Abstract:
A scale controller system and method of using the system is disclosed. The scale controller is adapted for use with a grain cart or similar implement that includes a discharge opening and conveyor. The system includes a scale and a plurality of sensors that work together to automate numerous functions that are typically performed manually. For example, the present invention discloses a system that automatically records the amount of material loaded or unloaded by continuously monitoring the load on a scale and the RPMs of a power take-off shaft that drives a conveyor.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application is based on and claims priority from U.S. Provisional Patent Application No. 61/405,279 filed on Oct. 21, 2010, and patent application Ser. No. 12/366,204 filed on Feb. 1, 2009, all of which are incorporated herein by reference in their entirety for all purposes. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates generally to the field of scale indicators and load cells for agricultural equipment. More particularly, the present invention relates to a scale system that includes start/stop controls. 
       BACKGROUND 
       [0003]    In the field of agricultural scale indicators and load cells, there is a need to mix, blend, apply, or transport a variety of forage products (such as hay, corn, wheat, cotton seed, etc.). In certain applications, it is important to know the weight of certain materials, and it is also important to know the amount of materials that have been loaded onto or off of a scale. Scales are used as data management tools as well as material management tools to help the operator load or unload the correct amount of material and provide data to managers for record keeping. Certain conventional scale controls have a number of control buttons that must be pressed, in a particular order and at predetermined times, in order to ensure the proper operation of the scale and the carrier to which the scale is applied, and in order to ensure proper collection of the data as the material is being loaded, transported and unloaded. It is desirable to simplify the actions required by the operator to control a process, and to reliably record the transfer of material to or from the grain cart. 
         [0004]    The scales and scale indicators described above are commonly used in conjunction with grain carts and other implements that load and unload bulk material. Grain carts are farm implements that are typically towed behind a tractor or other engine-driven vehicle and include a number of components. Farmers use grain carts to transport harvested grain from other implements, such as combines, and deliver the grain to trucks or other hauling devices away from the harvest field. The use of grain carts allows the harvester to remain in the field without having to return to a grain storage area to unload. 
         [0005]    Grain carts typically include a storage carrier that further includes a hopper with a capacity ranging from several hundred to over one thousand bushels of grain. To unload the grain from the cart, grain carts employ a conveying device such as an auger or conveyor (“conveyor”) to draw grain from the bottom of the hopper and convey it through a chute that deposits the grain wherever it is needed. The conveyor transports grain from the base of the hopper upward so that it may be deposited into another container. 
         [0006]    At the bottom of the hopper, where the conveyor meets the hopper, is typically a door that must be opened in order for grain to flow onto the conveyor. The door serves the important purpose of keeping the grain or other material in the hopper until the operator desires to remove the material, and also of allowing the conveyor to come up to speed while under minimal load before the grain is loaded onto the conveyor. To provide power to the conveyor, grain carts are typically driven by a Power Take-Off (“PTO”) driveshaft typically located at the rear end of a tractor. A PTO is typically powered by the tractor&#39;s engine. 
         [0007]    Without a door separating the grain in the hopper from the conveyor, the conveyor would have to bear the entire weight of the grain present in the grain cart to begin conveying grain up the conveyor. Typical PTOs are not capable of generating the necessary torque to overcome such a load. In fact, if the conveyor is not up to the proper speed prior to opening of the door, the increased load may cause the PTO, or the engine driving the PTO, to stall, or other equipment to malfunction. To minimize the risk of stalling and malfunction, grain cart operators must be cognizant of their engine RPMs before starting the unloading process. 
         [0008]    The current procedure for loading or unloading grain is complicated, involving a multitude of steps. As one specific example, using a Digi-Star Weigh Scale system to unload material already present in a carrier, where the display shows the current weight in the carrier includes the following steps: (1) the operator pressing the [Tare] button to zero-out the weight display, (2) the operator engaging the tractor PTO shaft to start the conveyor/auger, (3) the operator opening the hopper door to begin the grain flow, (4) when unloading is complete, the operator closing the hopper door, (5) the operator disengaging the PTO shaft to stop the conveyor/auger, (6) the operator pressing the [Print] button to save to a storage medium the amount that was off-loaded, and (7) the operator pressing the [Gross/Net] button, causing the display to show the weight of the materials remaining in the carrier. 
         [0009]    This procedure is complicated, and is not easily explained or taught to an untrained, casual or part-time operator, and so a need exists for a simpler and more understandable scale control system. For example, there may be times when the operator forgets to press the [Tare] or [Print] key, causing the records reported to management to be inaccurate. The present invention provides an improvement over conventional operation of these scales. 
       SUMMARY 
       [0010]    The present invention relates to a scale that includes an automatic start/stop function. According to the invention, an automatic start/stop control uses weight change, one or more sensors, or both the weight change and the sensor(s), to automatically start or stop a process. The invention also includes one or more sensors that monitor the PTO RPMs. This automatic start/stop control can be used to automatically start and stop the control process for applying manure, unloading grain, feeding animals, etc. from a storage carrier. Weight changes and process control information may be displayed to the operator during or in connection with use. 
         [0011]    The Automatic Start/Stop control works similarly to pressing the [Start/Stop] key on the indicator, but eliminates the requirement of having the operator manually press the [Start/Stop] key during the load/unload operation. Once the operator has positioned the implement and is ready to begin the unloading process, the operator simply starts the equipment by engaging the PTO to start the conveyor. Next, the scale automatically determines that the process has started and either enters the “Start” mode or the “Stop” mode, as appropriate, depending on the state of the process. The Automatic Start/Stop control can be overridden by manually pressing the [Start/Stop] key. 
         [0012]    The Automatic Start/Stop control system includes one or more sensors that continuously monitor the PTO RPMs and the load present on the conveyor. The entrance to the conveyor is separated from the material by the hopper door. The hopper door may be mechanically or hydraulically activated. In the present invention, the scale controller continuously monitors the RPMs of the PTO. Once the PTO speed reaches a level at which a stall is unlikely, the operator may open the door, thus starting the unloading process. 
         [0013]    Depending on the implement, it may be possible to determine the weight of the material that is contained on the conveyor when the cart is unloading. Knowing that weight allows the operator to close the hopper door when the unloading process is nearing completion so that a minimal amount of material remains on the conveyor when the unloading process is complete. This is advantageous because it helps minimize waste and simplifies cleanup of the conveyor. 
         [0014]    The Automatic Start/Stop control therefore ensures that the process will start or stop even if the operator forgets to press the [Start/Stop] key. Further, the Automatic Start/Stop control simplifies the actions required by the operator to control a process. Throughout the lifetime of the scale, the addition of the Automatic Start/Stop control would save hundreds, if not thousands of button presses. 
         [0015]    It will be understood by those skilled in the art that one or more aspects of this invention can meet certain objectives, while one or more other aspects can lead to certain other objectives. Other objects, features, benefits and advantages of the present invention will be apparent in this summary and descriptions of the disclosed embodiment, and will be readily apparent to those skilled in the art. Such objects, features, benefits and advantages will be apparent from the above as taken in conjunction with the accompanying figures and all reasonable inferences to be drawn therefrom. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]      FIG. 1  is a view of a typical tractor/grain cart configuration in accordance with the present invention. 
           [0017]      FIG. 2  is a view of the control panel on a scale controller in accordance with the present invention. 
           [0018]      FIG. 3  is a block schematic showing the unloading process of grain in accordance with the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0019]    The present invention may be susceptible to embodiments in different forms. For example, a storage carrier for storing bulk material may be included in a variety of implements, including those that may be mobile or stationary. Such implements include but are not limited to grain carts, feed mixers, manure spreaders, grain bins, and seed tenders. 
         [0020]    Referring now to  FIG. 1 , one embodiment of the automatic start/stop control in accordance with the invention is shown. A grain cart  100  comprises a storage carrier  105  that is configured to store material in a hopper  110  and discharge the material through an opening  120  at the base of the hopper  110 . The storage carrier  105  includes a loadcell  130  that continuously monitors the weight of material present in the storage carrier  110 . The loadcell  130  may be located in a number of locations, including but not limited to a hitch  132  or wheel axle  134 . The opening  120  at the base of the carrier  110  is separated from a conveyor  140  by a hopper door  150 . The hopper door  150  may be mechanically, hydraulically, or electrically actuated. The conveyor  140  is typically either an auger or belt conveyor. The conveyor  140  is driven by a PTO shaft  210  which is in turn driven by the engine or other power source of a tractor  200 . There is a sensor  160  on the grain cart  100  that monitors the RPMs of the PTO shaft  210 . The entire system is controlled by an operator  220  who sits in the cab  230  of the tractor  200 . Inside the cab  230  is a scale control panel  300  that includes a plurality of buttons and a display. 
         [0021]    Turning now to  FIG. 2 , a view of the scale control panel  300  is shown in accordance with the present invention. The scale control panel  300  includes a display  310 , on which various information is displayed. The scale control panel  300  also includes a plurality of buttons  320  on its face that control various functions of the automatic start/stop system. 
         [0022]      FIG. 3  is a flow chart  400  that illustrates a typical unloading sequence performed in accordance with the present invention. First, at step  410 , the control panel  300  is turned on when the operator  220  starts the tractor  200 . Next, at step  415  the operator  220  starts the PTO shaft  210 . At decision gate  420 , the sensor  160  that monitors the RPM&#39;s of the PTO shaft  210  is configured such that when the RPM&#39;s of the PTO shaft  210  reach a pre-determined speed at which the conveyor  140  may be safely loaded with material, the scale control system, at step  430 , enters a “start” sequence. Next, at step  440 , upon entering the “start” sequence, the operator  220  opens hopper door  150  to load the conveyor  140  with material. During the unloading sequence, at decision gate  445 , the loadcell  130  continuously monitors the weight present in the hopper  110 . Additionally, the sensor  160  on the PTO shaft  210  continuously monitors the RPM&#39;s of the PTO shaft  210 . The system may notify the operator  220  if the RPM&#39;s of the PTO shaft  210  drop below a pre-determined value, prompting the operator  220  to manually adjust the opening of the hopper door  150  to decrease the flow rate of material onto the conveyor  140  to prevent a stall. 
         [0023]    At step  450 , when a pre-determined amount of material is unloaded from the hopper  110 , the hopper door  150  may be closed, at which time any remaining material on the conveyor  140  is unloaded. Next, at step  460 , the operator  220  disengages the PTO shaft  210 . At step  470 , when the conveyor  140  is completely unloaded, the system enters a “stop” sequence, thus completing the unloading sequence. Finally, at step  480 , the amount of weight unloaded is recorded onto storage media. 
       Example #1 
       [0024]    The Automatic Start/Stop control can be used to automatically start, stop and record unloading material, such as grains, from a grain cart into a truck. The following is an example to demonstrate how the control would be used in this process. 
         [0025]    The scale would have already been turned on and zero/balanced prior to obtaining the load from the combine. Once that load is obtained, and the operator of the grain cart decides to unload, the operator cart would pull alongside a truck and extend the grain cart auger over the truck hopper. The scale keeps a record of the gross weight and continuously monitors the load for weight changes. Once the conveyor is positioned properly, the operator begins the unloading process by engaging the PTO, thus starting the conveyor. When the system senses that the PTO is turning at or above a pre-designated RPM, and the operator confirms that the cart is properly positioned for unloading the grain from the cart, and opens the hopper door to allow grain to flow onto the conveyor. Thus the “Start” process is automatically begun by the scale. The operator continues to unload the amount desired and the scale continues to monitor the weight of the grain cart. Once the desired amount has been unloaded, the operator will stop unloading by closing the hopper door. The scale will sense that the weight stops changing and the scale will perform various checks to verify that the operator has finished unloading grain from the cart and automatically activate the “Stop” process for the scale. The data associated with this process, such as total weight unloaded, date, time, location, etc., is recorded at this time and the scale returns to weighing. 
       Example #2 
       [0026]    This example is similar to Example #1, but is used to unload manure. 
         [0027]    The scale would have already been turned on and zero/balanced prior to being loaded with manure. To unload, the operator of a manure spreader would enter the field and activate the PTO and hydraulics. Up to this point, the scale has been keeping a record of the gross weight loaded and continuously monitors the load for weight changes and changes in PTO RPM and hydraulic pressure. When the operator starts the manure spreading process, the sensors change states, which indicates that the operator has started unloading manure. The scale senses the activated sensors, does various checks to confirm that the operator is actually unloading the manure from the spreader and automatically begins the “Start” process. The operator continues to unload the amount of manure desired and the scale continues to monitor the sensors and the weight of the manure. Once the sensor is de-activated or the desired amount of manure has been unloaded, the scale will perform various checks to verify that the operator has finished unloading manure from the spreader and automatically activate the “Stop” process for the scale. The data associated with this process, such as total weight unloaded, date, time, location, etc., is recorded at this time and the scale returns to weighing. 
       Example #3 
       [0028]    This example is similar to Example #1, but is used to unload feed for livestock. 
         [0029]    The Automatic Start/Stop control can be used to automatically start, stop and record unloading material, such as feed from a feed mixer into a feed bunk in a pen. The following is an example to demonstrate how the control would be used in this process. 
         [0030]    The scale would have already been turned on and zero/balanced prior to the feed mixer being loaded with the various components of the rations to be mixed, and the mixer will have already mixed the components to arrive at the mixed ration. To unload, the operator of the feed mixer would pull alongside the feed bunk for the pen and start the feed mixer. The scale maintains a record of the gross weight when loaded and continuously monitors the mixer for weight changes. When the operator starts unloading feed to the feed bunk, the scale senses the weight changing and does various checks to verify that the operator is actually unloading feed from the mixer. When the scale senses a change in weight, it automatically begins recording, thus automatically beginning the “Start” process. The operator continues to unload the amount desired and the scale continues to monitor the weight of the feed mixer. Once the desired amount has been unloaded to that feed bunk, the system will automatically stop the unload process. When the weight stops changing, the scale will perform various checks to verify that the unloading process is complete and automatically activate the “Stop” process for the scale. The data associated with this process, such as total weight unloaded, date, time, location, etc., is recorded at this time and the scale returns to weighing. 
       Example #4 
       [0031]    This example is similar to Example #3, but includes a PTO sensor attached to the machine that helps identify when the operator is able to start and stop unloading by monitoring the speed at which the PTO shaft is spinning at any given time. 
         [0032]    The scale would have already been turned on and zero/balanced prior to the feed mixer being loaded with the rations to be mixed, and the mixer will have mixed the components. To unload, the operator of the feed mixer would pull alongside the feed bunk for the pen and start the feed mixer. The scale maintains a record of the gross weight when the feed mixer is loaded and continuously monitors the weight and sensor for changes that indicate that the operator has activated the feed mixer for unloading. When the scale senses the sensor activate, it does various checks to verify that the operator is actually unloading the feed from the mixer. Thus the scale automatically begins the “Start” process. The operator continues to unload the amount desired and the scale continues to monitor the weight of the feed mixer and the sensor. Once the sensor is de-activated or the desired amount has been unloaded, the scale will perform various checks to verify that the operator has finished unloading feed from the feed mixer and automatically activate the “Stop” process for the scale. The data associated with this process, such as total weight unloaded, date, time, location, etc., is recorded at this time and the scale returns to weighing. 
         [0033]    Although the invention has been herein described in what is presently perceived to be the most practical and preferred embodiments, it is to be understood that the invention is not intended to be limited to the specific embodiments set forth above. Rather, it is recognized that modifications may be made by one of skill in the art of the invention without departing from the spirit or intent of the invention and, therefore, the invention is to be taken as including all reasonable equivalents to the subject matter of the appended claims and the description of the invention herein.