Device and method for outloading bulk materials

Abstract: An apparatus for removing bulk materials from a laterally enclosed storage area (10) wherein the apparatus may be substantially buried within the bulk material (11). The apparatus includes a support column (16) mounted at a base into a support floor (25). An auger (17) is attached by means of an axial mount at the base of the support column for enabling rotational inclination of the auger from (i) a vertical orientation vertical orientation wherein the auger is nearly parallel with the vertical axis of the support column, (ii) through intermediate angles of inclination (54), to (iii) a substantially horizontal orientation (55) wherein the auger is adjacent to the support floor. The suspension cable (61) is coupled between the support column and auger to enable selective adjustment of auger inclination. A rotational displacement drive (35) is coupled to the support column to rotate the column about its vertical axis, along with the attached auger. A rotational drive motor (51) is mounted at a distal end of the auger. Rotation of the auger, along with revolution of the support column provide for progressive removal of conical layers of surface material with each 360 degree revolution. Continued inclination to the horizontal level enables the total volume of the storage area to be out loaded.

Description: This invention relates to an apparatus for removing bulk materials from a laterally enclosed storage area, wherein the apparatus may be substantially buried within the bulk material as well as to a method using such an apparatus. Bulk storage of materials such as grain, cement, dry fuels and other commodities poses many problems which ultimately affect the availability of food, fuels and construction materials upon which each nation's economy depends. These problems range from storage requirements to special handling needs in material transport. The most difficult challenges typically arise when the bulk materials require both a controlled storage environment and unique handling profile during loading and unloading in storage areas. Such materials include cement and similar bulk commodities which must be stored in a dry atmosphere. Because such materials require total enclosure for protection from the elements, convenient access for retrieval is typically limited. Although movable roofing permits direct use of scoop shovels and buckets to raise the bulk material to nearby trucks or rail cars, such facilities and methods are labor intensive and require a significant capital investment for equipment and special construction of buildings. As a consequence, industrial trends have focused on reducing the cost of storage and handling by simplifying construction of storage areas. In an apparatus as known from US-A 3 788 445, the inner end of the auger is pivotally connected to the lower end of the support column. The drive motor for the auger is provided within the support column. Two ropes are affixed to the auger near to its distal end and can be pulled by a winch mechanism provided in the middle region of the support column in order to raise or lower the distal end of the auger. If the auger is not raised when filling the storage area, the auger can be buried completely below the stored material. In operation, the auger conveys the material towards the foot region of the support column and into a hopper from which the material drops on to a conveyor provided below the floor of the storage area. Filling of the storage area is accomplished via the top of a dome storage structure. Thus, with reference to the claims, said apparatus does not comprise an auger support frame and the motor is not mounted on the distal end of the auger system. Another type of apparatus for removing bulk materials from an enclosed storage area is known from US-A 2 863 576. Two radially extending conveyors are pivotally connected a central and hollow column to substantially float on the top surface of the stored material. The conveyors bring the material from the top surface into the interior of the column where it drops downwardly into a stationary auger mechanism for unloading the storage area. Each conveyor is provided with a drive motor on its distal end distant from the central column. There is a limitation for use of the apparatus with bulk materials having physical properties similar to grains or cement and other dry goods which are subject to greater compaction. These materials will naturally congeal to a rigid mass under the weight of the stored upper layers. This mass is difficult to break up and effectively blobs gravity flow into the outlet. Because the conveyor assembly is designed to float on top of the material, it has no significant influence on desired sub-surface material movement. In view of these problems, access for problems of stored material has generally been provided by lateral doors or openings at the base of the storage dome. These doors permit front loaders to use scoop buckets to transport the material. Unfortunately, highly compacted commodities such as cement do not readily collapse with removal of under support material. Indeed, a front loader may form a cavern opening of considerable size within the rigid base layer of material which could collapse without warning. This is one of the reasons why such apparatuses have experienced only limited commercial success. It is an object of the present invention to provide an apparatus as firstly mentioned which is capable of processing compaction materials such as cement as well as looser materials such as grain, and which is useful within a dome structure which permits a complete filling with essentially burying the material removing apparatus used in outloading the storage area. The apparatus ought to be capable to process