Abstract:
A system and method for changing a flow rate and direction of dry bulk material supplied from an elevated source via an angled spout to an adjustable spout end having an oversized input sleeve with internal baffles therein.

Description:
BACKGROUND OF INVENTION 
     In recent years, grain elevators and feed mills have necessarily become increasingly efficient in their operations. Many customers of elevators and feed mills now operate on a “just-in-time” basis. Consequently, it is becoming increasingly important to minimize the duration of any elevator or mill downtime. 
     In the past, grain handling equipment manufacturers have sold adjustable spout ends which are placed at a lower end of an upwardly angled spout. The spout ends are typically disposed over the center of a grain bin, and the spout ends typically direct material into the center of the bin in a substantially vertical column. One example of such an adjustable spout end is the “Original Style” Adjustable Spout End made by Nolin Milling, Inc. of Dickens, Iowa. This adjustable spout end has a pivoting top flange which bolts, clamps or is welded, etc. to a spout which supplies material from an elevated position. This spout end includes a plurality of internal baffles fixed in a stationary bottom section which is fixed to the top of the bin. These baffles are known to cause a backing up of the material within the adjustable spout end when material is provided at a sufficiently high flow rate. Once a sufficient flow is present, the grain entering the adjustable spout end strikes the reservoir of grain backing up. The incoming grain is thereby relatively gently decelerated by collision with the numerous movable grain particles building up inside the adjustable spout end. Once the grain is slowed and transformed into a substantially vertical columnar flow, it enters the top of the bin. 
     While these adjustable spout ends have enjoyed much success and have been used extensively in the past, they do have some drawbacks. 
     First of all, the effectiveness and efficiency of the grain-to-grain deceleration, occurring when incoming grain strikes grain pooling within the adjustable spout end, is at least somewhat dependent upon the angle between the incoming spout and the baffles fixed within the adjustable spout end and upon the flow rate of material through the spout. These adjustable spout ends generally operate optimally at a maximum spout flow rate and at some angle of arrival between 38 degrees and 90 degrees. These adjustable spout ends often operate sub-optimally as the flow rate decreases and/or the angle of the spout departs from the optimal orientation. 
     Secondly, repair and/or replacement of these adjustable spout ends often require considerable precision in situ cutting of the spout (often to within {fraction (1/16)} th  of an inch), and, therefore, much time and attention are required. In some cases, such as replacement of a spout end located inside a grain elevator or feed mill, etc. (because of the danger of a grain dust explosion), it may be necessary to obtain a “hot work permit” and to completely shut down the entire operation while any in situ welding or spout cutting is performed. 
     Thirdly, due to normal thermal and load-related expansion and contraction of the spout and the grain bin, the adjustable spout end and its connections to the spout and the grain bin may become distressed and distorted, thereby requiring repair and/or replacement. 
     Fourthly, the spouts may periodically need to be rotated so as to cause wear to occur more evenly and thereby extend the useful life of the spout. When this task is performed, it is often necessary to unbolt both ends of the spout and support the spout with a crane. This high level of effort and expense often discourages proper maintenance of the spouts. 
     Consequently, there exists a need for improved methods and systems for providing, maintaining, repairing and replacing equipment for delivering and decelerating dry bulk material in an efficient manner. 
     SUMMARY OF INVENTION 
     It is an object of the present invention to provide a system and method for decelerating dry bulk material in an efficient manner. 
     It is a feature of the present invention to utilize a pivoting oversized input spout sleeve. 
     It is an advantage of the present invention to simplify and enhance the coupling of the adjustable spout end to the spout. 
     It is another feature of the present invention to integrate a series of baffles within the pivoting input spout sleeve. 
     It is another advantage of the present invention to reduce the differential in baffle performance as a function of spout angle, thereby providing a more consistently gentle deceleration of material being handled. 
     It is yet another feature of the present invention to include a series of outlets from the oversized input spout sleeve. 
     It is yet another advantage of the present invention to permit variable flow rates, including minimal flow rates, while concomitantly providing for self-cleaning capabilities, over a wide range of spout angles. 
     The present invention is an apparatus and method for decelerating dry bulk material into a container, designed to satisfy the aforementioned needs, provide the previously stated objects, include the above-listed features, and achieve the already articulated advantages. The present invention is carried out in a “wasted time-less” manner in a sense that the time consumed in properly maintaining a functional spout end system, over its lifetime, has been greatly reduced. 
     Accordingly, the present invention is a system and method including an adjustable spout end having an oversized pivoting input sleeve with internal baffles therein. 
    
    
     BRIEF DESCRIPTION OF DRAWINGS 
     The invention may be more fully understood by reading the following description of the preferred embodiments of the invention, in conjunction with the appended drawings wherein: 
     FIG. 1 is a perspective view of a grain elevator system of the present invention. 
     FIG. 2 is a more detailed partially cut-away view of the adjustable spout end  108  of FIG.  1 . 
     FIG. 3 is a perspective view of a bottom side of a preferred embodiment of the present invention having a round pipe for oversized spout receiving sleeve  202 . 
     FIG. 4 is a perspective representation of a top view of the oversized spout receiving sleeve  202  of FIGS. 2 and 3. 
     FIG. 5 is a perspective cut-away representation of the oversized spout receiving sleeve  202  of FIGS. 2,  3 , and  4  which reveals the internal baffle  240 . 
    
    
     DETAILED DESCRIPTION 
     Now referring to the drawings wherein like numerals refer to like matter throughout, and more specifically referring to FIG. 1, there is shown a grain elevator system of the present invention generally designated  100 , including an elevated position  102  from which grain or other dry bulk material is provided to a grain bin  104 , via an angled gravity flow down spout  106  with a novel adjustable spout end  108  disposed at its lower end. The entire grain elevator system  100 , except for adjustable spout end  108 , are well known in the industry. 
     Now referring to FIG. 2, there is shown a more detailed view of the adjustable spout end  108  of FIG. 1, including an oversized spout receiving sleeve  202 , which has an internal dimension larger than the external dimension of angled gravity flow down spout  106 . Both angled gravity flow down spout  106  and oversized spout receiving sleeve  202  are shown as being pipes having a circular cross section. It should be understood that this is only one embodiment of the present invention. Angled gravity flow down spout  106  and oversized spout receiving sleeve  202  could be any shaped member, conduit, channel, pipe, tube, chute, shaft, such as, but not limited to, a square or round chute (FIG.  2 ). Various other shapes and configurations of angled gravity flow down spout  106  and oversized spout receiving sleeve  202  could be envisioned as well, so long as such other configurations permit angled gravity flow down spout  106  to be received into oversized spout receiving sleeve  202 . However, the present invention could be constructed such that angled gravity flow down spout  106  slides over oversized spout receiving sleeve  202 . (In such cases, it then could be called an undersized spout insert  202 .) In a preferred embodiment, angled gravity flow down spout  106  may have an exterior circumference of 8 inches, and the interior circumference of oversized spout receiving sleeve  202  would be slightly larger than  8  inches so as to allow angled gravity flow down spout  106  to easily slide into oversized spout receiving sleeve  202 . In a preferred embodiment, angled gravity flow down spout  106  is gravity fed; however, in some instances, it may be desired to have some mechanism for assisting material in flowing through the spout, such as, but not limited to, a conveyor, auger or other material moving apparatus. 
     Oversized spout receiving sleeve  202  is shown having an oversized spout receiving sleeve top end  204 , which receives angled gravity flow down spout  106  and is further shown having an oversized spout receiving sleeve bottom end  206  from which the grain is dispensed from oversized spout receiving sleeve  202 . Oversized spout receiving sleeve  202  can be made of any suitable material, but it is preferred that it be made of the same material or a material with similar properties as the material of angled gravity flow down spout  106 . In a preferred embodiment, oversized spout receiving sleeve  202  is a steel pipe. Angled gravity flow down spout  106  preferably extends into oversized spout receiving sleeve  202  by a predetermined sleeve penetration distance. The predetermined sleeve penetration distance can be variable, depending upon each particular application. Some of the factors which can be used to determine the predetermined penetration distance would be the amount of expansion and contraction of the grain bin  104  resulting from loading forces, as well as thermal expansion characteristics of grain bin  104 , thermal coefficients of expansion of angled gravity flow down spout  106 , measurement tolerances for cutting a length of angled gravity flow down spout  106 , and other suitable factors. 
     Adjustable spout end  108  has an adjustable spout end main body  208  with a slot therein for receiving oversized spout receiving sleeve  202  at various angular orientations. Adjustable spout end main body  208  may be many shapes, but a shape of a thick substantially circular disk standing on edge may be preferred. The slot in the top edge of adjustable spout end main body  208  is covered by an adjustable spout end main body sliding top section  210 , through which oversized spout receiving sleeve  202  extends. Oversized spout receiving sleeve  202  is preferably pivotally mounted on a pin  211 , which pivoting relationship, indicated by arrows  213 , can be selectively enabled or disabled by tightening a tensioning nut on said pin  211 . Adjustable spout end main body  208  includes an adjustable spout end main body fixed bottom section  212 , which has an adjustable spout end main body fixed bottom section material outlet opening  214 , which is coupled to grain bin  104  (FIG. 1) via an adjustable spout end main body fixed bottom section bin attachment flange  216 , preferably by bolting, but other suitable means of attachment may be substituted when desired. In a preferred embodiment, adjustable spout end main body  208  is made of steel. 
     Oversized spout receiving sleeve top end  204  is protected from the elements by oversized spout receiving sleeve top end covering sleeve  218 , which is coupled to angled gravity flow down spout  106  by oversized spout receiving sleeve top end covering sleeve mounting clamp  220  or other suitable means for attachment. Oversized spout receiving sleeve top end covering sleeve  218  prevents rain from entering into oversized spout receiving sleeve top end  204  and further helps to prevent grain dust, etc. from exiting into the air through oversized spout receiving sleeve top end  204 . In applications where adjustable spout end  108  is deployed inside a closed building, it may be desired that oversized spout receiving sleeve top end covering sleeve mounting clamp  220  may be sealed to angled gravity flow down spout  106  using any suitable sealing means, such as gaskets, caulking, etc. Similarly, a silicone seal  219  or the like may be used to seal the bottom edge of oversized spout receiving sleeve top end covering sleeve  218  to the side of oversized spout receiving sleeve  202 , so that grain dust does not escape. Of course, if oversized spout receiving sleeve  202  were inserted into angled gravity flow down spout  106  instead of vice versa, then it may not be necessary to include oversized spout receiving sleeve top end covering sleeve  218  and oversized spout receiving sleeve top end covering sleeve mounting clamp  220 . 
     Also shown in FIG. 2 are the four openings  231 ,  232 ,  233 , and  234  through which grain may exit oversized spout receiving sleeve  202 . These openings may be created by cutting holes in the oversized spout receiving sleeve bottom end  206 . The size, placement and orientation of these openings are important to the optimal operation of the present invention. The internal baffle  240  is shown as well. First end  241  may be a plate welded to an end portion of oversized spout receiving sleeve  202 . Similarly, second end  242  can be another plate welded to an end portion of oversized spout receiving sleeve  202 . Wear plates  252 , which are intended to extend the life of adjustable spout end main body  208 , may be installed within adjustable spout end main body  208 , such that said wear plates are readily replaceable in the event of degradation resulting from impact of grain incident thereon. 
     Now referring to FIG. 3, there is shown a bottom view of a preferred embodiment of the present invention where the oversized spout receiving sleeve  202  is a round pipe. 
     Now referring to FIG. 4, there is a top view of the oversized spout receiving sleeve  202  of FIGS. 2 and 3. 
     Now referring to FIG. 5, there is shown a partially cut-away view of the oversized spout receiving sleeve  202  of FIGS. 2,  3 , and  4 , which reveal the internal baffle  240 . 
     In operation, the apparatus and method of the present invention as described in the Figures, could function as follows: 
     Assume an increasing flow rate. As grain flows down through angled gravity flow down spout  106 , past oversized spout receiving sleeve top end covering sleeve mounting clamp  220 , also through oversized spout receiving sleeve top end covering sleeve  218 , and then past oversized spout receiving sleeve top end  204  of and also through oversized spout receiving sleeve  202 , it exits angled gravity flow down spout  106  and is carried by oversized spout receiving sleeve  202 . As the grain flows through oversized spout receiving sleeve  202 , it first exits through openings  231  or  232 . As the flow rate increases, an impact buffering pile of grain begins to build next to first end  241 . As the flow rate increases further, it begins to overflow past first end  241  and begins to flow out opening  233 . As the flow rate increases further, a second impact buffering pile begins to build next to second end  242 , until it backs up and the grain begins to flow out opening  234 . Consequently, the grain will primarily exit the oversized spout receiving sleeve  202  at certain low flow rates through opening  231 ; as the flow rate increases, then opening  232  will begin to flow with the highest rate, then opening  233  will begin to flow, and finally opening  234  will flow. If the flow of grain down oversized spout receiving sleeve  202  is terminated, then the present invention is designed to permit the grain therein to fully drain from inside the adjustable spout end  108 . 
     In a preferred embodiment of the present invention where adjustable spout end  108  is an 8-inch spout (exterior dimension), opening  231  could be 2.25 inches by 1.125 inches (arc length). Opening  232  would be 5 inches by 2.15 inches (arc length). Opening  233  would be 4 inches by 8 inches (diameter), and opening  234  would be 5 inches by 7.5 inches (arc length). 
     Throughout this description, reference is made to grain, grain handling, grain elevators, grain bins and to feed and feed mills, because it is believed that the beneficial aspects of the present invention would be most readily apparent when used in connection with grain and feed; however, it should be understood that the present invention is not intended to be limited to grain and feed handling and should be hereby construed to include other agricultural and non-agricultural applications as well. For example only, and not intended as a limitation, the dry bulk material may be corn, soybeans, wheat, rice, almonds, walnuts, peas, coffee beans, paint pigment, or any free-flowing dry bulk material. The term “dry bulk material” is intended to refer to the above-listed materials and other materials having similar properties. 
     In operation, the bulk material delivery system of the present invention could be assembled as follows: 
     1. An angled gravity flow down spout  106  is coupled at its upper end to a source of dry bulk material. 
     2. Oversized spout receiving sleeve top end covering sleeve  218  and oversized spout receiving sleeve top end covering sleeve mounting clamp  220  are slid over the bottom end of angled gravity flow down spout  106 . 
     3. Oversized spout receiving sleeve  202  is slid over the bottom end of angled gravity flow down spout  106 . 
     4. Oversized spout receiving sleeve  202  is pivoted about pin  211  so as to provide the proper angle between angled gravity flow down spout  106  and the top of grain bin  104 . 
     5. The adjustable spout end  108  is attached to the top of grain bin  104 . 
     6. The nut on pin  211  is tightened to prevent unwanted pivoting of oversized spout receiving sleeve  202 . 
     7. Oversized spout receiving sleeve top end covering sleeve  218  is slid down angled gravity flow down spout  106  past oversized spout receiving sleeve top end  204 , but preferably not so far that the top of oversized spout receiving sleeve top end covering sleeve  218  or oversized spout receiving sleeve top end covering sleeve mounting clamp  220  actually contacts oversized spout receiving sleeve top end  204 . The gap which is left between oversized spout receiving sleeve top end  204  and the top of oversized spout receiving sleeve top end covering sleeve  218  is done so as to permit expansion and contraction of the various components of the system. 
     8. In some situations, it may be desirable to place a seal  219  between the bottom edge of oversized spout receiving sleeve top end covering sleeve  218  and the exterior of oversized spout receiving sleeve  202 . 
     In operation, the bulk material delivery system  100  of the present invention could be at least partially maintained as follows: 
     To extend the life of angled gravity flow down spout  106 , it may need to be rotated. The process for rotating angled gravity flow down spout  106  could be accomplished as follows: 
     1. Angled gravity flow down spout  106  is detached at its top end from elevated position  102 . 
     2. Angled gravity flow down spout  106  can be rotated without the need for detaching the bottom of angled gravity flow down spout  106  for adjustable spout end  108 . 
     3. The angled gravity flow down spout  106  can then be reattached at the elevated position  102 . 
     It is thought that the method and apparatus of the present invention will be understood from the foregoing description and that it will be apparent that various changes may be made in the form, construct steps, and arrangement of the parts and steps thereof, without departing from the spirit and scope of the invention or sacrificing all of their material advantages. The form herein described is merely a preferred exemplary embodiment thereof.