Patent Publication Number: US-11041674-B2

Title: Material agitator

Description:
TECHNICAL FIELD 
     Embodiments described herein generally relate to methods and devices for agitating material. 
     BACKGROUND 
     Malting is a method of turning granular material such as cereal grains into malt. Malting generally begins once a particular material is in a receptacle and has been submerged in water for a predetermined amount of time. This step is known as steeping. 
     After steeping, the material is moved to a different receptacle for germination and kilning. In this step the material begins to grow and is dried. During the germination stage, it is important that the material is agitated (i.e., stirred) in order to avoid heating or matting. If a batch mats, it will spoil and become unusable. 
     Existing techniques for agitating material generally involve using vertical augers. Vertical augers are traditionally suspended from a gantry and move slowly back and forth in a receptacle holding a particular material. The back-and-forth motion of the auger agitates the material. 
     Vertical augers, however, often do not allow for much flexibility in operation. For example, if the auger flight is fixed and the gantry speed and rotational speed are set, the auger may be unable to accommodate different types of material or different operational requirements. 
     A need exists, therefore, for agitator devices and methods that overcome the above disadvantages of existing devices and methods. 
     SUMMARY 
     This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description section. This summary is not intended to identify or exclude key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. 
     In one aspect, embodiments relate to an agitator. The agitator includes a shaft, an arm extending substantially orthogonally from the shaft, and at least one knife per arm extending substantially orthogonally from the arm. 
     In some embodiments, the agitator further includes at least one agitator element extending between two knives. In some embodiments, each of the two knives include a plurality of apertures configured to receive the at least one agitator element. In some embodiments, the agitator further includes at least one horizontal support placed between the two knives and attached to each knife. In some embodiments, the placement of the at least one agitator element is adjustable. In some embodiments, the tension on each of the at least one agitator element is individually adjustable. 
     In some embodiments the agitator further includes at least one agitator element extending between the shaft and a knife. 
     In some embodiments, the agitator further includes a movement mechanism rotatably coupled to the shaft. In some embodiments, the at least one knife is affixed to the arm. 
     In some embodiments, the arm includes a proximal end and a distal end, the distal end having an additional knife hanging therefrom that has at least one side rake secured thereon. In some embodiments, the side rake includes at least one of a vertical hanging wire and at least one flexible pad. 
     In some embodiments, the agitator further includes a bottom rake horizontally attached to the at least one knife. In some embodiments, the bottom rake includes at least one rigid pad and at least one flexible pad. 
     In some embodiments, the agitator is operably positioned in a receptacle. 
     In some embodiments, the agitator further includes at least a second arm extending substantially orthogonally from the shaft, and at least one knife extending substantially orthogonally from the second arm. 
     In some embodiments, the agitator further includes at least one delta blade affixed to the at least one knife. 
     In some embodiments, the agitator further includes a chain extending from a first knife to a second knife or from a first knife to the shaft. 
     In some embodiments, the agitator further includes a cable extending from a first knife to a second knife or from a first knife to the shaft. 
     In some embodiments, the agitator further includes a rigid material extending from a first knife to a second knife or from a first knife to the shaft. 
     According to another aspect, embodiments relate to a method of agitating receptacle content. The method includes operably positioning the agitator described above in a receptacle, filling the receptacle with a granular material, and rotating the shaft of the agitator. 
     In some embodiments, the agitator described above further includes at least one agitator element extending between two knives. In some embodiments, the method further includes adjusting the tension on the at least one agitator element. 
     According to yet another aspect, embodiments relate to an agitator. The agitator includes a vertical shaft; an arm extending substantially horizontally from the vertical shaft; at least one knife extending substantially orthogonally from the arm; and at least one agitator element extending from the at least one knife. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       Non-limiting and non-exhaustive embodiments of the invention are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified. 
