Abstract:
A system is provided for feeding a stream of material. The system includes a feeder, a material density portion, a detector, a weight calculator and an indicator. The feeder can output a portion of the stream of the material from a first position to a second position. The material density portion can generate a density signal based on the density of the material. The detector can detect a volume of the portion of the stream of the material without contacting the portion of the stream of the material and can generate a volume signal based on the detected volume. The weight calculator can calculate a weight based on the density signal and the volume signal and can generate a weight signal. The indicator can provide an indication signal based on the weight signal.

Description:
BACKGROUND 
     In industry, batching systems are used to continuously divide large amount of material or objects into smaller portions that can then be packaged for distribution. Conventional batching systems are typically very flexible. If more than one type of material is being produced, with conventional batching systems, it is possible to continue running a batching system with no changeover of parts. This allows the batching process to continue uninterrupted saving valuable time and money. 
     Modern batching systems are very versatile and can be used with several different types of materials. It is possible to package material by count, weight, or volume, depending on the needs of the user. Batching systems can be used in short or long term production runs with a variety of product sizes. 
     Perhaps the most valuable benefit that batching systems provide is accuracy. Batching systems can optically scan and verify the amount of material in each batch. This allows for a better and more precise packaged product. 
       FIGS. 1A-C  illustrate a conventional material batching system  100  at times t 0 , t 1 , and t 2 , respectively. For purposes of discussion, presume that system  100  is batching oats. 
     As illustrated in  FIG. 1A , system  100  includes a feeder or feeding portion  102 , a deflector  104 , a collector  106 , a collector  108 , a scale  110 , a scale  112  and a controller  114 . 
     Deflector  104  is arranged to receive a stream of material  116  from feeding portion  102 . Collector  106  is arranged to receive a stream of material  118  from deflector  104 . Collector  108  is additionally arranged to receive stream of material  118  from deflector  104 . Controller  114  is arranged to receive a weight signal  120  from scale  110  and to receive a weight signal  122  from scale  112 . Deflector  104  is arranged to receive a deflector control signal  124  from controller  114 . Feeding portion  102  is arranged to receive a feeding portion control signal  126  from controller  114 . 
     Feeding portion  102  may be any known device or system that is able to feed material from a source (not shown) to deflector  104 . Non-limiting examples of feeding portion  102  include a hopper, a conveyer belt, a screw, etc. 
     Deflector  104  may be any known device or system that is able to receive material from feeding portion  102  and then dispense the material into one of collector  106  and collector  108 . In particular, in a first state, deflector  104  deflects stream of material  116  from feeding portion  102  as stream of material  118  into collector  106 . In a second state, deflector  104  deflects stream of material  116  from feeding portion  102  as stream of material  118  into collector  108 . Non-limiting examples of deflector  104  include a deflector as described in U.S. Pat. No. 6,799,684 B2, the entire disclosure of which is incorporated herein. 
     Collector  106  and collector  108  may be any known device or system that is able to receive material from deflector  104 . Scales  110  and  112  may be any known device or system that is able to determine the weight of material stored in collector  106  and collector  108 , respectively. Non-limiting examples of collector  106  and collector  108 , include boxes, bags, containers, or drums. 
     Controller  114  may be any system or device that is operable to control feeding portion  102  and deflector  104 . Non-limiting examples of controller  114 , include a computer, server, or motor. 
     A user may use system  100  to batch an amount of material into smaller predetermined amounts, or batches. For purposes of discussion, presume that a user (not shown) uses system  100  to batch oats. In general a bulk source of material is provided to a receiving receptacle. The material is fed from the receptacle onto feeding portion  102  in a steady stream which is then carried to the end of feeding portion  102 , where the material falls off as stream of material  116 . The material falls off of feeding portion  102  and is deflected into collector  106 . Scale  110  measures the amount of material being deflected into collector  106  until it finds that the amount of material has reached the predetermined limit. 
