Abstract:
A motorized hopper door actuation system for use in conjunction with a hopper vehicle having at least one hopper door for removing product therefrom. The motorized hopper door actuation system includes a motor, mounting mechanism and control mechanism. The motor is operatively attached to the hopper door. The mounting mechanism is operatively attached to the hopper vehicle. The control means is operably attached to the motor.

Description:
FIELD OF THE INVENTION 
       [0001]    The invention generally relates to an actuator system. More particularly, the invention relates to a motorized hopper door actuation system. 
       BACKGROUND OF THE INVENTION 
       [0002]    Various commodities such as grain, fertilizer and sand are transported in bulk in hopper-style vehicles. These hopper-style vehicles may take a variety of configurations depending on the intended use. Examples of the hopper-style vehicles are trailers and railroad cars. 
         [0003]    The commodities are typically placed into the hopper-style vehicles through an open upper portion. One configuration for removing the commodities is through trap doors that are mounted in a lower surface of the hopper. Two primary configurations for the trap doors are sliding and pivoting. 
         [0004]    The sliding trap doors are typically operated by manually turning a crank handle connected to a drive shaft that engages the trap door and causes the trap door to slide between the open and closed positions. Depending on a variety of factors such as the size of the trap door, the shape of the trap door and the weight of the product stored in the hopper-style vehicle, the force required to actuate the trap door may be greater than certain operators can easily produce by hand. 
         [0005]    In some cases, motors have been used to turn the drive shaft. When a motor unit is used, it is desirable that the motor unit may be quickly and easily installed. It is also desirable that the motor unit can be easily serviced without significant interruption in the ability to use the trailer on which the motor unit is installed if a motor failure occurs. 
         [0006]    A prior art hopper door motor system is marketed by Roll Rite, LLC, of Alger, Mich. During installation the manual drive system is detached from the trailer, modified to attach the motor and then reinstalled on the trailer. Thereafter, limit switches are attached at locations around the hopper door and a remote mounted electronic control box must be connected to operate the system. A guard is also typically attached to the modified drive system to protect the motor from damage. A drawback of this system is that extensive labor is required to install and service the system, which necessitates removing the trailer from service and increasing the cost of installation. 
       SUMMARY OF THE INVENTION 
       [0007]    The present invention overcomes the shortcomings of the prior art motorized hopper door actuation systems by providing a simplified design with the drive motor, motor control circuit, power connections and a drive shaft for manual operation integrated into the actuator system. With these functions integrated into one assembly, installation time is greatly reduced. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    The accompanying drawings are included to provide a further understanding of embodiments and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments and together with the description serve to explain principles of embodiments. Other embodiments and many of the intended advantages of embodiments will be readily appreciated as they become better understood by reference to the following detailed description. The elements of the drawings are not necessarily to scale relative to each other. Like reference numerals designate corresponding similar parts. 
           [0009]      FIG. 1  is a front view of a motorized hopper door actuation system according to an embodiment of the invention. 
           [0010]      FIG. 2  is a rear view of the motorized hopper door actuation system. 
           [0011]      FIG. 3  is a side view of the motorized hopper door actuation system. 
           [0012]      FIG. 4  is a perspective view of the motorized hopper door actuation system attached to a trailer. 
           [0013]      FIG. 5  is a perspective view of the motorized hopper door actuation system with a handle attached hereto for manual operation. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0014]    An embodiment of the invention is directed to a motorized hopper door actuation system, as illustrated at  10  in the figures. The motorized hopper door actuation system  10  is attached to a hopper door  12  on a trailer  14 . The motorized hopper door actuation system  10  may be readily attached to the trailer  14  with minimal reconfiguration of the trailer  14 . While the motorized hopper door actuation system  10  is described herein with respect to use in conjunction with a trailer  14 , a person of skill in the art will appreciate that it is possible to adapt the concepts of the invention for use in conjunction with other hopper-style vehicles. 
