Abstract:
Disclosed is a system for precisely controlling distribution of saline, which employs a 6-bit manifold employing 6 solenoid valves for controlling the flow of hydraulic fluid therethrough. The manifold is in hydraulic fluid communication with motor valves. A mathematical formula or a lookup table determines the amount of saline distributed. The system is devoid of feedback. The 6-bit manifold can be employed on a salt spreader vehicle for controlling an improved flighted auger assembly for distributing granular salt from the rear of a salt spreader vehicle. The auger assembly has 3-stages of increasing diameter flights. The largest flight is at a discharge end of the auger assembly. A choke surrounds the ultimate auger flight at the auger assembly discharge end. The space between the choke and the ultimate flight is between about ⅛ and ¼ inch.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    None. 
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH 
       [0002]    Not applicable. 
       BACKGROUND 
       [0003]    The present disclosure relates to roadway snow and ice control and more particularly to a system that employs a six-bit hydraulic manifold onboard a dump truck and in a stationary brine control assembly. 
         [0004]    A variety of commercial proposals involve spreading granular salt, brine, or brined salt on roadways for snow and ice control. Such proposals include, for example, U.S. Pat. Nos. Re 33,835, 5,318,226, 5,988,535, 6,446,879, and 7,108,196. A related proposal for making brine is found in U.S. Pat. No. 6,736,153. 
         [0005]    Despite such advances in this art, inconsistence in salt spreader output from the dump truck, auger bypass, and inaccurate reporting of salt usage still exist. Considering that in a moderately severe winter, salt usage by the State of Ohio, for example, could exceed $100,000,000 annually, there is a strong drive to improve such salt roadway distribution. 
         [0006]    One method to decrease salt usage would be to enable salt spreader trucks to place light loads (say, 100 to 200 pounds/mile). Right now minimum accurate salt usage ranges from about 400 pounds/mile on up to 1,000 pounds/mile or more. 
         [0007]    Of course, additional improvements in the salt spreading operation could save additional governmental funds, as well as more reliably spread salt and brined salt on roadways for ice and snow control. 
         [0008]    It is to such improvements that the present disclosure is addressed. 
       BRIEF SUMMARY 
       [0009]    Disclosed is a system for precisely controlling distribution of saline, which employs a 6-bit manifold employing 6 solenoid valves for controlling the flow of hydraulic fluid therethrough. The manifold is in hydraulic fluid communication with motor valves. A mathematical formula or a lookup table determines the amount of saline distributed. The system is devoid of feedback. The 6-bit manifold can be employed on a salt spreader vehicle for controlling an improved flighted auger assembly for distributing granular salt from the rear of a salt spreader vehicle. The auger assembly has 3-stages of increasing diameter flights. The largest flight is at a discharge end of the auger assembly. A choke surrounds the ultimate auger flight at the auger assembly discharge end. The space between the choke and the ultimate flight is between about ⅛ and ¼ inch. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    For a fuller understanding of the nature and advantages of the present method and process, reference should be had to the following detailed description taken in connection with the accompanying drawings, in which: 
           [0011]      FIG. 1  is an overhead layout of salt, brine, and brined salt generation station; and a salt truck loading/washing operation; 
           [0012]      FIG. 2  is piping schematic for the layout in  FIG. 1 ; 
           [0013]      FIG. 3  is an overhead schematic for the brine making and brine storage tanks and associated piping; 
           [0014]      FIG. 4  is an overhead schematic of the wastewater recycling tank and associated piping; 
           [0015]      FIG. 5  is an overhead schematic of the blend tank and associated piping; 
           [0016]      FIG. 6  is an overhead schematic of the calcium chloride (CaCl) tank and associated piping; 
           [0017]      FIG. 7  is an overhead schematic of the BEET tank and associated piping; 
           [0018]      FIG. 8  is schematic hydraulic diagram showing the components employed in the new 6-bit hydraulic manifold for the brine station; 
           [0019]      FIG. 9  is block diagram illustrating the operation of the truck fill by the end user using the operator key fob;  FIG. 10  is a block diagram illustrating the operation of the recipe setup by the station manager; 
           [0020]      FIG. 11  is the control panel used by the end user for selecting the desired truck fill; 
           [0021]      FIG. 12  is a perspective view of a key fob; 
           [0022]      FIG. 13  is the control panel; 
           [0023]      FIG. 14  is the control pad on the control panel used by the station manager of  FIG. 13 ; 
           [0024]      FIG. 15  is left elevational view of a truck outfitted with the six-bit hydraulic manifold and other features disclosed herein; 
           [0025]      FIG. 16  is the rear elevational view of the truck of  FIG. 15 ; 
           [0026]      FIG. 17  is side sectional view of the 3-stage auger with tight choke, as carried by the rear of the truck of  FIG. 16 ; 
           [0027]      FIG. 18  is a sectional view through line  18 - 18  of  FIG. 17 ; 
           [0028]      FIG. 19  is schematic hydraulic diagram showing the components employed in the new 6-bit hydraulic manifold for the salt spreader on the truck of  FIG. 16 ; 
           [0029]      FIG. 20  graphically plots steps versus gallons per minute of salt in tests of the disclosed apparatus; 
           [0030]      FIG. 21  is the salt truck control panel; 
           [0031]      FIG. 22  is an exemplary table of the disclosed six-bit manifold valve positions for its  63  steps; and 
           [0032]      FIG. 23  is a block diagram of a control circuit that may be employed for the salt truck. 
           [0033]    The drawings will be described in greater detail below. 
       
    
    
     DETAILED DESCRIPTION 
       [0034]    As disclosed above, the ability to dispense salt in finer quantities is one way to reduce unnecessary use/consumption of salt in connection with the formation of brine and the dispensing on roadways of salt, brine, and brined salt. The six-bit manifold disclosed herein is a component that achieves such reduced salt consumption, along with additional features disclosed herein. 
         [0035]    Referring initially to  FIG. 1 , an overhead layout of salt, brine, and brined salt generation station; and a salt truck loading/washing operation is depicted. A brine truck,  10 , is seen in a wash bay,  12 , by while a salt spreader truck,  14 , loaded with granular salt is seen in its salt loading position. A control room,  16 , also is seen within the building complex along with an equipment room,  18 . Wash bay  12  has a power washer control panel,  20 , located along one of the walls common with equipment room  18 . A key fob sensor panel,  22 , is located on one of the outside walls of control room  16 . A recipe control panel,  24 , is located on one of the inside walls of control room  16 . 
         [0036]    Housed within building area,  26 , as indicated by the dashed line, is the brining complex, such as is described in U.S. Pat. No. 6,736,153. Components include a brine/vegetable matter tank,  28  (BEET), recycle tank (RECYC),  30 , calcium chloride tank,  32  (CaCl), blend tank,  34  (BLEND), a first brine tank,  36  (BRINE), a second brine tank,  38  (BRINE), a brine maker,  40 , a semi fill hose,  42 , and truck fill hose,  44 . Each of the tanks 28-38 are 10,000 gallon tanks made of and/or lined with material resistant to corrosion by salt and brine. 
         [0037]    Referring now to the piping schematic in  FIG. 2 , each brine tank  36  and  38  is in fluid connection with a positive displacement pump,  46  and  48 , respectively, which pumps are powered by hydraulic motors,  50  and  52 , respectively. The output from the brine tank pumps  46  and  48  runs to bypass valve,  54 , one branch recycling to positive displacement pumps  44  and  48  and the other branch running through a check valve,  56 , and into a mixer tube,  58 . 
         [0038]    BEET tank  28  also has a positive displacement pump,  60 , powered by a hydraulic motor,  62 , running to a bypass valve,  64 , having a recirculation line indicated by the dotted line and also running through a check valve,  66 , into mixer tube  58 . In similar fashion, CaCl tank  32  also has a positive displacement pump,  68 , powered by a hydraulic motor,  70 , running to a bypass valve,  72 , having a recirculation line indicated by the dotted line and also running through a check valve,  74 , into mixer tube  58 . 
         [0039]    The flow exiting mixer tube  58  runs through a valve,  76 , which has a flow back through a check valve,  78 , into blend tank  34  and a flow running through a check valve,  80 , to another tee,  82 , and into truck fill hose  44 . The material in blend tank  34  flows through a check valve,  84 , into tee  82  and onward to truck fill hose  44 . 
         [0040]    Material in brine tank  38  can be pumped by a pump,  86 , through a check valve,  88 , and into a tee,  90 , to truck fill hose  44 . Alternatively, material in brine tank  38  can be pumped by a high volume pump,  92 , and into semi fill hose  42 . 
         [0041]    Referring now to  FIG. 3 , brine tanks  36  and  38  are seen. As mentioned earlier, each tank has a maximum capacity of 10,000 gallons. Brine tank  36  is connected to brine tank  38  through a line  47 . A sensor, such as a float sensor,  94 , indicates that brine tank  38  is filled to capacity, which causes any brine flow into brine tank  36  and  38  to cease. Brine tank  36 / 38  can be filled from brine maker  40 , which receives material from RECYC tank  30  and/or domestic water, which flows using a centrifugal pump,  95 , and into brine maker  40 . A recirculation loop,  96 , uses another centrifugal pump,  98 . A centrifugal pump,  100 , pumps brine from brine maker  40  into brine tanks  36  and  38 . 
         [0042]    Referring now to  FIG. 4 , RECYC tank  30  is fitted with a float sensor,  102 , indicates that RECYC tank  30  is filled to capacity, which causes any flow into RECYC tank  30  to cease. Material used in wash bay  12  is collected and recycled into RECYC tank  30 , through a heater,  104 , which keeps RECYC tank from freezing. 
         [0043]    Referring now to  FIG. 5 , a sensor, such as a float sensor,  106 , indicates that BLEND tank  34  is filled to capacity, which causes any flow into BLEND tank  34  to cease. Material from mixing tube  58  can flow into a recirculation loop,  108 , powered by a pump,  110 , for causing a circulation flow inside BLEND tank  34  with provision to divert the recirculation loop flow to fill hose  44 . 
         [0044]    Referring to  FIG. 6 , CaCl tank  32  is shown with provision of its contents, 30% aqueous calcium chloride, to calcium chloride pump,  68 , in  FIG. 2 . Again, the capacity of CaCl tank  32  is 10,000 gallons. 
         [0045]    Referring to  FIG. 7 , BEET tank  28  is shown with a recirculation loop,  112 , for causing a recirculation flow thereinside using another centrifugal pump,  114 . While this tank often will be filled with byproduct from sugar beet production, other vegetable material may be used alone and/or in addition to the indicated sugar beet byproduct. Such vegetable material further depresses the freezing point of brine. 
         [0046]    Referring now to  FIG. 8  whereat a schematic hydraulic diagram showing the components employed in the new 6-bit hydraulic manifold for the brine station is set forth. Important in using such 6-bit hydraulic manifold is that no feedback loop is required. Simply, such 6-bit hydraulic manifold provides  63  steps in controlling flow, which yields an error of about 2% at most and often less than about 1%. In particular, such manifold relies simply on 6 precise orifices that can be used in any combination, yielding the noted 63 steps. Only one of the three 6-bit manifolds will be described in detail, as the other two shows 6-bit hydraulic manifolds operate in precisely the same fashion. General operation of a similar 4-bit device is disclosed in U.S. Pat. No. 7,108,196 (FIG. 6). The present 6-bit manifold operates in similar fashion. 
         [0047]    Referring now to a 6-bit hydraulic manifold,  116 , six-solenoid controlled orifices of different size are shown. In particular, a solenoid,  118 , uses a suitably sized orifice for a 0.25 gpm (gallon per minute) flow; a solenoid,  120 , uses a suitably sized orifice for a 0.5 gpm (gallon per minute) flow; a solenoid,  122 , uses a suitably sized orifice for a 1.0 gpm (gallon per minute) flow; a solenoid,  124 , uses a suitably sized orifice for a 2.0 gpm (gallon per minute) flow; a solenoid,  126 , uses a suitably sized orifice for a 4.0 gpm (gallon per minute) flow; and a solenoid,  128 , uses a suitably sized orifice for a 8.0 gpm (gallon per minute) flow. Manifolds  130  and  132  are identical to manifold  116 . Manifold  116  controls the BEET tank; manifold  130  controls the CaCl tank; and manifold  132  controls the Brine tank  38 . 
         [0048]    Associated with manifold  116  is a compensator,  134 , functioning to provide a constant speed or pressure drop for motor  62  BEET tank  28 . Compensators  136  and  138  generally provide the same function as compensator  134  for CaCl tank motor  70  and the brine tank motors  50  and  52 , respectively. Operator input for the mixing of concentration in BEET tank  28  is at pump  60 ; pump  58  for CaCl tank  32 , and pumps  46 / 48  controlled by valve  140  and manifold  132  for brine tanks  36 ,  38 . Operator input for motor  85  of pump  86  is through valve  142  (truck fill brine only) and motor  91  of pump  92  through valve  44  (semi fill), and motor  109  of pump  110  through valve  146  (stir blend tank or truck fill from blend tank) and motor  113  of pump  114  through valve  148  (stir BEET tank). 
         [0049]    Referring now to  FIGS. 9-12 , displayed is the block diagram illustrating the operation of the truck fill by the end user using an operator key fob,  158  (see  FIG. 12 ), and key fob sensor panel  22  (see  FIG. 1 ). Operation commences at START at block  160  with the truck operator scanning key fob  158  at block  162  by passing key fob  158  over sensor area,  168  of panel  22  (see  FIG. 11 ). At block  164 , the operator rotates a knob,  170  on panel  22  (see  FIG. 11 ), to select filling a semi, filling a truck with brine, or filling a truck with a mixed recipe. If the operator selects “Semi”, the operation proceeds to block  172  where the operator pulls a button,  174  on panel  22  ( FIG. 11 ). Operation then proceeds to block  176  where the computer selects semi fill pump. Operation next proceeds to block  178  where the pump  92  is activated to begin delivery of product into the semi. At block  180 , the operator pushes button  174  to stop pump delivery of product. Operation then ends at block  182 . 
         [0050]    When the operator rotates knob  170  to select “mix”, operation proceeds to block  184  where the operator pulls knob  174  “on”. Operation proceeds to box  186  where the computer selects the current mix recipe. Operation then proceeds to box  188  where the pumps  46 ,  48 ,  60 , and  68  are activated to begin delivery of product. At box  190 , the operator pushes knob  174  in to stop delivery of product. Operation then ends at box  192 . 
         [0051]    When the operator rotates knob  170  to select “brine”, operation proceeds to block  194  where the operator pulls knob  174  “on”. Operation proceeds to box  196  where the computer selects brine only pump  86 . Operation then proceeds to box  198  where pump  86  is activated to begin delivery of product. At box  200 , the operator pushes knob  174  in to stop delivery of product. Operation then ends at box  202 . 
         [0052]    Referring now to  FIGS. 10-14 , control panel  24  is shown in  FIG. 13  containing an interactive display,  204 , shown enlarged in  FIG. 14 . The block diagram in  FIG. 10  starts at box  206  with the plant operator at box  208  selecting values for flow rate for brine, CaCl, BEET or other agricultural agent, each by percentage. Such selection is made on control panel  204  as indicated by the numerical values of percent displayed thereon. The computer automatically calculates the flow rates for each tank based on the percentages inputted with an indicated delivery rate. Operation proceeds to block  210  where the operator saves the recipe by assigning a one or two character value using the lower number inputs on control panel  204 . At block  212 , the operator can recall any saved recipe by entering the correct assigned number. Operation ends at block  214 . 
         [0053]    The computer retains a formula in memory for calculating/determining the combination of each aperture to be open/closed by their respective solenoid valves. As an example of such calculations for Brine and CaCl, the following is given: 
         [0000]      AG_GPM=0.356*AG_SET 
         [0000]      CALC_GPM=0.356*CALC_SET 
         [0000]      BRINE_GPM=0.712*BRINE_SET 
         [0000]      TOTAL_GPM=AG_GPM+CALC_GPM+BRINE_GPM 
         [0000]      AG_%—(AG_GPM/TOTALGPM)*100
 
         [0000]      CALC_%=(CALC_GPM/TOTALGPM)*100 
         [0000]      BRINE_%=(BRINE_GPM/TOTALGPM)*100 
         [0054]    Referring now to  FIGS. 15 and 16 , delivery truck  14  is illustrated. For a detailed description of it, reference is made to the description of truck 10 in U.S. Pat. No. 6,382,535. The &#39;535 truck will be the same as the present truck, except for the use of the 6-bit manifold and modified auger disclosed herein. 
         [0055]    Referring now to  FIGS. 17 and 18 , an auger assembly,  216 , includes a housing,  218 , and auger  220  having 3-stages,  220   a,    220   b,  and  220   c,  each with increasing flight diameter, respectively. A motor,  221 , drives auger  220 . At the discharge end of the auger, a housing,  228 , houses auger  220 . A close fitting choke,  230 , fits around the end flight on auger  220  to ensure a reliable and consistent delivery of salt. A gap of around ⅛ to ¼ inch between the choke and auger flight is desired. The increasing diameter flights help resist cavitation and ensure the ability to delivery salt at the low rates discussed above. Additionally, an eccentric vibrator,  231  ( FIG. 15 ) was added to the bed of truck  14  to assist in urging salt to be moved from the bed to the auger when the salt was near exhaustion. A sensor activates the vibrator when the rate of salt feed to the auger diminishes through pressure switches  236  and  238  in  FIG. 19 . 
         [0056]    Referring to  FIG. 19  where the 6-bit manifold for truck  14  is set forth, it is substantially similar to the 6-bit manifold described in  FIG. 8  for the brine plant. In the present truck 6-bit manifold, the apertures are designed for ¼, ½, 1, 2, 4, and 8 GPM (gallons per minute). Sixty-three steps, thus, are possible from such manifold design for enabling delivery from as little as 100 pounds/mile on up to 1,000 pounds/mile or greater with intermediate values of 200, 300, 400, 500 pounds/mile, etc., fully implementable. 
         [0057]    Unlike the plant 6-bit manifold, the truck 6-bit manifold uses a lookup table, an example of which is given in  FIG. 22 . Manifold  232  controls the auger/spreader and utilizes solenoid valves  234   a  (0.25 gpm),  234   b  (0.5 gpm),  234   c  (1.0 gpm),  234   d  (2.0 gpm),  234   e  (4.0 m gpm), and  234   f  (8.0 gpm). A temperature sensor is seen at  242 . The main relief is seen at  244 . Item  245  is the auger compensator input. Manifold  246  controls the spinner and manifold  247  controls the wetting, as is described in U.S. Pat. 7,108,196, so a detailed description of these will not be given herein. The same is true for bed/plow sections  248  and  249 . 
         [0058]      FIG. 20  graphically plots steps versus gallons per minute of brine in tests of the disclosed apparatus in  FIG. 19 . The truck operator control panel is illustrated in  FIG. 21 . Its operation is as described in U.S. Pat. No. 7,108,196. 
         [0059]    Referring to  FIG. 23 , a block diagrammatic representation of a microprocessor driven control function for vehicle  14  and it associated snow-ice control features is identified generally at  250 . The control function operates in conjunction with six sensor functions. In this regard, a hydraulic system low fluid sensor is provided as represented at block  252 . A hydraulic system temperature sensor function is provided as represented at block  253 . Hydraulic system low-pressure sensor function is provided as represented at block  254 , and a hydraulic system high-pressure sensor is provided as represented at block  255 . The functions represented at blocks  252 - 255  provide inputs as represented at respective lines  258 - 261  to the analog-to-digital function represented at sub-block  264  of a microprocessor represented at block  266 . Microprocessor  266  may be provided as a type 68HC11 marketed by Motorola Corporation. Device  266  is a high-density complimentary metal oxide semi-conductor with an eight-bit MCU with on-chip peripheral capabilities. These peripheral functions include an eight-channel analog-to-digital (NO) converter as noted above. An asynchronous serial communication interface is provided and a separate synchronous serial peripheral interface is included. Its main sixteen-bit, free-running timer system has three input capture lines, five-compare lines, and a real time interrupt function. An eight-bit pulse accumulator sub-system can count external events or measure external periods. Device  266  performs in conjunction with memory (EPROM) as represented at bi-directional bus  270  and block  272 . Communication also is provided via bus  270  with random access memory (RAM) as represented at  274  and function  274  may be provided, for example, as an OS  1644  non-volatile time-keeping RAM marketed by Dallas Semi-Conductor Corporation. The LCD display is represented at block  276 . A type DV-16100 S1FBLY assembly, which consists of an LCD display, a CMOS driver and a CMOS LSI controller marketed by Display International of Oviedo, Fla., may provide this function. Digital sensor inputs to the microprocessor function  266  are provided from a speed sensor represented at block  278  and line  280 . In general, the speed sensor will output 40,000 pulses per mile of vehicle travel, which equates to 7.5 pulses per foot. A two-speed sensor digital input is supplied to microprocessor  266  as represented at block  282  and line  284 . 
         [0060]    The circuit power supply is represented at block  286 . This power supply, providing two levels of power, distributes such levels where required as represented at arrow  288 . Supply  286  is activated from the switch inputs of truck control panel ( FIG. 21 ) and represented in the instant figure at block  290  and arrow  292 . These various console and auxiliary console or control box switch inputs as represented at block  290  also are directed, as represented at arrow  294  to serial parallel loading shift registers as represented at block  296 . As represented by bus  298 , communication with the function at block  296  is provided with the microprocessor function represented at block  266 . Bus  298  also is seen directed to a  48 -channel driver function represented at block  300 . Function  300  may be implemented with a 48-channel serial-to-parallel converter with high voltage push-pull outputs marketed as a type HV9308 by Supertex, Inc. The output of the driver function represented at block  300  is directed, as represented by arrow  302 , to an array of metal-oxide semiconductor field effect transistors (MOSFETS) as represented at block  304 . 
         [0061]    These devices may be provided as auto-protected MOSFETS type VNP10N07F1 marketed by SGS-Thomson Microelectronics, Inc. The outputs from the MOSFET array represented at block  304  are directed as represented by arrow  306  to solenoid actuators as represented at block  308 . An RS232 port is provided within the control function  250  as represented at block  310  and arrow  312  communicating with microprocessor function  266 . 
         [0062]    While the device and method have been described with reference to various embodiments, those skilled in the art will understand that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope and essence of the disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof. Therefore, it is intended that the disclosure not be limited to the particular embodiments disclosed, but that the disclosure will include all embodiments falling within the scope of the appended claims. In this application all units are in the metric system and all amounts and percentages are by weight, unless otherwise expressly indicated. Also, all citations referred herein are expressly incorporated herein by reference.