Integrated magnetic particle separating valve and method

A magnetic particle separating valve that includes a valve body adapted for allowing particulate matter to flow vertically through the valve from an upstream to a downstream side. A discharge flow control apparatus is positioned in the valve body and includes a plurality of blades positioned in the valve body and movable between a fully open to a fully closed position to control the rate of discharge of material from the valve. Each of the plurality of blades includes a magnet positioned on the respective blade in a flow proximity position to attract and remove magnetically attractable particles from the particulate matter flowing past the blades.

TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

This application relates to an integrated magnetic particle separating valve, a method of separating magnetic particles from a moving stream of bulk materials, and more specifically to the manner in which products stored in bulk are discharged. Bulk materials of the type relevant to this application include many types of granular and powder materials that are stored in hoppers, silos, bins, and bulk bags before being conveyed to another location to use in a process. Prior to use the bulk material may have been processed using equipment with metal components that can potentially contaminate the bulk material with metal particles. These undesirable magnetic contaminants must be removed from the bulk material to improve the quality and safety of the material. This is particularly important where the bulk material is used in food processing.

There are several devices, generally referred to as “valves”, that are available and that utilize moving blades to “control” or constrict the discharge of a bulk material through an opening and close the opening for the purpose of preventing material flow, or partially close the opening to reduce the material flow rate. However, there are inefficiencies and disadvantages inherent in these currently available devices that limit the removal of metal particles without the use of a secondary device.

There is a need for a valve that efficiently controls the flow of material from a bulk storage apparatus that includes multiple options that can improve process efficiency and reduce the space required to separate magnetic contamination from the material. There is also a need to provide a valve that efficiently controls the flow of material from a bulk storage apparatus quickly while providing enhanced cleaning capability and material screening functions with feed accuracy and material safety.

BRIEF SUMMARY

It is therefore an object of the invention to provide a controlled material feed from a vessel by using actuated rotating blades that are provided with position control.

It is another object of the invention to provide controlled material feed from a vessel wherein the blades are positioned on one or more planes, and provide multiple positions of opening restriction required to achieve a desired flow rate from the vessel.

It is another object of the invention to permit the positon of the blades to be derived from a ‘loss in weight’ signal generated in real time as the bag contents are being discharged.

It is another object of the invention to provide a method for removing magnetic particles from a moving material stream in accordance with the disclosure of this application.

These and other objects and advantages of the invention are achieved by providing the embodiments described below.

According to embodiments of the invention, a magnetic particle separating valve includes a valve body adapted for allowing particulate matter to flow vertically through the valve from an upstream side to a downstream side; a discharge flow control apparatus positioned in the valve body, the discharge flow control apparatus comprising a plurality of blades positioned in the valve body; where the discharge flow control apparatus is adapted for moving among a plurality of positions and selectively stopping at each of the plurality of positions in order to control a rate of discharge of the particulate matter from the upstream side, thereby resulting in a stopping position when the discharge flow control apparatus selectively stops. The magnetic particle separating valve also includes at least one magnet adapted for positioning proximate one of the plurality of blades in a flow proximity position; where the magnet is configured to attract and remove magnetically attractable particles from the particulate matter flowing past the blades.

In some embodiments, the plurality of positions comprises a fully open position wherein the plurality of blades collectively define a plurality of substantially vertical planes, a fully closed position, wherein the plurality of blades are substantially ninety degrees offset from the vertical planes, thereby forming a substantially horizontal plane, and a plurality of intermediate positions between the fully open position and the fully closed position.

In some embodiments, the plurality of blades are positioned on one or more planes.

In some embodiments, the magnet has an elongate shape and is substantially disposed within the blade.

In some embodiments, the magnet comprises a tube bar magnet.

In some embodiments, the magnet is substantially disposed within the blade and the blade is substantially non-magnetic.

In some embodiments, the magnetic particle separating valve also includes a magnet drawer assembly comprising a plurality of magnets each adapted for positioning proximate one of the plurality of blades in a flow proximity position, wherein the magnet drawer assembly is adapted for: (i) insertion into the magnet particle separating valve in order to enable attraction and removal of magnetically attractable particles from the particulate matter flowing past the blades; and (ii) removal from the magnet particle separating valve.

