Abstract:
A mixing apparatus includes a hopper, a reel, and at least one auger. The hopper defines first and second chambers. The first chamber is disposed adjacent to the second chamber. The reel is disposed within the first chamber. The reel includes first and second hubs configured to rotate and at least one connecting member connecting the first hub to the second hub. The at least one auger is disposed in the second chamber. The first and second hubs rotate about a common axis of rotation. No connecting member connects a center of the first hub to a center of the second hub along the axis of rotation. An attachment point between each connecting member and the first hub is circumferentially offset with respect to an attachment point between the same connecting member and the second hub.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This document claims the benefit of U.S. Provisional Application No. 61/365,699, entitled “Enhanced Reel For Agricultural Mixer,” filed Jul. 19, 2010, the entire contents of which are hereby incorporated by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to a mixer using a reel and also to a particular reel configuration individually arranged with or without the mixer. One example of the mixer provides a mixing apparatus including two augers with axes offset from a reel axis. 
     2. Description of the Related Art 
     Industrial mixers, and in particular animal feed mixers, are commonly used in combination with one or more augers and/or reels. Such reels were typically arranged similar to riverboat paddle wheels with a center drive shaft and outer shafts or paddles disposed on the outer ends of spokes extending from the center drive shaft. For example, U.S. Pat. No. 7,566,166 to Neier et al. describes an animal feed mixer having staggered rotor paddles. The entire content of Neier et al. is incorporated herein by reference. Earlier devices include U.S. Pat. No. 4,506,990, U.S. Pat. No. 4,597,672, U.S. Pat. No. 4,741,625, U.S. Pat. No. 4,756,626, U.S. Pat. No. 4,799,800, U.S. Pat. No. 4,896,970, U.S. Pat. No. 5,143,310, U.S. Patent Application Publication No. 2009/0268549, and International Publication No. WO 2010/029525 A1, the content of each of which is incorporated by reference herein in its entirety. 
     SUMMARY OF THE INVENTION 
     The inventors recognized certain issues arisen with the above-noted related art machines. In particular, “pulsing” may occur when large chunks of feed are moved at one time via the reel toward the augers. Such pulsing may cause inaccuracy in scales used to weigh the apparatus and weigh the feed inside the apparatus to determine the amount of mix or feed initially within the apparatus and discharged from the apparatus during a given period of time inaccurate. In other words, the pulsing may cause fluctuations in the readings of the scales while the reel is rotating. 
     Additionally, as conventional devices typically required a centralized drive shaft connecting the ends or hubs of the reel, clogging or partial solidification of the mix disposed adjacent to the reel could occur. In other words, the mix located within the diameter of the reel could itself rotate as a solid “barrel-like” partially solidified structure. Thus, mixing efficiency could be reduced. 
     Accordingly, one aspect of the present invention provides a reel for a mixing apparatus in which no centralized drive shaft connects the ends, i.e., hubs or “stars” used to support the mixing bars of the reel. 
     Another aspect of the invention provides a helical structure to the bars used for mixing in the reel. The helical nature of the bars may reduce or eliminate the pulsing effect noted above. These aspects may be implemented separately or in combination with each other. 
     One aspect of the invention provides a mixing apparatus which includes a hopper, a reel, and at least one auger. The hopper defines first and second chambers. The first chamber is disposed adjacent to the second chamber. The reel is disposed within the first chamber. The reel includes first and second hubs configured to rotate and at least one connecting member connecting the first hub to the second hub. The at least one auger is disposed in the second chamber. The first and second hubs rotate about a common axis of rotation. No connecting member connects a center of the first hub to a center of the second hub along the axis of rotation. An attachment point between each connecting member and the first hub is circumferentially offset with respect to an attachment point between the same connecting member and the second hub. 
     Another aspect of the invention provides a mixing apparatus which includes a hopper, a reel, at least one primary member, at least one auger, and at least one secondary member. The hopper defines first and second chambers. The first chamber is disposed adjacent to the second chamber. The reel is disposed within the first chamber. The reel includes first and second hubs configured to rotate about a common axis of rotation. The at least one primary member connects the first hub to the second hub and is configured to sweep a cylindrical volume while the first and second hubs rotate. The at least one auger is disposed in the second chamber. The at least one secondary member is disposed at a non-zero angle relative to the axis of rotation of the first and second hubs such that the secondary member passes through the cylindrical volume while the first and second hubs rotate. 
