Abstract:
A system comprising a teat preparation cup coupled to a vacuum pump. A first pressure sensor measures the vacuum level of the vacuum pump. A second pressure sensor measures vacuum level inside the preparation cup. The system further comprises a controller comprising an interface, a memory, and a processor. 
     The processor determines if the vacuum pump has sufficient vacuum level and communicates instructions to induce a partial vacuum in the teat preparation cup. The processor determines if the teat preparation cup has a vacuum level greater than a vacuum threshold value and when this condition is achieved, communicates instructions to initiate a teat preparation cycle comprising allowing fluid flowing from a fluid source container through the teat preparation cup into a fluid disposal container.

Description:
TECHNICAL FIELD OF THE INVENTION 
       [0001]    This invention relates generally to dairy equipment and more specifically to a system and method for detecting preparation cup attachment. 
       BACKGROUND OF THE INVENTION 
       [0002]    Dairy farming is becoming an increasingly automated industry. In the industry, preparing teats before milking them is often desirable and required by government regulations. Present teat preparation systems are lacking in several respects. The present invention addresses some of the deficiencies in teat preparation systems. 
       SUMMARY OF THE INVENTION 
       [0003]    A system comprising a teat preparation cup coupled to a fluid source container and a fluid disposal container is disclosed. The teat preparation cup is further coupled to a vacuum pump, wherein the vacuum pump is operable to change air pressure inside the teat preparation cup. A first pressure sensor measures the pressure of the vacuum pump. A second pressure sensor measures pressure inside the preparation cup. The system further comprises a controller comprising an interface, a memory, and a processor. The interface is operable to communicate with the vacuum pump, the first pressure sensor, and second pressure sensor. The memory is operable to store a first vacuum threshold value and a second vacuum threshold value. The processor is operable to receive information indicating an attempt to attach the teat preparation cup onto a teat. The processor is further operable to receive information from the first pressure sensor to determine if the vacuum pump has a vacuum level that is greater than the first vacuum threshold value. If the vacuum pump vacuum level is greater than the first threshold value, the processor is operable to communicate instructions to increase vacuum in the teat preparation cup using the vacuum pump. The processor is further operable to receive information from the second pressure sensor to determine if the teat preparation cup has a vacuum level that is greater than the second vacuum threshold value. If the teat preparation cup vacuum level is greater than the second vacuum threshold value, the processor is operable to communicate instructions to initiate a teat preparation cycle comprising allowing fluid flow from the fluid source container through the teat preparation cup into the fluid disposal container. 
         [0004]    The present embodiment presents several technical advantages. For example, in the present embodiment, the teat preparation cycle is not initiated until the controller determines that the vacuum pump is ready to increase vacuum in the teat preparation cup. This avoids attempting to induce a vacuum in the preparation cup using insufficient vacuum level from the vacuum pump. Further, in the present embodiment, the controller ensures that the vacuum level inside the teat preparation cup is above a predetermined vacuum threshold indicating that the teat preparation cup is securely attached to a teat before initiating a teat preparation cycle. 
         [0005]    Certain embodiments of the present disclosure may include some, all, or none of these advantages. One or more other technical advantages may be readily apparent to those skilled in the art from the figures, descriptions, and claims included herein. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]    To provide a more complete understanding of the present disclosure and the features and advantages thereof, reference is made to the following description taken in conjunction with the accompanying drawings, in which: 
           [0007]      FIG. 1  illustrates a general overview of a dairy milking system; 
           [0008]      FIG. 2  illustrates a process for detecting preparation cup attachment; and 
           [0009]      FIG. 3  illustrates one embodiment of a preparation cup. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0010]    Embodiments of the present disclosure and its advantages are best understood by referring to  FIGS. 1 through 3  of the drawings, like numerals being used for like and corresponding parts of the various drawings. 
         [0011]    In the dairy industry, collecting milk from dairy livestock such as cows is an important part of dairy farming. The process of collecting milk typically involves preparing dairy livestock teats by treating the teats with preparatory fluid such as detergent and other chemicals prior to milking the teats to extract milk. This is generally done by first placing a teat inside a teat preparation cup and then running a teat preparation cycle for washing the teat with the preparatory fluid. During the teat preparation cycle, preparatory fluid flows through the preparation cup into a fluid disposal chamber. After this preparation process, the teat is milked using a separate milking cup. 
