Abstract:
An unloader for discharging and feeding dry, granular type materials from bulk bags. Among the many improvements of the discharge apparatus is an open frame and offset discharge location. Other improvements include an I-Beam and frame design that keeps the hoist movement within the four corner posts of the frame. The unloader may be provided with vibrators, vibration isolators, or load cells to assist in the discharge function.

Description:
BACKGROUND  
         [0001]    1. Field of Invention  
           [0002]    This invention relates to unloaders for discharging dry and semi-dry materials from bulk bags.  
           [0003]    2. Description of Related Art  
           [0004]    As many processors improve their operations by using bulk bags, instead of handling and manually dumping 50 lbs. and 100 lbs. paper bags, the need for a safer, more compact and flexible frame design of bulk bag unloaders has grown.  
           [0005]    One of the more vexing problems in handling bulk bags is the requirement of a tall, four-posted frame with a cantilevered I-Beam that extends outward at the top of the frame so that a bulk bag can be lifted from its pallet on the floor up and onto the discharge apparatus of the unloader frame. The typical unloader frame is generally equipped with several diagonal and horizontal bracing structures between the four vertical, corner posts and hoist apparatus. This extra bracing around the frame makes it difficult to interface other types of feeding, dust collection and discharge equipment close to the discharge spout location of the bulk bag. Other problems and hazards are created when lifting a heavy bulk bag with the extended I-Beam configuration.  
         SUMMARY  
         [0006]    It is the object of the invention to use a smaller footprint for a bulk bag unloader.  
           [0007]    Another object of the invention is lift and discharge a bulk bag on a standard sized unloader frame without the use of a cantilevered I-Beam. Another object of the invention is to provide a safer method of lifting a bulk bag for unloading.  
           [0008]    Yet another object of the invention is to provide a more open and accessible frame around the bulk bag when it placed on the unloader.  
           [0009]    Another object of the invention is to use a pick-up location and discharge location within the area of a four-posted unloader frame.  
           [0010]    Another object of the invention is to allow other types of conveying, dust collection and metering devices to be interfaced with the unloader frame closer to the discharge spout of the bulk bag.  
           [0011]    Yet another object of the invention is to eliminate the use of secondary bracing structures on the unloading frame.  
           [0012]    Another object of the invention is to provide greater flexibility to where the horizontal frames may be located on the four-vertical posts.  
       
    
    
     DRAWINGS  
       [0013]    [0013]FIG. 1 is a side view of a bulk bag unloader with one bag positioned for discharge while a second bag is staged on the floor waiting to be lifted into position and discharged.  
         [0014]    [0014]FIG. 2 is a side view of a bulk bag unloader frame with the hoist in position to lift a full bulk bag from its pallet on the floor to the discharge position.  
         [0015]    [0015]FIG. 3 is a front view of a bulk bag lowered over the base ram and tray support for discharging.  
         [0016]    [0016]FIG. 4 is a top of a bulk bag unloader with an open side and offset discharge location.  
         [0017]    [0017]FIG. 5 is a side view of a bulk bag unloader showing details of the bag support means. 
     
