WO2005099351A2

WO2005099351A2 - A batching apparatus and method thereof

Info

Publication number: WO2005099351A2
Application number: PCT/IL2005/000403
Authority: WO
Inventors: Akiva Pinto
Original assignee: Akiva Pinto
Priority date: 2004-04-18
Filing date: 2005-04-18
Publication date: 2005-10-27
Also published as: WO2005099351A3; IL161474A0; DE112005000857T5

Abstract

A feeding apparatus consisting of a supply hopper (100) and a weighing hopper (150). Feeding of material from the supply hopper (100) to the weighing hopper (150) varies between a bulk feed rate and a fine feed rate by varying the size of the opening of the supply hopper aperture by independently controlling the two closing flaps (410,420). There may be more than two flaps, and the flaps may vary in size relative to one another.

Description

A BATCHING APPARATUS AND METHOD THEREOF

FIELD OF THE INVENTION

The present invention generally relates to a batching apparatus and method for delivering exact amounts of bulk material at a fast rate. More specifically, the present invention relates to a batching apparatus useful for a gradual and controlled feed of bulk material to a weigh hopper.

BACKGROUND OF THE INVENTION

A weigh pan or hopper delivering pre-specified amounts of loose material in bulk is well known in the art. This weigh hopper accumulated the bulk material and releases it when it reaches a pre-specified weight, or at the end of a pre-specified duration of accumulation. It is known that he higher the rate of accumulation the harder it is to maintain a pre- specified accuracy of released mass. Therefore a weigh pan or hopper is sometimes fed by a retaining pan or hopper, which releases the bulk material in a controlled way.

US Pat No. 3,856,097 discloses an automatic scale control system for weighing continuous batches of a fluent product wherein a bulk feed delivers a product from a supply to the scale at a bulk rate and a dribble feed delivers the product from the supply to the scale at a dribble rate lower than the bulk rate, and does not show how a product can be delivered from a supply to the scale at a constant maximum rate.

US Pat No. 4,130,171 presents a rotating retaining hopper feeding a product to a rotating hopper. US Pat No. 4,478,301 presents an apparatus for controlling the filling of weigh pans for producing a predetermined blend of fibers which does not show how variations in the actual rate in which the pans are fed are prevented from causing variations in the weight ratio of fibers in the blend. US Pat No. 4,638,875 presents a blending system weighing unit comprising weigh pans into which fibers are fed and in which feeding stops at one stage pending a dump command, an thus feeding does not take place at a constant maximum rate. US Pat No. 4,766,966 presents a retaining hopper feeding a product to a weigh hopper via an aperture of continuously variable size or via a three state aperture. This is a relatively cumbersome mechanism, and thus prone to failure. German Pat No. 19856447 teaches changing the rate in which a product is fed to a weigh pan as a function of time. An simple and cost effective apparatus and method for delivering exact amounts of bulk material at a fast rate thus meets a long felt need.

SUMMARY OF THE INVENTION

It is thus in the scope of the present invention to provide an apparatus and method for delivering exact amounts of bulk material at a fast rate using a weigh hopper and a retaining hopper in a simple and efficient mechanism which is surprisingly missing in the art.

It is the core of the present invention to provide an apparatus and a method for feeding bulk material to a weigh hopper comprising a retaining hopper containing the bulk material to be weighed located directly adjacent to the -weigh hopper, said retaining hopper having an aperture through which product in the retaining hopper is supplied to the weigh hopper, and a set of two valves controlling the size of said aperture, and a weight comparator comparing the weight of bulk material in said weigh hopper to three pre- specified values, and generating three control signal, a control signal per each pre- specified value, and also to trigger the closure and the opening of the valves by the control signals.

BRIEF DESCRIPTION OF THE INVENTION

In order to understand the invention and to see how it may be implemented in practice, a preferred embodiment will now be described, by way of non-limiting example only, with reference to the accompanying drawing, in which figure 1 schematically presents apparatus for delivering exact amounts of bulk material at a fast rate comprising a retaining hopper feeding a weigh hopper through an aperture that opens at times and closes at times; figures 2A and 2B present a graph describing periodically filling a weigh hopper at a roughly constant rate; figures 2C and 2D present a graph describing periodically filling a weigh hopper at a diminishing rate; figures 3 presents a graph describing periodically filling a weigh hopper through an aperture of diminishing area; figure 4A schematically presents a set of valves opening and closing an aperture and comprising two flaps; figure 4B schematically presents a set of valves opening and closing aperture an and comprising four flaps; figure 5 schematically presents a set of valves opening and closing an aperture and comprising two flaps; and figure 6 schematically presents the generation of control signals dependent on weight.