         [0015]    The motorized hopper door actuation system  10  may generally include a mounting structure  20 , a drive motor  22  and a control module  24 . The mounting structure  20  attaches the drive motor and the control module  24  to the trailer  14  in engagement with the hopper door  12 . 
         [0016]    The mounting structure  20  may include a mounting section  30 , an arm section  32  and a main section  34  that are operably attached to each other. In certain embodiments, the mounting section  30  may be pivotally attached to the main section  34  with the arm section  32 . 
         [0017]    Pivotally attaching these components enables the motorized hopper door actuation system  10  to be used in conjunction with trailers  14  having a variety of configurations. Pivotally attaching these components also enables the motorized hopper door actuation system  10  to be readily moved between motorized and manual configurations, as is described in more detail herein. 
         [0018]    The mounting section  30  is configured for use in attaching the motorized hopper door actuation system  10  to the trailer  14 . The mounting section  30  may be fabricated from a variety of materials that are selected to provide the mounting section  30  with sufficient structural rigidity such that the mounting section  30  resists deformation when used. A non-limiting example of a suitable material for use in fabricating the mounting section  30  is a metal sheet having a thickness of about ¼ of an inch. In certain embodiments, a corrosion resistance material may be applied to the metal sheet. 
         [0019]    The mounting section  30  may have a plurality of apertures  40  formed therein that are each adapted to receive bolts  42 . The apertures  40  may be configured to generally conform to aperture patterns that are used for attaching manual gear boxes to trailers. Configuring the mounting section  30  in this manner enables the motorized hopper door actuation system  10  to be attached to the trailer  14  without forming any additional apertures in the trailer  14 . 
         [0020]    Using bolts  42  to attach the motorized hopper door actuation system  10  to the trailer enables the motorized hopper door actuation system  10  to be rapidly attached to the trailer  14  during the initial installation as well as to be rapidly detached from the trailer  14  for performing maintenance on the motorized hopper door actuation system  10 . 
         [0021]    A person of skill in the art will appreciate that alternate techniques may be used to attach the motorized hopper door actuation system  10  to the trailer  14 . Non-limiting examples of the alternate mounting techniques include clamping and welding. 
         [0022]    The arm section  32  may be pivotally attached to at least one arm  46  that extends from the mounting section  30 . The arm section  32  may be selected with a length that enables the main section  34  to be generally aligned to a hopper drive shaft  50 . To enhance the strength of the arm section  32 , the arm section  32  may be formed with a generally U-shaped configuration. 
         [0023]    Similar to the mounting section  30 , the arm section  32  may be fabricated from a variety of materials that are selected to provide the arm section  32  with sufficient structural rigidity such that the arm section  32  resists deformation when used. A non-limiting example of a suitable material for use in fabricating the arm section  32  is a metal sheet having a thickness of about ¼ of an inch. In certain embodiments, a corrosion resistance material may be applied to the metal sheet. 
         [0024]    The main section  34  may be pivotally attached to an end of the arm section  32  that is opposite the mounting section  30 . The main section  34  may include more than one aperture  36  at which the arm section  32  is attached to the main section  34 . Fabricating the main section  34  in this manner enables the motorized hopper door actuation system  10  to be configured for use with a large variety of trailers  14 . 
         [0025]    The main section  34  may be selected with a width that generally conforms to a length and a width of a drive motor  22 . In addition to facilitating mounting of the drive motor  22  in the motorized hopper door actuation system  10 , the main section  34  may extend at least partially over at least a side of the drive motor  22  to protect the drive motor  22  from damage as the trailer  14  to which the motorized hopper door actuation system  10  moves along a road or other surface. 
         [0026]    The main section  34  may be fabricated from a variety of materials that are selected to provide the main section  34  with sufficient structural rigidity such that the main section  34  resists deformation when used. For example, the main section  34  should resist deformation when the motor  22  operates under stall conditions. A non-limiting example of a suitable material for use in fabricating the main section  34  is a metal sheet having a thickness of about ¼ of an inch. In certain embodiments, a corrosion resistance material may be applied to the metal sheet. 