In some embodiments, the magnetic particle separating valve also includes at least one sensor adapted for sensing a loss of weight characteristic associated with an upstream vessel as the particulate matter flows through the discharge flow control apparatus and generating in real time a loss-in-weight signal based thereon; and a control device electrically coupled with the at least one sensor and adapted for (i) receiving the loss-in-weight signal, and (ii) sending one or more control signals to the discharge flow control apparatus to cause the plurality of blades to move from one position to another position of the plurality of positions in order to control the rate of discharge of the particulate matter. In some such embodiments, the magnetic particle separating valve also includes an actuator electrically coupled with the control device and operatively coupled with the discharge flow control apparatus and configured to receive the one or more control signals from the control device; and cause at least one of the plurality of blades to move from one position to another position of the plurality of positions in order to control the rate of discharge of the particulate matter.

In some embodiments, the magnetic particle separating valve also includes a sensor for detecting an amount of magnetically attractable particles that have been attracted to one or more of the blades and generating in real time a magnetic particle signal; and a control device for receiving the magnetic particle signal from the sensor and causing a responding action. In some such embodiments, the control device is further configured to send one or more control signals to the discharge flow control apparatus to cause the plurality of blades to move from one position to another position of the plurality of positions in order to control the rate of discharge of the particulate matter. In some of these embodiments, the magnetic particle separating valve also includes an actuator electrically coupled with the control device and operatively coupled with the discharge flow control apparatus and configured to receive the one or more control signals from the control device; and cause the plurality of blades to move from one position to another position of the plurality of positions in order to control the rate of discharge of the particulate matter.

In other such embodiments, the magnetic particle separating valve also includes a magnet drawer assembly comprising a plurality of magnets each adapted for positioning proximate one of the plurality of blades in a flow proximity position, wherein the magnet drawer assembly is adapted for (i) insertion into the magnet particle separating valve in order to enable attraction and removal of magnetically attractable particles from the particulate matter flowing past the blades, thereby resulting in an inserted position; and (ii) removal from the magnet particle separating valve, thereby resulting in a removed position, where the control device is further configured to send one or more control signals to the discharge flow control apparatus to cause the magnet drawer assembly to move (i) from the inserted position to the removed position or (ii) from the removed position to the inserted position. In some such embodiments, the magnetic particle separating valve also includes an actuator electrically coupled with the control device and operatively coupled with the discharge flow control apparatus and configured to receive the one or more control signals from the control device; and cause the magnet drawer assembly to move (i) from the inserted position to the removed position or (ii) from the removed position to the inserted position.

According to embodiments of the invention, a method for removing magnetically attractable particles from a flow of particulate matter using a magnetic particle separating valve having a valve body and a discharge flow control apparatus positioned in the body for allowing particulate matter to flow vertically through the valve from an upstream side to a downstream side includes attracting magnetically attractable particles from the particulate matter flowing through the valve, thereby removing the particles from the flowing matter; and removing the magnetically attractable particles from the valve.

In some embodiments, the method includes inserting a magnet drawer assembly comprising a plurality of magnets into the discharge flow control apparatus in order to configure the magnetic separating valve to attract the magnetically attractable particles; and removing the magnet drawer assembly from the discharge flow control apparatus.

In some embodiments, the method includes providing the magnetic particle separating valve having a valve body and a discharge flow control apparatus positioned in the body for allowing particulate matter to flow vertically through the valve from an upstream side to a downstream side.

In some embodiments, the method includes controlling a rate of discharge of the particulate matter by moving the discharge flow control apparatus among a plurality of positions. In some such embodiments, controlling includes sensing a loss of weight characteristic associated with an upstream vessel as the particulate matter flows through the discharge flow control apparatus; generating, in real time and based on the sensed loss of weight characteristic, a loss-in-weight signal representing; and moving the discharge flow control apparatus among the plurality of positions to vary a flow rate of the particulate matter from the upstream side to the downstream side.

According to embodiments of the invention, a system for removing magnetically attractable particles from a particulate matter flow includes a magnetic particle separating valve, comprising a valve body adapted for allowing particulate matter to flow vertically through the valve from an upstream side to a downstream side; and a discharge flow control apparatus positioned in the valve body, the discharge flow control apparatus comprising a plurality of blades positioned in the valve body; and at least one magnet adapted for positioning proximate one of the plurality of blades in a flow proximity position, the magnet configured to attract and remove magnetically attractable particles from the particulate matter flowing past the blades; a particulate matter vessel adapted for housing particulate matter on the upstream side of the valve, the vessel having an aperture at its distal end proximate the valve such that particulate matter flows vertically from the vessel through the valve to the downstream side of the valve; and at least one agitator operatively coupled with the magnetic particle separating valve and adapted for agitating the particulate matter to induce flow through the valve.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout. Referring now to the drawings and the listing of machine components set out below, the invention according to a preferred embodiment is described in further detail.

Referring toFIGS. 1-3, embodiments of the invention provide for a discharge flow control apparatus10for adjustably controlling the size of the blade openings12to control the rate of discharge of material14from a vessel16. The discharge flow control apparatus10includes multiple aligned axially mounted pivoting blades20that can be set at variable angles and collectively define a flat plane when fully closed, or multiple vertical planes when fully open. The fully open position is ninety degrees (90°) offset from the horizontal fully closed plane (0°). Each of the blades20is controlled by one actuator22that is adapted to move a shaft24that rotates from zero degrees (0°) to ninety degrees (90°). The movement of the shaft24rotates a lever26mounted to the actuator shaft24that has a tie rod28attached at either end, and the tie rods28move relative to the movement of the shafts24. This creates vertical movement of the first and second tie rod28where the upper end (30) of the tie rod28causes movement in a mechanism32(which is a parallelogram in some embodiments) that is attached to the blades20. Movement of the mechanism32creates rotation of the blades20about their respective axes34. A plurality of sensors36, such as load cells, monitor weight reduction in the vessel16feeding the valve38in real time as the material14, such as particulate material or contents, flows from the vessel16through the valve blades20and provide output signals (not shown) indicating a weight reduction. A control device700(seeFIG. 7) receives the output signals from the sensors36and sends feedback control signals (not shown) to the valve blade actuator22that moves the mechanism32to control the size of the blade opening12and control the rate of discharge.

In accordance with another embodiment of the invention, the actuator22includes positon control feedback sensors40that provide additional input changes to the control device700and confirm the position of the valve blades20.

More specifically, the integrated magnetic particle separating valve38shown in the drawings is a gravity fed device, typically located on the discharge assembly of a bulk material storage vessel16. The valve38is connected to the vessel16via a flanged top surface and secured by bolting the flange44of the valve38to the flange52of the vessel16. The purpose of the valve38is to control the flow (as represented by arrows46inFIG. 3) of material14from the storage vessel16and to separate magnetic particulate contaminants (not shown) from the bulk material14as it flows through the valve38. Flow is achieved by closing an orifice to prevent flow and then varying the opening of the orifice from partially open to fully open to achieve the desired flow rate through the orifice. The valve38will be sized to suit the appropriate bulk material flowrate required.

The valve38includes a two-part body that can be considered as an upper body48and a lower body50. The upper body48has a top surface44(or flange) that connects to a vessel16and supports the valve38. The lower body50is suspended from the upper body48by four tie rods54with tie rod end bearings56that allow the lower body50to swing like a pendulum below the upper body48. The upper body48is typically fixed, whereas the lower body50is free to swing as discussed. The upper body48and lower body50are connected by a sleeve58, which may be made of a flexible material and formed to have a flanged face on the upper and lower surfaces to connect the upper and lower bodies48and50and still allow movement of the lower body50relative to the upper body48, that is fixed to the vessel16. The lower body50has several blades20located within the orifice. Each of the blades20is mounted and constrained to pivot on its respective axis34and each is interconnected by a lever mechanism that rotates the blades20in unison and relative to the orifice and valve body. The blades20can be constructed from a material that it suitable as a bearing at the pivot points. The construction of each blade20includes an internal bore60that is adapted to mount a bar magnet62. The magnet62propagates a magnetic field (not shown) within the valve38opening that attracts passing magnetic particles (not shown) onto the surface64of the blade20and prevents the particles from passing through with the bulk material14.

The magnets62are mounted to a frame66that allows them to be withdrawn from the valve38to permit the outer surface64of the blades20to be cleaned. The design of the blades20permits the blade20and magnet assembly68to be withdrawn together for cleaning outside of the bulk material14flow path. Another feature of the design is to include a screen70mounted above the blades20to further remove contaminants.

The valve38includes two counter-rotating vibrators72that produce a linear force in the direction of the pivot assembly that causes the lower body50to move relative to the upper body48and the constraints of the tie bar54pivots56. The purpose of the vibration is to promote material flow through the restricted valve blade20openings12. The blade angle is variable and can be adjusted to prevent material flow when the blades20are partially open. Material flow depends on the material properties, such as angle of repose, particle size, density and also the environment where the valve38is located. The vibration causes movement of the material particles and allows the blade angle to be adjusted to reduce material flow.

A variable valve position controller or control device720(seeFIG. 7) can be included that is responsive to a sensor782such as a strain gauge that produces a signal that material14is flowing and adjusts the opening12to meet the desired flow rate. The valve38blades20are actuated by a chain or linkage74driven by a powered actuator22that produces a rotational movement to open and close the blades20. A chute76, into which the material flows by gravity through the valve38, is located on the lower valve section. This chute76is connected to the valve38by a flanged connection78on the chute upper surface80and the valve body lower section bottom surface82.