DETAILED DESCRIPTION OF THE INVENTION

The following description is provided, alongside all chapters of the present invention, so as to enable any person skilled in the art to make use of said invention and sets forth the best modes contemplated by the inventor of carrying out this invention. Various modifications, however, will remain apparent to those skilled in the art, since the generic priaciples of the present invention have been defined specifically to provide an apparatus and method for delivering exact amounts of bulk material at a fast rate.

The term 'hopper' refers in the present invention to any receptacle for delivering loose material in bulk (such as fiber, grain or coal), which is often funnel-shaped.

The term Naive' refers in the present invention to any a mechanical device by which the flow of loose material in bulk may be started, stopped, or regulated by a movable part that opens, shuts, or partially obstructs one or more ports or passageways, or to the movable part of such a device An apparatus according to the present invention comprises a weigh hopper and a retaining hopper. The retaining hopper retains the product to be weighed, and is feeding the weigh hopper. The retaining hopper comprises an aperture through which is supplied to the weigh hopper, and the aperture is controlled by two independent valves.

Each of the independent valves is opened whenever the product in the weigh hopper reaches a value pre-specified for the valve, and it is closed whenever the product in said weigh hopper reaches another value pre-specified for the valve.

It is hence according to one embodiment of the present invention to present a useful apparatus adapted for a gradual and controlled feed of bulk material to a weigh hopper. This apparatus comprising inter alia a retaining hopper, a weight hopper and a weight comparator. The aforesaid retaining hopper is containing at least a portion of the bulk material to be weighed. It is comprised of at least one aperture outlet through which bulk material is supplied gradually to said weigh hopper. The size of said aperture is controlled by a means of a set of a first closeable valve and a second closeable valve. The aforesaid weight hopper is adapted to receive said bulk material in a controllable manner from the retaining hopper, preferably located above or adjacent said weight hopper.

The aforementioned weight comparator is further adapted to compare the weight of the bulk material in said weigh hopper with a first, second and third predetermined values and to transmit a plurality of a first, second and third weight control signals to said first and second valves at the time or in a case that the weight of the bulk material is equal or grater than said predetermined values. A forth control signal is provided whereat all material is dropped from weigh pan 150.

It is in the scope of the present invention wherein said first control signal triggers the closure of said first valve; said second control signal triggers the closure of said second valve; said third control signal triggers the opening of the opening valve of weigh pan 150 and said forth control signal triggers both opening the set of two valves simultaneously and closing said opening valve of weigh pan 150 an vice versa.

According to yet another embodiment of the present invention, the first and/or the second closeable valves are adapted to form a butterfly valve; a shutter-like shutter, a hinge- containing regulating member or any combination thereof. It is well in the scope of the present invention wherein first and the second valves are differ their either size or shape. The size ratio between the first valve and the second valves may be ranging from 1:3 to 1:5; more specifically, this ratio is 1:4 in the manner that the first valve is adapted to close about 80% of the aforesaid aperture and send valve is shutting about 20% of the aperture,

Reference is made now to figure 1, presenting a schematic and generalized presentation of the aforementioned novel apparatus for delivering exact amounts of bulk material at a fast rate. Arrow 110 represents the flow of bulk material into retaining hopper or pan 100. The bulk material is any type of loose material, such as fiber, grain or coal. Arrow 120 represents the flow of material from hopper 100 to a weigh hopper or pan 150 through a variable aperture 140. Arrows 102 and 103 show movement of aperture 140 as it opens at times and closes at times. Arrow 130 represents the flow of material from weigh pan towards some downstream process or machinery through a variable aperture 180. Arrows 152 represent the rotating movement of aperture 180 as it opens at times and closes at times.

According to one specific embodiment of the present invention, a blending process comprising at least two apparatuses as defined in any of the above. At least one apparatus is located at the beginning of the line (i.e., master apparatus) and at least a second apparatus is located downstream (i.e., slave apparatus). Said master is targeting said slave a plurality of signals, so that a defined blending ratio is obtained.

Spring 161 is a schematic symbol representing any kind of weight sensing device that is coupled through coupler 160 to weigh pan 150. It measures the weight of weigh hopper 150 and its contents against a stable base or reference 162. The primary function of weigh hopper 150 is to periodically accumulate material and discharge it. Arrow 170 represents a control signal triggering the discharge and originating for the measurement of weight. A similar control signal 190 controls the discharge of material retained in hopper 100.

Hoppers 100 and 150 are schematically depicted as boxes, but in practice they are often tunnel shaped. Hoppers 100 and 150 may be vibrated to better discharge the bulk material stored in them.

Reference is made now to figure 2A presenting a graph describing periodically filling a weigh hopper at a constant rate. Weight increases linearly with time, until it reaches a threshold value W at time T, and it increases no longer. At time T the weigh hopper discharges, the weight decreases to its minimum value, and the cycle repeats.