         [0027]    The drive motor  22  may be removably attached to the main section  34  such as by using a plurality of bolts  62 . The main section  34  may include an aperture  64  in an end thereof through which a motor output coupler  66  may extend. The motor output coupler  66  is operably attached to the drive motor  22 . 
         [0028]    A manual drive system  70  may also be mounted to the main section  34 . The manual drive system  70  enables the motorized hopper door actuation system  10  to be used when power is not available for the drive motor  22  or when there is a malfunction in the drive motor  22 . 
         [0029]    The manual drive system  70  also enables the hopper door  12  to continue to be operated when the drive motor  22  is detached from the other components of the motorized hopper door actuation system  10 , which allows the trailer  14  to continue to be used while the drive motor  22  is being serviced. 
         [0030]    The manual drive system  70  may generally include a shaft  72  that is formed with a length that is greater than a length of the main section  34 . The shaft  72  is mounted for rotational motion with respect to the main section  34  about a central axis of the shaft  72 . Depending on the anticipated force needed to rotate the shaft  72 , at least one bearing may be provided to attach the shaft  72  to the main section  34 . 
         [0031]    Depending on the force that needs to be applied to move the hopper door  12  between the open and closed positions, the manual drive system  70  may include a plurality of gears that engage each other to thereby reduce the amount of force needed to rotate the shaft  72 . 
         [0032]    A manual drive output coupler  74  may be provided at a first end of the shaft  72  for attaching the shaft  72  to the hopper drive shaft  50 . A person of skill in the art will appreciate that a variety of techniques may be used for attaching the manual drive output coupler  74  to the hopper drive shaft  50 . 
         [0033]    In one configuration, an end of the hopper drive shaft  50  is cut off and then attached to the manual drive output coupler  74 . The cut off portion of the hopper drive shaft may be attached to the motorized hopper door actuation system  10  using the manual drive input coupler  82 . Configuring the system in this manner enables the crank handle  84  that was previously used to operate the hopper door  12  to be used in conjunction with the motorized hopper door actuator system  10 . 
         [0034]    A non-limiting example of one such attachment technique is forming the hopper drive shaft  50  with a generally cylindrical outer surface having a first diameter. The manual drive output coupler  74  may be formed with cylindrical recess  78  having a second diameter that is slightly larger than the first diameter. Using this configuration enables the hopper drive shaft  50  to be extended into the manual drive output coupler  74 . 
         [0035]    A fastener such as a bolt  80  may be extended through apertures in the manual drive output coupler  74  and the hopper drive shaft  50  to retain the hopper drive shaft  50  in a stationary position with respect to the manual drive output coupler  74 . 
         [0036]    A manual drive input coupler  82  may be attached to a second end of the shaft  72  for attachment to a handle  84 . A person of skill in the art will appreciate that a variety of techniques may be used for attaching the manual drive input coupler  82  to the handle  84 . A non-limiting example of one such attachment technique is forming the handle  84  with a generally cylindrical outer surface having a first diameter. The manual drive input coupler  82  may be formed with cylindrical recess  88  having a second diameter that is slightly larger than the first diameter. Using this configuration enables the handle  84  to be extended into the manual drive input coupler  82 . 
         [0037]    A fastener such as a bolt  90  may be extended through apertures in the manual drive input coupler  82  and the handle  84  to retain the handle  84  in a stationary position with respect to the manual drive input coupler  82 . 
         [0038]    A manual drive locking mechanism  92  may be provided on the motorized hopper door actuation system  10 . The manual drive locking mechanism  92  may be a pin that is oriented generally parallel to the shaft  72 . The manual drive locking mechanism  92  is movable between an engaged position and a disengaged position. When the manual drive locking mechanism  92  is in the engaged position, the manual drive locking mechanism  92  may engage a slotted wheel attached to the coupler and thereby prevent the shaft  72  from rotating. The manual drive locking mechanism  92  thereby prevents inadvertent opening of the hopper door caused by rotation of the shaft  72 . When it is desired to manually open the hopper door  12 , the manual drive locking mechanism  92  is moved to the disengaged position to allow the shaft  72  to rotate. 