     The predetermined limit is based on volume, or weight, of material that can be fit into a package. At this time controller  114 , switches the deflector to a different position and begins filling up collector  108 . While this is happening the material in collector  106  may be taken and emptied into a packaging system which can then be shipped. Once emptied, collector  106  is put back into position until scale  112  has measured that collector  108  is full. Now controller  114  switches the deflector and material is deposited into collector  106  once again. Collector  108  can be taken and emptied into a packaging system and then returned. 
     In operation, a large volume of oats (not shown) are dumped into a receiving receptacle (not shown), which feeds the dumped oats to feeding portion  102 . The oats are conveyed from one end of feeding portion  102  (closest to the receiving receptacle) to the other end of feeding portion  102 , where they continue as stream of material  116 . 
     Deflector  104  will be in one of two states. In its first state, deflector  104  will deflect stream of material  116  into collector  106  as stream of material  118 . In its second state, deflector  104  will deflect stream of material  116  into collector  108  as stream of material  118 . Controller  114  will instruct deflector  106 , via deflector control signal  124 , to periodically switch between the first state and the second state. Accordingly, deflector  106  will periodically fill collector  106  or collector  108 . 
     Controller  114  outputs deflector control signal  124  based on weight signals  120  and  122 . In particular, controller  114  instructs deflector  104 , via deflector control signal  124 , to deflect stream of material  116  as stream of material  118  from collector  106  to collector  108  based on weight signal  120 . Similarly, controller  114  instructs deflector  104 , via deflector control signal  124 , to deflect stream of material  116  as stream of material  118  from collector  108  to collector  106  based on weight signal  122 . This will be described, with additional reference to  FIGS. 1B-C . 
     For purposes of discussion, presume that the oats are to be shipped in 10 lb bags. In such a case, collector  106  and collector  108  are going to be large enough to accept a volume of oats equal to 10 lbs. At time t 0 , as shown in  FIG. 1A , deflector  104  is in a first wherein stream of material  116  is deflected as stream of material  118  into collector  106 . Weight scale  110  measures the weight of oats in collector  106 . Weight scale  110  provides the measured weight, by way of weight signal  120 , to controller  114 . 
     As shown in  FIG. 1B , the amount of oats in collector  106  is approaching a volume of oats equal to 10 lbs. When the measured weight of the accumulated amount of oats in collector  106  has reached the predetermined threshold, in this example 10 lbs, controller  114  sends deflector control signal  124  to deflector  104 . Once deflector  104  has received deflector control signal  124 , it will change to its second state. At this time deflector  104  will deflect stream of material  116  as stream of material  118  into collector  108 . 
       FIG. 1C  illustrates system  100  at time t 2 , at this time collector  106  had reached its predetermined weight threshold and collector  108  is now being filled up with a new batch of oats. At this time, while collector  108  is being filled, collector  106  may be removed from system  100  to be emptied and then returned to its position in system  100  as show in  FIGS. 1A-C . 
     A problem with these systems is accuracy and overflow beyond a predetermined threshold. More specifically when a conventional batching system is operating, it is very hard to batch an exact weight of material. For example, for purposes of discussion, presume that the system is arranged to batch 1000 oz. portions of a material. An overflow of 2 oz. is a relatively small error −0.2%. This is a relatively small overflow and may even be within tolerances set for the batch size. However, the accuracy of the batch becomes more important as the predetermined threshold becomes smaller. For example, for purposes of discussion, now presume that the system is arranged to batch 10 oz. portions of a material. In this case, an overflow of 2 oz. is a 20% error. As batch sizes become smaller, accuracy becomes more important. Accuracy of the batch becomes even more critical with regulated materials such as various chemicals and medications. It is particularly important that the amount of material being batched is accurate, and the way this is done in conventional systems is by measuring the weight of the material that has been batched. 
     The way that the issue of accuracy is addressed in conventional batching systems is by slowing of feeding portion  102 . When controller  114  detects that the weight of material within collector  106  is approaching the predetermined threshold, controller  114  instructs feeding portion  102  to slow down by way of feeding portion control signal  126 . As feeding portion  102  slows the feed of stream of material  116 , a more gradual approach to the predetermined threshold is achieved. This method of slowing down the batching process allows better accuracy and prevents overflow of the material being batched. 
     Another problem with conventional batching systems is that there is no way to detect the mass of material left in stream of material  116  and stream of material  118 . When controller  114  calculates that the weight of material in collector  106  has reached the predetermined threshold it will signal deflector  104  to move from state one to state two and begin filling up collector  108 . While this deflector state change is occurring, there is still material falling in stream of material  116  as well as stream of material  118 . Material in stream of material  116  and stream of material  118  that is still falling will fall into collector  106  and will contribute to the overflow of material past the predetermined threshold. 
     Both problems with conventional batching systems, slowing of feeding portion  102  and overflow due to material left in stream of material  116  and stream of material  118 , stem from the weight of material in collector  106  being measured continuously. In other words, in conventional batching systems, the weight of the material in the batch (actually in the collector) is measured to determine when the batch meets the predetermined amount. 
     What is needed is a system and method that can accurately determine the weight of a batch of material in real time, without slowing feeding portion  102  and preventing the unknown amount of material in stream of material  116  and stream of material  118  from falling into collector  106 . 
     BRIEF SUMMARY 
     The present invention provides a system and method that can accurately determine the weight of a batch of material in real time, without slowing the feeding speed of the material. 
     In accordance with an aspect of the present invention, a system is provided for feeding a stream of material. The system includes a feeding portion, a material density portion, a detector, a weight calculator or calculating portion and an indicator. The feeding portion can output a portion of the stream of the material from a first position to a second position. The material density portion can generate a density signal based on the density of the material. The detector can detect a volume of the portion of the stream of the material without contacting the portion of the stream of the material and can generate a volume signal based on the detected volume. The weight calculating portion can calculate a weight based on the density signal and the volume signal and can generate a weight signal. The indicator can provide an indication signal based on the weight signal. 
     Additional advantages and novel features of the invention are set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following or may be learned by practice of the invention. The advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims. 
    
    
     
       BRIEF SUMMARY OF THE DRAWINGS 
       The accompanying drawings, which are incorporated in and form a part of the specification, illustrate exemplary embodiments of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings: 
         FIGS. 1A-C  illustrates a conventional material batching system at times t 0 , t 1 , and t 2 , respectively; 
         FIGS. 2A-C  illustrate an example material batching system in accordance with aspects of the present invention, at times t 0 , t 1 , and t 2 , respectively; 
         FIG. 3  illustrates another example material batching system in accordance with aspects of the present invention at time t 0 ; and 
         FIG. 4  illustrates an example method of using a batching system in accordance with aspects of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     In contrast with conventional batching systems, in accordance with aspects of the present invention, the weight of the material in the batch (actually in the collector) is not measured to determine when the batch meets the predetermined amount. In accordance with aspects of the present invention, a known density of the material being batched is used. The volume of material being batched in measured in real time, before it is collected in the collector. With the known density and measured volume, an accurate mass (and therefore weight of material) being batched can be accurately determined in real time before it is collected in the collector. Accordingly, in accordance with aspects of the present invention, a batching system need not slow down its feeding process and will nevertheless consistently provide an accurate batching amount for each batch without overshooting a predetermined threshold. 
     In one example embodiment, the density of the material is a priori information. For example a supplier of the material being batched will provide the batching system operator with the known density of the material being batched. This density is then used with a real time measured volume of the material being batched, to determine in real time the mass, and therefore the weight, of the material being batched. 
     In another example embodiment, the density of the material being batched is first calculated based on a measured weight and a measured volume. This calculated density is then subsequently used with a real time measurement of volume to calculate a mass, and therefore weight, of the material being batched. 
     The present invention provides a process for batching material without a need for an entire system slowdown. This process greatly increases efficiency over that of a conventional batching system. 
     In one aspect of the present invention, density is input to a controller before the batching process begins. In this system a density is input by a user and is then used in conjunction with a volume detector to calculate an exact weight of material that is being batched. Mass is equal to volume multiplied by density, so with density and volume known it is very simple for the controller to calculate mass. Weight equals mass multiplied by gravity, and since both of these variables are known the controller can calculate a weight at any given time. Once the controller has determined that the weight in a collector has reached a predetermined amount, based on detected volume, it can instantly switch the deflector to another position and will begin filling a second collector. At this point the first collector may be emptied or sent to a packaging system, and a new collector may be placed in the system. Once the controller has determined that the second collector is full it will switch the deflector back to its first position and begin filling the new collector. This process may continue for as long as needed with no system slowdown, or as fast as collectors can be taken and replaced. 
