Abstract:
A control assembly for use in a feed delivery assembly comprises a housing having an inlet, an outlet, and a chamber between said inlet and outlet. The chamber is opened in a plane parallel, but radially offset from, an axis of the inlet and outlet. A tube member is removably receivable in the chamber. The removable tube member includes a tube having a length sufficient to span a distance between the inlet and outlet tubes. At least one infrared emitter and at least one infrared receiver are mounted on the tube member tube and are positioned to be opposed to each other such that the receiver will receive and detect light from the emitter. The emitter and receiver are operatively connected to a controller. The controller emits a signal when it is determined that the light from the emitter to the receiver is interrupted.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Application No. 61/150,454 filed Feb. 6, 2009, and which is incorporated herein by reference. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable. 
     BACKGROUND OF THE INVENTION 
     This application relates to controllers for feed delivery systems, and in particular to a controller which utilizes infrared sensors to determine when feed has stopped flowing through a feed delivery system. 
     Infrared sensors for use in feed delivery systems are known. For example, Controltech Corporation of Bondurant, Iowa sells a feed controller which utilized infrared sensors under the name HALO™. However, in controllers such as the Halo controller the infrared light transmitter (i.e., an LED) and the infrared light sensor or receiver are in the tube through which the feed passes, and are thus directly exposed to, and in contact with, the feed. Thus, the sensor components can become covered in feed dust. Further, the feed dust could infiltrate the electronics of the controller, and affect the operation of the controller. 
     Additionally, feed controllers are placed directly in the drop tube of a feed system, and define or form part of the drop tube. Should the controller become inoperable for some reason, the drop tube must be disassembled to remove the controller. 
     It would be desirable to provide a controller which utilizes infrared sensing technology, but in which the emitter and receiver are protected from the dust of the feed environment. It would also be desirable to provide a controller can be easily repaired or replaced without the need to disassemble the drop tube in which the controller is positioned. 
     BRIEF SUMMARY OF THE INVENTION 
     A control assembly for use in a feed delivery assembly comprises a housing having an inlet, an outlet, and a chamber between said inlet and outlet. The chamber is opened in a plane parallel, but radially offset from, an axis of the inlet and outlet. A tube member is removably receivable in the chamber. The removable tube member includes a tube having a length sufficient to span a distance between the inlet and outlet tubes. At least one infrared emitter and at least one infrared receiver are mounted on the tube member tube and are positioned to be opposed to each other such that the receiver will receive and detect light from the emitter. The emitter and receiver are operatively connected to a controller. The controller emits a signal when it is determined that the light from the emitter to the receiver is interrupted. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is a schematic of a feed system incorporating a feed controller; 
         FIGS. 2A  and B are perspective and exploded views, respectively, of an illustrative infrared controller assembly constructed in accordance with the claims; 
         FIGS. 3A  and B are top plan and top perspective views, respectively, of a housing of the assembly; 
         FIGS. 4A-D  are perspective, side elevational, top plan, and bottom plan views, respectively of a tube member of the assembly; 
         FIGS. 5A-B  are perspective and front elevational views, respectively of a flexible control board of the controller in a curved condition; 
         FIG. 5C  is a plan view of the flexible control board in a flat condition; 
         FIG. 6  is a top perspective view of the assembly with a cover removed showing the tube member with the control board positioned in the housing; and 
         FIG. 7  is a top perspective view of the assembly with the cover and control board removed showing the tube member in the housing. 
     
    
    
     Corresponding reference numerals will be used throughout the several figures of the drawings. 
     DETAILED DESCRIPTION OF THE INVENTION 
     The following detailed description illustrates the invention by way of example and not by way of limitation. This description will clearly enable one skilled in the art to make and use the invention, and describes several embodiments, adaptations, variations, alternatives and uses of the invention, including what I presently believe is the best mode of carrying out the invention. Additionally, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. 
