Abstract:
A vertical grain cleaner having an intake manifold modified to reduce the formation of vortexes and pressure imbalances based on the flow of aspiration air through the cleaner. An intake manifold with a louver defining one or more apertures that allows air to pass through the louver. Methods of operating vertical grain cleaners.

Description:
RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application Ser. No. 61/466,613, filed Mar. 23, 2011, titled Vertical Drop Product Cleaner with Perforated Intake Manifold, the contents of which are hereby incorporated by reference. 
    
    
     TECHNICAL FIELD 
     The application relates to vertical drop product cleaners. 
     BACKGROUND 
     Vertical drop product cleaners generally rely upon an upward vertical air movement through a granular product falling under gravitational influence and a horizontal or transverse airflow to separate the fines and foreign material from the product and carry it away therefrom. Such cleaners remove fines and foreign material from dry, free flowing particulate matter by using substantially perpendicular air flows through the flowing product. 
     SUMMARY 
     According to one aspect of the invention, a vertical grain cleaner is provided having an intake manifold modified to reduce the formation of vortexes and pressure imbalances based on the flow of aspiration air through the cleaner. In some embodiments, an intake manifold of the cleaner includes a louver defining one or more apertures that allow air to pass through the louver. In certain embodiments, the one or more apertures include a plurality of apertures arranged in a series of rows and columns. Such embodiments can be referred to as “perforated” and/or “fenestrated.” 
     Such intake manifolds improve the stability of airflow, and reduce or eliminate vortices. Further, the airflow through the perforated manifold aerates the product and better disperses the product within the boundaries of the cleaner&#39;s downward chamber. Such embodiments are useful for increasing the cleaning efficiency of the cleaner, allowing for greater product throughput for a given size of cleaner compared to a cleaner without an intake manifold with apertures. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following drawings are illustrative of particular embodiments of the invention and therefore do not limit the scope of the invention. The drawings are not necessarily to scale and are intended for use in conjunction with the explanations in the following detailed description. Embodiments of the invention will hereinafter be described in conjunction with the appended drawings, wherein like numerals denote like elements. 
         FIG. 1  is a side elevation, partial cross sectional view showing an apparatus in accordance with an embodiment of the invention in an open circuit configuration fluidly connected to a cyclone-type dust collector and blower. 
         FIG. 2  is an exploded perspective view of an aspirator cleaner in accordance with an embodiment of the invention. 
         FIGS. 3A and 3B  are an end view of the apparatus shown in  FIG. 1  in a partial cross sectional view. 
     
    
    
     DETAILED DESCRIPTION 
     The following detailed description is exemplary in nature and is not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the following description provides practical illustrations for implementing exemplary embodiments. Utilizing the teaching provided herein, those skilled in the art will recognize that many of the examples have suitable alternatives that can be utilized. 
     A representative cleaner useful in embodiments of the invention will now be described. However it should be noted that the described cleaner is merely representative, and embodiments of the invention include other cleaners and cleaner configurations.  FIG. 1  illustrates a side elevation, partial cross sectional view, of a product cleaner apparatus  10 . The cleaner  10  is shown in an open circuit configuration, that is, in a configuration where air from the ambient environment is continuously drawn therein by a negative air pressure created by a fan or blower  12  of known type. The cleaner  10  is shown attached to a cyclone-type dust collector  14  of known type. 
     Representative blower  12  includes a motor  16  that drives an impeller (not seen) contained within a blower housing  18  that is driven by the motor  16  through a belt  20  extending between a pulley  22  attached to the motor  16  and a pulley  24  attached to the impeller. The blower  12  blows air out through an air outlet  26  as indicated by arrow  28 . 
     Blower  12  is shown fluidly connected to the dust collector  14  by an air outlet  30 . Fines and other foreign material  32  settle out of the air flow passing through the collector  14  and drop out of the bottom thereof through an outlet  34  where it can be collected and disposed of. The dust collector  14  in turn can be fluidly connected to the product cleaner  10  by an air outlet  36 . Air flows into the cleaner  10  from the ambient environment as indicated by arrow  38  as a result of the negative air pressure created by the blower  12 . This air flow  38  into the cleaner  10  can be used to remove fines and other foreign materials from the product to be cleaned. 
     A representative embodiment of a cleaner  10  will now be described with principal reference to  FIGS. 1 ,  3 A and  3 B. Cleaner  10  includes a charging inlet  40  into which dirty product  42  to be cleaned can be placed in known manner. In the embodiment shown, the dirty product  42  is held in a charging hopper  44  and metered into housing  46  by a metering reel  48  disposed within the hopper  44 . The metering reel  48  acts to deliver product  42  into the housing  46  in a controlled, measured manner, and can be mounted for rotation on a shaft  50  that can be rotated in known manner. In the embodiments shown, dirty product  42  is received between the substantially radially extending vanes  52  of the metering reel  48  along the top thereof and carried by the rotation of the reel  48  to a hopper discharge outlet  54  therebelow such that the dirty product  42  can fall into the housing  46 , as best seen in  FIG. 1 . 
     The embodiment of the housing  46  as seen in  FIG. 2  comprises an external skeleton  55 . As shown, skeleton  55  includes upright corner members  56 , illustrated in phantom outline, and transverse members  58  extending between the corner members  56  at opposite ends thereof. As shown, skeleton  55  has a substantially rectangular cross section. Housing  46  further includes a pair of end panels  60  mounted to opposing sides of the housing  46  in any known manner such as nuts and bolts. End panels  60  may include Lexan™ synthetic material. Other materials (e.g., transparent materials) may also be used for the end panels. To facilitate their removal, end panels  60  may be attached by means of hand manipulable fasteners such as wing nuts or the like. 
     In the embodiment shown, housing  46  also includes a pair of mounting rails  62  and  64  attached at the upper end thereof and a pair of mounting rails  66  and  68  attached at the lower end thereof. Mounting rails  62 ,  64 ,  66 , and  68  are attached to the skeleton  55  by means of elongate attachment members  70  that are attached to the transverse members  58 . As shown, members  70  have a cylindrical configuration and provide a stand-off function of spacing the mounting rails inwardly from the transverse members  58 . 
     As shown, mounting rails  62  and  66  removably mount an inlet manifold  72  and mounting rails  64  and  68  removably mount an outlet manifold  74 . Manifolds  72  and  74  are mounted within housing  46  by the rails  62 - 68  so as to be spaced apart and define therebetween a separation plenum  76 . Hopper discharge outlet  54  feeds dirty product  42  into the separation plenum  76  for cleaning of fines and foreign matter from the product. 
     In some embodiments, inlet manifold  72  comprises a pair of ribs  78  and  80  that extend substantially upright. Ribs  78  and  80  each can include a slot  82  configured to receive and slide upon the lower mounting rail  66  when the inlet manifold  72  is disposed in position in housing  46 . Thus, the slots may be configured to have a configuration that matches that of the mounting rail  66 , which as shown in the present embodiment is substantially rectangular but could take on other configurations. 
     Ribs  78  and  80  may be configured to mount thereto a plurality of middle louvers  84 , a top louver  84 , and a bottom louver  88 . As shown, the louvers  84 - 88  are spaced apart so as to define air inlet channels  90  therebetween. 
     In the embodiment shown, each middle louver  84  includes upper and lower inlet lips  92  and  94 , respectively. Upper inlet lips  92  are shown extending outward in the direction of the inwardly moving airflow  38  while lower inlet lips  94  are shown extending inwardly into the separation plenum  76 . The lips  92  and  94  are interconnected by a substantially vertically extending louver member  96 . 
     As shown best in  FIG. 2 , in accordance with an embodiment of the invention at least one of the louvers further defines at least one aperture  97 . Such a louver improves the stability of downward airflow, and reduces or eliminates vortices. Further, the airflow through the apertured louver aerates the product and better disperses the product within the boundaries of the cleaner&#39;s separation plenum. Such embodiments are useful for increasing the cleaning efficiency of the cleaner, allowing for greater product throughput for a given size of cleaner compared to a cleaner without an intake manifold with apertures. 
     The at least one aperture  97  can include any useful shape (e.g., oval, circle, slot) or configuration. In certain embodiments, at least one louver includes a plurality of apertures arranged in a series of rows and columns, and can be said to be perforated or fenestrated. In specific embodiments, the at least one louver includes between about 20 and about 50% (e.g., about 35%) open area defined the by at least one aperture. In some embodiments, the inlet manifold includes a series of louvers that each define a plurality of apertures. 
     In embodiments where the louver includes an upper inlet lip  92 , a lower inlet lip  94 , and a vertically extending louver member  96  extending between the upper inlet lip and the lower inlet lip, at least one aperture  97  can be included in the upper inlet lip, the lower inlet lip, or the vertically extending louver member. In other embodiments, the louver includes at least one aperture in the upper inlet lip, the lower inlet lip, and the vertically extending louver member. In yet other embodiments, the louver includes a plurality of apertures in the upper inlet lip, the lower inlet lip, and the vertically extending louver member. In other embodiments, the louver includes a plurality of apertures in the upper inlet lip or the lower inlet lip, and the vertically extending louver member. Apertures included in the vertically extending louver member will reside in a substantially vertical plane. 
     As shown, some embodiments of the cleaner have a plurality of louvers (e.g., five). In such embodiments, between one and all of the louvers can include any of the aperture configurations described herein, and the remaining louvers can be provided without apertures. For example, the uppermost louver can be provided without apertures, while each louver below the uppermost louver can be provided with apertures. In other embodiments, the uppermost two louvers can be provided without apertures, while each louver below the second uppermost louver can be provided with apertures. 
     Returning to describing the representative embodiment of a cleaner, top louver  84  can include a lower lip  98  that extends into the space between the manifolds, an upright extending member  96 , and a hook element  102 . Hook element  102  can be configured to extend over and somewhat around mounting rail  62  and to be slidably received thereby. Thus, when it is desired to clean, maintain or replace the inlet manifold  72 , the end panel  60  can be removed and the manifold  72  can be slidably removed from the housing of the product cleaner  10 . The cleaning, maintenance or replacement of the manifold can be accomplished and the manifold restored to its operational position within the housing  46 . As shown, the hook element  102  can comprise a first, upwardly and outwardly extending member  104  and a second, downwardly and outwardly extending member  106 . Members  104  and  106  together create a recess  108  at the members&#39; juncture therebelow. The recess  108  receives the mounting rail  62 . Thus, as shown, hook element  102  comprises a pair of angularly disposed members that create a hook by which the inlet manifold  72  can be supported from the mounting rail  62 . 
     The lower louver  88  can include an upper lip  92  similar to the upper lips of the middle louvers  84 . As shown, lower louver  88  has no lower lip, though such a lip could be provided if desired. 
     In some embodiments, outlet manifold  74  can also include a pair of upright extending ribs and a plurality of longitudinally, that is, substantially horizontally extending louvers. In such embodiments, outlet manifold  74  includes ribs  110  and  112 , top louver  114 , middle louvers  116 ,  118 ,  120 , and  122 , and bottom louver  124 . The outlet manifold louvers are spaced vertically apart from each other along the upward extent of the ribs  110  and  112  and extend substantially the entire length of the housing  46 . As with the inlet manifold  72 , the spacing of the louvers  116 - 124  creates air outlets  126  for the transverse air flows with five such outlets being shown in  FIGS. 3A and 3B . A sixth air outlet  128  can be created between the outlet manifold top louver  114  and a downwardly depending member  130  attached to the charging hopper  44  and extending into the hopper discharge outlet  54 . 
     As shown, outlet manifold top louver  114  comprises a hook element  132 , an upright or substantially vertically extending member  134 , and a lower lip element  136 . In the embodiment shown, lower lip element  136  comprises, as shown, a first inward and downward extending segment  138  and a second inward and downwardly extending segment  140  angularly disposed relative to the first segment  138 . The hook element  132  includes first and second hook angularly disposed members  142  and  144 , respectively, which can be similar to the first and second hook members  104  and  106  of the top louver  84  of the inlet manifold  72 . The juncture of the first and second hook members  142  and  144  forms a recess  146  to slidably receive the mounting rail  64 . 
     The middle louvers  116 - 120  of the embodiment shown each include an upper lip  148 , a lower lip element  136 , and an upright or substantially vertically extending member  150  therebetween. The upper lips  148  of one louver and the lower lip element of the next adjacent louver therebelow define the air outlets  126  therebetween. The lower louver  122  includes an extended upper lip  152  and an upright or substantially vertically extending member  154 . The ribs  110  and  112  each include slots  82  at their lower ends that are configured to slidably receive the mounting rail  68 . In some embodiments, the outlet manifold louver can be substantially free from apertures. 
     Embodiments of the outlet manifold  74  can thus be slidably removed from the housing  46  as desired for cleaning, maintenance or replacement by the operator of apparatus  10 . Where such remedial work is desired, the end panel  60  can be removed, the outlet manifold can be slid outwardly on the mounting rails and the remedial work accomplished. It will be observed with respect to  FIG. 2  that the ribs  82  each include at least one flange  156  extending therefrom substantially parallel with the extent of the louvers and including a bolt hole or aperture  158  by which the louvers of manifold  74  can be removably secured to the ribs. The louvers can also be welded to the ribs if desired. Inlet manifold ribs  82  are similarly constructed, though such flanges and are not shown therefore. 
     Referring now to  FIGS. 1 ,  3 A and  3 B, it will be observed that the present invention  10  may be equipped with a velocity control module  160 . Module  160  can be attached to the air inlet side of the housing  46  and include a plurality of dampers that can be selectively adjusted to control the airflow passing through each of the air inlets  90 . The adjustment for the individual air inlets can be made manually or automatically based upon sensed readings of the air flow through the individual air inlets. 
     In the embodiment shown, module  160  includes a module housing  162 . Mounted therein are a plurality of dampers  164 ,  166 ,  168 ,  170 ,  172 , and  174  that extend substantially the length of the housing  46 . Each damper  164 - 172  can be mounted for synchronous rotation with and on a damper shaft  176 . Each damper  164 - 172  includes a pair of damper vanes  178 - 180  that extend outwardly from the shaft  174 . The vanes  178  and  180  can each include a radially inward first portion  182  and a radially outward second portion  184  angularly disposed relative thereto. Each damper  164 - 174  can be contained within its own damper unit or air passage comprising end walls  186  and  188  of the module  160  ceiling and floor elements. In the embodiment shown, damper  164  has a ceiling element  190  and a floor element  192  while damper  166  immediately therebelow has a ceiling element formed by floor element  192  of damper  164  and a floor element  194 . The module  160  can include a plurality of inwardly and downwardly extending dividers  190 ,  192 ,  194 ,  196 ,  198 ,  200 , and  202  that engage the upper lips  92  of the inlet manifold louvers so as to cooperate in defining a flow path or air passage for ambient air entering the velocity control module and the product cleaner  10 . Each air passage can communicate with one of said air inlets  92 . Rotation of the shafts  176  can cause the vanes to rotate therewith and to open or close the air passage accordingly. That is, rotation of the shafts  176  and thus the vanes can change the size of the corresponding air passage and enable the operator to control the air flow through the passage into its respective air inlet  92 . With the use of the velocity control module  160  the volume and velocity of ambient air entering the cleaner  10  can be controlled such that the cleaning operation can more efficiently take place. 
     The operation of a representative cleaner will now be described. Referring to  FIG. 1 , it will be observed that product enters the cleaner  10  and can be metered into the separation plenum  76 . As the product falls under gravitational influence it cascades alternately back and forth across the plenum  76  due to the action of engaging the upper and lower lips of the louvers forming the inlet and outlet manifolds. Thus, as a representative example of such falling action, falling product will engage the lower lip element  136  of an air outlet manifold louver and be directed thereby, that is, given a velocity component substantially transverse to the gravitational velocity, in the direction of the opposing air inlet manifold louver on the opposing side of the separation plenum  76 . The product will “bounce” to the other side of the separation plenum where it will engage the upright portion  96  and lower lip  94  of an inlet manifold louver, the lower lip  94  redirecting the falling product back across again. It this way the falling product can be tumbled by the inwardly extending lower lips of the manifold louvers to expose the surface of the granular product to the upward and transverse air flow through the apparatus for removal of fines and other materials and to expose the fines and foreign materials to the air flow to allow and facilitate its removal from the falling product, thus cleaning it. 
     Referring now to  FIGS. 1 and 3B , as the falling product encounters the lower lip  94  of the lower louver  88  it falls into a discharge hopper  204 . Hopper  204  may include a spring loaded or biased discharge gate  206  as shown. The cleaned product  210  will fall out of the hopper  204  through a discharge chute  208  and into the appropriate product conveyor (not shown) to be conveyed away for use or transport as desired. 
     Air can be moved (e.g., forced or drawn) through the separation plenum via a blower  12 . Blower  12  can create a negative air pressure within the apparatus  10 , causing ambient air to enter the velocity control module  160  as indicated by arrow  38  and pass through the apparatus shown in  FIG. 1  to exit therefrom as indicated by arrow  28 . More specifically, ambient air can enter the velocity control module  160  and pass through the air inlets  90  and apertures  97  into the separation plenum  76  as indicated by arrows  220  and  221 , respectively, shown in  FIGS. 3A and 3B . 
     As the air flow  220  enters the separation plenum it will split into an upwardly directed air flow through the falling product  42 , as indicated by arrow  222 , and a transverse air flow exiting the through the air outlets  126  as indicated by arrow  224 . The upward air flow  222  “fluffs” the falling product and separates the fines and foreign materials contained therein therefrom, allowing the transverse air flow  226  to carry the fines and foreign materials away through the air outlets  126  and into the air outlet  36  to the collector  14  where it settles out as previously described. In this manner, then, the dirty product  42  can be cleaned to yield clean product  210  and fines and foreign materials  32 . 
     Because of the presence of the apertures  97 , air flow will be improved. More specifically, such apertures will improve the stability of airflow and reduce or eliminate vortices. Further, the airflow through the aperture aerates the product and better disperses the product within the boundaries of the cleaner&#39;s separation plenum. Such embodiments are useful for increasing the cleaning efficiency of the cleaner, allowing for greater product throughput. 
     In the foregoing detailed description, the invention has been described with reference to specific embodiments. However, it may be appreciated that various modifications and changes can be made without departing from the scope of the invention.