all forms of dry, particular bulk materials, even when the outloading structure is generally buried in a vertical orientation in the bulk materials, yet is capable of processing the total quantity of stored material within the containing structure. This is achieved with the apparatus as disclosed in claim 1 and by the method as disclosed in independent claim 13. The support frame functions to support the auger and enabling it to rotate about its longitudinal axis as well as in rotation about the support column. The mounting of the rotational drive motor for the auger at the distal end of the auger support frame facilitates to keep the drive motor above a top level of the stored bulk material. When filling the storage area, the auger is positioned in vertical orientation aside the central support column. Bulk material is loaded from above to at least partially bury the vertical auger within the bulk material. The bulk material loaded can extend to the top of the auger just below the drive motor attached thereto. In this condition, the full length of the auger is virtually buried within the bulk material. As soon as the drive motor is actuated, bulk material along the support column is broken up permitting some free fall of material into an outlet below the support column. The auger is then set in rotation about the support column, cutting additional compacted material freely and pulling it into the lower volumn above the outlet. Thereafter the auger and its support frame are sequentially and incrementally lowered in an inclined manner away from the support column. Accordingly, continued revolution of the auger within incremental lowering results in removal of successive layers of bulk material to the area of the outlet port. The method permits processing of both contacting and non-contacting bulk material and facilitates the use of a simple inexpensive outloading system which does not depend on complex suspending structures or continuous flowability of bulk materials. An embodiment of the invention will be described with the help of the drawings. In the drawings is: Figure 1, a medial cross section of a dome storage structure containing an apparatus for removing bulk material, Figure 2, a segmented partial cut-away section of a support column with attached auger in vertical orientation at one side thereof, Figure 3, a partial view at the base of the support column with the auger transport apparatus in horizontal ground level position. Figure 1 shows a dome structure 10 which operates as a total enclosure for stored bulk material 11. The material has been loaded by a conventional loading conveyor 12 through an inlet 13 at the top of the dome structure 10. The bulk material falls through openings 14 and spread across the entire chamber of the dome structure 10, reaching a top level as indicated at 15. The bulk material 11 has substantially covered a central support column 16 and attached auger transport devices 17 and 18. The dome construction 10 has been illustrated with the present invention because of its particular advantage within the hemispherical dome shape wherein the auger device 17 is comparable to a radial distance throughout the contained volume of the storage area. In addition, however, the domed construction is representative of the more difficult storage problems, particularly in terms of outloading compacted materials. Accordingly, this embodiment incorporates the more stringent of material transport conditions wherein access to the contained volumes are limited to an upper opening 13 and a lower outlet 19. It will be apparent to those skilled in the art that the same principles applied with respect to this dome structure could be applied with respect to any enclosed storage area having lateral confinement. The apparatus of the present invention includes a support column 16 which has a top end 20, a bottom end 21 and a vertical axis 22. The support column comprises a steel post which is hollow down its length except for a pair of deflection plates 23 which divert bulk materials transported from the loading conveyor 12 through lateral openings 14 in the support column. This support column is vertically positioned in a base mount 24 which is attached between the bottom end of the support column 21 and a support floor 25 contained within the storage area. This base mount provides fixed vertical orientation with respect to the support column within a central section of the storage area. In the illustrated embodiment, this base mount is configured for rotational movement about the vertical axis 22. Specifically, the base mount includes an annular converging channel or hopper 26 whose bottom end 29 defines an outlet port which disposes the bulk materials onto a conveyor belt or other transport means for carriage to a pickup location such as transport trucks or rail cars. This channeling hopper 26 is supported on a parallity of rollers or bearings 27 which ride on a support ring 28 structurally configured to bear the load of the support column 16 and its attached augers 17 and 18. The support column 16 is integrally coupled to the channelling hopper 26 with brace members 30 which are welded at the base of the support column on one side and a lower portion of the hopper structure on the other side. This permits a protective flap 32 to slide along the top hopper edge 31 and protect against grain falling free of the hopper. In essence, this flap 32 operates as an angular sleeve to channel material from the storage area into the outlet 29 while the hopper is rotating in concert with the support column. Similarly, the top end 20 is supported in a rotational configuration within the top opening 33 of the dome. A set of rollers or bearings 34 stabilize the support column 16 in vertical orientation. A drive motor 35 and chain drive 36 are coupled at the top of the support column 16 and operate as a rotational displacement means to rotate the support column about its vertical axis 22. The respective base mount 24 and upper roller system 34 cooperate to fix the support column 16 in a sturdy, rotational configuration at a central section of the storage area. Rotation rate about the vertical axis 22 is adjusted to the outflow rate of stored material and is governed by the chain drive 36 and electric motor 35, which is housed exterior to the dome structure 10. This enables maintenance to be performed with respect to this drive system without need for access within the dome interior. Attached to the support column is at least one auger support frame 40 and 41. Figure 1 shows a support column having two such support frames and attached auger assemblies 17 and 18, further description shall be directed toward the auger configuration 17 alone. It is to be understood that a comparable description could be provided with respect to the second auger 18 which is illustrated in Figure 1. Figures 2 and 3 do not include the second auger in view of its symmetrical duplicity with the disclosure relating to auger 17. The auger support frame 40 includes a base end 42, intermediate section 43 and distal end 44. The assembled configuration of these components forms an elongate truss support span which extends from the top end 44 to the bottom end 42 and includes mounting end plates 45 and 46 with bearing mounts coupled thereto for receiving the respective base end 47 and distal end 48 of the auger 17. This auger 17 is configured for rotational movement about its rotational axis 50 and functions to drag particular bulk materials along the length of the auger toward the hopper 26 and dispensing outlet 27. The auger support frame 40 operates to support the auger 17 during this rotational movement, and provide means for inclining this auger at varying angles as it revolves about the support column 16. The present invention requires mounting of a rotational drive motor 51 at the distal end 48 with respect to the end plate 46 on the auger support frame. This is in direct contrast with prior art trends of positioning the drive motor on auger transport systems near the support column, and at a base end of the auger. Disposition of the drive motor 51 at a distal end of the auger maintains the motor above the top level 15 of bulk material. For example, with full capacity storage as shown in Figure 1, the drive motor 51 stands above the material level 15 by virtue of its vertical orientation. During outloading, the auger is gradually displaced in a conical revolution pattern, cutting away respectively at conical layers of bulk material. As the auger is further inclined away from the central column 16 (see phantom line examples 54 and 55), rotational drive motor 51 is always positioned above material storage levels. This preserves life of the motor and facilitates its continuous operation to service all stages of outloading. This is in direct contrast with prior art systems which depend primarily on free fall of the bulk materials through the outlet. In these prior art embodiments, the auger transport system is primarily functioning to collect a remaining portion of bulk materials left around the periphery of the floor wherein the inclination of stored materials the longer facilitates free fall of the particulate matter to the outlet. The present invention adopts a new strategy which comprehends not only the flowable grain material of prior art auger applications, but also covers materials such as cement and other highly compactable substances. Inclination of the auger 17 is enabled by use of an axial mount 57 which couples between the base of the auger support frame 42 and a bottom end of the support column 16. This structure permits the auger support frame to rotate vertically about the axial mount 57 to enable rotation inclination of the auger and support frame from (i) a vertical orientation (solid line representation of item 17) wherein the auger is nearly parallel with the vertical axis 22 of the support column, (ii) through intermediate angles of inclination (represented by phantom line drawing 54) to (iii) a substantially horizontal orientation (representation 55) wherein the auger is adjacent to the support floor of the storage area. Selection of the specific inclination angle is accomplished by use or a variable suspension means 60 which is coupled between the support column and the auger support frame and enables various selection and adjustment of auger inclination by permitting rotational inclination with respect to the axial mount. Specifically, this suspension means includes the suspension cable 61 which is attached at a first point of attachment 62 near the top end of the support column. This cable is next supported on a first pulley 63 which is attached near the distal end of the auger support frame 44. This cable is further supported on a second pulley 64 which is attached to the support column between the first point of attachment and the top end 20 of the support column. A second end of the suspension cable is coupled to a winch or other drive system 65 having a fixed location with respect to the support column. The winch operates in a conventional manner to reel in and let out suspension cable to selectively incline the auger at a desired position. The winch operates as a control means for incrementally advancing the auger through a series of predetermined inclinations which increase in angle of inclination with respect to the support column with each successive 360 degree revolution of the auger about the vertical axis 22. It will be apparent that although only two inclined positions are reflected in Figure 1, the variety of inclination angles is