         [0039]    The drive motor  22  may have a variety of sizes depending on the force needed to move the hopper door  12  between the closed and opened positions. In certain embodiments, the drive motor  22  may be electrically or hydraulically operated. 
         [0040]    The motor  22  may be formed with a sufficient strength to resist damage to the components inside of the motor  22 , such as armature and gears, when subjected to intermittent stalls in which power is provided to the motor  22  and the motor  22  is prevented from rotating. Stalling occurs when the hopper door  12  reaches an end of its operable range and power continues to be provided to the motor  22  such as when the operator does not realize that the hopper door  12  has reached the end of its operable range. 
         [0041]    In certain embodiments, the motor  22  may resist damage when stalled for a period of up to about 2 minutes. One such feature of the motor  22  that enables the motor  22  to withstand damage during a stall is that the wiring in the armature has a long thermal constant. 
         [0042]    When the drive motor  22  is electrically operated, it may have a strength of up to about 500 foot-pounds. In certain embodiments, the drive motor  22  has a strength of between about 200 and 300 foot-pounds. In other embodiments, the drive motor  22  has a strength of about 250 foot-pounds. 
         [0043]    The drive motor  22  may include a braking mechanism that prevents inadvertent rotation of the motor output coupler  66 . The braking mechanism may automatically engage when power to the drive motor  22  is turned off. 
         [0044]    To protect the drive motor  22  as well as the other components on the trailer  14 , the motorized hopper door actuation system  10  may include a circuit breaker (not shown). In certain embodiments, the circuit breaker may have a rating of up to about 100 amps. In other embodiments, the circuit breaker may have a rating of about 80 amps. In still other embodiments, the circuit breaker may have a rating of between about 20 amps and about 50 amps. Alternatively or additionally, electronic current limiting systems may be used in conjunction with the motorized hopper door actuation system  10 . 
         [0045]    The drive motor  22  may be connected to the control module  24  that controls power to the drive motor  22  and thereby controls the operation of the drive motor  22 . The control module  24  may be mounted on the arm section  22 . Mounting the control module  24  in this manner not only reduces the time to attach the motorized hopper door actuation system  10  to the trailer  14  but also reduces the number of holes that must be formed in the trailer  14 . 
         [0046]    The control module  24  may include a switching mechanism  94  that controls delivery of electrical current to the drive motor  22 . In certain embodiments, the switching mechanism  94  may be a single button. When the button is activated, the control module  24  may be turned on. When the button is activated again, the control module  24  may be turned off. 
         [0047]    In an alternative embodiment where the drive motor  22  is a hydraulic motor, the switching mechanism  94  controls the delivery of hydraulic fluid to the drive motor  22 . Depending on the configuration of the control module  24 , the control module  24  may include electric relays and/or solenoids. 
         [0048]    The control module  24  may include circuitry that monitors the amount of time that the drive motor  22  has been activated such that the drive motor  22  does not attempt to move the hopper door  12  beyond the operational path of the hopper door  12 , which could cause damage to the hopper door  12  and/or the components of the motorized hopper door actuation system  10 . The motorized hopper door actuation system  10  thereby does not require limit switches to be attached to the trailer  14 . 
         [0049]    The control module  24  may include a substantially sealed outer enclosure that protects the components from physical damage or damage caused by contact with materials such as moisture. 
         [0050]    The control module  24  includes at least one power connection  96 . The power connection  96  may take a variety of forms that are manually operable or operable using a tool. One such suitable configuration for the power connection  96  is a nut that engages a threaded post extending from the control module  24 . 
         [0051]    The power connection  96  thereby enables connection and disconnection of wires  98  without having to open the control module  24 . To protect the power connection  96  from damage, the power connection  96  may be placed on a back side of the arm section  22 . 