     A feed delivery system  10  typically includes a hopper  12  containing feed, a plurality of feed bins  14 , and a feed delivery tube  16  which delivers the feed from the hopper to the bins. Typically, an auger (not shown) extends through the delivery tube  16  and is driven by a motor  18  to carry the feed from the hopper  12  through the tube  16  to the bins  14 . Additionally, the system  10  has drop tubes  20  which extend downwardly from the delivery tube  16  to the bins  14 , there being at least one drop tube per bin. As can be appreciated, when the respective bins are full of feed, their respective drop tubes fill with feed. As the bins are filled, their drop tubes will fill with feed in a consecutive manner. When the drop tube of the last bin in the system fills with feed, all the bins have been filled with feed. Typically, a controller  22  is provided in the last drop tube. The controller  22  includes a sensor to determine when the drop tube fills with feed. Upon sensing this condition, the controller sends a signal which deactivates the motor  18  to stop delivery of feed through the system  10 . 
     The controller  22  can comprise a control assembly  30 , such as shown generally in  FIGS. 2A and 2B . The control assembly  30  comprises a housing  32  having an inlet tube  34 , an outlet tube  36 , and a chamber  38  positioned between and in line with the inlet and outlet tubes. The inlet and outlet tubes are sized to be connected to the tubing which comprises the drop tube  20  in which the control assembly is positioned. As shown, the inlet tube  34  is larger than the outlet tube  36 . Hence, with the configuration shown, the outlet tube is received in a lower portion of the drop tube and the inlet tube  34  receives an upper portion of the drop tube. However, both the inlet and outlet tubes could receive, or be received by, their respective portions of the drop tube. Alternatively, the inlet tube could be received by the upper portion of the drop tube and the outlet tube could receive the upper portion of the drop tube. In a further alternative, a coupler could be used to connect the inlet and outlet tubes to the drop tube. As can be appreciated, the housing  32  (and hence the control assembly  30 ) can be placed in the drop tube  20  by most any acceptable method which will allow feed to pass through the housing (as will be described below). 
     Turning to  FIGS. 3A and 3B , the housing chamber  38  is defined by front and back walls  40   a,b , side walls  42  and a bottom  44 . The inner surfaces of the front and back walls  40   a,b  slope downwardly and inwardly, such that the bottoms of the walls  40   a,b  are closer together than the tops of the walls  40   a,b . The side walls  42  include an upper section  42   a , a mid-section  42   b , and a lower inwardly inclined section  42   c  ( FIG. 3B ). A step  46  is formed between the upper and mid-sections  42   a  and  42   b , such that the mid-section  42   b  of the side walls  42  is positioned inwardly relative to the upper section  42   a . The lower inclined section  42   c  merges or joins with the chamber bottom  44  which is curved. Positioning posts  48  are positioned on the step  46 . Two positioning posts are shown in each step, but more (or fewer) could be provided if desired. As seen in  FIG. 3B , the inlet and outlet tubes  34  and  36  intersect the front and back walls  40   a,b  such that the bottoms of the tubes are spaced slightly from the bottom  44  of the chamber. Lastly, the chamber  38  is provided with a pair of wire connectors  50  which are positioned on the housing chamber front wall  40   a . The wire connectors  50  are comprised of metal and define a bore which extends through the connectors  50 . The connectors  50  can each include a main portion having a stem which extends through a hole in the wall  40   a  and a securing member which holds the connector main portion in place. For example, the stem can be threaded, and the securing member can be a nut-like member. 
     A tube member  52  ( FIGS. 4A-D ) is received in the chamber  38 . The tube member comprises a tube  54  of a diameter substantially equal to the diameter of the junctions of the inlet and outlet tubes  34 ,  36  with the chamber  38 . The tube  54  has a length substantially equal to the distance between the front and back chamber walls  40   a,b . Further, the opposite ends of the tube have a slope or incline corresponding to the slope or incline of the chamber walls. Hence, when the tube member  52  is received in the chamber, the tube  54  will define a passage between the inlet and outlet tubes  34 ,  36  to form a substantially continuous flow passage through the control assembly  30 . The tube  54  includes circumferentially extending slots  56   a,b . Two slots  56   a  are formed on opposing sides of the tube  54  and two slots  56   b  are formed on the top and bottom of the tube  54 . As best seen in  FIGS. 4A-D , the slots  56   a  are aligned with and face each other and the slots  56   b  are aligned with and face each other. However, the slots  56   a  and  56   b  are axially offset from each other. Additionally, an axially extending slot  58  is positioned between the top circumferentially extending slot  56   b  and one of the side circumferentially extending slots  56   a . The axially extending slot is shown to have a length such that one end of the slot is approximately aligned with the side slot  56   a  and the other end is approximately aligned with the side slot  56   b , as best seen in  FIG. 4B . 
     Front and back walls  60  extend outwardly from opposite ends of the tube  54 . The walls  60  are sized and shaped to correspond to the size and shape of the chamber  38 , such that the walls  60  can be received in the chamber  38 . As best seen in  FIG. 4B , the walls  60  are not perpendicular to the axis of the tube  54 . Rather, the walls  60  slope downwardly and inwardly, such that the bottom of the opposed walls  60  are closer together than the top of the opposed walls  60 . A groove  62  ( FIG. 4A ) can be formed in the walls  60  around the tube  54 . The grooves  62  can receive sealing elements, such as O-rings, to form a seal between the tube member  52  and the inlet and outlet tubes  34 ,  36  of the housing  32 . A connector  64  extends between the front and back walls  60 , preferably at the top thereof; and mounting members or flanges  66  extend outwardly from the connectors  64 . The mounting members or flanges  66  are sized to be received on top of the step  46  in the housing chamber  38 . The mounting flanges  66  each have a pair of positioning openings  68  which are sized and positioned to fit over the positioning posts  48  of the chamber step  46 . The sides of the tube member  52  are opened to allow access to the tube  54 . That is, the tube  54  is not fully enclosed. Preferably, at least the tube  54  of the tube member  52  is made from a material through which infrared light can pass. Hence, the tube  54  is at least translucent, and preferably transparent, to infrared light, such that infrared light can pass through the wall defining the tube  54 . 
     The tube  54  and the walls  60  of the tube member  52  are sized and shaped such that when the tube member  52  is received in the chamber  38 , the tube  54  will be coaxially aligned with the inlet and outlet tubes  34 ,  36  of the housing  32 . Thus, the housing inlet tube  34 , the tube member tube  54 , and the housing outlet tube  36  define a portion of the drop tube of the feeding system. 
     A flexible circuit board  70  ( FIGS. 5A-C ) is wrapped about the tube  54  of the tube member  52 . The flexible circuit board  70  includes a microprocessor or controller  72  on one surface of the board  70  and a plurality of infrared emitters  74  and infrared receivers  76  on an opposite surface of the board. The infrared emitters and receivers are electrically connected to the controller, for example, by printed circuits in the flexible circuit board  70 . The flexible circuit board  70  is shown in a flat—unrolled—condition in  FIG. 5C . As seen therein, the infrared receivers  76  and the infrared emitters  74  are formed in groups of three. Further, there are two groups of receivers  76  and two groups of emitters  74 , the two groups being offset from each other. The infrared receivers and the infrared emitters are positioned on the circuit board, and the circuit board is sized, such that when the board is wrapped about the tube  34 , the infrared emitters  74  will be opposed to the infrared receivers  76 , as can be seen in  FIG. 5B . Further, as seen, the infrared receivers and emitters are on an inner surface of the circle defined by the circuit board, and the controller  72  is on an outer surface of the circle defined by the circuit board  70 . This provides for two sets of emitters/receivers which emit infrared light at approximately right angles to each other and axially off set from each other. As is known, the receivers detect the light from the emitters. When the light beam is cut, the controller will detect such, and issue a signal indicative of the fact that the light beam has been cut. 
     Returning to  FIG. 2B , the control assembly  30  lastly includes a gasket  80  which is sized to fit on top of the chamber  38  and a cover  82  which is secured to the chamber  80 , for example, by means of screws  84 . The cover  82  thus closes the chamber  38 . 
     To assemble the control assembly  30 , initially the flexible circuit board  70  is wrapped about the tube member tube  54 . The circumferential slots  56   a,b  of the tube  54  are positioned such that the emitters  74  (which can be LEDs) and receivers  76  of the circuit board  70  will align with the slots  56   a,b . The tube member  52  with the circuit board  70  is then placed in the chamber  38 . When placed in the chamber  38 , the mounting flanges  66  of the tube member  52  rest on the chamber step  42   c  with the mounting holes  68  of the flanges  66  receiving the step positioning posts  48 . As noted above, the tube member tube  54  connects the inlet and outlet tubes  34 ,  36  of the housing to define a flow passage through the assembly  30 . The fit between the tube member and chamber is preferably a tight fit so that the tube member will not be easily dislodged from the chamber, and to help form the seal between the tube member and the chamber around the junction between the tube  54  and the inlet and outlet tubes  34 , 36 , so as to reduce the possibility of particulate matter from exiting the flow path. However, if desired, the tube member  52  can be secured in place by screws which extend through the mounting flanges  66  into the housing step  46 . Leads from the controller/microprocessor  72  are connected to the wire connectors  50  of the housing. The gasket  80  and cover  82  are then positioned over the chamber to close the chamber. The control assembly  30  can then be placed in line in a drop tube  20 . The control assembly can be placed in electrical communication with the controller for the system (which activates and deactivates the motor  18 ) by means of wires (not shown) which are connected at one end to the wire connectors  50  on the control assembly  30  (and thus are in communication with the circuit board  70 ) and are connected at the other end to the system controller. If desired, a wireless communication could be provided for, in lieu of the wired connection between the circuit board  70  and the system controller. 
     In operation, feed will flow through the drop tube  20 , as generally described above. When the feed fills up the drop tube  20  containing the control assembly  30 , the feed will fill the control assembly tube  54  and the light beam (from the emitters  74  to the receivers  76 ) will be interrupted. This will cause the circuit board controller  72  to send a signal to the system controller, and, the system controller will deactivate the auger motor  18  to stop the flow of feed through the feed system  10 . 
     As can be appreciated, the infrared emitters and receivers are recessed relative to the inner surface of the tube member tube  54  (through which grain flows). Thus, the infrared emitters and receivers are protected from direct contact with the feed. This will help keep the emitters and receivers clean. Further, because the tube  34  is made from infrared translucent or transparent material, the slots  56   a,b  need not extend all the way through the tube wall or can even be omitted. In the former case, the slots would be formed in the outer surface of the tube wall. In either event, this will totally isolate the emitters and receivers from the feed flowing through the tube  54 , thereby preventing feed dust and particles from contacting the electronic components of the sensor assembly  30 . The provision of the slots places the emitters and receivers closer to the flowing feed, and limits the amount of tubing material through which the infrared light must pass. The slots can be formed as grooves in the outer surface or the slots can pass through the tube  34 , in which case the emitters and receivers are recessed from the flowing feed. In the former case, the emitters and receivers remain totally isolated from the flowing feed; and in the latter case the emitters and receivers are protected from the flowing feed by their being recessed relative to the inner surface of the tube. 
     Additionally, the tube assembly  52  is not permanently fixed in place. It can be removed for cleaning, repair or replacement without the need to disconnect the housing  32  from the drop tube. As can be appreciated, the fact that the housing does not need to be removed in order to repair or replace the sensor assembly greatly eases the ability to repair or replace the sensor assembly. 
     As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. For example, if the slots extend through the tube member tube  54 , the tube member tube could be made from material which is opaque to infrared light. This example is merely illustrative.