     Another aspect of the invention provides a mixing apparatus which includes a hopper, a reel, at least one wiper, and at least one auger. The hopper defines first and second chambers. The first chamber is disposed adjacent to the second chamber. The reel is disposed within the first chamber. The reel includes first and second hubs configured to rotate and at least one connecting member connecting the first hub to the second hub. The first and second hubs are configured to rotate about a common axis of rotation, and no connecting member connects a center of the first hub to a center of the second hub along the axis of rotation. The at least one wiper is connected to the at least one connecting member. Each wiper is connected to only one connecting member. The at least one auger is disposed in the second chamber. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein: 
         FIG. 1  is an isometric view of a reel according to one aspect of the invention; 
         FIG. 2  is a second isometric view of the apparatus depicted in  FIG. 1 ; 
         FIG. 3  is a side view, directly perpendicular to the axis of rotation of the reel depicted in  FIG. 2 ; 
         FIG. 4  is an axial view taken along one end of the reel depicted in  FIG. 3 ; 
         FIG. 5  is an isometric view of the reel using partial wipers; 
         FIG. 6  is a second isometric view of the reel depicted in  FIG. 5 ; 
         FIG. 7  is a third isometric view of the reel depicted in  FIG. 5 ; 
         FIG. 8  is an axial view of the reel depicted in  FIG. 5 ; 
         FIG. 9  is an isometric view of the reel including adjustable paddles; 
         FIG. 10  is another view of the reel depicted in  FIG. 9 ; 
         FIG. 11  is an alternate embodiment of the reel depicted in  FIG. 9  with a different type of rotational unit for the paddles; 
         FIG. 12  is an end view of the arrangement depicted in  FIG. 11 ; 
         FIG. 13  depicts an isometric view of a portion of a mixing apparatus with a reel and pair of augers removed; 
         FIG. 14  is an end view with a cutaway of the mixing apparatus depicted in  FIG. 13 . 
         FIG. 15  is an isometric view of a portion of the mixing apparatus with the augers in place, but the reel removed; 
         FIG. 16  is an isometric view of the apparatus depicted in  FIG. 15  with the reel installed; 
         FIG. 17  is a cut-away end view of the apparatus depicted in  FIG. 15  with the reel installed. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views. 
     With reference to  FIG. 1 , one example of a reel  10  is depicted as an isometric view. The reel  10  includes at least one contoured bar  20  working as a connecting member that connects a first hub or star  40  to a second hub or star  50 . The contoured bar  20  typically includes a wiper, for example, full wiper  30  along its edge. A full wiper typically extends along at least 90% of the axial length of the contoured bar  20 , preferably along the entire axial length. The full wiper  30 , or partial wiper in some cases, pushes mixing material along an interior surface of a hopper defining the boundary of a first chamber  110  (see  FIG. 14 ). The reel  10  rotates within the first chamber  110  and lifts material upward and over a divider  105  and into an area for mixing via one or more augers  130 ,  140  (see  FIGS. 15 and 17 ). 
     The contoured shape of the contoured bar  20  allows the contoured bar to remain a constant distance from a wall of the first chamber  110 . Additionally, the contoured shape allows the first star  40  to be offset rotationally from the second star  50 . In other words, as the contoured bar  20  extends from the first star  40  to the second star  50 , the contoured bar follows a helical path. As shown in  FIG. 1 , the connection points of the ends of the contoured bars  20  are circumferentially offset such that ends are not directly across from each other, in the axial direction. A plurality of the contoured bars, for example five as shown in the example depicted in  FIG. 1 , forms the general shape of a helix when viewed together with the first and second stars  40 ,  50 . One benefit of the above-noted arrangement is that, as the reel  10  rotates, feed or another mixing material will fall from the contoured bar  20  across the divider  105  gradually as the leading part of the contoured bar  20  passes by the critical angle of rotation that allows for the feed or other mixing material to release from the contoured bar  20 . Thus, in contrast to providing a straight bar connecting, for example, a twelve o&#39;clock position on a star synchronized with rotation with a twelve o&#39;clock position on another star, the helical arrangement depicted in  FIG. 1  allows a gradual release of material from the reel  10 . This gradual release may ameliorate or eliminate “pulsing” inasmuch as the material leaving the contoured bar  20  leaves the contoured bar  20  over a longer period of time. 
     The contoured bar  20  can be used exclusively or in combination with straight bars connecting points of the first and second stars  40 ,  50 . In one optional arrangement, an auxiliary stirrer  60 , also referred to as an auxiliary member, connects one non-axial position on one of the stars  40 ,  50  with another non-axial position on another of the stars  40 ,  50 . The contoured bars  20  can be understood to be primary members that connect the first and second stars, and the auxiliary stirrer  60  can be understood to a secondary member that, as shown in  FIG. 1 , passes through an interior portion of the helix defined by the contoured bars  20 . The auxiliary stirrer  60  may disrupt any standing waves or patterns of rotation created by the reel  10 , and therefore, provide higher mixing efficiency. In one embodiment, the auxiliary stirrer is a bar, similar or perhaps different in size from the contoured bars  20 . In another embodiment, the auxiliary stirrer  60  is a chain. In yet another embodiment, the auxiliary stirrer  60  is a cable such as a steel cable, for example. The auxiliary stirrer  60  may connect one non-axial point on one star to another non-axial point on the opposite star. Additionally, in one embodiment, the auxiliary stirrer  60  may connect an axial point on one star with another non-axial point on another star. However, in order to prevent packing within the helix of the reel  10 , it is preferred that no shaft or rigid member connect the axial points on each of the stars  40 ,  50  to each other. In other words, it is desirable to keep the interior of the reel  10  somewhat open, and therefore, a direct connection between the center points of the stars with a solid shaft, hollow pipe, frame work, or other such member is avoided in many of the embodiments of the reel  10 . However, some configurations of the reel  10  provide one or more helical contoured bars  20  in combination with a center shaft or other such central member. 
     The auxiliary stirrer  60  acts to disrupt standing waves within the cylindrical area swept by the bars  20 . In other words, the auxiliary stirrer passes through a cylindrical area swept by the bars  20  (which is typically hollow), and the auxiliary stirrer  60  breaks up or stirs material that otherwise might remain in this within this swept cylindrical area undisturbed the same way material within the eye of a hurricane might be undisturbed as long as it is within the eye. 
     As shown in  FIGS. 1 ,  2 ,  3 , and  4 , the contoured bars  20  may include full wipers  30  extending along a majority of the length of the contoured bar  20 . In this embodiment, each of the plurality of contoured bars  20  in combination with its associated full wiper  30  sweeps most or all of the interior of the first chamber as the reel rotates. 
     In another embodiment, shown in  FIG. 5 , the full wiper  30  is replaced with one or more partial wipers  35  on one or more of the contoured bars  20 . A partial wiper  35  typically extends along no more than 10% of the axial length of the contoured bar  20  in order to provide increased randomness to the mixing. Although  FIG. 5  depicts only partial wipers  35 , some embodiments of the inventive reel  10  combine contoured bars  20  with straight bars and/or full wipers  30 . In other words, the reel can include at least one straight bar, contoured bar  20 , full wiper  30 , and/or partial wiper  35 . Additionally, the auxiliary stirrer  60  may be used with any of the above-noted arrangements. In one embodiment, the wipers  35  can be designed to move to relieve pressure caused by the mixed material. The wipers  35  can further be designed to move and remain in an adjusted position (not return to the normal mixing position). This design may use a shear type mounting bolt. In a further variation, the wipers  35  can move and return to the normal mixing position. This design may use a compression or torsion spring to return the wipers  35  to the normal mixing position. 
     Again referring to  FIG. 1 , the first and second stars  40  and  50  typically include some form of connection for the contoured bars  20 . This connection may be by direct welding. Direct welding is typically the simplest method of connecting the contoured bars  20  to the stars  40 ,  50 . However, in another embodiment, the contoured bars  20  are connected to the stars  40 ,  50  via mechanically coupled connections  25 , which are typically screwed, clamped, or bolted connections. In this manner, the contoured bars  20  may be removed from the stars  40 ,  50  and replaced with different configurations or replaced when damaged, for example, in the event a rock is placed within the apparatus and damages the reel. 
     Similarly, the auxiliary stirrer  60  may be bolted to the stars or connected via some other detachable configuration. Likewise, as shown in  FIG. 5 , the partial wiper  35  may be connected to the contoured bar  20  via a wiper connection  37 . In some regards, the wipers  30 ,  35  may be considered consumable devices inasmuch as they are sometimes made of semi-rigid or partially flexible materials such as plastic or rubber, although other materials such as steel may be used. Therefore, after long periods of rotation of the reel  10 , the wipers  30 ,  35  will gradually wear away. Therefore, it is beneficial to provide a removable connection connecting the full wiper  30  or the partial wiper  35  to the contoured bar  20 . Typically, this connection between the contoured bar  20  and the wiper  30  or  35  will be via bolted clamp or direct bolting or screwing. 