Reference is made now to figure 2B presenting a graph describing periodically filling a weigh hopper at an essentially constant rate. Weight increases roughly linearly with time, but the linear increase may be avoided when the bulk material is not an ideal liquid. Figure 2B shows that the rate of increase of weight is not certain at the time T, which causes inaccuracy in the value W.

Reference is made now to figure 2C presenting a graph describing periodically filling a weigh hopper at an ideal diminishing rate. The rate of weight increase at time T is lower than the average rate.

The rate depicted is the rate in which product is fed to weigh hopper, as shown by arrow 120 described in reference to figure 1, while the rate to the retaining hoper, as shown by arrow 110, can be kept constant and as high as desired.

Reference is thus made now to figure 2D presenting a graph describing periodically filling a weigh hopper at a diminishing rate. The low rate at time T allows better accuracy for weight W even in spite of depicted perturbations.

Reference is made now to figure 3 presenting a graph describing periodically filling a weigh hopper through an aperture of diminishing area. At product is first accumulated at a fast rate through a large aperture, and then accumulated at a slow rate through a small aperture. For the brief period of the discharge of the weigh hoper the aperture is reduced to minimum to decrease uncertainty in discharged weight.

Reference is made now to figure 4A schematically presenting a set valves opening and closing an aperture 100 and comprising two unequal size rotating flaps 410 and 420 movable on axle 430 and 440 with the rotation maneuver 441 and 431, respectively. According to the present invention, flaps 410 and 420 rotate independently. The size of each valve may very, such as in the manner that the size of the first valve is about four times bigger than the second valve. A large aperture forms when both are open, and a small aperture forms when only one is open. The aperture size is minimal when both flaps are shut. Reference is made now to figure 4B schematically presenting a set of sliding flaps opening and closing an aperture 100 above a conveyer belt carrying material A according to yet another embodiment of the present invention; wherein raw material B is flowing (120) to a retaining hover (100) before its leaving (130) to a weight hoper. Aperture (100) comprising inter alia four flaps 450, 460, 470 and 480 adapted to slide horizontally along their longitudinal axis by means of four shafts, such as shaft 465 in communication with flap 460. Haps 450 and 470 may be coupled, so that flap 450 is open simultaneously when flap 470 is open and vice versa. Alternatively or additionally, flaps 460 and 480 coupled, so that flap 460 is open simultaneously when flap 480 is open, and vise versa. Also according to the present invention, the valve formed by one or more flap maneuver is independent of other flaps' maneuvers, so that one valve can be open while the other is shut. For the sake of example and explanation, flap 470 is showed to be open, so that a material is exit on the right side of the conveyer belt; and further wherein flap 460 is illustrated in its open conformation, being maneuvered to the right (466), so that a left hand opening is provided (130B).

This novel apparatus is surprisingly provided for that the material density will be even distributed on dropped area. This is especially useful in blending first highly open fibers with low density together with a second or more high-density fibers.

The device according to the present invention is adapted to blend a predetermined measure material A with a predetermined measure of material B. and to ensure homogenization of said material B on the whole width of its adjacent conveyer belt carrying said material B to process.

According to a preferred embodiment of the present invention one of the two valves comprises more than one flap, as is the case for butterfly valve, and all flaps belonging to one valve open a shut in unison. Said butterfly valve may be also provided for an even distributed fiber drop on the blending conveyer (121B).

Reference is thus made now to figure 5 schematically presenting a set of valves opening and closing aperture 500 of retaining hopper 550 and comprising two flaps 510 and 520. Both flaps are shown moving on one hinge 530.

Figure 4A represents another embodiment of the present invention in which the flaps are rotated on hinges perpendicular to the direction of material flow. Figure 5 represents another preferred embodiment of the present invention in which the flaps are rotated on hinges parallel to the direction of material flow.

Figure 4A represents another embodiment of the present invention in which each of the flaps is rotated on its own hinge. Figure 5 represents another preferred embodiment of the present invention in which the flaps are rotated on one common hinge.

Figure 4A represents another embodiment of the present invention in which the flaps are rectangular. Figure 5 represents another preferred embodiment of the present invention in which the flaps triangular.

Rectangular aperture 400 described in reference to figures 4A and 4B, and circular aperture 500 described in reference to figure 5 are two embodiments of aperture 140 described in reference to figure 1.

Reference is made now to figure 6 schematically presenting the weighting apparatus comprising blocks 160, 161 and 162 described in reference to figure 1. A ruler 600 marks three positions as indicated by three left pointing arrows. Figure 6 depicts a simple preferred embodiment of the present invention, in which the weight in the weigh pan presses through coupler 16O against spring 161 resting against base 162. The heavier the weigh pan, the lower coupler 160, and the closest its position, marked by a right pointing arrow, to base 162. Thus the three left pointing arrows marked on ruler 600 correspond to three values of weight in a weigh pan. According to the present invention a control signal is generated whenever the right facing arrow touches on a left facing arrow, and there are three such signals, collectively marked by arrow 190 described in reference to figure 1. Also according to the present invention, these three signals trigger the opening and closing of valves and correspond to the three values of aperture area A shown in figure 3.