         [0012]    It is advantageous to use robotics to perform these repetitive teat preparation and milking steps. As one example, a robotic arm can be used to automatically attach the teat preparation cup to a teat and then initiate the teat preparation cycle. Attaching a teat preparation cup to a teat may involve inducing a vacuum inside the teat preparation cup after a teat is placed inside the cup so that the cup forms a suction that holds onto the teat. However, determining whether the preparation cup has securely attached onto a teat presents myriad challenges. For instance, after the location of a teat has been determined, a cow may move before the robot can position the preparation cup onto a teat. Similarly, the preparation cup may only partially attach onto a teat and may either fall off during the teat preparation cycle or expose only a part of the teat to the preparatory fluid. Further, the teat preparation cup may attach onto the dairy livestock&#39;s udder instead of onto a teat thereby causing the electronics to falsely register a secure teat attachment of the preparation cup. 
         [0013]    The embodiments of the present disclosure address several of these challenges. In one embodiment, a teat attachment detection system is disclosed that measures the pressure of a vacuum pump and the pressure inside a teat preparation cup to determine if the preparation cup has securely attached onto a teat. In the system, a controller receives an indication that a robotic arm or other similar apparatus has positioned the teat preparation cup onto a teat. Then, the controller determines if the vacuum pump is primed to induce sufficient vacuum to securely attach the preparation cup onto the teat. If so, the vacuum pump induces a vacuum in the teat preparation cup. If the teat preparation cup is aligned with the teat, the induced vacuum from the vacuum pump causes the preparation cup to become securely attached onto the teat. The controller then receives a value of the vacuum level inside the preparation cup. The controller uses this value to determine whether or not the preparation cup is securely attached to the teat. If the preparation cup is not securely attached to the teat, the controller transmits instructions to reattach the preparation cup to the teat. 
         [0014]    The present disclosure will be described in more detail using  FIGS. 1 through 3 .  FIG. 1  illustrates a general overview of a dairy milking system for preparing and milking a dairy livestock.  FIG. 2  illustrates a process for detecting secure attachment of a preparation cup to a teat.  FIG. 3  illustrates one embodiment of a preparation cup for use in the preparing of dairy livestock teats. Although the figures and following description relate to the attachment of a preparation cup to a teat, the disclosed system may be used in conjunction with a milking cup or any other related cup or container. 
         [0015]      FIG. 1  illustrates a system  10  for preparing a teat  12  for milking. In system  10 , robotic arm  14  positions preparation cup  16  onto a teat  12 . Once preparation cup  16  is securely attached onto teat  12 , preparatory fluid flows from a fluid container  18  into preparation cup  16 . The preparatory fluid disinfects and otherwise prepares teat  12  inside preparation cup  16  and then flows out of preparation cup  16  and into a collection vessel  20 . Controller  22  receives pressure readings from a first sensor  24  to determine if vacuum pump  26  is charged and operable to induce sufficient vacuum to securely attach preparation cup  16  onto teat  12 . Controller  22  also receives pressure readings from a second sensor  28  to confirm that preparation cup  16  is securely attached onto teat  12 . 
         [0016]    Teat  12  may be one or more teats of any suitable dairy livestock. For example, teat  12  may belong to a cow, buffalo, goat, or any other suitable livestock. In various embodiments, the dairy livestock may have a plurality of teats  12 . Generally, dairy livestock such as cows have four teats  12 . Teats  12  typically extend from an udder  30 . 
         [0017]    In system  10 , robotic arm  14  may be any robotic device operable to extend beneath a dairy livestock and position preparation cup  16  onto a teat  12 . In one embodiment, robotic arm  14  may be operable to communicate with controller  22  and receive information and instructions for moving in various directions. As an example, controller  22  may instruct robotic arm  14  to position preparation cup  16  onto a teat  12 . Robotic arm  14  may also send controller  22  information indicating that robotic arm  14  executed instructions provided by controller  22 , that robotic arm  14  encountered an error, that robotic arm  14  is not powered on or any other similar suitable instructions. 
         [0018]    Preparation cup  16  may be any suitable container or conduit through which fluid may flow and can be positioned onto a teat  12 . In one embodiment, preparation cup  16  is made of a flexible material which may compress or expand in response to changes in internal and external air pressure. Preparation cup  16  may have multiple openings. A first opening of preparation cup  16  may be large enough for teat  14  to be inserted into preparation cup  16 . A second opening of preparation cup  16  may serve as an ingress for preparatory fluid such as detergents and treatment chemicals to flow into preparation cup  16 . A third opening of preparation cup  16  may serve an egress through which the treatment fluid exits the preparation cup  16 . A fourth opening of preparation cup  16  may server a conduit between vacuum pump  26  and preparation cup  16  through which vacuum pump  26  may regulate the air pressure in and around preparation cup  16 . One embodiment of such a preparation cup is described below in relation to  FIG. 3 . 
         [0019]    Vacuum pump  26  may be any suitable electromechanical or mechanical device including a positive displacement pump, a momentum transfer pump, a regenerative pump, an entrapment pump or any other suitable pump that is operable to remove air and other gasses from an environment to generate a partial vacuum. In some embodiments, vacuum pump  26  may be operable to generate a vacuum level, relative to ambient atmospheric pressure, of more than twelve inches Hg. In certain embodiments, there is a vacuum bleed-off if vacuum pump  26  remains unused for a period of time. In such embodiments, vacuum pump  26  requires time to recharge after a delay in use. In one embodiment, vacuum pump  26  may require 15-20 seconds to charge before it may regenerate a vacuum level of twelve inches Hg. or more. 
         [0020]    Vacuum pump  26  may be coupled to a first sensor  24 . First sensor  24  is any type of pressure sensor including an absolute pressure sensor, gauge pressure sensor, differential pressure sensor, sealed pressure sensor or any other suitable device operable to measure the vacuum level buildup of vacuum pump  26 . First sensor  24  generates an electrical signal in response to the pressure exerted upon it. In one embodiment, first sensor  24  may be positioned inside or near vacuum pump  26  to measure the vacuum level buildup of vacuum pump  26 . 
         [0021]    Fluid container  18  and collection vessel  20  may be any containers that are operable to hold preparatory fluid. Fluid container  18  may hold preparatory fluid before the fluid is used to prepare a teat  12  for milking. Fluid container  18  may be made of any suitable material and may hold any suitable preparatory fluids including water, detergent, and treatment fluids. Similarly, collection vessel  20  may be made of any suitable material operable to contain preparatory fluid after the fluid has been used to treat and/or prepare teat  12 , In the illustrated embodiment, collection vessel  20  is connected to vacuum pump  26  via airway  48  having one or more shutoff valves  50 . Collection vessel  20  is further connected to preparation cup  16  by airway  52 . In other embodiments, vacuum pump  26  may be directly connected to preparation cup  16  via one or more airways. 
         [0022]    Second sensor  28  may be any type of pressure sensor including a device that is similar to or different than first sensor  24 . Second sensor  28  may be operable to measure the vacuum level inside preparation cup  16 . Second sensor  28  may be positioned at any suitable location within system  10 . In one embodiment, the vacuum level inside collection vessel  20  may be similar to the vacuum level inside preparation cup  16 . In such an embodiment, second sensor  28  may be positioned inside collection vessel  20  to measure the vacuum level inside preparation cup  16 . In other embodiments, second sensor  28  may be positioned at any other suitable location in system  10 . 
         [0023]    Both first sensor  24  and second sensor  28  may communicably coupled to controller  22 . In one embodiment, first sensor  24  and second sensor  28  may communicate with controller  22  via network  32 . 
         [0024]    Network  32  may include any interconnecting system capable of transmitting audio, video, signals, data, messages, or any combination of the preceding. Network  32  may include all or a portion of a public switched telephone network (PSTN), a public or private data network, a local area network (LAN), a metropolitan area network (MAN), a wide area network (WAN), a local, regional, or global communication or computer network, such as the Internet, a wireline or wireless network, an enterprise intranet, or any other suitable communication link, including combinations thereof, operable to facilitate communication between the components of system  10 . 
         [0025]    Controller  22  may comprise an interface  34 , a processor  36 , and a memory  38 . The components of controller  22  may interact with each other to receive information from sensors  24  and  28  and robotic arm  14 , process that information, and determine whether a preparation cup  16  is securely attached to a teat  12 . 
         [0026]    Interface  34  represents any port or connection, real or virtual, including any suitable hardware and/or software, including protocol conversion and data processing capabilities, to communicate through a LAN, WAN, or other communication system that allows controller  22  to exchange information with sensors  24  and  28 , robotic arm  14 , or any other components of system  10 . Interface  34  receives information from and transmits information to the various components of system  10 . Interface  34  may communicate with processor  36  and memory  38 . 
         [0027]    Processor  36  may be any electronic circuitry, including, but not limited to microprocessors, application specific integrated circuits (ASIC), application specific instruction set processor (ASIP), and/or state machines, that communicatively couples interface  34  and memory  38  and controls the operation of controller  22 . In some embodiments, processor  36  may be single core or multi-core having a single chip containing two or more processing devices. Processor  36  may be 8-bit, 16-bit, 32-bit, 64-bit or of any other suitable architecture. Processor  36  may comprise an arithmetic logic unit (ALU) for performing arithmetic and logic operations, processor registers that supply operands to the ALU and store the results of ALU operations, and a control unit that fetches instructions from memory and executes them by directing the coordinated operations of the ALU, registers and other components. Processor  36  may include other hardware and software that operates to control and process information. Processor  36  may execute computer-executable program instructions stored in memory  38 . Processor  36  is not limited to a single processing device and may encompass multiple processing devices. 
         [0028]    Memory  38  may include any one or a combination of volatile or non-volatile local or remote devices suitable for storing information. For example, memory  38  may include RAM, ROM, flash memory, magnetic storage devices, optical storage devices, network storage devices, cloud storage devices, solid state devices, or any other suitable information storage device or a combination of these devices. Memory  38  stores, either permanently or temporarily, data, operational software, other information for processor  36 , other components of controller  22 , or other components of system  10 . For example, memory  38  may store user preferences or default settings for operating controller  22 . Memory  38  may store information in one or more databases, file systems, tree structures, relational databases, any other suitable storage system, or any combination thereof. Furthermore, different information stored in memory  38  may use any of these storage systems. The information stored in memory  38  may be encrypted or unencrypted, compressed or uncompressed, and static or editable. Memory  38  may store information in one or more caches. 
         [0029]    Memory  38  may store a vacuum pump vacuum threshold  40  and a preparation cup vacuum threshold  42 . Vacuum pump vacuum threshold  40  may be a minimum acceptable vacuum level inside vacuum pump  26  before vacuum pump  26  may be used to generate a partial vacuum within preparation cup  16 . In one embodiment, vacuum pump vacuum threshold  40  may be twelve inches Hg. In such an embodiment, vacuum pump  26  may not be operable to generate an acceptable vacuum level in and around preparation cup  16  until vacuum pump  26  is operable to internally generate a vacuum level of at least twelve inches Hg of vacuum with respect to ambient atmospheric pressure. 
         [0030]    Preparation cup vacuum threshold  42  may be a minimum vacuum level value for indicating a secure attachment of preparation cup  16  to teat  12 . In one embodiment, a preparation cup vacuum threshold value of twelve inches Hg. or above may indicate a secure attachment. Memory  38  may also store a squawking threshold value  44  indicating if an incomplete attachment has occurred between preparation cup  16  and teat  12 . In one embodiment, the squawking threshold value  44  may be eight point three (8.3) inches Hg. and values between the squawking threshold value  44  and preparation cup vacuum threshold value  42  may indicate an incomplete attachment. Further, a vacuum level value of below the squawking threshold value  44  may indicate that preparation cup  16  failed to attach to teat  12 . Additionally, memory  38  may also store a number of attempts threshold  46 . Number of attempts threshold  46  is the number of times system  10  may attempt to securely attach preparation cup  16  onto teat  12  before system  10  aborts the attachment process. In one embodiment, the number of attempts threshold  46  may be three attempts and if the number of actual attempts reaches three attempts, system  10  may abort the attachment process. 
         [0031]    In operation, controller  22  receives information via network  32  that robotic arm  14  has positioned preparation cup  16  onto a teat  12 . First sensor  24  then measures the induced vacuum buildup within vacuum pump  26  and transmits that information to controller  22 . If the induced vacuum buildup within vacuum pump  26  is greater than the vacuum pump vacuum threshold  40 , controller  22  transmits instructions to open shutoff valve  50  in airway  48  between vacuum pump  26  and collection vessel  20 . Because collection vessel  20  is connected to preparation cup  16  by one or more airways, opening shutoff valve  50  causes vacuum pump  26  to induce a partial vacuum inside preparation cup  16 . Second sensor  28  then measures the vacuum level inside preparation cup  16  and transmits that information to controller  22 . If the vacuum level inside preparation cup  16  is above preparation cup vacuum threshold  42  indicating that preparation cup  16  is securely attached onto teat  12 , controller  22  initiates the preparation cycle causing preparatory fluid to flow from preparatory fluid container  18 , through preparation cup  16 , into collection vessel  20 . 
         [0032]      FIG. 2  illustrates a process  100  for detecting secure attachment of preparation cup  16  to a teat  12 . In process  100 , at step  102 , controller  22  receives information that robotic arm  14  has attempted to position preparation cup  16  onto a teat  12  and controller  22  increments the number of attempts to attach preparation cup  16  onto teat  12  by one. At step  104 , controller  22  receives a pressure value of the vacuum level inside vacuum pump  26  from first sensor  24 . Controller  22  compares the received vacuum level value against vacuum pump vacuum threshold  40  to determine if the measured vacuum level from first sensor  24  is equal to or greater than vacuum pump vacuum threshold  40 . If the measured vacuum level value is lower than vacuum pump vacuum threshold  40 , then at step  106 , controller  22  waits for a predetermined period of time, for example five seconds, for vacuum pump  26  to charge. 
         [0033]    Once the received vacuum level value equals or exceeds vacuum pump vacuum threshold  40 , at step  108 , controller  22  transmits instructions to open shutoff valve  50  between vacuum pump  26  and collection vessel  20  to allow vacuum pump  26  to induce a partial vacuum inside preparation cup  16  via collection vessel  20 . Next, at step  110 , second sensor  28  measures the vacuum level inside collection vessel  20 . Because the vacuum level inside collection vessel  20  is similar to the vacuum level inside preparation cup  16 , second sensor  28  determines the vacuum level inside preparation cup  16  by measuring the vacuum level inside collection vessel  20 . In one embodiment, second sensor  28  collects a series of vacuum level data points. For example, second sensor  28  may collect ten to fifty pressure values of the vacuum level inside preparation cup  16 . Next, as step  112 , controller  22  may determine statistics such as mean, median, mode, max, min, and standard deviation of the measured vacuum level values. Controller  22  then compares one or more of the determined and/or measured vacuum level values against the preparation cup vacuum threshold  42 . Next, at step  114 , controller  22  determines if the determined and/or measured vacuum value is at or above the preparation cup vacuum threshold  42 . If the measured and/or determined vacuum value is at or above the preparation cup vacuum threshold  42 , then, at step  116 , controller  22  transmits instructions to initiate the prep cycle causing preparatory fluid to flow from preparatory fluid container  18  through preparation cup  16  into collection vessel  20 . 
         [0034]    If the measured and/or determined vacuum value is below preparation cup vacuum threshold  42 , controller  22  compares the actual number of attempts to attach preparation cup  16  onto teat  12  against the number of attempts threshold  46  at step  118 . In one embodiment, if the measured and/or determined vacuum value is below preparation cup vacuum threshold  42  but above squawking threshold  44 , controller  22  may also inform the user that there has been an incomplete attachment. If the actual number of attempts has reached or exceeded the number of attempts threshold  46 , then at step  120 , controller  22  instructs robotic arm  14  to end process  100 . Controller  22  may end process  100  in any suitable manner including by communicating instructions to move robotic arm  14  to a retracted position where robotic arm  14  moves down and away from the dairy livestock. If the actual number of attempts is below number of attempts threshold  46 , controller  22  instructs robotic arm  14  to reattach preparation cup  16  onto teat  12  at step  122  and reinitiates process  100  at step  102 . In this manner, system  10  initiates the prep cycle if preparation cup  16  is securely attached to a teat  12 . Otherwise, system  10  attempts to reattach preparation cup  16  to teat  12 . 
         [0035]      FIG. 3  illustrates one embodiment of preparation cup  16 . In this embodiment, preparation cup  16  has a first inlet  150 , a second inlet  152 , a third inlet  154 , and an egress  156 . Preparation cup  16  also has a liner  158  with openings  160  formed therein. During a prep cycle, before any preparatory fluids are dispensed, a teat  12  is positioned inside first inlet  150  and vacuum pump  26  creates a partial vacuum inside preparation cup  16  via egress  156 . If sensor  28  registers a vacuum level greater than or equal to preparation cup vacuum threshold  42 , preparatory fluid flows into the liner  158  of preparation cup  16  through third inlet  154  and flows out of egress  156 . 
         [0036]    In such an embodiment, if preparation cup  16  attaches onto an udder or other surface instead of a teat  12  during process  100 , air and other fluids flow into preparation cup  16  through openings  160  in liner  158 . This airflow into preparation cup  16  prevents adequate vacuum from being induced inside liner  158  and preparation cup  16 . Because, in case of such a faulty attachment, there is inadequate vacuum induced inside liner  158  and preparation cup  16 , second sensor  28  measures a low vacuum value and controller  22  issues an instruction to retry attachment at step  122 . 
         [0037]    Although several embodiments have been illustrated and described in detail, it will be recognized that substitutions and alterations are possible without departing from the spirit and scope of the present disclosure, as defined by the appended claims. To aid the Patent Office, and any readers of any patent issued on this application in interpreting the claims appended hereto, applicants do not invoke 35 U.S.C. §112(f) as it exists on the date of filing hereof unless the words “means for” or “step for” are explicitly used in the particular claim.