         [0052]    The control module  24  may be programmed to automatically turn off after a selected period of time of inactivity. In certain embodiments, the control module  24  may be programmed to turn off after 5 minutes of inactivity. 
         [0053]    While it is possible to control the operation of the motorized hopper door actuation system  10  by physically touching the switching mechanism  94 , it is also possible to provide either wired or wireless connection between the control module  24  and a remote control that is located inside of the cab. The remote control thereby enables the hopper door  12  to be opened and closed without the operator leaving the cab. In addition to controlling the motorized hopper door actuation system  10 , it is possible for the remote control to also activate and deactivate other components on the trailer or cab such as a covering system that extends over an upper surface of the trailer. 
         [0054]    The motorized hopper door actuation system  10  may provide an insulated mounting of the electrical components contained therein. Using a dielectric insulator between the mounting bracket and the trailer prevents galvanic corrosion between the trailer and the motorized hopper door actuation system  10 . 
         [0055]    To provide further protection to the components in the motorized hopper door actuation system  10 , it is possible to mount a mud flap  98  to a side of the main section  24 . The mud flap  98  also prevents external elements such as rain and mud from coming into contact with the drive motor  22  or other components inside of the main section  24 . 
         [0056]    The mud flap  98  may be fabricated from a durable material that resists breaking from contact by external objects as the trailer is moving to thereby prevent such objects from contacting the drive motor  22 . 
         [0057]    The mud flap  98  may be formed with a length that is approximately the same as a length of the main section  24 . The mud flap  98  may be formed with a height that is greater than a height of the main section  24  such that the mud flap  98  extends below a lower surface of the main section  24 . 
         [0058]    In operation, if used on the trailer, a gear box (not shown) is detached from the hopper drive shaft  50 . Prior to attaching the motorized hopper door actuation system  10 , it may be necessary to shorten the hopper drive shaft  50  so that the motorized hopper door actuation system  10  may be located as close as possible to the surface of the trailer  14 . 
         [0059]    Next, the motor output coupler  66  is aligned with the hopper drive shaft  50  and a bolt  80  is extended through both the hopper drive shaft  50  and the motor output coupler  66  to attach these two components together. Alternatively, these components may be attached together after the mounting section  30  is attached to the trailer  14 . 
         [0060]    The mounting section  30  is attached to the trailer  14 . As indicated above, bolts may be used to attach the mounting section  30  to the trailer  14  because the bolts enable the motorized hopper door actuation system  10  to be detached from the trailer  14 . 
         [0061]    The power connections  96  are attached to a power source either on the trailer  14  or the cab attached thereto. The hopper door  12  may be operated by using the control module  24  either directly or using the remote control. 
         [0062]    If desired to operate the motorized hopper door actuation system  10  in the manual mode, the hopper drive shaft  50  is detached from the motor output coupler  66  and at least one of the motorized hopper door actuation system  10  and the hopper drive shaft  50  is shifted so that the hopper drive shaft  50  is aligned with the manual drive output coupler  74  on the first end of the shaft  72 . The manual drive output coupler  74  may be attached to the hopper drive shaft  50  with the bolt  80 . 
         [0063]    The handle  84  is attached to the manual drive input coupler  82  and the manual drive locking system  98  is moved to the disengaged position. Thereafter, the handle  84  may be rotated to move the hopper door  12  between the open and closed positions. When done moving the hopper door  12 , the manual drive locking system  98  is moved to the engaged position to prevent inadvertent movement of the hopper door  12 . 
         [0064]    In the preceding detailed description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. In this regard, directional terminology, such as “top,” “bottom,” “front,” “back,” “leading,” “trailing,” etc., is used with reference to the orientation of the Figure(s) being described. Because components of embodiments can be positioned in a number of different orientations, the directional terminology is used for purposes of illustration and is in no way limiting. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. The preceding detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims. 
         [0065]    It is contemplated that features disclosed in this application, as well as those described in the above applications incorporated by reference, can be mixed and matched to suit particular circumstances. Various other modifications and changes will be apparent to those of ordinary skill.