     In another aspect of the present invention, scales are placed under the collectors at the beginning of the process. These scales provide a weight measurement which is used by the controller in conjunction with a volume measurement which is provided by a detector. Weight is equal to mass multiplied by gravity, so with weight measured a mass can be calculated. Density is equal to mass divided by volume, so with an initial values for volume and mass found the controller may easily calculate the density of the material being provided. This calculated density is then used in conjunction with the volume measurement provided by the detector to calculate an accurate weight in any given collector. Once the controller has determined that the weight in a collector has reached a predetermined amount it can instantly switch the deflector to another position and will begin filling a second collector. At this point the first collector may be emptied or sent to a packaging system, and a new collector may be placed in the system. Once controller has determined that the second collector is full it will switch the deflector back to its first position and begin filling the new collector. This process may continue for as long as needed with no system slowdown, or as fast as collectors can be taken and replaced. 
     Example systems in accordance with aspects of the present invention will now be described with reference to  FIGS. 2A-4 . 
       FIGS. 2A-C  illustrate an example material batching system  200  in accordance with aspects of the present invention, at times t 0 , t 1 , and t 2 , respectively. 
     As illustrated in  FIG. 2A , system  200  includes feeding portion  102 , a detector  202 , deflector  104 , collector  106  collector  106 , collector  108  and a controller  204 . 
     As shown in  FIG. 2A , detector  202  is arranged to detect a volume of material within stream of material  116 . Controller  204  is arranged to receive a detector signal  206  from detector  202 . Deflector  106  is arranged to receive deflector control signal  124  from controller  204 . 
     Detector  202  may be any system or device that is operable to detect the volume of material in stream of material  116 . Controller  204  may be any system or device that is operable to deflector  104 . 
     In operation, a large volume of oats (not shown) are dumped into a receiving receptacle (not shown), which feeds the dumped oats to feeding portion  102 . The oats are conveyed from one end of feeding portion  102  (closest to the receiving receptacle) to the other end of feeding portion  102 , where they continue as stream of material  116 . 
     Detector  202  is positioned immediately before deflector  104  and is operable to measure the volume of material falling in stream of material  116 . Deflector  104  will be feeding in one of two states, deflector  104  will deflect stream of material  116  into collector  106  as stream of material  118 . In its second state, deflector  104  will deflect stream of material  116  into collector  108  as stream of material  118 . Controller  114  will instruct deflector  104 , via deflector control signal  124 , to periodically switch between the first state and the second state. Accordingly, deflector  104  will periodically fill collector  106  or collector  108 . 
     Detector  202  sends volume signal  206  to controller  204 . In this example embodiment, controller  204  has a user interface (not shown) that can be used to input a density of the material being batched. For purposes of this discussion the provider of the oats will know that oats have a given density×per cubic centimeter and will enter this parameter into controller  204 . With density and the detected volume known, controller  204  can calculate weight. 
     Controller  204  outputs deflector control signal  124  based on the weight it calculates. In particular, controller  204  instructs deflector  104 , via deflector control signal  124 , to deflect stream of material  116  as stream of material  118  from collector  106  to collector  108  based on the calculated weight. Similarly, controller  204  instructs deflector  104 , via deflector control signal  124  to deflect stream of material  116  as stream of material  118  from collector  108  to collector  106  based on calculated weight. This will now be described, with additional reference to  FIGS. 2A-C . 
     For purposes of discussion, presume that the oats are to be shipped in 10 lb bags. In such a case, collector  106  and collector  108  are going to be large enough to accept a volume of oats equal to 10 lbs. At time t 0 , as shown in  FIG. 2A , deflector  104  is in a first wherein stream of material  116  is deflected as stream of material  118  into collector  106 . With density entered into controller  202  and volume provided by detector  202 , via volume signal  206 , controller  202  may calculate a weight. 