         FIG. 1  illustrates a system in accordance with one embodiment; 
         FIG. 2  illustrates an agitator in accordance with one embodiment; 
         FIGS. 3A-D  illustrate an agitator with agitator elements in accordance with various embodiments; 
         FIG. 4  illustrates an agitator in accordance with another embodiment; 
         FIG. 5  illustrates the knife of  FIGS. 2-4  in accordance with one embodiment; 
         FIG. 6  illustrates the bottom rake of  FIG. 4  in accordance with one embodiment; 
         FIG. 7  illustrates the side rake of  FIG. 4  in accordance with one embodiment; 
         FIG. 8  illustrates an agitator in accordance with another embodiment; 
         FIG. 9  illustrates a top view of the agitator of  FIG. 8  in accordance with another embodiment; 
         FIG. 10  illustrates an agitator with delta blades in accordance with one embodiment; and 
         FIG. 11  depicts a flowchart of a method of agitating receptacle content in accordance with one embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Various embodiments are described more fully below with reference to the accompanying drawings, which form a part hereof, and which show specific exemplary embodiments. However, the concepts of the present disclosure may be implemented in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided as part of a thorough and complete disclosure, to fully convey the scope of the concepts, techniques and implementations of the present disclosure to those skilled in the art. Embodiments may be practiced as methods, systems or devices. Accordingly, embodiments may take the form of a hardware implementation, an entirely software implementation or an implementation combining software and hardware aspects. The following detailed description is, therefore, not to be taken in a limiting sense. 
     Reference in the specification to “one embodiment” or to “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least one example implementation or technique in accordance with the present disclosure. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment. 
     In addition, the language used in the specification has been principally selected for readability and instructional purposes and may not have been selected to delineate or circumscribe the disclosed subject matter. Accordingly, the present disclosure is intended to be illustrative, and not limiting, of the scope of the concepts discussed herein. 
     Embodiments described herein are directed towards an agitator used in processes such as malting a granular material. In some embodiments, the agitator may be implemented in mid-sized, stacked, modulator malting facilities. 
     In some embodiments, the agitator may include a shaft, at least one arm extending from the shaft, and one or more knives hanging or otherwise extending downward from the arm. In some of these embodiments, the shaft may be positioned vertically in a receptacle containing a granular material. The agitator may further include at least one agitator element extending between the knives, as well as a bottom and/or a side rake to prevent matting along the floor and sides of the receptacle, respectively. 
     The agitator of various embodiments described herein overcomes the disadvantages of existing agitation devices and techniques. For one, the agitator described herein can operate in receptacles with shallow beds. Additionally, the agitator described herein can be adjusted to accommodate different types of material and for different types of processes. 
       FIG. 1  illustrates a system  100  that may be used for malting that may implement the agitator described herein. This malting system  100  may comprise two receptacles: an upper receptacle  102  and a lower receptacle  104  below the upper receptacle  102 . The system  100  may further include a center shaft  106  that originates in the upper receptacle  102 , extends through a gearbox  108  that is operably configured with a motor  110 , and into the lower receptacle  104 . 
     The gearbox  108  and motor  110  may be affixed between the upper receptacle  102  and the lower receptacle  104 . For example, the gearbox  108  may sit between the receptacles  102  and  104  on top of horizontal pipes  112  that connect to vertical support pipes  114 . 
     The agitator in accordance with various embodiments may be positioned in the lower receptacle  104  to agitate material therein.  FIG. 2  illustrates a side view of an agitator  200  in accordance with one embodiment. As seen in  FIG. 2 , the agitator  200  includes the shaft  106  (shown in  FIG. 1 ), an arm  202  extending substantially orthogonally from the shaft  106 , and a knife  204  hanging or otherwise extending substantially orthogonally from the arm  202 . 
     In use, the gearbox  108  and motor  110  power the shaft  106  to rotate about its axis  106   a  in the lower receptacle  104 . As the shaft  106  rotates, the arm  202  rotates around the shaft  106 , thereby moving the knife  204  a circular motion through the material in the lower receptacle  104 . This motion of the knife  204  therefore agitates the material in the lower receptacle  104 . 
     In some embodiments, the agitator may further include one or more agitator elements to provide additional agitation. For example,  FIG. 3A  illustrates an agitator  300   a  that may be similar to the agitator  200  of  FIG. 2 . However, in this embodiment, the agitator  300  includes agitator elements  302   a  and  304   a . These agitator elements  302   a  and  304   a  (illustrated as wires/cables with different amounts of tension) provide additional agitation as they break up the planes of the material during operation. 
     Although the agitator elements  302   a  and  304   a  are illustrated as wires, it is contemplated that other types of agitator elements may be used. For example,  FIG. 3B  illustrates an agitator  300   b  with an agitator element  304   b  configured as a cable (e.g., a stainless steel cable). As another example,  FIG. 3C  illustrates an agitator  300   c  with an agitator element  304   c  configured as a chain. As yet another example,  FIG. 3D  illustrates an agitator  300   d  with an agitator element  304   d  configured as a rigid material. The exact configuration of the agitator element(s) may vary as long as they can agitate material as desired. 
       FIG. 4  illustrates yet another embodiment of an agitator  400 . In  FIG. 4 , the agitator  400  includes an arm  402  with multiple knives  404  extending substantially orthogonally therefrom. The agitator  400  of  FIG. 4  may also include one or more horizontal supports  406  positioned between the knives  404 . The agitator  404  also includes several agitator elements  408  (illustrated as wires) extending between the knives  404 . 
       FIG. 5  illustrates a knife  500  in accordance with one embodiment. The knife  500  may be similar to the knives shown in  FIGS. 2-4 . As seen in  FIG. 5 , the knife  500  includes a straight leading edge  502  and a tapered trailing edge  504 . However, a device of any suitable shape may be used as long as it can agitate material as required and support any desired agitator element(s). The knife  500  may also include a plurality of apertures  506  configured to receive agitator elements such as wires, cables, etc. The apertures  506  may be spaced one inch apart, for example. 
     The knife  500  is also illustrated with a horizontal support  508  such as the horizontal support  406  of  FIG. 4  secured thereon. The position of the horizontal support(s)  508  may of course vary by, e.g., securing them in different apertures  506  and may depend on the material in the lower receptacle  104 . 
     As seen in  FIGS. 2-4 , the knife or knives may hang from or otherwise be affixed to the arm and extend substantially orthogonally from the arm at a downward angle (i.e., into the receptacle). The knives therefore serve two functions. First, the knives themselves function as agitators that break up the material as they pass through the material. Second, the knives may hold or otherwise support the agitator elements that pass through and agitate the material. 
     In some embodiments, the agitator may include at least two knives (as in  FIG. 4 ). In other embodiments, the agitator may include only one knife (as in  FIGS. 2 and 3A -D). It should be noted, however, that any number of knives may be used. 
     The agitator elements of various embodiments may be staggered and act as individual agitators that break up material such as grain. By staggering the agitator elements, the agitator avoids placing too much structure in one area. In this context, the term “structure” may refer to the planes that are created as the agitator elements pass through the material. Accordingly, it may be desirable to have agitator elements spaced apart from each other, as well as to have different amounts of tension on each individual agitator element. 
     For example, the wires  302   a  and  304   a  of  FIG. 3  have different amounts of tension. Wire  304   a  has less tension than wire  302   a , and is illustrated as “sagging.” These wires or other types of agitator elements may be strung through the apertures  506  of the knife or knives and fixed (e.g., knotted) to the knives to stay in place. In some embodiments, the agitator element(s) may be affixed to a knife or knives using a clamping device. The technique used to secure the agitator element(s) to the knives, as well as the shaft, may of course vary as long as the features of the various embodiments described herein may be accomplished. 
     An operator is therefore able to change the spacing and also the tension of each agitator element based on the specific needs of, for example, the material to be agitated. This allows the agitator of various embodiments to be tailored to meet the specific requirements of a given operation. 
     This allows a malting facility (or any other type of facility) to use less power while still providing the desired agitation. Accordingly, this extends the life of the motor  110 , extends the life of the agitator, and reduces the energy expended as well as operational costs. 
     Referring back to  FIG. 4 , the agitator  400  may also include one or more bottom rakes  410 . The bottom rakes  410  pass along the floor of the lower receptacle  104  to prevent material from matting along the floor. 
       FIG. 6  illustrates the bottom rake  410  of  FIG. 4  in more detail. The bottom rakes  410  may include a plurality of staggered finger portions  602 . These finger portions  602  may be made out of stainless steel, for example. 
     Each finger portion  602  may further include a silicone pad  604  secured thereon. The silicone pads  604  protect the floor  606  of the lower receptacle  104  and may compensate for tolerances in receptacle height and any non-flat portions of the receptacle floor  606 . 
     Referring back to  FIG. 4 , the agitator  400  may also include one or more side rakes  412 . The side rakes  412  may be in contact with or otherwise close to the side interior of the lower receptacle  104  to prevent material from matting thereon. 
       FIG. 7  illustrates the side rake  412  of  FIG. 4  in more detail. The side rake  412  may include a distal knife  404  extending vertically downward from the arm  402 . The side rake  412  may include multiple brackets  702  attached to the distal knife  404 . The brackets  702  may be secured to one or more of the apertures in the knife  404 . 
     Similar to the bottom rake  410 , each bracket  702  may include a silicone pad  704  secured thereon. The elasticity of the silicone pads  704  may compensate for tolerances or discrepancies in receptacle diameter and acts to prevent any material from matting on the receptacle side. 
     In addition to the silicone pads  704 , the side rake  412  may also include a wire  706  (or other type of agitator element) that is run vertically through each layer of the side rake  412 . This wire  706  provides an additional agitation tool that prevents material from matting or otherwise accumulating on the side of the receptacle. With this wire  706 , the side rake  412  in accordance with these embodiments extends out to the edge of the receptacle  104  as far as possible while maintaining as little load as possible. 
     The above discussions regarding the configuration of the agitator and the components thereof are merely exemplary. For example, the bottom rake  410  and/or the side rake  412  of  FIG. 4  may be configured with the agitators of  FIGS. 2 and 3A -D. It is contemplated that the agitator may be configured in a variety of additional ways as well. 
     For example,  FIG. 8  illustrates an agitator  800  in accordance with another embodiment. In this embodiment, the agitator  800  includes a shaft  802 , a first arm  804  extending from the shaft  802 , and a second arm  806  extending from the shaft  802 . Arms  804  and  806  may each include one or more knives  808  with agitator elements  810  that are strategically placed to agitate material. 
     Arm  804  may include agitator elements  810  placed between a proximal knife (closest to the shaft  802 ) and a middle knife, and arm  806  may include agitator elements  810  placed between a middle knife and a distal knife (placed away from the shaft  802 ). Using two arms such as in  FIG. 8  reduces the bending load on the gear box bearings as the arms more equally counterbalance the bending loads. 
       FIG. 9  illustrates a top view of the agitator  800  of  FIG. 8  operably positioned within the lower receptacle  104 . As can be seen from this top view, the agitator elements  810  are operably positioned with respect to the arms  804  and  806 . As the arms  804  and  806  rotate about the shaft  802 , the agitator elements  810  pass through or otherwise agitate the material  902  within the lower receptacle  104 . 
       FIG. 10  illustrates an agitator  1000  in accordance with another embodiment. In this embodiment, an arm  1002  may include a plurality of knives  1004 , and the agitator elements may be configured as delta blades  1006 . The number and/or placement of the delta blades  1006  may vary as well as long as the knives  1004  and the delta blades  1006  may agitate the material as required. 
       FIG. 11  depicts a flowchart of a method  1100  of agitating receptacle content in accordance with one embodiment. This method  1100  may be performed using an agitator such as the agitators of  FIGS. 2-4, 8, and 10 . As described above, these agitators may include a shaft, at least one arm, and at least one knife extending from the arm(s). In some embodiments, the agitator may also include at least one agitator element extending between the shaft and a knife, between two knives, etc. 
     Step  1102  involves operably positioning the agitator in a receptacle. The receptacle may be any receptacle used to hold material for processing, such as the lower receptacle  104  of  FIG. 1 . 
     Step  1104  is optional and involves adjusting the tension of at least one agitator element. If one or more agitator elements are included as part of the agitator such as in  FIGS. 3 and 4 , an operator may adjust the tension (and/or placement) of the agitator elements based on specific operational requirements. 
     Step  1106  involves filling the receptacle with a material. In some embodiments, this may be a granular material used in a malting process. 
     Step  1108  involves rotating the shaft of the agitator. The shaft may be rotated by a movement mechanism such as the gearbox  108  and motor  110  of  FIG. 1 , for example. As the shaft rotates, the arm, knife or knives, as well as any agitator elements may pass through and therefore agitate the material in the receptacle. 
     The methods, systems, and devices discussed above are examples. Various configurations may omit, substitute, or add various procedures or components as appropriate. For instance, in alternative configurations, the methods may be performed in an order different from that described, and that various steps may be added, omitted, or combined. Also, features described with respect to certain configurations may be combined in various other configurations. Different aspects and elements of the configurations may be combined in a similar manner. Also, technology evolves and, thus, many of the elements are examples and do not limit the scope of the disclosure or claims. 
     Embodiments of the present disclosure, for example, are described above with reference to block diagrams and/or operational illustrations of methods, systems, and computer program products according to embodiments of the present disclosure. The functions/acts noted in the blocks may occur out of the order as shown in any flowchart. For example, two blocks shown in succession may in fact be executed substantially concurrent or the blocks may sometimes be executed in the reverse order, depending upon the functionality/acts involved. Additionally, or alternatively, not all of the blocks shown in any flowchart need to be performed and/or executed. For example, if a given flowchart has five blocks containing functions/acts, it may be the case that only three of the five blocks are performed and/or executed. In this example, any of the three of the five blocks may be performed and/or executed. 
     A statement that a value exceeds (or is more than) a first threshold value is equivalent to a statement that the value meets or exceeds a second threshold value that is slightly greater than the first threshold value, e.g., the second threshold value being one value higher than the first threshold value in the resolution of a relevant system. A statement that a value is less than (or is within) a first threshold value is equivalent to a statement that the value is less than or equal to a second threshold value that is slightly lower than the first threshold value, e.g., the second threshold value being one value lower than the first threshold value in the resolution of the relevant system. 
     Specific details are given in the description to provide a thorough understanding of example configurations (including implementations). However, configurations may be practiced without these specific details. For example, well-known circuits, processes, algorithms, structures, and techniques have been shown without unnecessary detail in order to avoid obscuring the configurations. This description provides example configurations only, and does not limit the scope, applicability, or configurations of the claims. Rather, the preceding description of the configurations will provide those skilled in the art with an enabling description for implementing described techniques. Various changes may be made in the function and arrangement of elements without departing from the spirit or scope of the disclosure. 
     Having described several example configurations, various modifications, alternative constructions, and equivalents may be used without departing from the spirit of the disclosure. For example, the above elements may be components of a larger system, wherein other rules may take precedence over or otherwise modify the application of various implementations or techniques of the present disclosure. Also, a number of steps may be undertaken before, during, or after the above elements are considered. 
     Having been provided with the description and illustration of the present application, one skilled in the art may envision variations, modifications, and alternate embodiments falling within the general inventive concept discussed in this application that do not depart from the scope of the following claims.