continuous from the vertical orientation shown in solid line for auger 17 through all intermediate angles to a horizontal configuration illustrated as item 55. Electrical support for the respective components is provided by conventional wiring configurations. For example, all wiring support for the rotational drive motor 35 and winch 65 are external to the dome and enable direct access for maintenance. Electrical support to the winch and its rotatable configuration as part of the support column is provided by a slipring assembly 69. The same conductive slipring provides an electrical connection identified by dashed line 70 which extends the length of the support column and passes from the base of the support column up through a central tube opening within the auger 17 to the drive motor 51. All electrical lines are appropriately anchored and shielded to prevent wear with the anticipated patterns of movement for both the auger and the support column. The unique advantages of this system of material transport within an enclosed storage area are readily apparent from the following description of methodology. Specific procedures of emplacement of the subject device within a storage area will be readily apparent from the foregoing discussion. Typical procedures would involve positioning the support column at a central location of the storage area. In a dome construction, this area would be the center point as illustrated in Figure 1. The present invention is particularly useful in a dome configuration because the auger is capable of sweeping through the full volume of the dome from top to floor level. This permits the dome to be used to its maximum capacity in storage while taking advantage of the simplicity of inloading and outloading with a material transport system as disclosed. Obviously, this same material transport system could be applied within a silo or cylindrical storage area, provided that the motor is maintained above the top layer of bulk material or is otherwise shielded for protection. This system could likewise be applied within an elongate storage area of rectangular configuration. In this circumstance, the material transport system illustrated in Figure 1 might be placed on a center track or rail such that it could be moved down the track to sweep through the storage area. Other configurations will be apparent to those skilled in the art, based on the understanding provided with respect to the disclosed material transport system. The next procedural step involves attaching the auger to the other support frame and attaching the auger support frame at the base of the support column by means of an axial amount which enables the described rotational inclination of the auger. The suspension cable is then coupled to the winch and adjustment system, and is placed in the vertical orientation. This system is now prepared for use. Loading operations proceed with transporting bulk materials along the loading conveyor 12 and into the storage area. As bulk materials falls within the storage area, natural accumulation develops as indicated by broken line 80 in Figure 1. Continued filling through the top opening 13 eventually results in capacity storage with a top level at solid line 15. At this stage, the auger systems are virtually buried within the accumulated materials. This storage mode and condition can continue for whatever duration of time as may be necessary. When outloading is required, the lower conveyor 82 is activated and particulate material flow along the conveyor direction. Some gravity flow without auger assist may occur to continue to feed the conveyor particular with flowable material such as grain. With more difficult contents, compaction may have occurred, resisting gravity flow. At this point, one or both augers 40 and 41 are activated with a rotation direction toward the outlet port 19. This rotary action breaks the center column of material free around the support column and allows this material to flow by gravity into the outlet 19. In some instances, compaction below the auger may choke particulate material from falling into the outlet. In this instance, air jets 84 are blasted to fracture such rigid materials and stimulate free flow. Particle movement is continued by activating the drive motor 35 and setting the support column 16 in rotation about its vertical axis. This rotation, with the continuing rotation of the respective augers maintains a steady flow of particulate matter toward the outlet 19. As the accumulated product around the support column is cleared, a conical void is partially formed. The winch 60 may then be activated to let out a segment of suspension cable to lower the auger to operate with respect to bulk materials which are not breaking free from a compacted configuration. The weight of the auger and attached motor assist the auger in extending to the available length of suspension cable as the auger cuts through the adjacent wall of material. By repeating this procedure, sequentially lengthening the suspension cable as the auger passes through each 360 degree revolution about the support column, the total material can be evacuated despite congealment or other forms of aggregation of the stored material, and despite its location with any part of the storage volume. Because of the simplicity of design, construction of the material transport system is economical and requires minimal maintenance. An additional advantage is its adaptability for application within a variety of containment areas involving lateral confinement. With respect to enclosing dome structures, the system offers a safe alternative to the prior art techniques of unloading material with front loaders through accessed doors which can lead not only to fatal accidents, but to destruction of the dome structure as well.