     As shown in  FIG. 2B , the amount of oats in collector  106  is approaching a volume of oats equal to 10 lbs. When the measured weight of the accumulated amount of oats in collector  106  has reached the predetermined threshold, in this example 10 lbs, controller  204  sends deflector control signal  124  to deflector  104 . Once deflector  104  has received deflector control signal  124 , it will change to its second state. At this time deflector  104  will deflect stream of material  116  as stream of material  118  into collector  108 . 
       FIG. 2C  illustrates system  200  at time t 2 , at this time collector  106  had reached its predetermined weight threshold and collector  108  is now being filled up with a new batch of oats. At this time, while collector  108  is being filled, collector  106  may be removed from system  200  to be emptied and then returned to its position in system  200  as shown in  FIGS. 2A-C . 
     In contrast with prior art system discussed above with reference to  FIGS. 1A-C , in accordance with aspects of the present invention, feed portion  102  does not need to slow down. Further, in accordance with aspects of the present invention, an accurate weight can always and quickly be loaded into collector  106  and collector  108 , because there is no longer any need to compensate for material left in stream  116  and stream  118 . 
       FIG. 3  illustrates another example material batching system  300  in accordance with aspects of the present invention at time t 0 . 
     As illustrated in the figure, system  300  includes feeding portion  102 , detector  202 , deflector  104 , collector  106 , collector  108 , scale  110 , scale  112 , and a controller  302 . 
     As shown in  FIG. 3 , detector  202  is arranged to detect a volume of material within stream of material  116 . Deflector  104  is arranged to receive stream of material  116  from feeding portion  102 . Collector  106  is arranged to receive stream of material  118  from deflector  104 . Collector  108  is additionally arranged to receive stream of material  118  from deflector  104 . Controller  302  is arranged to receive weight signal  120  from scale  110  and to receive weight signal  122  from scale  112 . In addition, controller  302  is arranged to receive volume signal  206  from detector  202 . Deflector  104  is arranged to receive deflector control signal  124  from controller  302 . 
     Controller  302  may be any system or device that is operable to deflector  104 . 
     In operation, a large volume of oats (not shown) are dumped into a receiving receptacle (not shown), which feeds the dumped oats to feeding portion  102 . The oats are conveyed from one end of feeding portion  102  (closest to the receiving receptacle) to the other end of feeding portion  102 , where they continue as stream of material  116 . 
     Detector  202  is positioned immediately before deflector  104  and is operable to measure the volume of material falling in stream of material  116 . Deflector  104  will be feeding in one of two states, deflector  104  will deflect stream of material  116  into collector  106  as stream of material  118 . In its second state, deflector  104  will deflect stream of material  116  into collector  108  as stream of material  118 . Controller  114  will instruct deflector  104 , via deflector control signal  124 , to periodically switch between the first state and the second state. Accordingly, deflector  104  will periodically fill collector  106  or collector  108 . 
     There is an initial measurement made by weight scale  110  or weight scale  112 , and sent to controller  302 , via weight signal  120  or weight signal  122 . Detector  202  is operable to send volume signal  206  to controller  302 . With volume and weight known controller  302  can calculate a density. After this initial calculation is performed the density calculated in conjunction with a volume measurement provided by detector  202  via volume signal  124 , an precise weight can be measured. 
     Controller  302  outputs deflector control signal  124  based on the weight it calculates. In particular, controller  302  instructs deflector  104 , via deflector control signal  124 , to deflect stream of material  116  as stream of material  118  from collector  106  to collector  108  based on the calculated weight. Similarly, controller  302  instructs deflector  104 , via deflector control signal  124  to deflect stream of material  116  as stream of material  118  from collector  108  to collector  106  based on calculated weight. This will now be described, with additional reference to  FIG. 3 . 
       FIG. 4  illustrates an example method of using a batching system in accordance with aspects of the present invention. 
