Abstract:
A stir alarm device for monitoring a forced air in-bin grain stirring system and alerting an individual when the stirring system malfunctions. The stir alarm device may include a movement device which is movably secured to the stirring system, such that movement of the stirring system causes movement of the movement device. The stir alarm device may further include a detection mechanism for monitoring the movement of the movement device. The stir alarm may also include a signaling device operably attached to the detection mechanism, the signaling device for signaling a malfunction when an amount of movement detected by the movement detection mechanism is below a threshold for a predetermined period of time and may include methods or components to control the operation of the stir machine and/or drying system.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    The present application claims priority to and incorporates herein by reference U.S. Provisional Patent Application Ser. No. 61/527,467 filed on Aug. 25, 2011. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates generally to grain storage and, more particularly, to a stir alarm device for integration with an in-bin grain stirring system, which is designed to monitor and alert an individual when the stirring system malfunctions. 
         [0003]    Grain bins are typically designed to process and store grains of all types. Oftentimes, grain bins include a drying system for heating and blowing air, which forces the heated air up through perforations located in the base of the bin so that it may contact the grain contained therein, such that the grain closest to the floor dries first. The grain is dried using either the “continuous flow method” or the “batch method”. The “continuous flow method” is a process of drying grain where sufficiently dried grain is continuously removed from the floor area of the bin as wet grain in added to the top of the bin. The “batch method” is a process of drying grain where the bin is partially or completely filled with wet grain and then the grain is stirred until all of the grain within the bin is sufficiently dried. When the “batch method” is employed, a stirring system is usually installed within each grain bin for mixing the grain in order to facilitate even drying. A typical stirring system includes an auger carriage which is suspended from the center of the bin&#39;s roof and a track which is mounted on the inside of the bin wall, the track being designed for receiving the auger carriage and allowing it to move along the bin&#39;s inner perimeter. This rotational movement is commonly referred to as “walking.” The auger carriage typically includes a plurality of vertical rotating augers, which the auger carriage pulls through the grain to mix it and to encourage even drying. As the augers turn, the rotation of the augers also assists the auger in walking through the grain. The speed of the auger carriage is controlled by a gear motor which is controlled by a tilt switch. If the auger carriage gets too far ahead of the augers, the augers tilt enough to actuate the tilt switch, which disengages the gear motor from driving the auger carriage to let the augers catch up. Depending on the level of moisture the grain contains and the volume of the grain, it can take between approximately 3 to 6 days (and sometimes longer) for the grain to reach a sufficiently dry state. 
         [0004]    Because a typical stirring system contains a number of component parts, any stirring system that is installed in a grain bin will experience periodic mechanical malfunctions. Furthermore, because the stirring system operates independently from the drying system, if the stirring system malfunctions, the grain directly above the drying system and in the proximity of the vertical augers will continue to dry beyond what is intended, while the rest of the grain in the bin remains wet. Thus, if the malfunction of the stirring system is not quickly detected and repaired, irreparable damage can occur to the stir machine as well as uneven and overdrying of grain and overgrinding of grain by the augers, resulting in lost time and money. At present, the only way to ensure even drying is for an individual to climb to the top of a ladder located on the side of the grain bin, open a door in the roof and watch for several minutes to confirm that the stirring system is operating correctly. Each bin must be checked numerous times every day (and night) throughout the drying process in order to prevent the grain from being unevenly dried and damaged in the stall zone. In addition to being time consuming and inconvenient, this practice of checking bins adds considerable stress during the harvest season. 
         [0005]    Thus, it would be advantageous to develop a stir alarm device which is designed to monitor the stirring system and alert an individual when a malfunction occurs. 
