Abstract:
An unloader for discharging and feeding dry, granular type materials from bulk bags. Among the many improvements of the discharge apparatus is an open frame ( 20 ) and offset discharge location. Other improvements include an I-beam ( 23 ) and frame design that keeps the hoist ( 25 ) movement within the four corner posts of the frame. The unloader may be provided with vibrators, vibration isolators, load cells, actuators ( 107, 108 ), massage paddles, or plates ( 106, 109 ) to assist in the discharge function.

Description:
BACKGROUND  
       [0001]     1. Field of Invention  
         [0002]     This invention relates to unloaders for discharging dry and semi-dry materials from bulk bags.  
         [0003]     2. Description of Related Art  
         [0004]     As many processors improve their operations by using bulk bags, instead of handling and manually dumping 50 lbs. and 100 lbs. paper bags, the need for a safer, more compact and flexible frame design of bulk bag unloaders has grown.  
         [0005]     One of the more vexing problems in handling bulk bags is the requirement of a tall, four-posted frame with a cantilevered I-Beam that extends outward at the top of the frame so that a bulk bag can be lifted from its pallet on the floor up and onto the discharge apparatus of the unloader frame. The typical unloader frame is generally equipped with several diagonal and horizontal bracing structures between the four vertical, corner posts and hoist apparatus. This extra bracing around the frame makes it difficult to interface other types of feeding, dust collection and discharge equipment close to the discharge spout location of the bulk bag. Other problems and hazards are created when lifting a heavy bulk bag with the extended I-Beam configuration.  
       SUMMARY  
       [0006]     It is the object of the invention to use a smaller footprint for a bulk bag unloader.  
         [0007]     Another object of the invention is lift and discharge a bulk bag on a standard sized unloader frame without the use of a cantilevered I-Beam. Another object of the invention is to provide a safer method of lifting a bulk bag for unloading.  
         [0008]     Yet another object of the invention is to provide a more open and accessible frame around the bulk bag when it placed on the unloader.  
         [0009]     Another object of the invention is to use a pick-up location and discharge location within the area of a four-posted unloader frame.  
         [0010]     Another object of the invention is to allow other types of conveying, dust collection and metering devices to be interfaced with the unloader frame closer to the discharge spout of the bulk bag.  
         [0011]     Yet another object of the invention is to eliminate the use of secondary bracing structures on the unloading frame.  
         [0012]     Another object of the invention is to provide greater flexibility to where the horizontal frames may be located on the four-vertical posts. 
     
    
     DRAWINGS  
       [0013]      FIG. 1  is a side view of a bulk bag unloader with one bag positioned for discharge while a second bag is staged on the floor waiting to be lifted into position and discharged.  
         [0014]      FIG. 2  is a side view of a bulk bag unloader frame with the hoist in position to lift a full bulk bag from its pallet on the floor to the discharge position.  
         [0015]      FIG. 3  is a front view of a bulk bag lowered over the base ram and tray support for discharging.  
         [0016]      FIG. 4  is a top of a bulk bag unloader with an open side and offset discharge location.  
         [0017]      FIG. 5  is a side view of a bulk bag unloader showing details of the bag support means.  
         [0018]      FIG. 6  is a side view of an unloader bag support hopper having massage paddles.  
         [0019]      FIG. 7  is a top view of the hopper of  FIG. 6 .  
         [0020]      FIG. 8  is a side view of the hopper shown in  FIG. 6  with a bag starting to be unloaded.  
         [0021]      FIG. 9  is a side view of the hopper and bag shown in  FIG. 8  with the bag unloaded.  
         [0022]      FIG. 10  is a top view of the mounting base showing a bottom actuator manifold and pressure regulator.  
         [0023]      FIG. 11  is an end view of an unloader of a bag lifted over a hopper for discharge, and the vertical centers of gravity of the bags being inside the frame.  
         [0024]      FIG. 12  is a front view of an unloader having a plurality of platform hoppers. 
     
    
     DESCRIPTION  
       [0025]      FIG. 1  is a side view of unloader frame  20 . Top frame support  21  is equipped with corner brackets  21 × and  21   y  ( 21   v  and  21   z  not shown) and bottom frame  21   a  is equipped with corner brackets  21   ax  and  21   ay  ( 21   av  and  21   az  not shown) to secure corner posts  22   a  and  22   b  ( 22   c  and  22   d  not shown) in position to form unloader frame  20 . Unlike other bulk bag unloaders, I-beam  23  does not extend outside of the perimeter of corner posts  22   a ,  22   b ,  22   c  and  22   d . I-beam  23  is secured to top frame  21  and allows hoist  25  to move between posts  22   a  and  22   b  via trolley  24 . Bag  29   a  is held in position by bag support frame  28  and bag support tray  85 . Bag support tray  85  may be located off center within the four corner posts  22   a ,  22   b ,  22   c  and  22   d . Bag  29   b  is on pallet  84  in a location within the four corner posts  22   a ,  22   b ,  22   c  and  22   d  so that it can be lifted with hoist  25  when moved to the left end of I-beam  23 . Corner brackets  2   lay ,  21   ax ,  21   av  and  21   az  of bottom frame  21   a  are designed to provide lateral support and can be located any where along the corner posts  22   a ,  22   b ,  22   c  and  22   d  to allow for the height of bag support tray  85  to be adjustable. Corner brackets  21   x ,  21   v ,  21   y  and  21   z  also add lateral support and rigidity to unloader frame  20  and may also be secured at any elevation.  
         [0026]      FIG. 2  is a side view of unloader frame  20  with hoist  25  moved along I-beam  23  via trolley  24  to a position over bag  29   b . Chain  26  and bag frame  28  are lowered for bag to be lifted. Bag  29   b  is staged in the open frame area of unloader  20  on floor  50 . Bag support tray  85  is empty, ready for bag  29   b  to be positioned thereon.  
         [0027]      FIG. 3  is a front view of unloader frame  20  with bag  29   b  lowered onto ram base  35  and bag support frame  85 . Bottom frame  21   a  does not have a support member located between vertical posts  22   a  and  22   d  to provide an open area directly under I-beam  23 , trolley  24  and hoist  25 .  
         [0028]      FIG. 4  is a top view of bottom frame  21   a  secured to vertical posts  22   a ,  22   b ,  22   c  and  22   d . Bag support tray is supported by cross beam supports  86   a  and  86   b . Pallet  84  is shown on floor in an open area of unloader frame  20 . Because a cross support brace is not used between vertical posts  22   a  and  22   d  of bottom frame  21   a  and the bag support tray  85  is located off center of unloader frame  20 , the I-Beam and Hoist Assembly (not shown) do not have to extend beyond vertical posts  22   a ,  22   b ,  22   c  and  22   d.    
         [0029]      FIG. 5  is an end view of the lower section of the unloader with seat housing  95  secured to vertical support post  22   a . Axle  97  of seat frame  96  is placed inside seat housing  95  to allow seat frame  96  to swivel off support post  22   a . Seat extension support  99 , with seat  100  attached, is mounted to seat frame  96  at pivot joint  98 . Seat  100  may be mounted in a stationary position or in a swivel and foldable configuration as shown, to assist operator with the set up and discharge of a bulk bag on the unloader. It is understood that any configuration of the unloader may be provided with a seat  100 , and not just the configuration shown in  FIG. 5 .  
         [0030]     To provide the unloader with a variety of discharge options to handle different sized bags and/or materials with varying flow characteristics, bag support hopper  87  is equipped with hopper brackets  88   a  and  88   b  ( 88   c  and  88   d  not shown) that may be supported by unloader frame brackets  89   a  and  89   b  ( 89   c  and  89   d  not shown) on horizontal support frames  21   a  and  21   b  ( 21   c  and  21   d  not shown). Bag support hopper  87  may be provided as a rectangular or conical shape with various slope angles. Spacers  90   a  and  90   b  ( 90   c  and  90   d  not shown) are positioned between hopper brackets  88   a  and  88   b  ( 88   c  and  88   d  not shown) and unloader frame brackets  89   a  and  89   b  ( 89   c  and  89   d  not shown). Spacers  90   a  and  90   b  ( 90   c  and  90   d  not shown) may be interchanged with vibration isolators, load cells or other discharge devices as the configuration dictates. It is intended that the vibration isolators, load cells, and other discharge devices fit in the same space as the spacers as shown in  FIG. 5  to facilitate manufacture and/or reconfiguration of the unloader. Spacers  90  may be supplied in one or more units as required to support bag support hopper  87 . If vibration is desired to assist in breaking up settled material inside the bulk bag, a vibrator may be secured to vibration flange  91  and vibration isolators used instead of spacers  90 . Hopper flange ring  92  on bag support hopper  87  is equipped with accessory mounting flange  92   a . Discharge device  94 , such as iris valve which is attached discharge device plate  93  may be fastened together using bolts, welds or with a V-band type clamp. Discharge device  94  may include valves, surge hoppers, filters, conveyors and the like.  
         [0031]      FIG. 6  is a side view a bag support hopper with mounting base  101  that may be secured to unloader frame brackets  89   a ,  89   b ,  89   c  and  89   d  (not shown) of unloader  20  (not shown.) To provide agitation to materials shipped in bulk bags, unloaders are often equipped with plunger devices and stretching mechanisms to empty bulk bags. These devices often require several feet of elevation space for mounting and operation. Mounting base  101  is equipped with pivoting massage paddles  104   a  and  104   b  to form a platform for bulk bags to be placed upon for unloading. When lower group of bottom actuators  107   a  and  107   b ; and upper group of top actuators  108   a  and  108   b  are deflated and at rest, massage paddles  104   a  and  104   b  form a shallow hopper surface of approximately 15 degrees with an elevation height of only about 30 cm (12 inches). Hopper flange ring  92  is attached to mounting  101  and may use an internal hopper ring  102  inside to direct the flow of material from a bulk bag (not shown) through a smaller valve or outlet opening of accessory mounting flange  92   a . Internal hopper ring  102  may have a vibrator (not shown) secured to it to help promote the flow of material from a bag. Top hinge ring plate  103  is secured to hopper flange ring  92  and mounting base  101  to provide support for hinges  105   a ,  105   c ,  105   d ,  105   e  and  105   b . Massage paddle assemblies that attached to hinges  105   c ,  105   d  and  105   e  are not shown. Sandwiched between the top actuators  108   a  and  108   b  and bottom actuators  107   a  and  107   b  are hinge plates  106   a  and  106   b  respectively. Massage paddles  104   a  and  104   b ; and hinges plates  106   a  and  106   b  incline and pivot inward using hinges  105   a  and  105   b  when bottom actuators  107   a  and  107   b  and or  108   a  and  108   b  are inflated with compressed air. As bottom actuators  107   a  and  107   b  and/or top actuators  108   a  and  108   b  are inflated, the angle of massage paddles  104   a  and  104   b  is increased to help dispense material in bag.  
         [0032]     Bottom restraints  110   a  and  110   b  are secured to mounting base  101  and hinge plates  106   a  and  106   b  to limit movement of actuators  107   a  and  107   b . Actuators  107   a ,  107   b ,  108   a  and  108   b  may rupture or become damaged if their movement is not limited by some type of mechanical linkage or stopping device. Bottom and top restraints  110   a ,  110   b ,  111   a  and  111   b  may be made of cable, chain or other types of linkage components. To provide a protective guard over and around the moving parts of adjustable bag hopper  114  assembly, including massage paddles  104   a  and  104   b , hinge plates  106   a  and  106   b  and actuators  107   a ,  107   b ,  108   a  and  108   b , flexible cover  112  is secured to the perimeter of mounting frame  101  at side joints  113   a  and  113   b  and over massage paddles  104   a  and  104   b  via top plates  109   a  and  109   b.    
         [0033]      FIG. 7  is a top view of adjustable bag hopper  114  with base mounting frame  101  having top hinge ring plate  103  with hinges  105   a ,  105   b ,  105   c ,  105   d ,  105   e ,  105   f ,  105   g  and  105   h  secured to it. Massage paddles  104   a ,  104   b ,  104   c ,  104   d ,  104   e ,  104   f ,  104   g  and  104   h ; and hinge plates  106   a ,  106   b ,  106   c ,  106   d ,  106   e ,  106   f ,  106   g  and  106   h  are secured to hinges  105   a ,  105   b ,  105   c ,  105   d ,  105   e ,  105   f ,  105   g  and  105   h  respectively.  
         [0034]     To move the top surface of massage paddles  104   a ,  104   b ,  104   c ,  104   d ,  104   e ,  104   f ,  104   g  and  104   h  from an angle of approximately 15 to 30 degrees to a maximum angle of approximately 70 to 85 degrees to help agitate and empty the contents of a bulk bag (not shown), bottom actuators  107   a ,  107   b ,  107   c ,  107   d ,  107   e ,  107   f ,  107   g  and  107   h  are secured to mounting base  101  and hinge plates  106   a ,  106   b ,  106   c ,  106   d ,  106   e ,  106   f ,  106   g  and  106   h  together with top actuators  108   a ,  108   b ,  108   c ,  108   d ,  108   e ,  108   f ,  108   g , and  108   h  secured to hinge plates  106   a ,  106   b ,  106   c ,  106   d ,  106   e ,  106   f ,  106   g  and  106   h  to massage paddles  104   a ,  104   b ,  104   c ,  104   d ,  104   e ,  104   f ,  104   g  and  104   h  respectively. Massage liner plates  109   a ,  109   b ,  109   c ,  109   d ,  109   f ,  109   g  and  109   h  may be used to hold flexible cover  112  massage paddles  104   a ,  104   b ,  104   c ,  104   d ,  104   e ,  104   f ,  104   g  and  104   h  respectively if flexible cover  112  (not shown) is used with adjustable bag hopper  114 . Cover ring  115  (not shown) is placed on top of flexible cover  112  and top hinge ring plate  103  around opening  116  to hold the edge of flexible cover  112  in place. Because many bulk bags are rectangular in shape and therefore materials does not always empty out of its corners even when stretched or otherwise massaged, corner massage paddles  104   c ,  104   e ,  104   h  and  104   f  are very effective in emptying bulk bag because they incline to a steep angle of about 80 to 90 degrees and push directly against the corners of a bag. In addition to corner massage paddles  104   c ,  104   e ,  104   h  and  104   f , side massage paddles  104   d ,  104   b ,  104   g  and  104   a  also incline to an angle of about 80 to 90 degrees to form a very steep sided hopper, capable of discharging almost all types of materials that are handled in bulk bags.  
         [0035]      FIG. 8  is a side view of bulk bag  29   b  placed on adjustable bag hopper  114  with bottom actuators  107   a  and  107   b  inflated to raise massage paddles  104   a  and  104   b  respectively to an angle of about 45 degrees. Actuators  107   a  and  107   b  may be inflated one or more times to break up and loosen material  29   c  in bag  29   b  for agitation purposes.  
         [0036]      FIG. 9  is a side view of adjustable bag hopper  114  with bottom actuators  107   a  and  107   b ; and top actuators  108   a  and  108   b  fully inflated to raise massage paddles  104   a  and  104   b  to an angle of approximately 80 to 90 degrees to provide complete emptying of bag  29   b . Internal hopper ring may be used with hopper flange ring  92  with vibrator  116  to aid in material discharge of a bulk bag. Because the adjustable bag hopper  114  can perform the complete discharge function for emptying bulk bags, which includes the agitation and massage function to break up caked and compacted materials; and also the ability to completely empty a bag without stretching it, adjustable bag hopper  114  may be mounted on portable unloaders, mixers and other types of vessels and equipment that bulk bags may be emptied from for applications that have in restricted head room areas and other space constraints.  
         [0037]      FIG. 10  is a top view of mounting base  101  with bottom actuator manifold  117   a  and bottom pressure regulator  118   a  assembly that supplies air to bottom actuators  107   a ,  107   b ,  107   c ,  107   d ,  107   e ,  107   f ,  107   g  and  107   h  through air lines  120   a ,  120   b ,  120   c ,  120   d ,  120   e ,  120   f ,  120   g  and  120   h  respectively. Top actuator manifold  117   b  and top pressure regulator  118   b  may supply air to top actuators  108   a ,  108   b ,  108   c ,  108   d ,  108   e ,  108   f ,  108   g  and  108   h  through air lines  119   a ,  119   b ,  119   c ,  119   d ,  119   e ,  119   f ,  119   g  and  119   h  respectively. Valves  121  (not shown) may control air-flow from compressors or other air sources to actuator manifolds  117   a  and  117   b  and pressure regulators  118   a  and  118   b  on a manual or automatic basis. Valves may be controlled by a PLC and or adjusted manually according to a particular discharge process.  
         [0038]      FIG. 11  is an end view of unloader  20  with bag  29   j  lifted over bag platform hopper  85   j  for discharge. Bag  29   f  on pallet  84  is placed between front posts  22   a  and  22   d  (not shown) of unloader  20  so that it is ready for placement on bag platform hopper  85   j  once bag  29   j  is emptied. The footprint of unloader  20  and bag  29   f  is typically smaller than the footprint of a cantilevered unloader (not shown) because the bag staged  29   f  is inside frame post  22   a  and  22   d  (not shown) of unloader  20 . Because bag platform hopper  85   j  is off center and positioned towards the back of unloader also allows for a smaller footprint than conventional, cantilevered I-Beam unloaders.  
         [0039]      FIG. 12  is a front view of unloader  20  having multiple bag platform hoppers  85   h ,  85   i  and  85   j . A single unloader  20  frame can be used to unload bags  29   h ,  29   i  and  29   j  on bag platform hoppers  85   h ,  85   i  and  85   j  respectively because the frame design does not require I-beam&#39;s  23   h ,  23   i  and  23   j  to be cantilevered. Also, because I-Beam&#39;s  23   h ,  23   i  and  23   j  are not cantilevered, unloader frame  20  does not require cross bracing supports as conventional cantilevered frames. Unloader  20  provides a single frame for multiple bag discharge locations that allows costs to be lower and smaller space requirements.  
         [0040]     While there have been described what are at present considered to be the preferred embodiments of this invention, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the invention, and it is, therefore, aimed to cover all such changes and modifications as fall within the true spirit and scope of the invention.