Abstract:
A device to fragment solidified bulk material is disclosed. The device comprises a hydraulic motor, a stationary assembly and rotating assemblies, wherein the rotating assemblies includes, a rotational upper whip mount assembly adapted to rotate in a direction, a rotational middle assembly perimeter adapted to rotate in the same direction as the rotational upper whip mount assembly, and a rotational lower whip mount assembly adapted to rotate in a direction opposite the rotational direction of the upper whip mount and middle perimeter assemblies, and a plurality of flails configured to fracture hardened, solidified bulk material while balancing the torque forces to more accurately keep the dual whip-head head in a desired location when operationally engaged with the bulk material.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to fragmenting solidified bulk materials to facilitate the flow and removal of such materials from containment vessels, including bins, silos, hoppers and other transport vessels. 
         [0003]    2. Description of the Prior Art 
         [0004]    Bulk materials left undisturbed in a containment vessel like a bin or silo tend to settle, compress, and eventually solidify into a hard, amalgamated solid that is difficult to remove from the vessel. This happens frequently at cement manufacturing plants. When such bulk material must be removed from the containment vessel, to increase its storage capacity for example, manual labor is often used to fragment and remove the material. Using picks and shovels in such an environment is time consuming and increases the potential for personal injury. 
         [0005]    To solve this problem, the applicant invented the BinWhip® system, which used a pneumatically-powered cleaning head and flails that was lowered into the containment vessel to fragment the solidified material instead of using human labor. The applicant later switched to a hydraulically-powered system. While effective, both the pneumatic and hydraulic systems used a cleaning head that rotated in one direction only. But because the BinWhip® represented a vast improvement over human labor, others in the industry copied applicant&#39;s pneumatic and hydraulic unidirectional systems. Thus, the current state of fragmentation systems that employ rotating flails to fragment solidified bulk materials uses a unidirectional cleaning head configured to spin in either a clockwise or counter-clockwise direction, but not simultaneously. 
         [0006]    Whether pneumatically or hydraulically driven, the cleaning head of such systems require a hose system to carry the pressurized fluid to a motor system, which is typically housed within or proximate the cleaning head. The reactive torque that results from the flails striking the solidified material, however, puts significant rotational forces on the hose connecting the power unit to the cleaning head. As rotational speeds increase to achieve greater striking force (i.e., increasing the rotational speed of the cleaning head and flails to increase the impact forces on the solidified material), the torque forces on the cleaning head and attached hose system also increase. Under conditions when the bulk material is resistant to fragmentation, like with cement for example, increasing the rotational speed beyond 400 RPM, for example, can cause the hose system to twist and coil back on itself, potentially damaging the hose system and increasing the risk of personal injury or property damage. Consequently, the hose system&#39;s resistance to the torque created by the rotating cleaning head and flails limits the speed and efficiency of unidirectional single head cleaning systems. 
         [0007]    Thus, there is a need for a system that can significantly the efficiency of fragmenting hardened, solidified bulk materials to assist in their removal from containment vessels. The disclosure herein accomplishes that objective. 
       BRIEF SUMMARY OF THE INVENTION 
       [0008]    The device disclosed herein is designed to facilitate the removal of hardened, solidified bulk material from containment vessels, including transport vehicles. The device is part of a system that includes a hydraulic power unit, which is operably connected to a manifold system, which in turn is operably connected to a hose system comprising a hose reel and hoses, which is attachable to a mount assembly attachable to a boom assembly including a safety anchor that is configured to stabilize the hoses. The counter-rotational dual whip-head head is attachable to the hose assembly and further comprises a stationary connection assembly to operably connect the hose system to at least one hydraulic motor, a rotational upper whip mount assembly, a middle assembly—the perimeter of which rotates in the same direction as the rotational upper whip mount assembly and a rotational lower whip mount assembly rotating in the opposite direction of the upper whip mount and middle assemblies, wherein the dual whip-head device is configured along a vertical axis. The middle assembly further comprises a stationary inner core comprising at least one hydraulic motor and at least one in-line gearbox. The gearbox includes a set of beveled gears—an upper and lower beveled gear—which are configured in separate horizontal planes and are operationally connected to each other by a plurality of pinion gears that rotate around a horizontal axis. The hydraulic motor directly drives the upper beveled gear. This in turn causes the pinion gears to rotate about a horizontal axis 90 degrees from the vertical axis of the hydraulic motor and gearbox. When the upper beveled gear is put in rotational movement by the hydraulic motor, the pinion gears, being engaged with both the upper and lower beveled gears, transfers an opposite-direction rotational force and movement to the lower beveled gear, which in turn drives an upper drive plate and an upper whip mount assembly in a rotational direction opposite the upper beveled gear. The pinion gears are fixed into position in the body of the gearbox so they supply rotation transfer only between the upper and lower beveled gears. The lower beveled gear drives the upper drive plate, the perimeter of the middle assembly, and the upper whip mount assembly in a rotational movement opposite the rotational movement of the lower whip mount assembly and the upper beveled gear. 
         [0009]    Two concentric shafts extend out the bottom of the gearbox. The first shaft is an inner solid shaft that is operably connected to the upper beveled gear. The second shaft is a hollow shaft that is operably connected to the lower beveled gear and rotates in the opposite direction around the inner shaft. A set of needle bearings separates the counter-rotating shafts to minimize any friction between them as they rotate. A keyless coupler is attachable on the outer shaft and is operably connected to an upper drive plate, which in turn is operably connected to a plurality of stand-off rods mounted on the upper drive plate that rotate around the outside of the gearbox and hydraulic motor and that connect to and drive the rotating perimeter of the middle and upper whip mount assemblies of the dual whip-head. 
         [0010]    A stationary connection assembly serves as the junction for the hydraulic supply and return lines that connect the hydraulic motor on one side and the hydraulic hoses on the other side. The dual whip-head (counter-rotational) can now be used in a very similar manner as a traditional single head (uni-rotational), but with a number of surprising advantages. 
         [0011]    First, the counter-rotational configuration of the dual whip-head balances the torque forces on the hydraulic hose, which allows greater rotational speeds and keeps the dual whip-head in place and prevents it from ‘walking’ across the surface of the bulk material in response to frictional forces between the rotating perimeter of the middle assembly and/or flails and the bulk material. This balancing of torque forces allows for more precise positioning of the dual whip-head. The use of counter-rotational dual whip-heads essentially doubles the fragmentation power of the system. The counter-rotational configuration of the instant disclosure also allows for fragmentation of stratified layers and ledges of bulk material that single-head systems find challenging because of the single operational plane of single-head systems. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0012]    The invention can be better understood by reference to the following drawings, wherein: 
           [0013]      FIG. 1  is an exploded view of an embodiment of the counter-rotational dual whip-head for fragmenting solidified bulk materials in containment vessels. 
           [0014]      FIG. 2  is a transparent view of an embodiment of a gearbox of the counter-rotational dual whip-head for fragmenting solidified bulk materials in containment vessels. 
           [0015]      FIG. 3  is a perspective view of a partially assembled counter-rotational dual whip-head for fragmenting solidified bulk materials in containment vessels. 
           [0016]      FIG. 4  is a perspective view of a partially assembled counter-rotational dual whip-head for fragmenting solidified bulk materials in containment vessels. 
           [0017]      FIG. 5  is a perspective view of a fully assembled counter-rotational dual whip-head for fragmenting solidified bulk materials in containment vessels. 
       
    
    
     DETAILED DESCRIPTION 
       [0018]    In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration specific embodiments or examples. These embodiments may be combined, other embodiments may be utilized, and structural, logical, and procedural changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims and their equivalents. 
         [0019]    As disclosed in  FIG. 1 , an embodiment of a counter-rotational whip head includes at least two bolts  101  that secure a stationary upper receiver  102  to a stationary lower receiver  107 . Straddling a rotating upper whip mount  105  are a seal  103  and a radial bearing  106  that allow the upper whip mount  105  to rotate under the power transferred by a hydraulically-powered gearbox  118  to a plurality of rotating drive stand-off rods  119  that are operably connected to the upper whip mount  105  by a plurality of bolts  104 . Flails  131  are attachable to the upper whip mount  105  via a plurality of adapter clevis&#39;s  134 . The flails  131  are secured to the adapter clevis&#39;s  134  by a plurality of nuts  132  and bolts  133 . 
         [0020]    The plurality of rotating drive stand-off rods  119  are further secured to an upper drive plate  120  with a plurality of bolts  121 . A plurality of fragmentation collars  117  may be secured to the stand-off rods  119 . The combined structure of these components serve to stabilize and unify the rotating middle section  502  of the whip head  501 . When the plurality of fragmentation collars  117  are secured between the upper whip mount  107  and the upper drive plate  120  by stacking the fragmentation collars  117  over the stand-off rods  119 , they comprise a rotating perimeter of the middle assembly. 
         [0021]    A plurality of bolts  104   a  also connect the stationary lower receiver  107  to the housing of the hydraulically-powered gearbox  118  via a plurality of shorter length stand-off rods  110 . Pressurized hydraulic fluid is transferred into and out of the hydraulic motor  114 , through a hydraulic fluid conduit system comprising a plurality of hydraulic flush fittings  108 , which are connectable to a pressurized hydraulic fluid source, a plurality of hydraulic adapters  109 , a plurality of upper elbow fittings  111 , a plurality of hydraulic pipes  112 , and a plurality of lower elbow fittings  113 . The lower elbow fittings  113  are, in turn, directly connected to the hydraulic motor  114 . The hydraulic motor  114  is secured to the gearbox case  200  with a plurality of bolts  115  and lock washers  116 . The hydraulic motor  114 , when put in rotational movement by the flow of the pressurized hydraulic fluid, transfers a rotational force to an encased gearbox  118   200 . The bolts  101 , stationary upper receiver  102 , bolts  104   a , radial bearing  106 , stationary lower receiver  107 , hydraulic flush fittings  108 , hydraulic adapters  109 , shorter length stand-off rods  110 , upper elbow fittings  111 , hydraulic pipes  112 , lower elbow fittings  113 , hydraulic motor  114 , bolts  115  and lock washers  116 , and encased gearbox  118  comprise a stationary, middle assembly. 
         [0022]    As disclosed in Hg.  2 , the encased gearbox  200  includes a set of beveled gears  201   202  configured in separate horizontal planes that are operably connected to each other by a plurality of pinion gears  203  that rotate around a horizontal axis. Engaging the hydraulic motor causes the upper bevel gear  201  to rotate on its vertical axis, which in turn causes the pinion gears  203  to rotate about a horizontal axis about 90 degrees from the vertical axis of the motor  114  and gearbox  200 . When the upper beveled gear  201  is put in rotational movement by the hydraulic motor  114 , the pinion gears  203 , being operably engaged with both the upper  201  and lower  202  beveled gear sets, transfers an opposite-direction rotational force and movement to the lower beveled  202  gear set. The upper beveled gear set  201  drives an inner solid shaft  204  that drives the lower whip mount  125 . The lower beveled gear set  202 , being in opposite rotational direction to the upper beveled gear  201 , drives an outer hollow shaft  205  that drives the rotational perimeter of the middle assembly  502  and the upper whip mount  105  in a rotational direction opposite the lower whip mount  125 . 
         [0023]    By way of non-limiting example only, if pressurized hydraulic fluid is introduced into the hydraulic motor  114  so that the motor  114  rotates in a counter-clockwise direction, that rotational movement is directly transferred to the upper beveled gear  201  and the inner solid shaft  204  that ultimately drives the lower whip mount  125  in the same counter-clockwise direction. Accordingly, the upper beveled gear  201 , being engaged with the pinion gears  203 , causes the lower beveled gear  202  and outer hollow shaft  205  to rotate in a clockwise direction. The upper drive plate  120  is connected to a keyless coupler  122  that in turn is operably connected to the outer hollow shaft  205 . Thus, as the outer hollow shaft  205  rotates in a clockwise direction, that rotational movement is transferred from the keyless coupler  122  to the upper drive plate  120  and the rotating drive stand-off rods  119  to rotate the perimeter of the middle assembly  502  and upper whip mount  105  in the same clockwise direction. The seal  103 , bolts,  104 , upper whip mount  105 , stand-off rods  119 , upper drive plate  120 , bolts  121 , and keyless coupler  122  comprise an upper whip mount assembly. 
         [0024]    Positioned between the rotating upper drive plate  120  and the lower whip mount  125  are a hub for a taper-lock bushing  123 , and a 1-inch taper lock bushing  124  that are configured to allow the lower whip mount  125  to rotate in the same direction as the inner shaft. The lower whip mount  125  is connected to a whip mount cover  128  with a plurality of pinions  126  and bolts  130 . A plurality of flails  131   a  may be secured between the lower whip mount  125  and the whip mount cover  128  with a plurality of nuts  127  and bolts  129 . The taper-lock bushing hub 123, 1-inch taper lock bushing  124 , lower whip mount  125 , pinions  126  and bolts  130 , nuts  127  and bolts  129 , and whip mount cover  128  comprise a lower whip mount assembly. 
         [0025]      FIG. 3  discloses the major components of the counter-rotational whip head, including the upper receiver  301 , the upper whip mount  302 , and the clevis assembly  303 , including its nuts and bolts  304  for attaching the flails  131  to the upper whip mount  302 .  FIG. 3  further discloses the shorter length stand-off rods  305 , the rotating drive stand-off rods  306 , the upper drive plate  307 , and the combined lower whip mount  308  and whip mount cover  309 . 
         [0026]      FIG. 4  discloses an embodiment that includes a middle assembly comprising a plurality of saw-toothed, fragmentation collars  117   401 . In this embodiment, the saw-toothed fragmentation collars  117   401  are stacked between the upper drive plate  102   307  and the upper whip mount  105   302  and include a plurality of holes  135  that correspond to the number and spacing of each rotating drive stand-off rod  119   306 . The fragmentation collars  117   401  are stacked, one on top of the other, by passing the holes in the collars  135  over the rotating drive stand-off rods  119   306  until the collars  117   401  are stacked securely between the upper drive plate  102   307  and the upper whip mount  105   302 . In such an embodiment, the saw-toothed fragmentation collars  117   401 , which are rotating in the same direction and speed as the upper whip mount  105   302 , provide an increased fragmentation surface that may be applied against the solidified material along with the flails  131   131   a.    
         [0027]      FIG. 5  discloses a completely assembled counter-rotational dual whip-head embodiment 501 that includes saw-toothed, fragmentation collars  502  chain link flails  503  on both upper and lower whip mounts. 
         [0028]    It is to be understood that the above description is intended to be illustrative and not restrictive. For example, the above-described embodiments and variations may be used in combination with each other. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.”