     Depending on the needs of the user, the distance of the contoured bars  20  from the walls of the first chamber  10  may be varied. For example, in one application, it may be desirable to have a minimal or small clearance between the contoured bar  20  and the wall of the chamber, for example, one inch or less. The wiper  30 ,  35  will typically close the gap between the contoured bar  20  and wall of the first chamber in order to brush against the wall during rotation. In some embodiments, the distance from the contoured bar  20  to the wall of the first chamber  110  varies along the axial length of the contoured bar  20 . In other words, at one end of the contoured bar  20 , the gap may be, for example, one inch; and at the other end of the contoured bar  20 , the gap may be three inches. Variations in the size of the full wiper  30  and/or partial wipers  35  may be used to make up the gap. In other words, the wiper may compensate for the change in distance between the bar  20  and wall. In other embodiments, the gap between the contoured bar  20  and the wall of the first chamber  110  remains the same along the axial length of the contoured bar  20 . 
     In some embodiments of the reel  10 , the coupled connection  25  may be used to replace the contoured bar  20  with a contoured bar  20  of a larger diameter, thus reducing the distance between the wall of the first chamber  110  and the surface of the contoured bar  20 . An alternate or supplemental way of altering the distance (gap) between the contoured bar  20  and the wall of the first chamber  110  is to change a connection point of the contoured bar  20  to the first or second stars  40 ,  50 . In other words, the center of the contoured bar  20  is positioned, radially, nearer or farther from the center of the star  40 ,  50 . The Applicants have found that changing the position of the contoured bars  20  in the radial direction or by changing the diameter of the contoured bars  20  alters the amount of horsepower required to rotate the reel. Unexpectedly, it appears that the maximum amount of horsepower required to rotate the reel through agricultural material is typically not required when the contoured bars  20  are positioned at the outermost radial position. Rather, the maximum horsepower is required for rotation of the reel  10  when the contoured bars  20  are positioned somewhat inward of the outermost radial position. 
     Regarding the wipers  30 ,  35 , it is preferred that the entire axial length of the reel  10  is wiped via one or a plurality of the wipers in combination. In other words, while it is not necessary for every wiper or even for one wiper to wipe the entire length of the reel  10 , some combination of the partial or full wipers should typically pass across the bottom of the chamber  110  at some point along every part or nearly every part of the axial length of the bottom of the chamber  110 . 
     Typically, the reel  10  will rotate such that the top part of the reel  10  moves in a direction away from the top of the upper auger  130 . Additionally, the reel  10  typically rotates at a speed of approximately 1 to 12 rpm, preferably, approximately 6 rpm. In a preferred embodiment, no connecting structure connects the centers of the hubs  40 ,  50 , and therefore, material can flow freely within the helix of the reel  10 , and a solid “barrel-like” compaction of the mixing material within the reel  10  may be prevented. Thus, a complete or partial free space extends from at least one of the hubs  40 , 50  toward the other of the hubs. In some embodiments, a slight amount of axial movement of the feed is created by the helical shape of the reel  10 . 
     In operation, the reel  10  pushes material over the divider  105  toward the upper and lower augers  130 ,  140 . The lower auger, during rotation, pushes the material toward a chute  150  (see  FIG. 14 ). The bottoms of the first and second chambers  110 ,  120  are curved bottoms  111 ,  121 , in order to accommodate the rotational movement of the reel  10  and lower auger  140 . 
     One or both of the stars  40 ,  50  may be driven via a motor and/or gear system. For example, a hydraulic or electric motor may be connected to the driven star directly or via a belt/chain and pulley arrangement. Additionally, the mixer  100  shown in  FIG. 14  may be connected to a truck, pulled behind a trailer, or set up as a stationary configuration. Feed or other mixing material will be typically added to the mixer  100  via an open top  160 . 
     Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. Thus, the reel and or mixing system may be used with or without a central shaft used to drive the hubs, but it is preferable to omit the central shaft or other such connecting structure in order to allow increased mixing effect. Additionally, while both straight and/or contoured bars may be used to connect the two hubs/stars, it is preferable that at least one contoured bar is used for connection. Any combination of the above-noted embodiments may be used. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.