It is yet second object of the present invention to provide a useful method for gradual and controlled feeding of bulk material to a weigh hopper. This method is provided by means of an apparatus as defined in any of the above, and comprising the following tree steps: comparing the weight of the bulk material accumulated at the retaining hoper, and in case that it is equal or grater than said second predetermined value, transmitting a second signal from said weight hoper so that said second valve is closed; comparing the weight of the bulk material accumulated at the retaining hoper, and in case that it is equal or grater than said third predetermined value, transmitting a third signal from said weight hoper so that the opening valve of weigh pan is open; sending a forth control signal which is triggering both opening the set of two valves simultaneously and closing said opening valve of weigh pan and vice versa.

The apparatus according to yet another embodiment of the present invention is related to a batcher adapted to weight a bulk material, and especially a textile fiber-like material. Said fiber like material may be selected form either synthetic or natural fibers; such as cotton, and polyester.

Claims

1. An apparatus useful for a gradual and controlled feed of bulk material to a weigh hopper comprising biter alia: a. a retaining hopper containing at least a portion of the bulk material to be weighed; comprised of at least one aperture outlet through which bulk material is supplied gradually to said weigh hopper; the size of said aperture is controlled by a means of a set of a first closeable valve and a second closeable valve; b. a weight hopper adapted to receive said bulk material in a controllable manner; c. a weight comparator adapted to compare the weight of the bulk material in said weigh hopper with a first, second and third predetermined values and to transmit a plurality of a first, second and third weight control signals to said first and second valves; wherein said weight of the bulk material is equal or grater than said predetermined values; a forth control signal is provided whereat all material is dropped from the weigh pan; wherein said first control signal triggers the closure of said first valve; said second control signal triggers the closure of said second valve; said third control signal triggers the opening of the opening valve of weigh pan and said forth control signal triggers both opening the set of two valves simultaneously and closing said opening valve of weigh pan and vice versa.

2. The apparatus according to claim 1, wherein said open or close positions are denoted for any gradual or proportional maneuver of the valve.

3. The apparatus according to claim 1, wherein said retaining hopper is disposed above said weigh hopper.

4. The apparatus according to claim 1, wherein said first and said second closeable valves are adapted to form a butterfly valve.

5. The apparatus according to claim 1, wherein the first and the second valves are of different size.

6. The apparatus according to claim 4, wherein the size ratio between the first valve and the second valves is ranging from 1:3 to 1 :5.

7. The apparatus according to claim 5, wherein the size ratio between the first valve and the second valves is 1:4.

8. The apparatus according to claim 1, wherein bulk material is a textile fiber-like material.

9. A blending process comprising at least two apparatuses as defined in claim 1 or in any of its dependent claims, wherein at least one apparatus is located at the beginning of the line (i.e., master apparatus) and at least a second apparatus is located downstream (i.e., slave apparatus); said master is targeting said slave a plurality of signals, so that a defined blending ratio is obtained.

10. The apparatus according to claim 1, wherein said valves are provided for an even distributed fiber drop on the blending conveyer.

11. A method of a gradual and controlled feeding of bulk material to a weigh hopper by means of an apparatus comprising ter alia: (t) a retaining hopper containing at least a portion of the bulk material to be weighed; comprised of at least one aperture outlet through which bulk material is supplied gradually to said weigh hopper; the size of said aperture is controlled by a means of a set of a first closeable valve and a second closeable valve; (it) a weight hopper adapted to received said bulk material in a controllable manner; and (Hi), a weight comparator adapted to compare the weight of the bulk material in said weigh hopper with a first, second, and third predetermined values and to transmit a plurality of a first, second and third weight control signals to said first and second valves; wherein said weight of the bulk u material is equal or grater than said predetermined values; a forth control signal is provided whereat all material is dropped from the weigh pan; said method comprising the following tree steps: a. comparing the weight of the bulk material accumulated at the retaining hoper, and in case that it is equal or grater than said first predetermined value, transmitting a first signal from said weight hoper so that said first valve is closed; b. comparing the weight of the bulk material accumulated at the retaining hoper, and in case that it is equal or grater than said second predetermined value, transmitting a second signal from said weight hoper so that said second valve is closed; c. comparing the weight of the bulk material accumulated at the retaining hoper, and in case that it is equal or grater than said third predetermined value, transmitting a third signal from said weight hoper so that the opening valve of weigh pan is open; d. sending a forth control signal which is triggering both opening the set of two valves simultaneously and closing said opening valve of weigh pan and vice versa.