    
     DESCRIPTION  
       [0018]    [0018]FIG. 1 is a side view of unloader frame  20 . Top frame support  21  is equipped with corner brackets  21   x  and  21   y  ( 21   v  and  21   z  not shown) and bottom frame  21   a  is equipped with corner brackets  21   ax  and  21   ay  ( 21   av  and  21   az  not shown) to secure corner posts  22   a  and  22   b  ( 22   c  and  22   d  not shown) in position to form unloader frame  20 . Unlike other bulk bag unloaders, I-beam  23  does not extend outside of the perimeter of corner posts  22   a ,  22   b ,  22   c  and  22   d . I-beam  23  is secured to top frame  21  and allows hoist  25  to move between posts  22   a  and  22   b  via trolley  24 . Bag  29   a  is held in position by bag support frame  28  and bag support tray  85 . Bag support tray  85  may be located off center within the four corner posts  22   a ,  22   b ,  22   c  and  22   d . Bag  29   b  is on pallet  84  in a location within the four corner posts  22   a ,  22   b ,  22   c  and  22   d  so that it can be lifted with hoist  25  when moved to the left end of I-beam  23 . Corner brackets  21   ay ,  21   ax ,  21   av  and  21   az  of bottom frame  21   a  are designed to provide lateral support and can be located any where along the corner posts  22   a ,  22   b ,  22   c  and  22   d  to allow for the height of bag support tray  85  to be adjustable. Corner brackets  21   x ,  21   v ,  21   y  and  21   z  also add lateral support and rigidity to unloader frame  20  and may also be secured at any elevation.  
         [0019]    [0019]FIG. 2 is a side view of unloader frame  20  with hoist  25  moved along I-beam  23  via trolley  24  to a position over bag  29   b . Chain  26  and bag frame  28  are lowered for bag to be lifted. Bag  29   b  is staged in the open frame area of unloader  20  on floor  50 . Bag support tray  85  is empty, ready for bag  29   b  to be positioned thereon.  
         [0020]    [0020]FIG. 3 is a front view of unloader frame  20  with bag  29   b  lowered onto ram base  35  and bag support frame  85 . Bottom frame  21   a  does not have a support member located between vertical posts  22   a  and  22   d  to provide an open area directly under I-beam  23 , trolley  24  and hoist  25 .  
         [0021]    [0021]FIG. 4 is a top view of bottom frame  21   a  secured to vertical posts  22   a ,  22   b ,  22   c  and  22   d . Bag support tray is supported by cross beam supports  86   a  and  86   b . Pallet  84  is shown on floor in an open area of unloader frame  20 . Because a cross support brace is not used between vertical posts  22   a  and  22   d  of bottom frame  21   a  and the bag support tray  85  is located off center of unloader frame  20 , the I-Beam and Hoist Assembly (not shown) do not have to extend beyond vertical posts  22   a ,  22   b ,  22   c  and  22   d.    
         [0022]    [0022]FIG. 5 is an end view of the lower section of the unloader with seat housing  95  secured to vertical support post  22   a . Axle  97  of seat frame  96  is placed inside seat housing  95  to allow seat frame  96  to swivel off support post  22   a . Seat extension support  99 , with seat  100  attached, is mounted to seat frame  96  at pivot joint  98 . Seat  100  may be mounted in a stationary position or in a swivel and foldable configuration as shown, to assist operator with the set up and discharge of a bulk bag on the unloader. It is understood that any configuration of the unloader may be provided with a seat  100 , and not just the configuration shown in FIG. 5.  
         [0023]    To provide the unloader with a variety of discharge options to handle different sized bags and/or materials with varying flow characteristics, bag support hopper  87  is equipped with hopper brackets  88   a  and  88   b  ( 88   c  and  88   d  not shown) that may be supported by unloader frame brackets  89   a  and  89   b  ( 89   c  and  89   d  not shown) on horizontal support frames  21   a  and  21   b  ( 21   c  and  21   d  not shown). Bag support hopper  87  may be provided as a rectangular or conical shape with various slope angles. Spacers  90   a  and  90   b  ( 90   c  and  90   d  not shown) are positioned between hopper brackets  88   a  and  88   b  ( 88   c  and  88   d  not shown) and unloader frame brackets  89   a  and  89   b  ( 89   c  and  89   d  not shown). Spacers  90   a  and  90   b  ( 90   c  and  90   d  not shown) may be interchanged with vibration isolators, load cells or other discharge devices as the configuration dictates. It is intended that the vibration isolators, load cells, and other discharge devices fit in the same space as the spacers as shown in FIG. 5 to facilitate manufacture and/or reconfiguration of the unloader. Spacers  90  may be supplied in one or more units as required to support bag support hopper  87 . If vibration is desired to assist in breaking up settled material inside the bulk bag, a vibrator may be secured to vibration flange  91  and vibration isolators used instead of spacers  90 . Hopper flange ring  92  on bag support hopper  87  is equipped with accessory mounting flange  92   a . Discharge device  94 , such as iris valve which is attached discharge device plate  93  may be fastened together using bolts, welds or with a V-band type clamp. Discharge device  94  may include valves, surge hoppers, filters, conveyors and the like.