Abstract:
A monitoring system functions both as a device for lifting the object and as a weighing system for monitoring or measuring the weight of an object, such as a feed bin. Various embodiments having a suspended load cell and methods of retrofitting the monitoring system to existing object are provided. Further, the accuracy provided by various embodiments enables one to accurately predict when the feed bin will be empty. Thus, the feed mill can be aware of anticipated needs days in advance, allowing the feed mill to better optimize its scheduling and deliveries.

Description:
RELATED APPLICATIONS 
     The present application is a continuation of U.S. patent application Ser. No. 13/157,483, filed Jun. 10, 2011, which is a continuation of U.S. patent application Ser. No. 12/109,841, filed Apr. 25, 2008, now U.S. Pat. No. 7,980,129, which claims the benefit of U.S. provisional application Ser. No. 60/913,961, filed Apr. 25, 2007, the disclosures of which are hereby incorporated by reference. 
    
    
     TECHNICAL BACKGROUND 
     The disclosure relates generally to monitors for measuring the weight of an object, such as a feed bin, and methods of installing such monitors. More particularly, the disclosure relates to monitors having a suspended load cell that is positioned above a bottom of a leg of the object. 
     BACKGROUND 
     Many animal finishing facilities have bulk bins and automated feed delivery systems. In theory, these bins and delivery systems are intended to assure an uninterrupted flow of feed to the feeder. In reality, however, various known delivery systems result in varying disruptions of feed availability, which may have very serious consequences. For example, out-of-feed events can cause animal health problems, such as ulcers, particularly in pigs. Other potential health problems include, for example, cannibalistic tail biting and Hemorrhagic Bowel Syndrome, which is often fatal to the animal. Moreover, it is believed that even one out-of-feed event can have a prolonged negative effect on weight gain. Paid dividends can be directly affected as a result. 
     Out-of-feed events can be caused by a variety of causes. One notable cause is human error. Human errors are generally associated with empty bins, which occur when feed is not ordered, prepared, and delivered in a timely manner. Other causes of out-of-feed events include, for example, bridging and rat-holing of the feed. In these cases, the feed still remains in the bin, but does not flow to the delivery or auger system. As a result, even though feed is present in the bin, it is not delivered to the animals. When this occurs, the feed delivery system may shut down due to its extended run timers. No feed is then delivered until the feed delivery system is manually reset. If producers are not closely monitoring the feed delivery system, animals can be without feed for extended periods of time. While out-of-feed events can be prevented, in practice, they occur quite often. 
     One method of preventing out-of-feed events involves personally checking each bin by climbing up a ladder to the top of the bin and visually noting and monitoring the level of the bin. This method is labor-intensive and can be quite dangerous, especially in frigid, icy, or wet weather. To save time and avoid safety risks associated with climbing to the top of the bin, some workers have resorted to physically hitting the bin to estimate the level of the feed by listening to the sound reverberation. This method, however, does not provide the producer with very accurate information. It is also still labor-intensive because the worker has to personally check each individual bin. Further, as compared to the past, it is now more common for farms to be isolated from the workers. As a result, it takes more effort to check and monitor the feed systems. Therefore, the feed bins often are not checked frequently enough to prevent out-of-feed events because it takes too much time to check the bins, and, additionally, rush orders are often not fulfilled quickly enough. 
     Accordingly, electronic monitors have been devised to monitor feed levels. These known electronic monitors are equipped with compression load cells positioned on a concrete slab underneath the bin legs. The load cells measure the amount of the feed in the bin and are able to track the level and the changes in the feed weight, for example, from deliveries and consumption. Some of these known electronic monitors can make feed level data available to producers by telephone. Many producers choose not to implement these known systems, however, because they are costly and are difficult to retrofit to existing bins. Separate jacks or cranes are required so that the bin legs can be raised approximately 3-4 inches off of the concrete slab. Raising the bin disrupts the connections between the bins and the conveyor pipes that carry the feed from the bin to the feeding point. Known electronic feed bin monitors can also be unreliable because they are often susceptible to adverse affects on the accuracy of their measurements due to ice and foreign material under the supporting mechanisms. These supporting mechanisms include foot pads that are bolted to the concrete slab beneath the bin. Bolting the foot pads to the concrete slab introduces torques that can twist the load cell system enough to produce false readings at times. 
     Some other known systems are sonar or ultrasound based. One drawback of such systems is that they only report a feed level, not weight. As a result, these systems have difficulty maintaining accuracy when, for example, there is bridging or rat-holing of feed, there are significant changes in feed density, or there are temperature variations. All of these events can alter the correlation between feed level and the true amount or weight of feed. Known sonar or ultrasound based systems can also only provide level monitoring. Thus, they cannot accurately measure feed delivered or consumed by weight. The present invention addresses problems associated with the related art. 
     SUMMARY OF THE DISCLOSURE 
     According to various example embodiments, a bin monitoring system functions both as a device for lifting the bin and as a weighing system for monitoring or measuring the level of feed in a feed bin. Various embodiments having a suspended load cell and methods of retrofitting the bin monitoring system to existing bins are provided. Further, the accuracy provided by various embodiments enable one to accurately predict when the feed bin will be empty. Thus, the feed mill can be aware of anticipated needs days in advance, allowing the feed mill to better optimize its scheduling and deliveries. 
     One embodiment is directed to a feed bin monitoring system that has a suspended load cell that accurately measures the amount of feed going into and out of a feed bin having bin legs that support the bin above a foundation. The feed bin monitoring system of this embodiment can quickly detect if no feed is being consumed by the animals due to, for example, bridging of the feed in the bin. The feed bin monitoring system includes a frame configured to be securable to the foundation. A load cell is joined to the frame and is configured to measure a weight of the bin. A lifting mechanism is arranged to selectively lift the bin leg, thus applying the load to the load cell. Another aspect of the invention is directed to a method of monitoring an amount of feed in a feed bin having a plurality of bin legs by operatively connecting at least one feed bin monitor to each of the bin legs and transmitting data collected from the load cell to a display device. 
     Another aspect of this invention is directed to a method of installing a bin monitoring system, such as described above, to a leg of a feed bin. The method generally includes the steps of securing the bin monitoring system to at least one of the bin legs and using a bolt to raise the bin legs preferably no more than approximately 0.5 inches above the ground, thus facilitating retrofitting of existing bins. 
     Various embodiments may provide certain advantages. For instance, feed levels can be monitored easily and accurately so that out-of-feed events can be significantly reduced. Also, feeding animals with feed bins equipped with automatic bin monitoring systems reduces the need for expedited orders and allows feed producers to predict production needs in advance. Feed throughput may be improved, and feed transportation costs may be reduced. Further, the bin monitoring systems described herein can be retrofitted to existing bins easily and inexpensively, thereby reducing implementation costs. 
     Additional objects, advantages, and features will become apparent from the following description and the claims that follow, considered in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is a front plan view of an embodiment of a bin monitoring system. 
         FIG. 1B  is a front view of the bin monitoring system similar to that of  FIG. 1A , wherein the bin monitoring system is operatively attached to a bin leg. 
         FIG. 1C  is an enlarged, partial, perspective view of the bin monitoring system illustrated in  FIG. 1B . 
         FIG. 1D  is a rear view of the bin monitoring system of  FIGS. 1B-1C  operatively connected to the bin leg. 
         FIG. 2A  is a side view of the bin monitoring system of  FIG. 1A . 
         FIG. 2B  is another side view of the bin monitoring system similar to that of  FIGS. 1B-1D , wherein the bin monitoring system is operatively attached to the bin leg. 
         FIG. 3A  is a front view of a frame of the bin monitoring system of  FIG. 1A  illustrating optional folding of the frame. 
         FIG. 3B  is a plan view of the completed frame of  FIG. 3A . 
         FIG. 3C  is a side view of the frame of  FIG. 3B . 
         FIG. 4A  is a plan view of a channel bracket of the bin monitoring system of  FIG. 1A . 
         FIG. 4B  is front view of the folded channel bracket of  FIG. 4A . 
         FIG. 4C  is a side view of the completed channel bracket of  FIG. 4B . 
         FIG. 5A  is a top view of a load block of the bin monitoring system of  FIG. 1A . 
         FIG. 5B  is a cross-sectional, side view of the load block of  FIG. 5A . 
         FIG. 6  is a view of a bin monitoring system attached to each leg of two adjacent bins according to another embodiment. 
         FIG. 7  illustrates another embodiment in which the channel bracket of  FIG. 1A  is replaced with an alternate mechanical connector including a chain link suspension. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The following description of various embodiments implemented in the context of monitoring the volume or weight of feed bins and installing such monitoring systems is to be construed by way of illustration rather than limitation. This description is not intended to limit the invention or its applications or uses. For example, while various embodiments are described as being implemented in this context, it will be appreciated that the principles of the disclosure are applicable to other environments, as will be apparent to one of ordinary skill in the art. 
     In the following description, numerous specific details are set forth in order to provide a thorough understanding of various embodiments. It will be apparent to one skilled in the art that some embodiments may be practiced without some or all of these specific details. In other instances, well known components and process steps have not been described in detail. 
     Embodiments of the bin monitoring system are illustrated in  FIGS. 1A-6 . Referring now in particular to  FIGS. 1A-3C and 6 , a bin monitoring system  10  includes a frame  12 . In some embodiments, the frame  12  is A-shaped and has a top  14  and two legs or supports  20   a  and  20   b  extending diagonally downward from the top  14 . In the illustrated embodiments, each support  20   a  and  20   b  has a respective flange  24   a  and  24   b  with at least one respective flange aperture  28   a  and  28   b  for anchoring the frame  12  to a foundation such as a concrete slab C, as most bins are installed on concrete slabs. The top  14  includes a bolt aperture  16  that receives a bolt  18  for securing the frame  12  to the top of a load cell  50 . In some embodiments, the frame  12  can be constructed of fabricated iron. Alternatively, the frame can be constructed of fabricated channel iron. 
     In some embodiments, the load cell  50  is implemented as an S-type load cell for measuring the tension or changing weight of a bin B. The bin monitoring system  10  incorporates the load cell  50  to measure the weight and changes of weight of the bin B. An example implementation of the load cell  50  is disclosed in U.S. patent application Ser. No. 11/422,910 of Jaeger et al., the teachings of which are herein incorporated by reference in their entirety. In some embodiments, the load cell  50  includes an electrical connection  52  having a wire that passes through an aperture  22  in one of the supports  20   a  and  20   b  to a transmitter (not shown) such that data collected from the load cell  50  can be accessed via a remote location such as, for example, by a wired, wireless, or mobile telephone or using a network such as the Internet. 
     It is further contemplated that the bin monitoring system  10  may be an element of a larger system in which the data transmitted may be compiled with other data, such as animal weights, so that multiple variables can be monitored and tracked in one central location. Such a larger system can also include, for example, a component for generating reports, such as a bin status report, a configuration report, an alarm settings report, a feed usage report, and a bin summary report. The bin status report may illustrate an image of a feed bin showing the current weight, alarm settings, and alarm conditions. The configuration report may list the configuration for the setup menu, interface menu, and computer port. The alarm settings report may list the alarm settings for each indicator. The feed usage report may list daily feed usage sorted by date and the total feed delivered for a selected date range. The bin summary report may list the current bin weights and any alarm conditions for the feed bins. 
     Now also referring to  FIGS. 4A-C , the bin monitoring system  10  additionally includes a mechanical connector, in this case a channel bracket  60 , that is used to connect the bin monitoring system  10  to a leg L of the bin B. The channel bracket  60  may be generally U-shaped, being deeper at the top than at the bottom, to correspond to the shape of the bin leg L. In some embodiments, the bin monitoring system  10  includes a limiting mechanism  66  to restrict the upward movement of the channel bracket  60 . The limiting mechanism  66  prevents the bin B from lifting and blowing over when, for example, there is a gust of wind and the bin B is empty. As shown, the limiting mechanism  66  may be a stop strap having bolt apertures  68  for use with a bolt  69  to secure the strap to the frame  12  as shown in  FIGS. 1A-1C . The channel bracket  60  further includes a slot  62  for receiving and in some instances, supporting a load block  70  and is deep enough such that when the channel bracket  60  is bolted to the bin leg L and the frame  12  is secured to the concrete slab C, the channel bracket  60  extends beyond the stop strap  66 , allowing it to contact and be restricted by the stop strap  66  when the bin B is lifted too high. This configuration is also illustrated in  FIG. 2A . In alternative embodiments, the channel bracket  60  may be replaced with a chain link suspension or mechanical connector  80  attached to a clevis  82 , as shown in  FIG. 7 , or another similar system. 
     Now further referring to  FIGS. 5A-5B , as previously mentioned, the bin monitoring system  10  further includes the load block  70 , which is received within the slot  62  of the channel bracket  60  and is supported by the channel bracket  60  until the bracket  60  is elevated. The load block  70  is illustrated in  FIGS. 5A-5B  as having a bolt aperture  72 . The load block  70  is placed in the slot  62  of the channel bracket  60 . A threaded bolt  65  is then placed through a bolt aperture  72  of the load block  70  and threaded into the load cell  50 . The load block  70  can move within the slot  62 . This configuration allows for some misalignment of the channel bracket  60 . 
     A typical feed bin has  4 ,  6 , or  8  generally U-shaped legs. The bin monitoring system  10  may be placed alongside each leg L and bolted to the concrete slab C with an anchor bolt  30  through two of the flange apertures  28   a  and  28   b . Two more bolts  65  may be pressed through the bolt holes  64  of the channel bracket  60  to connect the bin monitoring system  10  to the bin leg L. 
     As described above, the bin monitoring system  10  includes the threaded bolt  18 , which secures the load cell  50  to the frame  12 . According to various embodiments, the bolt  18  also serves as a jack to lift and support the load cell  50  when the load cell  50  is suspended off of the concrete slab C. In some embodiments, the bin monitoring system  10  jacks up the bin B no higher than about 0.75 inches, preferably no higher than about 0.5 inches above the concrete slab C. Because installing the bin monitoring system  10  does not require the bin B to be significantly lifted, existing bins may be retrofitted without having to empty the bin or disconnect flex augers and associated piping. 
     To install the bin monitoring system  10  according to one example method, the load cell  50 , frame  12 , and limiting mechanism  66  are operatively assembled. The footpads are then disconnected from the bin legs L. Next, two 0.5 inch holes are drilled into the bin legs L for the channel bracket  60 . In the next step, the channel bracket  60  is first mounted adjacent the side of the leg L such that any space in between the channel bracket  60  and the leg L is reduced. Once the channel bracket  60  is attached adjacent the leg L, the frame  12  is aligned to the bin leg L and is secured with concrete anchor bolts  30 . The channel bracket  60  is connected to a threaded load cell  50  by a threaded bolt  40  that can also function as a jack to lift the bin leg L. As the bolt  40  is rotated, e.g., seven times, the load cell  50  is moved upwards and correspondingly moves the bin leg L upwards. In the next step, a summing box or the transmitter (not shown) is mounted to the bin B and is operatively connected to the load cell(s)  50 . Next, the summing box can be wired to the bin monitoring system  10 . Next, wiring to the load cell  50  is secured to the bin support frame, e.g., using one or more cable ties. The bin monitoring system  10  is then connected to the on-site network to enable communication with a remote monitoring system. Next, preferably three of the bin legs L are electrically grounded above each frame using the anchor bolts. 
     As described above, the bin monitoring system  10  can be used to determine how much feed enters and exits a feed bin. In this way, the bin monitoring system  10  facilitates the determination of when more feed should be ordered. In addition, the bin monitoring system  10  facilitates verifying how much feed is actually delivered when the bins are refilled and how much is being consumed. As a result, potential out-of-feed events can be monitored, animal performance based on feed consumption can be correlated, and future bin levels can be predicted accurately. 
     As demonstrated by the foregoing discussion, various embodiments may provide certain benefits. For instance, the bin monitoring system  10  can greatly reduce monitoring costs. The required labor can be reduced because multiple bin feed levels can be quickly, simultaneously, and accurately monitored at a central location, as compared with the conventional approach of visually inspecting each bin individually. Safety hazards can also be reduced because workers do not need to climb feed bins to inspect them. 
     Additionally, logistical savings can be realized by the bin monitoring system  10 . Typically, feed mills have large demands on Mondays and Fridays. On these days, the mills run over capacity and often need to pay overtime to drivers and milling employees to fill tanks for the weekend or to catch up and fill empty tanks on Mondays. On Tuesdays, Wednesdays, and Thursdays, the mills run under capacity. Use of the bin monitoring system  10  allow the feed mill to level its production flow out over the week by delivering feed early to some bins and just-in-time to others. Accurate monitoring of feed bins allows producers to better predict and schedule when they will need to replenish the feed bins, which in turn will reduce the amount of expedited orders and allow the feed mill to plan their production. By allowing the feed mill to better plan its production, the feed mill can schedule the bottlenecks to the maximum increasing throughput. Overtime is saved in both the feed mill and the trucking, and the incidence of empty compartments or “air tons” can be reduced. Rush orders can be eliminated by better planning, thus greatly reducing the frequency of expedited orders and the associated expense. 
     It will be understood by those who practice the embodiments described herein and those skilled in the art that various modifications and improvements may be made without departing from the spirit and scope of the disclosed embodiments. The scope of protection afforded is to be determined solely by the claims and by the breadth of interpretation allowed by law.