Claims: An apparatus for removing bulk materials (11) from a laterally enclosed storage area wherein the apparatus may be substantially buried within the bulk material, said apparatus comprising: a support column (16) having a top end (20), a bottom end (21), and a vertical axis (22); a base mount (24) configured for attachment between the bottom end (21) of the support column (16) and a support surface (25) within a central section of the storage area; a nontelescoping auger (17,18) of fixed length configured for rotational movement about a longitudinal axis (50) when buried under the bulk material (11) and being useful for dragging particular bulk material (11) along a length of the auger (17,18) towards a dispensing outlet (29) near the bottom end (21) of the support column (16), said auger (17,18) having a base end (47) and a distal end (48); an auger support frame (40) having a base end (42), intermediate support section (43), and distal end (44), said distal end (44) being coupled to the distal end (48) of the auger (17,18) and being adapted with means for supporting the auger during rotational movement; a rotational drive motor (51) mounted at the distal end of the auger support frame (40) to maintain the motor (51) above a top level (15) of the bulk material (11), said drive motor (51) further including means to apply a rotational drive force to the auger (17,18) about the longitudinal axis (50) when in a buried configuration; an axial mount (57) coupled between the base of the auger support frame (40) and bottom end (21) of the support column (16), said axial mount (57) including means for enabling rotational inclination of the auger (17,18) and support frame (40) from (i) a vertical orientation wherein the auger is nearly parallel with the vertical axis (22) of the support column (16), (ii) through intermediate angles of inclination, to (iii) a substantially horizontal orientation wherein the auger (17,18) is adjacent the support floor (25) of the storage area; variable suspension means (60) coupled between the support column (16) and the auger support frame (40) for enabling variable selection and adjustment of auger inclination by permitting rotational inclination with respect to the axial mount (57); and rotational displacement means coupled to the auger support frame (40) for rotating the auger (17,18) and support frame (40) about the vertical axis (22) of the support column (16) to thereby provide for progressive removal of conical layers of surface material with each successive 360 degree rotation of the auger and support frame. An apparatus as defined in claim 1, characterised in that the rotational displacement means comprises rotational means (27,28) coupled at the bottom end (21) of the support column (16) to enable the support column (16) to rotate about its vertical axis (22), said rotational displacement means further including a drive motor (35) for rotating the support column (16) at a controlled rate in combination with rotational movement of the auger (17,18). An apparatus as defined in claim 1, characterised in that the support frame (40) comprises an elongate truss support span extending from the distal end (48) of the auger (17,18) to the opposing base end (47) and including opposing end plates (46,45) having bearing mounts which couple at the respective base and distal ends of the auger (17,18). An apparatus as defined in claim 1, characterised in that the varible suspension means (60) comprises a suspension cable (61) coupled in tension between the support column (16) and the auger support frame (40). An apparatus as defined in claim 4, characterised in that a first end (62) of the suspension cable (61) is attached at a first point of attachment near the top end (20) of the support column (16), said cable (61) being next supported on a first pulley (63) attached near the distal end (48) of the auger support frame (40), said cable (61) being further supported on a second pulley (64) attached to the support column (16) between the first point (62) of attachment and the top end (20) of the support column, a second end of the suspension cable being applied to a winch (65) having a fixed location with respect to the support column (16) and being operable to reel in and let out suspension cable to selectively incline the auger. An apparatus as defined in claim 5, characterised by a dome storage structure (10) having a top opening (33) centrally disposed with respect to the remaining dome structure (10), said winch (65) being mounted at a top exterior surface of the enclosing dome storage structure (10) adjacent to the top end (20) of the support column (16), said suspension cable (61) extending from the winch (65) along the support column (16) to the second pulley (64). An apparatus as defined in claim 1, characterised in that the variable suspension means (60) further includes control means for incrementally advancing the auger through a series of predetermined inclinations to sequentially remove conical layers of bulk material (11) symmetrically about the support column (16). An apparatus as defined in claim 1, further characterised by compressed air jet openings at the base of the support column (16) and having a directional orientation adapted for triggering displacement of compacted bulk material upon ejection of compressed air. An apparatus as defined in claim 1, characterised in that a second nontelescoping auger (18) supported on a second auger support frame (41), said second support frame (41) being coupled to the support column (16) approximately along a plane defined by the first auger (17) and the support column (16), but on an opposite side of the support column (16), said second support frame (41) including an axial mount (57) and variable suspension means (60) as defined in claim 1, and including a rotational drive motor (51) on the distal end (48) of the second auger(18). A storage area including an apparatus as defined in claim 1, further including a dome storage structure (10) having a top opening (33) centrally disposed with respect to the remaining dome structure; a support floor (25) formed as a flat slab with a perimeter boundary defined by base edges of the dome structure, said support floor (25) including an outlet port (19), centrally located within the support floor, said outlet port (19) being coupled to a subfloor passage (82) configured to receive bulk materials by gravity flow for subsequent conveyor delivery to an exterior pickup location; said support column (16) being attached to the support floor (25) with its vertical axis (22) in approximate alignment with the outlet port (19) such that bulk materials (11) dragged by the auger (17,18) drop into the outlet port (19) for subsequent removal. A storage area as defined in claim. 10, characterised in that the top opening (33) is slightly larger in size than a diameter of the support column (16), the top end (20) of the support column (16) extending through the opening (33) and above a surrounding top area of the dome structure (10), said rotational displacement means being attached at the surrounding top area of the dome structure adjacent the top end of the support column (16) to impose a drive force to rotate the support column (16) and attached auger (17,18) and support frame (40). A storage area as defined in claim 11,, characterised in that the top opening (33) further includes a rotational bearing collar (34) coupled to the dome structure (10) and journalled around the top end (20) of the support column (16), said base end (21) of the column (16) also including means for rotational attachment with respect to the support floor (25), thereby securing the support column (16) rigidly in vertical orientation with respect to the dome structure (10) in a rotatable configuration. A method for removing bulk materials from a laterally enclosed storage area wherein the apparatus may be substantially buried within the bulk material, said method comprising the steps of: positioning a support column having a top end, a bottom end, and a vertical axis at a central location of the storage area; securing a base mount between the bottom end of the support column and a support floor contained within the storage area, said base mount providing a fixed vertical orientation to the support column within a central section of the storage area; attaching to an auger support frame an aguer configured for rotational movement about its rotational axis and being useful for dragging particular bulk materials along the length of the auger towards a dispensing outlet near the base of the support column, said auger having a base end and a distal end; attaching the auger support frame at a base end thereof to the support column with an axial mount for enabling rotational inclincation of the auger and support frame from (i) a vertical orientation wherein the auger is nearly parallel with the vertical axis of the support column, (ii) through intermediate angles of inclination, to (iii) a substantially horizontal orientation wherein the auger is adjacent to the support floor of the storage area; coupling a rotational drive motor at the distal end of the auger and support frame to maintain the motor above a top level of the bulk material, said drive motor further including means to apply a rotational drive force to the auger about its rotational axis; positioning the auger in vertical orientation; loading the storage area with bulk material from above the auger to at least partially bury the auger within the bulk material; commencing removal of the bulk material by activating the rotational drive motor on the auger, thereby initiating free fall of the stored bulk materials through an outlet port in support flooring of the storage area; rotating the auger about the vertical axis of the support column to remove a conical volume of bulk material; and sequentially and incrementally lowering the auger with each successive revolution to remove successive layers of bulk material. A method as defined in claim 13, characterised by the additional step of breaking up initial compaction of bulk material at a base layer of storage by ejecting a sudden blast of compressed air near the base of the support column.

Inventors: CAMPBELL DAVID R, CAMPBELL, DAVID R.
Applicants: CAMBELT INT CORP, CAMBELT INTERNATIONAL CORPORATION
Application year: 1991
Main classification: B65G65
IPC codes: B65G65