Referring toFIG. 3, consolidated particulate material17is shown within the vessel16. An optional flow promoter19may be used to induce flow of difficult materials. The flow promoter19is attached to the lower section50of the valve38. When the vibrators72cause vibrations (as represented by vibration lines73), the flow promoter19vibrates within the material, thereby activating particulate matter within the vessel16, as illustrated by the activated particulate matter18inFIG. 3and promoting flow of the material through the valve38. Anti-vibration links77may be used in or near the chute76in order to reduce transfer of vibration from the lower section50to the chute76.

The multiple blade construction and bar magnet locations within the blades20are perpendicular to the defined bulk material flow column and provide increased surface area contact with the material flow. This increases the potential for magnetic particles to be attracted to the outer surface64of the blades20. This advantage of creating a defined column of bulk material and the additional control of material flow through the valve38with the possibility of multiple sets of blades20on different planes will result in increased contaminant separation form the bulk material.

Referring now toFIGS. 4A-5I, an embodiment of an integrated magnetic particle separating valve39is shown. In several of the figures, the valve39includes both a lower section86and an upper section84. The valve39is similar to valve38, but is shown in these figures removed from elements of an entire discharge flow control apparatus10(seeFIG. 1) for ease of understanding. In some figures, the valve39as shown with both upper and lower sections, and in others the upper section is absent from the figures for clarity. The valve39is configured for installation in a discharge flow control apparatus10, such as the apparatus shown inFIG. 1. For example, the lower section86may be attached to vibrators (which can be electric and/or pneumatic). The lower section86may connect to the next process by way of a sleeve such as a flexible connector. The next process may be a transition chute76discussed above. A flexible coupling may link the upper and lower sections and isolate vibration. The upper section84attaches to a hopper/silo flange.

A linkage74or manual lever is connected to a lever mechanism with a rotating fulcrum attached to the blades20. The linkage74may be moved in order to open, partially open and fully close the blades20. As discussed above, each of the blades20has a flat top surface64. The blades have internal bores60for receiving the magnets62. When the linkage74is moved, the blades rotate in unison about their respective axes from fully closed to full open positions. Blade actuation may be performed by pneumatic and/or electric actuation and can have variable blade stopping positions from zero degrees (0°) to ninety degrees (90°) as discussed above with regard to valve38.

In accordance with another embodiment of the invention as illustrated inFIG. 6, a method600is provided for removing magnetic particles from a moving material stream in accordance with the disclosure of this application. The first step, as represented by block610, is the optional step of providing a magnetic particle separating valve. The valve has a valve body and a discharge flow control apparatus positioned in the body for allowing particulate matter to flow vertically through the valve from an upstream side to a downstream side of the valve. The valve provided in step610may be the same or similar to valves38and/or39discussed above.

The next step, as represented by block620, is the optional step of controlling a rate of discharge of the particulate matter by moving the discharge flow control apparatus among a plurality of positions. This step may be performed by the electronic feedback systems discussed above and with reference toFIG. 7below.

The next step, as represented by block630, is to attract magnetically attractable particles from the particulate matter flowing through the valve, thereby removing the particles from the flowing matter. This step is performed, at least in part, by a valve such as valve38and/or39discussed above, and more specifically is performed by magnets62installed/inserted within blades20of the valves38and/or39.

The final step shown in the flowchart, as represented by block640, is to remove the magnetically attractable particles from the valve. This may be done manually or automatically. When flow of the particulate material is stopped, a user may remove the magnetically attractable particles from the valve, for example, by removing the magnets from the blades, such as by removing a magnet assembly from the valve. The blades are, in some embodiments, made of non-magnetic material, and therefore, the magnetically attractable particles will be free for removal from the blades when the magnets are removed from the blades. The blades may be rotated such that their surfaces are non-horizontal and the magnetically attractable particles may fall into a receptacle.

Alternatively, the removal process may be performed automatically. For example, sensors may be disposed on or near the surfaces of the blades to detect when a threshold amount of magnetically attractable particles have been collected on the surfaces of the blades. A control device, such as control device720inFIG. 7, may receive signals from the sensors and, once the threshold amount of magnetically attractable particles has been reached, generates and transmits control signals to cease flow of the particulate matter from the vessel. In some cases, a magnetically attractable particle receptacle is moved into the chute by an actuator, in response to control signals from the control device, for receiving the magnetically attractable particles. Then, the magnet assembly is removed from the valve by an actuator receiving control signals from the control device. The magnetic particles are collected in the receptacle and the process described above is reversed when all or most of the magnetic particles have been removed from the blades and collected in the receptacle. Once the process is reversed, that is, the receptacle is removed so that normal operation of the chute may resume, and the magnet assembly is re-installed into the valve, normal material flow is resumed.