       SUMMARY OF THE INVENTION 
       [0006]    The present invention is directed to a stir alarm device which is designed for monitoring and alerting an individual when the stirring system installed within a grain bin malfunctions. A typical prior art grain bin includes a stirring system for mixing the grain within the bin to ensure that the heated air created by the drying system evenly dries the grain. Specifically, the stirring system is operably secured to the center of the bin&#39;s roof by a suspension mechanism, creating an axis on which the stirring system rotates. The stirring system further includes an auger carriage which extends outwardly from the axis point and is movably secured to a track located on the inside wall of the bin. The track is designed to receive the auger carriage, allowing it to rotate within the grain bin. The auger carriage further includes a rotary contact providing voltage to components, and a plurality of revolving augers which may be evenly spaced across the length of the auger carriage. As the auger carriage rotates around the grain bin it pulls each of the augers through the grain, facilitating mixing and even drying. 
         [0007]    The stir alarm device is operably attached to the stirring system and is designed for monitoring and alerting an individual when malfunctions occur. The device includes a movement device coupled to an existing stirring system, such that movement of the stirring system causes movement of the movement device. The movement device may be a carousel that revolves around a central axis thereof, or a trolley which rides along the track around the inner circumference of the bin as the auger carriage moves therealong. The stir alarm device may also include a detection mechanism for monitoring the movement of the movement device, and a signaling device for signaling a malfunction when an amount of movement detected by the movement detection mechanism is below a threshold for a predetermined period of time. The device may also include a microprocessor for receiving and monitoring information collected by the device and for alerting the individual if a malfunction occurs. 
         [0008]    Specific advantages and features of the present assembly will be apparent from the accompanying drawings and the description of several illustrative embodiments of the present invention. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1A  illustrates an environmental view of a prior art grain bin with the roof removed to show a stirring system housed within. 
           [0010]      FIG. 1B  illustrates an exemplary control box according to an embodiment of the present invention. 
           [0011]      FIG. 2A  is a perspective view of one embodiment of a stir alarm device incorporating a carousel, according to an embodiment of the present invention. 
           [0012]      FIG. 2B  is an exploded view of the stir alarm device of  FIG. 2A . 
           [0013]      FIG. 3  is a perspective view of another embodiment of a stir alarm device which incorporates a carousel, according to an embodiment of the present invention. 
           [0014]      FIG. 4  is a perspective view of one embodiment of a stir alarm device which incorporates a carousel, according to an embodiment of the present invention. 
           [0015]      FIG. 5  is a perspective view of one embodiment of a stir alarm device which incorporates a trolley as connected to an auger carriage, with a zoomed-in section focusing on the stir alarm device, according to an embodiment of the present invention. 
           [0016]      FIG. 6  is a perspective view of one embodiment of a stir alarm device which incorporates a trolley as connected to an auger carriage, with a zoomed-in section focusing on the stir alarm device, according to an embodiment of the present invention. 
           [0017]      FIG. 7  is a perspective view of one embodiment of a stir alarm device which incorporates a trolley as connected to an auger carriage, with a zoomed-in section focusing on the stir alarm device, according to an embodiment of the present invention. 
       
    
    
       [0018]    It should be understood that the present drawings are not necessarily to scale and that the embodiments disclosed herein are sometimes illustrated by fragmentary views. In certain instances, details which are not necessary for an understanding of the present invention or which render other details difficult to perceive may have been omitted. It should also be understood that the invention is not necessarily limited to the particular embodiments illustrated herein. Like numbers utilized throughout the various figures designate like or similar parts or structure. 
       DETAILED DESCRIPTION 
       [0019]    Referring now to the drawings, more particularly by reference numbers,  FIG. 1A  illustrates one embodiment of a typical prior art grain bin  10  with a roof  12 , shown removed so as to expose one embodiment of a typical stirring system  14  installed within the grain bin  10 . The grain bin  10  typically includes a drying system (not shown) for heating and blowing air, which forces the heated air up through perforations located in the base of the grain bin  10  so that it may contact the grain contained therein. The stirring system  14  may be operably secured to the center of the roof  12  by a suspension mechanism  16 , creating an axis about which an auger carriage  18  rotates. The auger carriage  18  extends outward from the axis point as a radius of the grain bin  10 , and is movably secured to a track  20  which extends around the inner circumference of bin  10 . The track  20  is designed for guiding the auger carriage  18  and allowing it to move along the inner perimeter of the grain bin  10 . The rotational movement of the auger carriage  18  is commonly referred to as “walking.” The auger carriage  18  further includes a plurality of revolving augers  22  which may be evenly spaced across the length of the auger carriage  18 . As the auger carriage  18  walks around the grain bin  10  it pulls each of the revolving augers  22  through the grain, facilitating mixing and even drying. 
         [0020]      FIG. 1B  illustrates an exemplary control box  1  for housing a controller  2 . Controller  2  is designed to receive and analyze signals regarding movement of the stirring system  14 . Controller  2  may initiate a malfunction alarm, and/or shut down the stirring system  14  and dryer (not shown). 
         [0021]    As can be seen in  FIGS. 2A ,  2 B,  3  and  4 , a stir alarm device  26  may include a carousel  32  which is operably attached to the proximate end of the auger carriage  18  (or other rotating component, preferably located at the axis point) by a bracket  30 . Rotational movement of the auger carriage  18  thereby causes the carousel  32  to revolve around the central axis. The device  26  further includes a movement detection mechanism  34  which is secured to a stationary portion of the suspension mechanism  16  by a bracket  28 . The detection mechanism  34  is positioned for monitoring the movement of the carousel  32  and configured to transmit a signal to a signaling device communicatively associated with a controller (as would be understood). In one embodiment, the detection mechanism may be connected to a wireless transceiver for transmitting a signal to a controller (not shown). Alternatively, the detection mechanism may be hardwired with such a controller. The controller may be responsible for analyzing the information received from the detection mechanism  34 , and for determining whether to take action. The controller may alert the user of a malfunction by sending a text and/or email message and/or making a telephone call to the user, and/or by causing a visual and/or auditory warning to commence, according to known systems and methods. 
         [0022]      FIGS. 2A and 2B  illustrate one carousel-specific embodiment of the device  26 A. In this embodiment, the detection mechanism  34 A is a proximity sensor designed to detect the presence of metal. The carousel  32 A may have a plurality of evenly spaced metal slats  36 , such that the spaces between the slats  36  form a plurality of slits  38 . The detection mechanism  34 A serves to detect transitions between the metal slats  36  and slits  38 , and to transmit a signal to the controller. 
         [0023]    In an alternative carousel-specific embodiment, as illustrated in  FIG. 3 , the device  26 B includes a carousel  32 B having a plurality of metal teeth  40 . In this embodiment, the detection mechanism  34 B is a proximity sensor designed to detect the presence of metal. The detection mechanism  34 B serves to detect transitions between each tooth projection and each recess, and to transmit a signal to the controller. Even after repeated use, these embodiments remain reliable, since the detection mechanism  34 A,  34 B is a proximity sensor capable of detecting metal through any dust and/or particulate matter that may collect on the carousel  32 A,  32 B. 
         [0024]    In still another carousel-specific embodiment, as illustrated in  FIG. 4 , the device  26 C includes a carousel  32 C having a plurality of geared teeth  42 . The device  26 C further including a detection mechanism  34 C which is secured to a stationary portion of the suspension mechanism  16 . The movement detection mechanism  34 C is positioned for monitoring the movement of the carousel  32 C. In this embodiment, as the carousel  32 C moves, the projection of a geared tooth  42  engages a lever  44  which is operably connected to the detection mechanism  34 C. Movement of the carousel  32 C causes the geared tooth  42  to interact with and actuate the lever  44 , thereby allowing the movement detection mechanism  34 C to detect movement of the carousel  32 C via the lever  44 . Each time a tooth  42  passes the lever  44 , the transition from a recess to a tooth  42  (or vice versa) causes the lever  44  to be actuated, and a transition is recorded. The detection mechanism  34 C is designed to transmit a signal to the controller. As shown in  FIG. 4 , the carousel  32 C includes two rows of such teeth  42  which are slightly offset from each other, though this is not required. Additional, offset rows of teeth simply provide for more transitions in a given period of time. 
