Abstract:
A grain bin access door and chute system that can be retrofitted into existing grain bins or installed in new grain bins. The access panel includes an outer door and an inner door and allows a user to quickly access and assess the grain within a bin without fear of falling into the grain or through the crust of grain which can form a bridge on the top of grain. The access door includes a lever-controlled chute door and pipe-chute connection. This allows grain to be gravity fed into awaiting grain trucks or rail cars without using a more dangerous grain auger and without relying on outside energy sources. Additionally, grain transferred through a gravity-fed method is less likely to become damaged than grain transferred through a grain auger. An optional grain agitator may likewise be installed within the grain bin.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority in U.S. Provisional Patent Application No. 61/603,164, filed Feb. 24, 2012, which is incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to a system and method for providing an alternative means for discharging grain from a grain bin, and more specifically to a specifically designed single or double access door and chute system providing an energy free, enhanced safety, multiple portal grain loading system with the ability to deal with clogged or crusted grain while minimizing waste and while also reducing the damage to the grain. 
     2. Description of the Related Art 
     Grain is typically stored in a grain bin prior to being transported to a remote location for processing, milling, or other purposes. Grain bins protect the grain from the elements and from pests. However, it is much simpler to load grain into a grain bin than it is to remove the grain from these bins and into transport vehicles, such as trucks or trains. Additional hazards also present themselves due to grain bin use. These hazards include but are not limited to a crust forming on the top or throughout the product, uneven emptying of the bin, the bin tipping or collapse, and the emptying augers becoming clogged. The greatest hazard of all is the temptation and need to enter the top of the grain bin from the top portal to remedy a problem. 
     Grain bin products are loaded into trucks and trailers by a system of augers. A large floor auger is beneath the floor of the bin on one side. It is filled by a center located sump drain and several smaller recessed port holes. The floor auger fills a second auger outside the grain bin that must raise the grain and fill the waiting transportation vehicle. The grain in the bin fills these augers by gravity flow. If there are no problems that exist with the grain, it will empty by this method until no further grain will flow. This will result in the remaining grain in the bin forming a steep 45 degree slope that will need to be unloaded by a third auger known as a sweep auger. The sweep auger needs to be started once it is uncovered by the grain flowing through the smaller recessed port holes under the sweep auger. It then circles the inside circumference of the grain bin with the center pivot located to empty the remaining grain into the sump of the floor auger. The resource system requires substantial electric for both of the grain bin augers, diesel or gas for the tractor to operate the lift auger and one to two people to operate and manage the equipment safely. The grain must flow problem free. The side walls of the grain bin must not fail. 
     A sweep auger is often placed on the floor of the grain bin to ensure no grain is left behind during a loading process. A sweep auger is a portable unguarded screw auger attached to a pivot that circles the perimeter of the storage bin and conveys grain into a center sump(s) located in the bin floor. The sumps are typically recesses located in the center of the bin. A second auger located below the floor then transports the grain to the exterior of the bin and allows the grain to be loaded by using a chute. The sweep auger cannot function until grain within the grain bin is at a level low enough to not obstruct the auger. 
     Grain augers have caused a number of injuries and deaths in recent years. Injuries range from lacerations, caused by falling onto or by lifting and moving the auger, to people becoming entrapped and crushed or suffocated after falling through the top layer of grain which can form a “crust” when moisture is present. Sweep augers also tend to cause a “funnel” effect when they are in operation, which can quickly draw a person down into the grain. 
     A grain bridge can form when grain on the surface is moldy or is frozen together to form a hard, thick crust. When grain is unloaded from a bin with a surface crust, a hollow cavity forms underneath the grain bridge. If anyone enters the bin and attempts to walk on the crusted surface, the additional weight will cause the crust to collapse and the individual could be partially or completely submerged instantly. The shifting grain can move the victim four to five feet from the point of entry where the victim was last seen, making it difficult to determine exactly where the victim is located. 
     It is therefore typically not recommended that a person enter a grain bin while grain remains in the bin. There is a need for an alternative method to both unload the grain and access the grain bin while grain remains in the bin without presenting danger to the user. 
     Heretofore there has not been available a grain bin access door and chute system with the advantages and features of the present invention. 
     SUMMARY OF THE INVENTION 
     The present invention relates to a grain bin access door and chute system that can be retrofitted into existing grain bins or installed in new grain bins. The access panel includes an outer door and an inner door. This access panel allows a user to quickly access and assess the grain within a bin without fear of falling into the grain or through the crust of grain which can form a bridge on the top of grain. An opening is present in the inner door to allow sampling of the grain without requiring complete access to the grain bin interior. The access door includes a lever-controlled chute door and pipe-chute connection. This allows grain to be gravity fed into awaiting grain trucks or rail cars without using a more dangerous grain auger and without relying on outside energy sources. Additionally, grain transferred through a gravity-fed method is less likely to become damaged than grain transferred through a grain auger. 
     An alternative embodiment of the presented invention includes an access door and chute placed on opposing sides of the grain bin to prevent grain from stacking up against one side of the grain bin, which could cause the bin to tip. 
     Another alternative embodiment of the present invention includes a feeder auger placed above the access door. This auger spans the length of the grain bin and helps to prevent grain from stacking up against one side of the grain bin, which could cause the bin to tip. 
     Access to the access door is reached using collapsible steps, a temporary ladder, or some other manner of access. For the safest approach, a set of steps is semi-permanently affixed to a platform located next to the access door. 
     A further aspect of the present invention relates to a grain agitator capable of preventing accretion, aggregation, accumulation, and clogging of grain within a typical grain bin. Grain can clump together and form a crust capable of blocking access ports beneath the grain bin which are used to feed the grain into a floor auger, which then allows the grain to be loaded into transport vehicles. It is an aspect of an embodiment of the present invention to ensure that the grain does not clump together. 
     It is a further aspect of an embodiment of the present invention to ensure that the grain bin floor grates remain unclogged during the loading procedure. 
     It is a further aspect of an embodiment of the present invention to that the agitator will function without the need to remove an existing sweep auger from within the grain bin. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The drawings constitute a part of this specification and include exemplary embodiments of the present invention illustrating various objects and features thereof. 
         FIG. 1  is a front elevational view of an embodiment of the present invention shown with a pipe chute attached. 
         FIG. 2  is a front elevational view of an embodiment of the present invention shown with an open exterior access door. 
         FIG. 3A  is a detailed front elevational view of an access panel inner door in a closed position. 
         FIG. 3B  is a detailed front elevational view of an access panel inner door in a partially-opened position. 
         FIG. 3C  is a detailed front elevational view of an access panel inner door opening on a hinged side as viewed from a position external to the grain bin. 
         FIG. 3D  is a detailed front elevational view of an access panel inner door opening on a hinged side as viewed from a position internal to the grain bin. 
         FIG. 4  is a detail elevational view demonstrating the mobility of the pipe chute. 
         FIG. 5A  is a detailed front elevational view of an alternative embodiment access panel inner door in a closed position. 
         FIG. 5B  is a detailed front elevational view of an alternative embodiment access panel inner door in a partially-opened position. 
         FIG. 6  is a side elevational view of an alternative embodiment of the present invention with a cut-away portion showing a transfer auger for evening stored grain placement. 
         FIG. 7  is a side elevational view of an alternative embodiment of the present invention with two access doors and two pipe chutes. 
         FIG. 8  is a sectional view of a grain bin silo containing an embodiment of the present invention. 
         FIG. 8A  is a detailed view taken about the arrow of  FIG. 8 . 
         FIG. 9  is a top plan view of a grain bin silo containing an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     I. Introduction and Environment 
     As required, detailed aspects of the present invention are disclosed herein, however, it is to be understood that the disclosed aspects are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art how to variously employ the present invention in virtually any appropriately detailed structure. 
     Certain terminology will be used in the following description for convenience in reference only and will not be limiting. For example, up, down, front, back, right and left refer to the invention as orientated in the view being referred to. The words, “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the aspect being described and designated parts thereof. Forwardly and rearwardly are generally in reference to the direction of travel, if appropriate. Said terminology will include the words specifically mentioned, derivatives thereof and words of similar meaning. 
     II. Preferred Embodiment or Aspect Grain Bin Access Door and Chute System  2   
     Referring to the drawings in more detail; the numeral  2  generally refers to a grain loading system which can be affixed to an existing grain bin silo  4  or included with a new grain bin unit.  FIG. 1  shows a typical grain bin  4  including a roof access hatch  6 , a standard side access door  8 , and a grain level  10 . The grain loading system  2  comprises a number of pieces which allow the grain to be loaded into a truck or railcar for shipment to a remote location. The main components are the access panel subsystem  3  and the grain chute subsystem  24 . 
     An access panel subsystem  3  which includes an outer access door  12  and a pair of inner access panels  30 ,  32 , is affixed to the grain bin  4  via a frame  36 . The frame may be affixed to the grain bin wall by using rivets  38  or by some other semi-permanent means. The two door system prevents weather and moisture from entering the grain bin through the access panel  3 . Moisture can cause the grain stored within the bin to crust over, clump together, and ultimately to rot. The ultimate goal of the present invention is to provide a grain loading means and an access means while preventing grain degradation. 
     The exterior access door  12  includes a pair of hinges  16 , a latch pin  14 , and a latch pin receiver  15 . The exterior door acts as a second layer of protection by preventing moisture from entering the grain bin  4 , and preventing grain from exiting the grain bin. As shown in  FIG. 2 , when the exterior door is swung into an open position the interior upper  32  and lower  30  doors are accessible. A wheel  34  or other mechanism is used to open the interior doors. A pair of sample doors  46  are placed into the upper access panel  32 . This opening allows testing of the grain to determine moisture level or grain level  10  while preventing the grain from actively exiting the bin  4  and without requiring full access to the bin. Having two sample doors allows the user to insert a grain vacuum for cleaning the grain into one of the doors while maintaining the second door for periodic grain testing. 
     As shown in  FIGS. 3A and 3B , when activated, the lower panel  30  slides up in front of the upper panel  32 . If the grain level  10  is above the level of the interior panels  30 ,  32 , the grain  33  will be fed via gravity out the doors where it can be loaded into a transport vehicle. The lower panel  30  can be raised or lowered to control the flow of grain  33 . The lower panel follows a pair of tracks  48  mounted on the rear face of the upper panel  32 , as shown in  FIG. 3D . 
     As shown in  FIGS. 3C and 3D , the internal panels may optionally attach to the frame  36  via a hinged connection. This allows the panels to swing inward and allow a person to access the internal space of the grain bin. This cannot be accomplished as long as the grain level  10  is higher than the access panel subsystem  3 . 
     The grain chute subsystem  24  includes at least a funnel  26  and a pipe chute  28  comprised of multiple sections. A porous floor grate  22  is mounted below the access panel subsystem  3  and adjacent to the standing platform  20 . This grate is made of steel or other suitable material such that a person may walk on top of the grate to access the interior of the grain bin  4 . The grate must also be porous enough to allow flowing grain to pass through the grate into the funnel  26  and through the pipe chute  28  to be loaded into a transport vehicle. 
     Larger pieces of clumped grain will be captured by the grate and effectively filtered out. An access stair  18  is affixed to the platform  20  and allows access from the ground. The access stair  18  optimally includes a safety rail  19 . The platform  20  similarly should include a safety rail  21 . 
     The standing platform  20  allows a user to clear clumped and rotten grain from the grate  22  while grain is exiting the grain bin and entering the funnel  26 . 
     As shown in  FIG. 4 , the chute subsystem  24  should be repositionable to allow loading of grain into transport vehicles with little effort. The pipe chute  28  may be made of multiple sections. At least one section may contain a hydraulic motor  42  which is remotely controlled. A preferred embodiment will include a hydraulic subsystem connecting to most or all of the pipe chute  28  sections. The hydraulic motor and subsystem are capable of controlling the movement of each pipe chute section. 
     A remote control sensor  44  is connected to said hydraulic motor  42  and subsystem. The sensor is capable of receiving wireless signals from a remote source which provide instructions for moving the pipe chute  28 . Signals are received by a remote control sensor  44  and fed to the hydraulic motor  42 , which moves the chute in at least one direction. A remote control unit is preferable because the chute will be located some distance off of the ground and if grain were to spill, the user should be as far from the chute as possible to prevent harm. 
     The pipe chute  28  should be capable of a wide range of movement, as indicated by the arrows in  FIG. 4 . Ideally the chute will be capable of rotating at least 180°, extending, retracting, raising, and lowering at will. This ensures that the system  2  will accommodate transport vehicles of all shapes and sizes, and grain bins  4  of all shapes and sizes. It should be further noted that the system  2  can be placed at any height on the wall of a grain bin. The higher the system is placed, the less grain can be gravity fed through the system. 
     III. Alternative Embodiment Access Panel Subsystem  153   
     As shown in  FIGS. 5A and 5B , the internal access panel  156  may be formed from only a single panel. The access panel  156  includes the sample access doors  158  and is affixed to a frame  162  which is connected to the grain bin  4  via rivets  160  or some other connection means. An access panel door handle wheel  154  is mounted on or near the frame. This wheel controls the access panel, allowing the panel to be raised or lowered. This allows the user to control the flow of grain exiting the grain bin, and also allows complete access to the internal space of the grain bin  4  when fully opened. A box  164  affixed to the internal face of the grain bin  4  receives the internal access panel  156  as it is being raised. The box  164  ensures that grain does not pour into the space between the door and the grain bin, causing the door to jam. 
     IV. Alternative Embodiment Grain Loading System  52   
       FIG. 6  demonstrates an alternative embodiment system for loading grain using a pipe chute  28 . During a normal procedure of loading grain via gravity using the pipe chute subsystem  24 , grain within the load bin could become stacked against the opposite wall. Such an overload on one single wall of the bin could cause the entire bin to tip, spilling the remaining grain and potentially injuring persons or equipment nearby. Additionally, often a grain crust  60  may form at the top layer of the grain  10 . This crust can remain even when the grain beneath it has been removed. Persons may accidentally attempt to walk on top of this crust or loosen the crust from beneath, resulting in injury or death to the user. 
     A large auger  54  spanning the diameter of the grain bin may be employed to stir up the grain along with the grain crust  60 . Further, this auger can be used to evenly distribute grain throughout the grain bin  4  and prevent tipping. The auger will move grain from the extreme opposite side of the bin  4  to the side where the chute subsystem  24  is located. The auger  54  may be powered by an electric motor  56  or by another suitable powering means. 
     Additionally, the larger auger can be activated while grain is being loaded into the grain bin  4  to ensure that the grain is evenly distributed within the bin. This will prevent grain from piling unevenly during the loading process which may cause tipping or otherwise damage equipment. 
     V. Alternative Embodiment Grain Loading System  102   
       FIG. 7  demonstrates yet another alternative embodiment system for loading grain using a pair of chute pipes  28  affixed to a pair of pipe chute subsystems  24  placed on opposing sides of a grain bin  4 . As mentioned previously, grain may tend to stack against one side of a grain bin if only one pipe chute subsystem  24  is utilized.  FIG. 6  demonstrates placing two of such systems onto a single grain bin  4  to ensure that the grain is evenly distributed from the grain bin, and the grain level  110  drops proportionally. Further, this alternative system allows two transport vehicles to be filled at the same time. 
     VI. Alternative Embodiment Grain Agitator  202   
     Referring to the drawings in more detail, the numeral  202  generally refers to a grain agitator system capable of stirring grain stored within a grain bin  204 , breaking up grain which may have accumulated or clumped together, and unclogging grain floor sumps  206  which feed into the floor/sump auger  210 . As shown in  FIG. 8 , a pair of mounts  214  are placed on the exterior of the grain bin and a rod axle  216  is run between the mounts, spanning the diameter of the grain bin  204 . The rod axle is rotated by a motor  222 . Seals  218  are placed where the rod  216  punctures the grain bin to prevent moisture from affecting the grain. 
     A number of blades  220  are mounted to the axle bar  216 . These blades are shaped to blend the grain and to break up existing clumps. The blades  220  may include a number of teeth  221  to aid in breaking up the clumped grain as shown in  FIG. 8A . 
     Typically, grain stored in the grain bin is gravity fed through the floor access grates  206  into the sump auger  210  which is powered by an electric or hydraulic motor  212  or by some other means. The grain follows the paths indicated by numeral  224  in  FIG. 8 . While a sweep auger  208  may be used when the grain is sufficiently low enough within the bin, grain clumps and crusts can cause issues for the sweep auger. 
     The blades  220  are optimally placed with relation to the floor access grates to ensure that the grates remain clear of clumped grain. The blades  220  also ensure that the grain remains evenly distributed within the grain bin to prevent tipping. Finally, the blades  220  can be used to break up a crust formed at the top surface of the grain within the grain bin. 
     The sweep auger  208  is placed perpendicular to the axle rod  216 , as shown more clearly in  FIG. 9 . This allows the user to keep the sweep auger within the grain bin at all times, even when it isn&#39;t being used, while allowing the additional functionality of the grain agitator system  202 . 
     The sweep auger may be activated when the grain is low enough. An indicator  215  located at the end of the axle rod or otherwise placed in relation to the agitator system  202  informs a user on the exterior of the grain bin  204  the direction of the blades  220  within the bin. This allows the user to ensure that the blades are rotated until they are parallel to the grain bin floor before the user starts the sweep auger  208 . 
     It is to be understood that while certain embodiments and/or aspects of the invention have been shown and described, the invention is not limited thereto and encompasses various other embodiments and aspects.