discharging, which allows the trailer TK to move a closed gate 32 over the grate and storage area 47, without causing a discharging hopper H1-H5 to spill its contents outside the grate and storage area 47. The fourth implication follows from the rule that an adjacent slide door or gate 30-38 is opened after discharging completes of the predecessor or prior hopper H1-H6.
[0206] 7. One definition of row. A person walking in snow will leave footprints. The footprints are commonly called a row of footprints, but they actually form two rows: one produced by the left foot, and one produced by the right foot. The slide doors or gates 30-38 of FIG. 10 can be similarly positioned into a left row and a right row. However, one definition of row in this case is determined by the sequence of slide doors or gates 30-38 which cross the grate and storage area 47 as the trailer TK moves either forward or backward. That sequence will be either (i) slide door or gate 30, slide door or gate 32, slide door or gate 34, slide door or gate 36 and slide door or gate 38; or (ii) slide door or gate 38, slide door or gate 36, slide door or gate 34, slide door or gate 32, and slide door or gate 30.
[0207] These two sequences can be termed spatial sequences. After a slide door or gate 30-38 opens, the next slide door or gate 30-38 to open must be adjacent physically to the just-discharged slide door or gate 30-38, but because the first slide door or gate 30-38 to discharge will be either slide door or gate 30 or slide door or gate 38, as stated above, then the next slide door or gate 30-38 to open will be that adjacent, which will be either slide door or gate 32 or slide door or gate 36, respectively.
[0208] A situation where two slide doors or gates 30-38 simultaneously cross the grate and storage area 47 is typically not preferred. However, if such a situation arises, such as when the hoppers H1-H5 are carrying the same materials M, then both slide doors or gates 30-38 may be opened at the same time or otherwise opened serially as described herein to discharge their respective hoppers H1-H5 into the grate and storage area 47.
[0209] 8. When the invention is installed on a hopper trailer, semi-truck, semi-trailer, grain carrier or other vehicle, for example as shown in FIG. 10, pressurized air 44 in FIG. 4 is delivered to spool valve 41. The pressurized air 44 can be provided by a pre-existing compressor on a truck (not shown) which pulls trailer TK, such as a truck compressor (not shown) that provides compressed air for air brakes. If the invention is installed on a railroad hopper car for example, a pre-existing source of compressed air can also be used.
[0210] 9. In a row of slide doors or gates 30-38 which are controlled by the invention, there will necessarily be a leading or forwardmost slide door or gate 30-38. The slide door or gate 30 in FIG. 10 is such a slide door or gate. The slide door or gate 30 will be the first slide door or gate to cross over the grate and storage area 47, when the trailer TK1 moves forward, that is, to the left in FIG. 10. One characteristic of the leading and trailing slide doors or gates, such as slide doors or gates 30 and 38, is that they have only a single adjacent slide door or gate, which is associated with another hopper. Leading slide door or gate 30 in FIG. 10 has a single adjacent slide door or gate 32, for example. If the trailer TK is driven in reverse, then slide door or gate 38 would be the leading slide door or gate. It has a single adjacent slide door or gate 36. All other slide doors or gates have two adjacent gate slide doors or gates as shown in FIG. 10. For example, the slide door or gate 34 has two neighbors, for example: slide door or gate 32 and slide door or gate 36.
[0211] 10. In another embodiment of the invention, a solenoid is actuated (1) by the actuation of the prior solenoid, but after a time delay, and (2) the time delay was established prior to the actuation of either solenoid. For example, in FIG. 8, actuation of solenoid SOL1 is accompanied by a voltage at point 92 (which is the cause of current running through SOL1). That voltage triggers timer TR2T into countdown and after the delay of that countdown, TR2T closes relay TR2, thereby actuating solenoid SOL2.
[0212] The length of the time delay is controlled by a knob 104 or setscrew contained in the timer module 102 (FIG. 8C). If the module contains a time-delay one-shot, a second knob 106 or setscrew, shown in phantom, can control the duration of the one-shot.
[0213] 11. One definition of proper operation of the multi-hopper vehicle TK is that no significant amount of cargo fails to reach the grate and storage area 47 in FIG. 10. This failure can occur if the trailer TK fails to advance after slide door or gate 30 has discharged the cargo of its hopper H1, thereby spilling the materials held by slide door or gate 32 onto the ground when slide door or gate 32 opens. One definition of significant is the amount of materials M which an ordinary workman can clean up and shovel into the grate and storage area 47 within a few minutes.
[0214] 12. FIG. 12 can define two terms, namely, dwell time DT and transit time TT, which are illustrated in FIG. 12. Trailer TK1, at the top of FIG. 12, remains stationary while slide door or gate 30 is opened and discharges hopper H1. This can be termed dwell time DT. Dwell time DT can be extended to allow for error. For example, if ordinary discharge time is twenty (20) seconds, DT may be made thirty (30) seconds. Assume, for simplicity of description, that all dwell times are the same, but they could be different or even some the same while others are different.
[0215] After slide door or gate 30 has completed discharging hopper H1, the trailer TK1 is moved to position TK2. The time allowed for this is transit time TT. Then slide door or gate 32 is opened, and the trailer TK3 remains stationary for dwell time DT, while slide door or gate 32 discharges hopper H2. So, the first event was that slide door or gate 30 is opened. Then, (DT+TT) seconds later, slide door or gate 32 is opened. Trailer TK3 remains stationary during opening of slide door or gate 32 and discharge of hopper H2 and then it moves to position TK4, which movement required transit time TT. Then, trailer TK opens slide door or gate 34, which opens (2DT+2TT) seconds after slide door or gate 30. Trailer TK remains stationary for a dwell time DT. This sequence repeats, for the remaining gates.
[0216] Stated another way, the trailer TK is positioned with the first slide door or gate 30 over the grate and storage area 47. The operator or driver presses the start switch 70 in FIGS. 8 and 9D. A delay may or may not occur before slide door or gate 30 opens. After slide door or slide door or gate 30 opens and hopper H1 is unloaded, the next slide door or slide door or gate 32 opens (DT+TT) seconds after 30. This DT is the dwell time for slide door or gate 30 to discharge. This TT is transit time for the trailer to get into position to discharge slide door or gate 32.
[0217] Next, slide door or gate 34 opens (2DT+2TT) seconds after slider door or gate 30.
[0218] Then, slider door or gate 36 opens (3DT+3TT) seconds after slider door or gate 30.
[0219] Then, slider door or gate 38 opens (4DT+4TT) seconds after slider door or gate 30.
[0220] The preceding processes or sequences assume that all dwell times DT are the same, but as stated earlier they can be different and selected by the user, as can be the transit times TT.
[0221] 13. Different materials flow from a given hopper H1-H5 at different rates. Further, a given material will probably flow from two different hoppers H1-H5 at two different rates. One reason is that the angles of the side walls will affect overall discharge rate. Another is that the size of the slide door or gate 30-38 will affect discharge rate. Still another example is the weight of the material itself.
[0222] The adjustability of the times T1-T4 in FIG. 5, as by using potentiometers P1-P4 in FIG. 7, and adjustability of the delay times D1-D4, as by using potentiometers P5-P8, allows a human operator to tune the operation of the hoppergatecontrol the system 100 to suit the hoppers in a given vehicle TK. Such tuning may not be necessary or even suitable for another vehicle having hoppers of similar capacity, at least for the reasons given in the preceding paragraph.
[0223] Several of the preceding embodiments describe the serial sequence in which the slide doors or gates 30-38 may be opened. It should be understood, however, that the controller 50 may be a programmable logic controller (PLC) that is capable of or adapted to be programmed such that each sliding door or gate 30-38 is individually controlled and timed. This also means that the sequence of opening the slide doors or gates 30-38 can be random and non-serial. For example, if the driver wanted to empty hopper H3, then hopper H5, then hopper H1, etc. the controller 50 can be programmed by manually adjusting the knobs described earlier herein for each driver 39.
[0224] 14. The controller 50 in FIG. 5 controls compressed air delivered to piston 40 in FIGS. 6 and 6A, by way of modulating the spool valve 41. The compressed air is provided by a conventional air supply associated with the vehicle carrying the hoppers. For example, both railroad cars and semi-trailers use air brakes which are energized by compressed air provided to them by the same source.
[0225] 15. A programmable digital controller, PDL, can be used to control the sequential actuation of the pistons 40 described above. FIGS. 13A, 13B and 13C symbolically explain one operation of one type of PDL. It actuates the relays L1-L4 in FIG. 13A, which correspond to relays such as TR1T/TR1 in FIGS. 11A and 11B.
[0226] It is common for a PDL to receive input signals from sensors, and issue output signals in response. For example, a PDL may receive input signals from two temperature sensors in two rooms in a building. When a sensor indicates that the temperature is below a limit, the PDL then issues a signal to a heater in the room to begin operation. When the sensor indicates that the temperature has reached a certain level, the PDL then shuts down the heater.
[0227] In one form of the invention, a PDL is used to issue the signals analogous to those on lines 52-58 in FIG. 5, but this PDL receives only one, and possibly two input signals and no others, namely, a start signal 60 in FIG. 5, and possibly a termination signal. For ease of understanding, an operation of one type of PDL will be illustrated.
[0228] Regarding FIG. 13B, when latching relay L receives a trigger signal, the latching relay L closes, and remains closed, as indicated.
[0229] When a one-shot relay OS receives a trigger signal, the one-shot relay OS closes, and then opens after a delay D.
[0230] When a time delayed latching relay TDL receives a trigger signal, the time delayed latching relay TDL closes after a delay dd and then remains closed.
[0231] When a time delayed one-shot relay TDOS receives a trigger signal, the time delayed one-shot relay TDOS closes after a delay dd and then opens after a delay D. As explained above, these types of relay can be used in various forms of the invention.
[0232] FIG. 13A illustrates a control which can actuate these types of relays. Four latching relays L1-L4 are shown. A symbolic rotary switch RSW is shown that is used by the operator. It is rotated to successively occupy the phantom positions shown, to thereby successively apply twelve (12) volts to lines 116, 118, 120, 122 in that order in the illustration. Twelve (12) volts are supplied by the vehicle's power supply (not shown). Rotary switch RSW can be rotated by the driver of the vehicle pulling the hopper trailer TK of FIG. 10. This rotation will cause opening of hopper gates, as explained immediately below and herein. Rotary switch RSW in FIG. 13A can be operated by an electric motor (not shown), which eliminates the need for the driver to rotate it.
[0233] It should be understood that the function of the rotary switch RSW can be replaced by digital circuitry, as shown in FIG. 13B. For example, in response to actuation of the input switch 70 in FIG. 8A, a 555 timer 111 in FIG. 13B can generate a sequence of pulses, which are fed to a counter 113 which counts up on two wires W1 and W2, from zero (i.e., 00 binary) to three (3) (i.e., eleven (11) binary). The count advances on each pulse from the 555 timer.
[0234] The count is applied to a data selector/decoder 114, which causes a pulse to appear on one of four output lines 116-122 in sequence as indicated. The output lines 116-122 correspond to lines 116, 118, 120, 122, respectively, in FIG. 13A. If the circuitry shown relies on TTL logic (Transistor-Transistor Logic, which produces signals in the range of 5 volts), buffers/amplifiers 124 can raise the voltage to 12 volts, thereby applying 12 volts, in sequence to lines 116, 118, 120, 122 as discussed above.
[0235] The speed of rotation of the rotary switch RSW (FIG. 13A), and the timing of the pulses on lines 116-122 in FIGS. 13A and 13B, are adjusted by the operator to give the proper timing of the hopper gates H1, H2 and so on.
[0236] FIG. 13A shows four rows R1-R4 of switches SW, which are analogous to ordinary snap-action wall switches used in a home. When the rotary switch RSW applies 12 volts to line 116, the switches which are closed in row R1 determine which relay L1-L4 is closed and thus determine which hopper gates (not shown in FIG. 13A) are opened. The same operation occurs when the rotary switch RSW applies twelve (12) volts to lines 120-122.