     Method  400  starts (S 402 ), and a density is determined (S 404 ). For example, with reference to system  200  as shown in  FIG. 2A , a density is entered into controller  204 , the density as discussed above may be provided by the material provider. Alternatively for example, with respect to  FIG. 3  an initial density may be calculated by controller  302  after receiving weight signal  120  or weight signal  122  in conjunction with volume signal  124 . 
     Material is then provided to the system (S 406 ). For example, as discussed above with reference system  200  and  300  to  FIGS. 2A-C  and  FIG. 3 , respectively, a bulk source of material is delivered to feeding portion  102  by a delivery apparatus. For purposes of explanation, in this example, feeding portion  102  includes a hopper. The oats are conveyed from one end of feeding portion  102  (closest to the receiving receptacle) to the other end of feeding portion  102 , where they continue as stream of material  116 . 
     A volume is then detected (S 408 ). For example, volume is detected by detector  202 , Detector  202  measures the volume of material in stream  116  as the stream passes through it. Detector  202  then sends volume signal  206  to controller  204  as seen in  FIGS. 2A-C  and to controller  302  as seen in  FIG. 3 . 
     Weight is then calculated (S 410 ). For example, with reference to system  200  as shown in  FIG. 2A-C , a volume and a density are entered into controller  204 . Controller  204  is able to calculate weight and send deflector control signal  124  as needed. Mass is equal to density multiplied by volume. Mass is easily calculated with a known density and volume. Weight is equal to mass multiplied by gravity, with mass previously being calculated and gravity known a weight can be calculated. 
     It is then determined whether the weight requirement is met (S 412 ). For example, a determined threshold value for weight is entered into the controller. This threshold could be the weight of material to be packaged, weight limit of a collector, or the weight limit of the packaging system being used. For example, with reference to system  200  as shown in  FIG. 2A-C , controller  204  is able to determine weight after knowing volume and density. Controller  204  determines whether the measured weight is equal to the predetermined threshold value. 
     If it is determined that the weight requirement is not met, then the material is continued to be supplied to the current collector (S 406 ). 
     If it is determined that the weight requirement is met, then the deflector changes states (S 414 ). If the weight requirement is met, controller  204  will send deflector control signal  124  to switch the state of deflector  104 . This state change will begin the process of filling the other empty collector so the currently filled collector may be emptied or switched. 
     Method  400  then ends (S 416 ). 
     In contrast with conventional batching systems, in accordance with aspects of the present invention, the weight of the material in the batch (actually in the collector) is not measured to determine when the batch meets the predetermined amount. In accordance with aspects of the present invention, a known density of the material being batched is used. The volume of material being batched in measured in real time, before it is collected in the collector. As a result, the present invention avoids the problems associated with conventional batching systems, namely: slowing of feeding portion and overflow of a batch due to material left in stream as it falls from the feeding portion to the collector. 
     In one aspect of the present invention, the density variable is input to a controller before the batching process begins. A detector measures the volume of the stream and also sends this information to the controller. With density and volume known the controller can calculate an accurate weight. Once the controller calculates that a predetermined weight limit has been met it can switch a deflector from state one to state two filling up a different collector. 
     In another aspect of the present invention, the density variable is calculated by using an initial weight measurement from a scale, along with the measured volume. From this point on the controller can use the calculated density along with the volume measured to calculate an accurate weight. Once the controller calculates that a predetermined weight limit has been met it can switch a deflector from state one to state two filling up a different collector. 
     A benefit of this process is that at no time does the feeding portion have to slow down so an accurate weight can be measured. The process allows for an exact weight to be calculated and also allows for an instantaneous deflector state change. This eliminates the overflow that is accompanied by not knowing the amount of material still falling in stream of material  116  and stream of material  118 . 
     Another benefit of the present invention is, using a known density of the material being batched and by accurately measuring the volume of material being batched in real time, an accurate mass, and therefore weight of material being batched can be accurately calculated in real time. Accordingly, a batching system need not slow down its feeding process and will nevertheless consistently provide an accurate batching amount for each batch without overshooting a predetermined threshold. 
     The foregoing description of various preferred embodiments of the invention have been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations arc possible in light of the above teaching. The example embodiments, as described above, were chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto.