Abstract:
A pressure accumulator tank system for applying a substance and a method of applying substance are provided. The pressure accumulator tank system of an embodiment includes a main distribution line, a main pump, a pressure switch and at least one feeding line. The main pump is configured to pump the substance into the main distribution line. The pressure switch is located in the main distribution line and is configured to control operation of the main pump to maintain a select pressure in the main distribution line. Each feeding line includes a feeding conduit, a pressure accumulator and a manifold. The feeding conduit is coupled to the main distribution line to receive the substance in the main distribution line. The pressure accumulator is coupled to provide a select pressure in the feeding conduit. The manifold has an inlet and at least one outlet. The inlet of the manifold is coupled to the feeding conduit. Each outlet is configured to output the substance to a distribution zone.

Description:
BACKGROUND  
       [0001]    Conveyer systems in commercial packing or packing operations require lubrication to ensure products pass through the conveyer systems as desired. Typically two types of lubrications are used. The first type is a concentrated lubricant that is diluted with water to form an aqueous lubricant solution. Although this type of lubrication system permits high-speed operation of conveyer systems, it requires a large amount of water. The large amount of water can cause an unduly wet environment which may not be desirable in a given operation. The second type of lubrication is called a dry lube. Dry lubes historically have referred to a lubricant composition with less than 50% water that is applied without dilution. Hence, large amounts of water are not needed to apply the lubricant. However, without the relatively low viscosity provided by the added water, applying the dry lube could be an issue. 
         [0002]    For the reasons stated above and for other reasons stated below which will become apparent to those skilled in the art upon reading and understanding the present specification, there is a need in the art for an effective and efficient method of applying dry lube. 
       SUMMARY OF INVENTION  
       [0003]    The above-mentioned problems of current systems are addressed by embodiments of the present invention and will be understood by reading and studying the following specification. The following summary is made by way of example and not by way of limitation. It is merely provided to aid the reader in understanding some of the aspects of the invention. 
         [0004]    In one embodiment, a pressure accumulator tank system for applying a substance is provided. The pressure accumulator tank system includes a main distribution line, a main pump, a pressure switch and at least one feeding line. The main pump is configured to pump the substance into the main distribution line. The pressure switch is located in the main distribution line and is configured to control operation of the main pump to maintain a select pressure in the main distribution line. Each feeding line includes a feeding conduit, a pressure accumulator and a manifold. The feeding conduit is coupled to the main distribution line to receive the substance in the main distribution line. The pressure accumulator is coupled to provide a select pressure in the feeding conduit. The manifold has an inlet and at least one outlet. The inlet of the manifold is coupled to the feeding conduit. Each outlet is configured to output the substance to a distribution zone. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0005]    The present invention can be more easily understood and further advantages and uses thereof more readily apparent, when considered in view of the detailed description and the following figures in which: 
           [0006]      FIG. 1  is a block diagram of a lubrication system of one embodiment of the present invention; 
           [0007]      FIG. 2  is a block diagram of a feeding line of a lubrication system of one embodiment of the present invention; 
           [0008]      FIG. 3  is lube system flow diagram of one embodiment of the present invention; 
           [0009]      FIG. 4  is an alarm flow diagram of one embodiment of the present invention; and 
           [0010]      FIG. 5  a zone dispensing flow diagram of one embodiment of the present invention. 
       
    
    
       [0011]    In accordance with common practice, the various described features are not drawn to scale but are drawn to emphasize specific features relevant to the present invention. Reference characters denote like elements throughout Figures and text. 
       DETAILED DESCRIPTION  
       [0012]    In the following 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 inventions may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that logical, mechanical and electrical 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 only by the claims and equivalents thereof. 
         [0013]    Embodiments of the present invention provide an effective and cost efficient lubrication system. Further benefits of embodiments include, but are not limited to, not requiring conduit and wiring from each production line to the lube pump location and not requiring an individual lube line from the pump to discharge headers. In embodiments the system pressure is stored at the point of usage and does not rely on the lube pump to deliver pressure and a volume of lube. This helps prevent inconsistent pressures and volumes due to the distance between a pump and the points of usage. Another advantage of the present invention is that multiple pumps are not required. 
         [0014]    Referring to  FIG. 1 , an exemplary embodiment of a lubrication system  100  is provided. As  FIG. 1  illustrates, the lubrication system  100  includes dry lube  104  that, in this example, is contained in a drum  102 . A main lube pump  110  is in fluid communication with the dry lube  104  in the drum  102  via pick up line  108  and pick up  106 . In one embodiment a spare lube pump  111  is used if the main lube pump  110  fails. The spare lube pump  111  is in fluid communication with the dry lube  104  also via pick up line  108  and pick up  106 . The main lube pump  110  and the spare lube pump  111  are generally referred to as pump  110  and pump  111  hereinafter. Pump  110 , or pump  111  if needed, pumps lube  104  from the drum  102  via pick up  106  and pick up line  108  into a main lube line  115 . In the embodiment of  FIG. 1 , pumps  110  and  111  are pneumatic pumps run by air supply  112 . A check valve  124  in the main line  115  is used to keep pressure off of the pump  110  or  111  when the pump  110  and  111  is not pumping. This prevents a back pressure from pushing lube through the pump&#39;s  110  or  111  diaphragm (not shown). Moreover, the check valve  124  ensures that when the pump  110  or  111  is activated that no pressure will be on the pump  110  or  111 . This prevents the pump  110  or  111  from locking up. Also illustrated in  FIG. 1  is a pressure gauge  140  that provides an indication of the pressure in the main lube line  115 . 
         [0015]    As discussed above, the pumps  110  and  111  are run by air supply  112 . The air supply  112  is operated with an activation circuit that includes a power supply  118 , a pump air solenoid  116  and a pressure switch  120 . As illustrated, the pump air solenoid  116  activates the air supply  112  when the pressure switch  120  is closed. In operation, the pressure switch  120 , in this embodiment, is a normally closed switch that opens at a select pressure. For example, the pressure switch  120  may open when the pressure in the main lube line  115  reaches 40 PSI and remains open until the pressure in the main line  115  goes below 35 PSI. Hence, in this example, the pump  110  or  111  is shut off once the pressure in the main line  115  reaches 40 PSI and then is started again when the pressure in the main line  115  lowers to 35 PSI. An example of a switch that could be used in embodiments is switch model number FSG2121CP made by the Square D manufacture, which has an operating range of 30-50 PSI. 
         [0016]    The embodiment of  FIG. 1  also includes an alarm circuit  130  that is used to shut down the lube pumps  110  and  111  if a problem exists. The alarm circuit  130  operates alarm switch  132  which opens to prevent the activation circuit from operating the pumps  110  and  111 . In this embodiment, the alarm circuit  103  is coupled to receive a low lube indicator signal from a low lube level circuit  128 . In this embodiment, the low level circuit  128  uses a float  126  attached to the pick up  106  in the barrel  102  to indicate if the level of lube  104  is low. This alarm prevents air from being pumped into pump  110  or  111 . If air inadvertently enters the pick up line  108  and enters the pump  110  or  111 , the pump  110  or  111  will have to be re-primed before it can be used. Hence, the low level circuit  128  prevents the pump  110  or  111  from having to be re-primed because of lack of lube  104 . The alarm circuit  130  in this embodiment is also connected to a timer circuit  134  that tracks the amount of time the lube pump  110  or  111  is running. If the lube pump  110  or  111  is running for a period of time that is longer than an anticipated period of time, the alarm circuit  130  opens the alarm switch  132  thereby stopping the lube pump  110  or  111 . The lube pump  110  or  111  running longer than anticipated can indicate a leak in the lubrication system  100 . In one embodiment, the alarm switch  132  has to be manually closed to reset the alarm system once the problem has been corrected. 
         [0017]    As illustrated, the lubrication system  100  includes the main distribution line  115  and feeding lines  150 - 1  through  150 -N. The feeding lines  150 - 1  through  150 -N, provide a path for the lube  102  to respective zones  152 ,  154  and  156 . The zones  152 ,  154  and  156  are points of distribution of the lubrication by means known in the art. In the example of  FIG. 1 , feeding line  150 - 1  includes zones  152 - 1  through  152 -N, feeding line  150 - 2  includes zones  154 - 1  through  154 -N and feeding line  150 -N includes zones  156 - 1  through  156 -N. As further illustrated in  FIG. 1 , each feeding line  150 - 1  through  150 -N includes its own pressure accumulator  151 - 1  through  151 -N. In particular, feeding line  150 - 1  includes pressure accumulator  151 - 1 , feeding line  150 - 2  includes pressure accumulator  151 - 2  and feeding line  150 -N includes pressure accumulator  151  -N. The pressure accumulators  151  - 1  though  151  -N (hereinafter collectively referred to as pressure accumulators  151 ) store pressure at the usage point thereby not requiring the receipt of pressure from a pump at a central location. The pressure accumulators  151  are coupled to a respective manifold  160  via conduit  158 . In particular, accumulator  151  - 1  is coupled to manifold  160 - 1  via conduit  158 - 1 , accumulator  151 - 2  is coupled to manifold  160 - 2  via conduit  158 - 2  and accumulator  151 -N is coupled to manifold  160 -N via conduit  158 -N. Embodiments can be used to retrofit existing lubrication systems. For example, referring to  FIG. 1 , a system that was originally designed to transmit wet lube that included a main line  115  and feeding conduits  158 - 1  through  158 -N can be retrofit with a dry lube delivery system as discussed above with the use of pressure accumulators  151 - 1  through  151 -N on the respective feeding conduits  158 - 1  through  158 -N. Hence, embodiments are not limited to new installations. 
         [0018]    Referring to  FIG. 2  an example of a feeding line  200  of an embodiment is illustrated in detail. As illustrated, the pressure accumulator  202  is coupled to a manifold  206  via feeding conduit  204 . Feeding conduit  204  receives the lube from the main lube line  115  as illustrated. The manifold  206  provides passages  205 - 1 ,  205 - 2  and  205 - 3  to associated zones  207 - 1 ,  107 - 2  and  207 - 3 . Although, three zones  207 - 1  through  207 - 3  are illustrated, the number of zones used will vary as dictated by the application. Hence the present application is not limited to the number of zones or the number of feeding lines. As illustrated in  FIG. 2 , solenoid valves  208 - 1 ,  208 - 2  and  208 - 3  are positioned between the manifold  206  and each zone  207 - 1 ,  207 - 2  and  207 - 3 . In particular, solenoid valve  208 - 1  is positioned between the manifold  206  and zone  207 - 1 , solenoid valve  208 - 2  is positioned between manifold  206  and zone  207 - 2  and solenoid valve  208 - 3  is positioned between manifold  206  and zone  207 - 3 . The solenoid valves  208 - 1 ,  208 - 2  and  208 - 3  are used to regulate the flow of lube  104  to the zones  207 - 1 ,  207 - 2  and  207 - 3 . The solenoid valves  208 - 1  through  208 - 3  are controlled by a controller  210 . The controller  210  controls the respective solenoid valves  208 - 1 ,  208 - 2  or  208 - 3  based on the lube requirement of a particular zone  207 - 1 ,  207 - 2  or  207 - 3 . In particular, the controller  210  controls the frequency of the activation of the solenoid valves  208 - 1 ,  208 - 2  and  208 - 3  (hereinafter collectively referred to as solenoid valves  208 ) as well as the duration that the solenoid valves  208  are open to obtain a desired coefficient of drag. The frequency and duration is based on the lube requirement for a particular zone  207 - 1 ,  207 - 2  and  207 - 3 . Each zone  207 - 1  through  207 - 3  may require its own unique frequency and duration of operation. In one embodiment the controller  210  is a mechanical device incorporating timers such as Ecolab&#39;s Dry Exx controller. In another embodiment, the controller  210  is a programmable logic controller. Further in one embodiment, the controller  210  has a communication connection  212  to the alarm circuit  130 . In this embodiment, the controller  210  closes the solenoid valves  208  when an alarm circuit signal indicating a problem with the lube system  100  has been received from the alarm circuit  130 . This effectively shuts down the entire lube system  100  when a problem occurs. 
         [0019]    In one embodiment, the pressure accumulator  202  is a 2 gallon pressure well tank pre-charged to a pressure of 21 PSI. An example of such a pressure well tank is made by WaterWorker having a model number of HT-2. This type of pressure accumulator is desirable because it has a low probability of failure. This is due to the fact that it will be used in ambient temperatures with no condensation which is unlike the conditions it was made to handle in well tank applications. Moreover, silicon based lubrication is likely to extend the life of a bladder in the presser well tank. In one embodiment, a larger diameter feeding line  204  is used than the diameter of the main lube line  115 . This minimizes a pressure drop to each zone over great distances. In one embodiment, a ¾ inch pipe is used for the feeding conduit  204  and a ½ pipe is used for the main lube line  115  (or main distribution line  115 ). Further in one embodiment, PVC pipes are used for the feeding conduit  204  and the main distribution line  115 . 
         [0020]      FIG. 3  illustrates a lube system flow diagram  300  of an embodiment. As illustrated, the process starts by activating a lube pump based on a pressure in a main lube line ( 302 ). The pump then pumps lube out of a lube container into the main lube line ( 304 ). In the meantime, pressure is provided in feeding lines ( 306 ). Each feeding line, in one embodiment, receives pressure from an associated pressure accumulator. Each feeding line is provided lube from the main lube line ( 308 ). The lube in each feeding line is selectively passed to an associated zone to lubricate the associated zones ( 310 ). 
         [0021]    Referring to  FIG. 4 , an alarm flow diagram of one embodiment is illustrated. In this embodiment, the level of lube in a delivery container is monitored ( 402 ). It is determined if the level is below a select level ( 404 ). If the level of lube is not below the select level ( 404 ), the level is continued to be monitored at ( 402 ). If the level is below the select level ( 404 ), the pump is stopped ( 410 ). The pump will remain stopped until a signal is received that indicates a new container of lube has replaced the empty container ( 412 ). Once that occurs, the lube system is re-started ( 414 ) and the level of lube is again monitored at ( 402 ). As the flow diagram also illustrates, the length of time the lube pump is running is also monitored ( 406 ). It is determined if the length is beyond a predetermined length of time ( 408 ). If the pump does not run longer than a select length of time ( 408 ), the running time of the pump is continued to be monitored at ( 406 ). If the pump runs longer than the select length of time ( 408 ), the lube pump is stopped ( 410 ). The pump will remain stopped until it receives a signal that a problem in the system has been corrected ( 412 ). Once that occurs, the lube system is re-started at ( 414 ) and the length of time the pump is running is again monitored at  406 . 
         [0022]    A zone dispensing flow diagram  500  of one embodiment is illustrated in  FIG. 5 . As illustrated this process starts by setting the length of time to dispense lube in each zone ( 502 ) and setting the frequency of lube dispensing in each zone ( 504 ). As discussed above, the dispensing length and frequency will depend on the specific application required in a zone. For example, in a conveyer system it may be desired to obtain certain coefficient of drag so that products such as bottles will travel on the conveyer as desired. Determining the select coefficient of drag and what duration and frequency achieves the select duration can be obtained by testing or by formulas as know in the art. Once the duration and frequency is known for each zone, the lube is dispensed accordingly ( 506 ). In one embodiment, the controller that controls the dispensing of the lube to the zones monitors an alarm controller for an alarm signal that would indicate a problem with the lube system ( 508 ). When no signal is detected ( 510 ), the system continues monitoring ( 508 ). When a signal is detected ( 510 ), the dispensing of lube to the zones is stopped ( 512 ). Once a signal is received that the problem is corrected ( 514 ), the system continues dispensing lube at ( 506 ). 
         [0023]    Some embodiments of the alarm circuit  103  of  FIG. 1  and the programmable logic controller  210  of  FIG. 2  incorporate a processor and memory to store instructions in implementing steps set out in the flow diagrams of  FIGS. 4 and 5 . A processor includes or functions with software programs, firmware or computer readable instructions for carrying out various methods, process tasks, calculations, and control functions. These instructions are typically tangibly embodied on any appropriate medium used for storage of computer readable instructions or data structures. Such computer readable media can be any available media that can be accessed by a general purpose or special purpose computer or processor, or any programmable logic device. Suitable computer readable media may include storage or memory media such as magnetic or optical media, e.g., disk or CD-ROM, volatile or non-volatile media such as RAM (e.g. SDRAM, DDR SDRAM, RDRAM, SRAM, etc.), ROM, EEPROM, flash memory, etc. 
         [0024]    Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement, which is calculated to achieve the same purpose, may be substituted for the specific embodiment shown. For example, the above description relates to the delivery of lube to provide lubrication to a system. However, the present invention contemplates the use of embodiments for applying other substances such as but not limited to chemical agents and pesticides. Accordingly, this application is intended to cover any adaptations or variations of the present invention. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.