[0237] Similarly, when the rotary switch RSW applies 12 volts to line 118, the switches SW in row R2 determine which relays L1-L4 are actuated at that time and thus which hopper gates ae opened. The switches SW in effect act as memory of the PDL.
[0238] FIGS. 14A-14D illustrate operation of the switches SW. In FIG. 14A, the switches enclosed in dashed boxes are closed. The others are open.
[0239] Application of twelve (12) volts to lines 116, 118, 120 and 122 in FIG. 14A will be described as follows.
[0240] When the rotary switch RSW of FIG. 13A applies 12 volts to line 116 in FIG. 14A, the closed switch 116a delivers twelve (12) volts to relay L1 in FIG. 13A.
[0241] When the rotary switch RSW of FIG. 13A applies twelve (12) volts to line 118 in FIG. 14A, the closed switch 118a delivers twelve (12) volts to relay L2 in FIG. 13A.
[0242] When the rotary switch RSW of FIG. 13A applies twelve (12) volts to line 120 in FIG. 14A, the closed switch 120a delivers twelve (12) volts to relay L3 in FIG. 13A.
[0243] When the rotary switch RSW of FIG. 13A applies twelve (12) volts to line 122 in FIG. 14A, the closed switch 122a delivers twelve (12) volts to relay L4 in FIG. 13A.
[0244] The open switches have no effect, or it could be said that the open switches keep their respective gates open.
[0245] It should be understood that this sequential application of twelve (12) volts to lines 116, 118, 120 and then 122 actuates relays L1, L2, L3, and L4 in FIG. 13A, in that order, to open their respective gates. The closed switches of FIG. 14B cause relays L4, L3, L2, and L1 in FIG. 13A to be actuated, in that order, as twelve (12) volts are applied to lines 116, 118, 120 and then 122.
[0246] The closed switches of FIG. 14C cause relays L2, L1, L4, and L3 in FIG. 13A to be actuated, in that order.
[0247] As to FIG. 14D, the open switches SW in row 1 cause nothing to happen when 12 volts are applied to line 116 in FIG. 13A and then relays L1 and L3 are actuated simultaneously, when row R2 is connected to 12 volts, and then relay L4, when row R3 is connected. Finally, nothing happens, when row R4 is connected.
[0248] FIG. 14D shows that switches SW can be programmed so that, sometimes, more than one gate is opened, as in row 2.
[0249] The apparatus of FIGS. 13A-13B represent the operation of a simple PDL controller. One advantage of using the switches SW of FIG. 13A is that the type of programming is visibly evident to the operator or user based upon the position (i.e., open or closed) of the switches' handles (handles are not explicitly shown). A a truck driver can discern from viewing the arrangement of switches SW in FIG. 14C, for example, that relays L2, L1, L4, and L3 will be actuated, in that order.
[0250] This has the benefit of eliminating any need to instruct the driver in the intricacies of programming a PDL. Further, it eliminates the expense of any computer-type display required for programming a PDL, and for displaying the sequence of gates which the PDL will open.
[0251] 16. The sixteen switches SW of FIG. 13A can be replaced by ordinary or conventional automotive fuses of the type shown in FIG. 13C. Specifically, the sixteen switches SW shown are replaced by sixteen respective sockets. Insertion of a fuse into a socket converts the socket into a closed switch SW; otherwise, the socket acts like an open switch SW.
[0252] 17. A significant feature of one form of the invention is that one or more of the hoppers H1-H5 may be equipped with multiple modes of opening its respective gate 30-38. One mode is the type described in connection with the prior art as shown in FIGS. 1, 2, and 3, where a person manually operates a crank to open a gate as in the prior art. The second mode is the system which includes piston 40 of FIG. 6, which implements one form of the invention. In one form of the invention, the driver has the option of using either mode.
[0253] 18. Another significant feature is that the controller 50 is timed such that the gate 30-36 of each hopper H1-H4 is opened when the gate is engaged with the grate 47 in FIG. 7A. Before that time, the gate remains closed.
[0254] 19. Assume that, at time T=0, a driver presses the start switch 70 in FIG. 8. That causes solenoid SOL1 to open its gate after time delay T1, which is the delay imposed by TR1T. At that moment when solenoid SOL1 is actuated, countdown of time T2 begins in timer TR2T. When the count of T2 reaches zero, solenoid SOL2 opens its gate, which occurs at time 0+T1+T2. This timing must be known to the driver because it constrains the path along which the vehicle is to be moved. In one form of the invention, the positions of dials or knobs 104 and 106 in FIG. 8C indicate the timing by indicating the respective delays at which each SOL in FIG. 8 is actuated.
[0255] 20. Times T1 and T2 of the preceding paragraph each specify both a time and a place. Each time is the time at which a gate opens, measured from a reference time. For example. If the reference is noon and T1 specifies forty (40) seconds, then the gate controlled by T1 will open at noon plus forth (40) seconds.
[0256] Time T1 also specifies a place. That is, T1 is set in a specific relay or timer TR1T in FIG. 8. That relay/timer TRIT is associated with a specific hopper H1-H5. Because the driver necessarily knows the contents of the hopper H1-H5, then T1 by its association with a specific hopper H1-H5, specifies a location where the hopper H1-H5 is to be discharged. Restated, the driver knows that T1 is associated with one specific hopper H1-H5, and time T2 is associated with another hopper H1-H5, and so on. Thus, in one embodiment each hopper H1-H5 has a known destination.
[0257] From another point of view, each relay TR2-TR6 in FIG. 8 has its own time (T1, T2, T3, etc.) and is associated with its own hopper H1-H5. Those two pieces of information are sufficient for the driver to know where each hopper H1-H5 is to be discharged and at what time.
[0258] From yet another point of view, because of the design of the system, a driver knows that: [0259] (1) time T1 controls gate 30, [0260] (2) gate 30 discharges hopper H1, [0261] (3) hopper H1 contains a first discharge material, and [0262] (4) the first discharge material is to be discharged at location Y.
[0263] Therefore, T1 tells the driver where to discharge hopper H1.
[0264] It is probably most common that all hoppers H1-H5 will be discharged into a common location, namely the storage area 47 in FIG. 10, but discharge at different locations is possible or the discharge may be spread.
[0265] 21. It is emphasized that knowledge by the driver of the various times, such as T1, T2, etc., does not amount to mere knowledge of a set of numbers or time intervals. The driver also has knowledge of the system 10, so that he knows that time T1 is associated with hopper H1, T2 is associated with H2, and so on. Restated as to time T1, the driver does not merely know some time T, which can be viewed as an abstract number. Instead, he knows a time T for Hopper H1. That is why this specific time is labeled T1, and not merely time T. T1 refers to hopper H1.
[0266] 22. In FIG. 8C, the knob 104 sets a timing delay, and the knob 104 itself is an indicator of the timing delay. The delay is actually set by the internal mechanism of the relay, as symbolically shown in FIGS. 9A-9D. The combination of the knob 104 and that mechanism controls the timing delay.
[0267] In one form of the invention, the indicator must be visible to the driver. Consequently, if the timing apparatus of invention is contained within the weatherproof box 120 of FIG. 11C, a window or display may be provided in the weatherproof box 120, for viewing the timing indicators. Other provision can be made for viewing the indicators, such as a camera which views the indicators, and a display on the box 120 which presents what the camera sees.
[0268] 23. The PLC design can be programmed to acuate slide doors or gates 30-38 in any order that the customer wants to program them too.
[0269] 24. The PLC design allows the customer to select all or individual slide doors or gates 30-38 as needed.
[0270] 25. The PLC design also allows the customer to use wireless access to remotely operate the system.
[0271] 26. The mechanical timer design can unload hoppers H1-H5 in numerical sequences according to wiring.
[0272] 27. It should be understood that that slide doors or gates 30-38 may be opened according to a plan, or convention, or specification, which resides outside the doors and their control system. The slide doors or gates 30-38 cannot be opened at random, unless this is desired by the user and a given slide door or gate 30-38 may be opened when it is in the correct position. The user may set out the required opening sequence in an instruction sheet or the user generate the instruction sheet in real-time, while he watches the trailer TK.
[0273] 28. The system 10 could also comprise the stop switch 70a that stops the operation of the system 10. The stop switch 70a could be automatic or immediate or the sequence of operation may continue until the last hopper H1-H5 is emptied. When the system 10 stops, all slide doors or gates 30-38 are closed automatically. Alternatively, the system 10 could be programmed so that the slide doors or gates 30-38 close one at a time after each hopper H1-H5 is unloaded.
ADDITIONAL EMBODIMENT
[0274] 29. FIG. 6 shows the controller 50 which issues the signal of duration D1 on line 52 which actuates the solenoid 42 as described earlier herein, which moves the spool 51 to admit air through line 48 which moves the pneumatic piston 40 leftward (as viewed in the figure), to actuate the gate 30 of the hopper H1.
[0275] FIG. 5 shows the controller 50 applying similar signals on lines 52-58 to thereby actuate four similar pistons 40, to actuate their associated pneumatic pistons. The controller 50 causes the first piston 40 to open its slide door or gate 30-38, and then closes that slide door or gate 30-38. Then a second slide door or gate 30-38 and then closes, then a third slide door or gate 30-38, and so on, as described earlier.
[0276] The controller 50 can take the form of a Programmable Logic Controller, PLC 107, shown in FIG. 11E, such as the controller manufactured by Eaton Industries GmbH. Such controllers are also called relay controllers. PLC 107 receives electric power from the twelve (12) volt system of the vehicle, as indicated. SOLENOID 1, SOLENOID 2, SOLENOID 3, and SOLENOID 4 correspond, for example, to solenoids 22 in FIG. 5.
[0277] When a START switch in FIG. 11E is pressed, twelve (12) volts are applied to the pin and the PLC 107 begins operation. It first closes switch Q1, thereby connecting SOLENOID 1 between 12 volts and ground, thereby actuating the spool valve (not shown) controlled by SOLENOID 1. SOLENOID 1 is analogous to the solenoid 42 in FIG. 5 which is fed by line 52. After SOLENOID 1 in FIG. 11E has been actuated for a time duration, analogous to duration D1 in FIG. 5, the PLC 107 may or may not de-energize SOLENOID 1, depending on the programming of PLC 107.
[0278] PLC 107 in FIG. 11E then closes switch Q2, thereby connecting SOLENOID 2 between twelve (12) volts and ground, thereby actuating the spool valve (not shown) controlled by SOLENOID 2. SOLENOID 2 is analogous to the solenoid 42 in FIG. 5 which is fed by line 54. After SOLENOID 2 in FIG. 11E has been actuated for a time duration, analogous to duration D2 in FIG. 5, the PLC 107 may or may not de-energize SOLENOID 2, depending on the programming of PLC 107.
[0279] PLC 107 in FIG. 11E then closes switch Q3, thereby connecting SOLENOID 3 between twelve (12) volts and ground, thereby actuating the spool valve (not shown) controlled by SOLENOID 3. SOLENOID 3 is analogous to the solenoid 42 in FIG. 5 which is fed by line 56. After SOLENOID 3 in FIG. 11E has been actuated for a time duration, analogous to duration D3 in FIG. 5, the PLC 107 may or may not de-energize SOLENOID 3, depending on the programming of PLC 107.
[0280] PLC 107 in FIG. 11E then closes switch Q4, thereby connecting SOLENOID 4 between twelve (12) volts and ground, thereby actuating the spool valve (not shown) controlled by SOLENOID 4. SOLENOID 4 is analogous to the solenoid 42 in FIG. 5 which is fed by line 58. After SOLENOID 4 in FIG. 11E has been actuated for a time duration, analogous to duration D4 in FIG. 5, the PLC 107 may or may not de-energize SOLENOID 4, depending on the programming of PLC 107.
[0281] This type of PLC 107 can be cascaded with similar PLCs, as shown in FIG. 11F, following the manufacturer's instructions. In FIG. 11F, PLC 130 is cascaded with PLC 107 of FIG. 11E. PLC 130 can take the form of a controller manufactured by Eaton Industries GmbH.
[0282] PLC 130 then actuates SOLENOID 5 after PLC 107 actuates SOLENOID 4 in FIG. 11E. PLC 130 then actuates SOLENOID 6 after SOLENOID 5.
[0283] This cascading allows a manufacturer to, for example, initially implement a PLC as in FIG. 11E, which controls a hopper system having four gates. But then the PLC can be expanded to handle, for example, six gates, as in FIG. 11F. This type of expansion can be economical because while a PLC may be available which will control six gates and could be used initially for a four-gate system, such a PLC tends to be more expensive than one which is limited to controlling four gates.
[0284] The particular PLCs shown in FIGS. 11E and 11F use solid state electronics, whose electrical properties are temperature-dependent. Specifications published by Eaton Industries GmbH state that, depending on temperature, the PLCs may gain, or lose, up to 5 seconds per day, or (equivalently) one-half hour per year. Thus, for example, if a given PLC is powered by a vehicle and is stored outdoors in winter for one month, the timing may change by 530, or 150 seconds, over than month.
[0285] Therefore, the programming of the PLC should accommodate those possible time losses. For example, if a hopper is to be held open for 30 seconds, then the programming must impose a correspondingly longer opening time. Alternatively, the time-of-day which the PLC computes could be set to 12:00 am every day at midnight. That would limit the time error to 5 seconds, because the error which accumulated in the previous 24 hours would be erased at midnight every day.
[0286] Eaton Industries GmbH offers software called EasySoft8 which facilitates generation of code for the PLC 107 and PLC 130 in FIG. 11F. This allows a manufacturer of the controller 50 in FIG. 5 or PLC 107 in FIG. 11E to generate a single program and load it into multiple controllers, as opposed to manually programming each individual controller by keying in symbols.
[0287] The presence of program code within the PLC points to a difference between use of a PLC and the embodiment of FIG. 8. In FIG. 8, relay TR1 closes after timer TR1T times out. The TR1T is a physical device that is present in the circuit shown. When relay TR1 closes, voltage is applied across solenoid SOL1, which opens a gate, and also causing timer TR2T to begin counting down. In FIG. 8, the timing is established by physical count-down timers, but in the case of the PLC shown in FIGS. 11E and 11F, any corresponding time intervals are determined by program code, or digital data.
[0288] 30. FIG. 15A shows a protective container 88 which contains a panel which supports the solenoid valves SOL and the timers TR. Air lines 95 extend from the container 88 and run to the pistons 40. In FIG. 15A, each gate 30-38 is operated by one piston 40, which is not shown in FIG. 15A.
[0289] 31. FIG. 15A shows the container 88 mounted on trailer TK1. The air lines 95 of FIG. 11 run through a protective pipe PP which is attached to the trailer TK1. FIG. 15B is a rear view of the trailer TK1. The pipe PP is located at a position which is protected by the lateral edge E of the trailer TK1. The pipe PP is located inboard of edge E as well as being inboard of the outer edge OE of the TIRES. As to the latter, the pipe PP is inboard of the outer edge OE by distance D.
[0290] Numerous modifications can be made to the embodiments herein described, without departing from the true spirit and scope of the invention.
[0291] This invention, including all embodiments shown and described herein, could be used alone or together and/or in combination with one or more of the features covered by one or more of the claims set forth herein, including but not limited to one or more of the features or steps mentioned in the Summary of the Invention and the claims.
[0292] While the system, apparatus and method herein described constitute preferred embodiments of this invention, it is to be understood that the invention is not limited to this precise system, apparatus and method, and that changes may be made therein without departing from the scope of the invention which is defined in the appended claims.