Referring now toFIG. 7, an environment in which a system for controlling the discharge flow control apparatus10is shown.

A user computer system750is operatively coupled, via a network772to the control device700and control device720. In this way, the user770may utilize the user computer systems750to administer operation of one or more magnetic particle separating valves.FIG. 4illustrates only one example of embodiments of a such an environment, and it will be appreciated that in other embodiments one or more of the systems (e.g., computers, control devices, sensors, actuators, valves, or other like components or systems) may be combined into a single system or be made up of multiple systems.

The network772may be a global area network (GAN), such as the Internet, a wide area network (WAN), a local area network (LAN), or any other type of network or combination of networks. The network772may provide for wireline, wireless, or a combination of wireline and wireless communication between devices on the network. The network may also be or represent hardline connections between and/or among certain components within the system. For example, in one embodiment, control device700is hardwired to specific sensor(s), such as load cells36used in the vessel to determine weight of matter. Control device720may be hardwired to specific sensor(s) such as strain gauges782as discussed above. In some embodiments, one of control device700or720also receives signals from other sensors784such as sensors to determine an amount of magnetically attractable particles that have accumulated on one or more blades of a valve as described herein. In some embodiments, a single control device may receive signals from all sensors associated with a valve system and may control most or all automatic operation of the valve and system. In other embodiments, multiple control devices control differing aspects of the flow system, as shown inFIG. 7.

As illustrated inFIG. 7, the user computer systems750may include a communication device762, a processing device764, and a memory device766. As used herein, the term “processing device” generally includes circuitry used for implementing the communication and/or logic functions of a particular system. For example, a processing device may include a digital signal processor device, a microprocessor device, and various analog-to-digital converters, digital-to-analog converters, and other support circuits and/or combinations of the foregoing. Control and signal processing functions of the system are allocated between these processing devices according to their respective capabilities. The processing device may include functionality to operate one or more software programs based on computer-readable instructions thereof, which may be stored in a memory device.

The processing device764is operatively coupled to the communication device762and the memory device766. The processing device764uses the communication device762to communicate with the network772and other devices on the network772, such as, but not limited to, control devices700and720. As such, the communication device762generally comprises a modem, server, or other device for communicating with other devices on the network772.

As further illustrated inFIG. 4, the user computer system750comprises computer-readable instructions768stored in the memory device766, which in one embodiment includes the computer-readable instructions768of a material flow application767. In some embodiments, the memory device766includes a datastore769for storing data related to the user computer system750and operation of the valve system, including but not limited to data created and/or used by sensors and/or control devices.

As further illustrated inFIG. 4, the control device700generally includes a communication device712, a processing device714, and a memory device716. The processing device714is operatively coupled to the communication device712and the memory device716. The processing device714uses the communication device712to communicate with the network772, and other devices on the network772.

Similarly, control device720may include a communication device742, a processing device744, and a memory device746. The processing device744is operatively coupled to the communication device742and the memory device746. The processing device744uses the communication device742to communicate with the network772, and other devices on the network772.

In some cases, one or both of control devices700and/or720(and/or other control devices) may be specific-purpose control devices that are hard-coded to perform a finite set of instructions based on differing signals received from operatively coupled sensors and actuators. In such cases, the material flow applications717and/or747may be hard-coded into the control device(s) as machine code. That is, the control devices may not be programmable in real-time, such as by communication with a user computer system750. In other embodiments, however, the control device(s) are configured for real-time or near real-time programming such that they may be controlled by the user computer system750.

An integrated magnetic particle separating valve and method according to the invention have been described with reference to specific embodiments and examples. Various details of the invention may be changed without departing from the scope of the invention. Furthermore, the foregoing description of the preferred embodiments of the invention and best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation, the invention being defined by the claims.

It is understood that the systems and devices described herein illustrate one embodiment of the invention. It is further understood that one or more of the systems, devices, or the like can be combined or separated in other embodiments and still function in the same or similar way as the embodiments described herein.

Embodiments of the present invention described above, with reference to flowchart illustrations and/or block diagrams of methods or apparatuses (the term “apparatus” including systems and computer program products), will be understood to include that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a particular machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create mechanisms for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.