         [0025]    In an alternative embodiment as shown in  FIGS. 5 ,  6  and  7 , the device  46  includes a trolley  48  which travels along track  20 , and is coupled to the auger carriage  18  by a bracket  50 . Further, the trolley  48  is movably engagable with the track  20  by a roller  52 . In one embodiment the device  46  is pulled behind the auger carriage  18  as it walks around the grain bin  10 . Associated with the roller  52  is a wheel  54  (which may be integral with or a part of roller  52 ) which revolves as the trolley  48  moves around the track  20 . The device  46  further includes a detection mechanism  56 , which is secured to the trolley  48 . The detection mechanism  56  is preferably positioned for monitoring the movement of the wheel  54 , and is configured to communicate through the signaling device  58  for transmitting a signal to the controller. In an alternative embodiment, rather than use a wireless signaling device, the detection mechanism  56  may be hardwired to the controller through a rotary contact. 
         [0026]      FIG. 5  illustrates one embodiment of such a trolley-type device  46 A. In this embodiment, the detection mechanism  56 A is a magnetic sensor designed to detect a magnetic field created. The wheel  54 A may have a plurality of magnetic discs  60  or magnetic wrap, evenly spaced around the perimeter thereof. The detection mechanism  56 A serves to detect transitions between the each of the magnetic discs  60  and the spaces therebetween. 
         [0027]      FIG. 6  illustrates yet another embodiment of the device  46 B. In this embodiment, the device  46 B includes a wheel  54 B having a plurality of metal teeth  62 . In this embodiment, the detection mechanism  56 B is a proximity sensor designed to detect the presence of metal. The detection mechanism  56 B serves to detect transitions between each tooth projection and recess. The detection mechanism  56 B communicates with signaling device  58  for transmitting a signal to the controller. In an alternative embodiment, rather than use a wireless signaling device, the detection mechanism  56 B may be hardwired to the controller through a rotary contact. 
         [0028]    In still another embodiment, as illustrated in  FIG. 7 , the device  46 C includes a wheel  54 C having a plurality of geared teeth  64 . The device  46 C further includes a detection mechanism  56 C which is positioned for monitoring the movement of the wheel  54 C. In this embodiment, as the wheel  54 C moves, each geared tooth  64  engages a lever  66  which is operably connected to the detection mechanism  56 C. Each time a tooth  64  passes the lever  66 , the transition from a recess to a tooth  64  (or vice versa) causes the lever  66  to be actuated, and a transition is recorded. The detection mechanism  56 C is designed to transmit a signal to the controller. In an alternative embodiment, rather than use a wireless signaling device, the detection mechanism  56 C may be hardwired to the controller through a rotary contact. 
         [0029]    A user may set the number of desired transitions and the predetermined period of time, as desired. Additionally, the stir alarm device  26 ,  46  will physically pause if the auger carriage  18  is intentionally paused to allow the augers  22  to catch up. The predetermined period of time may be set high enough to take into account any standard pause time for the auger carriage  18 . 
         [0030]    The stir alarm device  26 ,  46  may also be used to track the position of the auger carriage  18  around the bin  10 . This may be accomplished by tracking the number of transitions counted by the detection mechanism  34 ,  56 , and using that number to determine the distance traveled by the trolley  48  or carousel  32 . A “home” condition may be initiated each time the trolley  48  or carousel  32  complete one entire revolution, such that the number of transitions is reset (if only for the purposes of determining the location of the auger carriage  18  within the bin  10 ). In this manner, the number of transitions since the home condition could be used to determine the location of the auger carriage  18  within the bin  10 . Alternatively, a physical switch could be installed at the home position which would be physically actuated by the trolley  48  as it passes, or by another lever on a carousel  32 , to initiate the home condition. Physical switches or other activation devices may also be installed around the bin  10  interior wall or track mounting brackets to determine the location of the auger carriage  18 . 
         [0031]    Thus, there has been shown and described an embodiment of a novel stir alarm device. As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. The terms “having” and “including” and similar terms as used in the foregoing specification are used in the sense of “optional” or “may include” and not as “required”. Many changes, modifications, variations and other uses and applications of the present invention will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow.