Abstract:
The Application discloses an in-line, high capacity apparatus, system and method for measuring and regulating a flowable material, such as seed, grain or other material. The disclosed generally functions by measuring the pressure applied to a rounded cap by the flowing material. In certain alternative embodiments, the apparatus and method allow the user to regulate the flow rate.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Application No. 61/918,433 filed Dec. 19, 2013 and entitled “Flow Regulator,” which is incorporated herein by reference. 
     
    
     TECHNICAL FIELD OF THE INVENTION 
       [0002]    The embodiments disclosed herein relate to various agricultural and industrial device components and related components, including pressure sensing devices, flow meters, and other related components. More specifically, this invention relates to apparatus, systems and methods for monitoring and regulating the rate of flow of material that is passing through a pipe or flow meter under continuous flow conditions. Further embodiments relate to apparatus, systems and methods for operating the above components. 
       BACKGROUND OF THE INVENTION 
       [0003]    Monitoring and managing material flow through a passageway at different checkpoints in the passageway in real time for conditioning of grains or seeds, for example, can increase operating efficiency and can improve profitability. 
         [0004]    Accurate flow measurement can result in improved process management and significant cost saving for companies handling high value products such as seeds and food grade materials, grain and feed handling, corn and soybean processing, popcorn, dry food ingredients, plastic pellets, and pharmaceuticals. Continuous monitoring of flow rates can also provide useful information for equipment adjustment or integrating with a process such as adding a chemical in seed treating or ingredients during food processing. 
         [0005]    Current technologies generally require the impact of the seed or other flowable matter on the sensing device. There is a need in the art for an apparatus and method that achieves this result without measuring impact. There is further need in the art for a device which allows the control the rate of flow of the flowable material. 
         [0006]    Exemplary embodiments of the flow meter measure the flow by way of pressure on a sensing cap, which can also be a displacement rather than impact. These embodiments of the flow meter allow the flow measurement of the material with less damage than that observed in the prior art, wherein the flow is obstructed by the impact on a surface or an impingement ring. 
         [0007]    It is thus an object of the embodiments disclosed herein to provide a method of measuring the weight of a flowable material based on gravity or some other pressure or force. It is a further object to provide an apparatus for measuring the flow of such material. It is a further object to provide a means of regulating the flow of such material. 
         [0008]    These and other objects will be apparent to those skilled in the art. 
       BRIEF SUMMARY OF THE INVENTION 
       [0009]    As discussed herein, the present invention relates to a method and apparatus for determining the weight of flowable material in unit time and the total weight during a time period of a material, particulate, slurry or liquid during conveyance with a sensing unit placed in the path of conveyance. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1A  is a schematic view of the exterior of an exemplary embodiment of the flow meter. 
           [0011]      FIG. 1B  is an exploded view of the exterior of an exemplary embodiment of the flow meter. 
           [0012]      FIG. 1C  is a cutaway view of an exemplary embodiment of the flow meter. 
           [0013]      FIG. 2A  is an exploded view of another aspect of certain implementations of the flow meter and associated devices, systems and methods. 
           [0014]      FIG. 2B  is an exploded view of another aspect of an exemplary embodiment of the flow meter. 
           [0015]      FIG. 2C  is an exploded view of another aspect of an exemplary embodiment of the flow meter. 
           [0016]      FIG. 3  is a cartoon schematic of another exemplary embodiment of the flow meter in operation. 
           [0017]      FIG. 3A  is a cross-sectional view of the housing and connector according to the embodiment in  FIG. 3 . 
           [0018]      FIG. 4  is an exterior view of another exemplary embodiment of the flow meter. 
           [0019]      FIG. 5  is a cutaway perspective view of another embodiment of the flow meter and associated devices, systems and methods. 
           [0020]      FIG. 5A  is a sideview perspective according to the exemplary embodiment of  FIG. 5 . 
           [0021]      FIG. 6  is a side-view schematic of an embodiment of an alternative embodiment of the flow regulator depicting the regulator in series with the flow meter. 
           [0022]      FIG. 7  is a top, cutaway view of the alternative embodiment of the flow regulation system featuring the frustoconical portion and overflow region. 
           [0023]      FIG. 8  is a perspective cutaway view of the embodiment of  FIG. 7 . 
       
    
    
     DETAILED DESCRIPTION 
       [0024]    The present disclosure relates to apparatus, systems and methods for determining the rate of flow of a material, particulate, slurry or liquid during conveyance with a sensing unit placed in the path of conveyance such that the flow is measured without a loss in capacity of the conveyance. Exemplary embodiments may contain a flow sensing unit, an integrator and software directed to the interpretation of the data received by the sensing unit and integrator. Further embodiments comprise a flow regulation mechanism. 
         [0025]      FIGS. 1A-5A  generally show several exemplary embodiments of the flow meter, according to a first embodiment.  FIGS. 6-8  depict views of a further embodiment of a flow regulator. It is understood that the various embodiments of flow meter disclosed herein can be incorporated into or used with any other known devices, systems and methods, including, but not limited to, the other flow meters and devices as defined herein. 
         [0026]    As depicted in  FIGS. 1A-1B , in certain embodiments the flow meter  10  consists of corresponding top  12  and bottom  14  beveled outer regions and an outer tube  16 , along with an inner unit  18  topped by a sensing cap  20 . As best shown in  FIG. 1C , the inner unit  18  is then suspended within the outer tube  16 . In certain embodiments, the inner unit  18  is topped by the sensing cap  20 , and is operationally and communicatively connected to the PLC, HMI or other processing unit  22 . These embodiments allow for high capacity throughput, as there is enough space between the inner and outer unit to maintain the capacity. Further, in certain embodiments, the flow meter allows for a reduction in the overall slowing effect caused by the impact of the flowable material on a measuring apparatus. This is achieved by measuring the overall displacement of the rounded cap relative to the inlet space, rather than measuring the impact as was done in the prior art. This is because the material in the present invention flows through a smaller inlet space above the cap, thereby merely changing the direction of the flow slightly, rather than causing impact. The rate of flow can thereby be measured by, in typical embodiments, measuring the pressure, or weight of the flowable material on the cap. Exemplary embodiments are thus able to measure both the weight of flowable material in unit time and the total throughput that has passed over the cap and through the flow meter. In certain embodiments, the sensing cap  20  has a slightly larger diameter than an inner unit  18 , so as to prevent the accumulation of dust and debris in the opening between the cap and the unit. 
         [0027]    Other advantages of the flow meter over the prior art include the uniformity of the flow and the ability to regulate flow (as shown in part in  FIGS. 5-8 ), particularly when the flowable material is being introduced to the system by way of a bucket elevator, or other means which introduces spikes or other variations in the typical flow speed. 
         [0028]    As best shown in  FIGS. 2A-2C , in some embodiments the inner unit  18  consists of a sensing unit  19 , comprising a cap  20  connected to a top plate  26 , which is operationally integrated with a bottom plate  28 , load cell  30  and spacer  32  so as to move the top plate  26  relative to the fixed or relatively stationary bottom plate  28 , thereby applying pressure to the load cell  30 . In some exemplary embodiments, a spacer  32  separates the top plate  26 , bottom plate  28  and/or load cell  30 . In some embodiments, a stopper  34  can be utilized to provide overload protection.  FIG. 2B  depicts a nut and bolt assembly  39  which can be used in certain embodiments to suspend the inner unit  18  and cap  20  within the housing  16 , as is depicted in  FIG. 2C . Other embodiments are possible. 
         [0029]      FIGS. 3-3A  illustrate an example of exemplary embodiments of the flow meter in operation. In operation, a material  40  is being passed through the flow meter  10  by way of gravity or some other force. While gravity is used in this particular embodiment, other forces or pressures can also be used to pass the material over the cap  20 . The material  40  is passed over the inner unit  18 , particularly the flow cap  20 , so as to depress the flow cap  20  relative to the bottom plate (not shown) and thereby translate the pressure into a readable signal by way of the load cell, for transmittal to the processing unit. The rounded cap  20  allows the flowable material to pass over it in layers, rather than by impact, such that, for example, a top, middle, and lower layer can be formed, with the top layer moving most quickly and the lower layer moving most slowly. For example, if the material is corn, certain implementations of the flow meter allow for layers of corn to be passing over the cap simultaneously, so as to provide a cushion and reduce the overall impact damage, such as seed splitting or breaking. Because of this layering, the flow meter can measure product-to-product contact, rather than only product-to-surface contact. This presents an improvement in the art over the prior methods involving getting rid of the seed or other material by impact and impingement.  FIG. 3A  shows a cross-section of a certain embodiment of exemplary embodiments from a top view, thereby illustrating the means by which the inner unit  18  is connected to the outer tube  16  by way of a connection  36 . As one of skill in the art would readily recognize, many possible structures could serve as a connection. 
         [0030]    Thus, the material entering the flow meter  10  flows over a sensing cap  20  so as to apply pressure on the cap corresponding to the weight of the material is measured with a load cell  30  arrangement underneath the sensing cap  20  for real-time analysis of the weight. The vertical gap between the inlet and sensing cap is such so that the layers of the material on the sensing cap keep moving downward freely by gravity, and reduces the material impacting the sensing surface, as is seen in the prior art. The electronic signal from the load cell arrangement is further amplified, processed, and converted to the desired unit of measure. 
         [0031]    As best shown in  FIG. 4 , in certain embodiments, a plurality of flow meters may be set in sequence. In these embodiments, for example, a first flow meter  50  can be provided without the load cell and sensor, so as to be used, for example, as a flow regulator prior to the flowable material entering a second flow meter  52 . Again, in this example, each flow meter  50 ,  52  consists of corresponding top  12  and bottom  14  beveled outer regions and an outer tube  16 . Further embodiments of the flow regulation are discussed in relation to  FIGS. 6-8 . 
         [0032]      FIG. 5  shows another exemplary embodiment of flow meter, wherein the flow meter  10  consists of corresponding top  12  and bottom  14  beveled outer regions and an outer tube  16 , along with an inner unit  18  topped by a sensing cap  20 . In this embodiment, the flow meter  10  also comprises an adjustment mechanism  60  which allows the adjustment of the overall distance  60 A,  60 B between the cap  20  and the flowable material inlet  62 . In certain embodiments, the adjustment mechanism  60  allows the flow meter to be customized—either manually or based on feedback from the PLC, HMI or other processing unit (not shown)—so as to adjust the flow rate and handling of the flowable material, to improve sensitivity, reduce noise, improve efficiency, and the like. As shown in  FIG. 5A , certain embodiments of the flow meter can also include a decoder  70  and stepping motor  72 , operationally coupled to the adjustment mechanism  60  by way of a screw or other adjustment means  80 , so as to regulate the overall distance  60 A,  60 B. Further, a flow readout  74  can be provided in certain embodiments, including, for example, the actual flow  76  and set flowrate  78 . 
         [0033]      FIGS. 6-8  disclose alternate exemplary embodiments of the flow regulation system also described in reference to  FIG. 4 . In these embodiments generally, a flow regulation unit  100  is mounted in the path of a flowing material, for example above a flow meter,  10  though the presence of such a flow meter  10  is not essential for function of the flow regulator  100 . Users may desire the regulation of flow of the flowable material without requiring the use of the flow meter for those applications as an improvement over prior art methods such as the “dead box,” “cushion box” or “end box,” as in many applications of flowable, granular material, the angle of flow must be relatively steep in order to promote flow, which can result in a high rate of travel of the flowable material through a column. The introduction of the present flow regulator addresses this by regulating the speed and rate of flow at some mid-point along the fall. 
         [0034]    In certain applications, this embodiment can be used in a situation where a flowable material such as seed is falling from a large distance or otherwise travelling at a high speed off of a conveyor or the like. In these embodiments, the flow regulator can be utilized to slow the rate of flow and/or speed, thereby reducing damage and causing the product to flow uniformly to the next step in operation. Further, in these embodiments, the damage to the flowable material can be reduced. In certain exemplary embodiments, the diameter of the bowl is such that the spacing between the bowl and the housing allows the desired flow capacity without resulting in plugging up the flow. 
         [0035]    In certain alternate embodiments, rather than utilizing the rounded cap discussed elsewhere herein (such as at  20  in  FIG. 1B ), the flow regulator  100  comprises regulation portion such as a frustoconical portion such as an inverted dome, or otherwise funneling region  102  (hereinafter also called a “bowl”) may be utilized, as is best shown in  FIGS. 7-8 . In these alternative embodiments, the bowl may further comprise at least one opening or apature  104  to receive the flowable material and regulate the flow. In certain of these embodiments, the aperture can be adjustable, such as by dilation, so as to further regulate the flow through that regulator. In further of these exemplary embodiments, the frustoconical portion  102  is suspended between the corresponding top  112  and bottom  114  beveled outer regions and the larger-diameter outer tube  116  (as is shown in  FIG. 6 ) by a plurality of supports  118 , so as to accommodate flow through the opening  104 . 
         [0036]    In these embodiments, the flowable material enters the flow regulator  100  from above, such that it is able to collect in the bowl  102  and collecting there before flowing through the opening  104  and exiting the column. As such, when the size of the opening  104  is adjusted appropriately, the flowable material will tend to “pool” in the bowl, such that the impact of the individual grains, seeds, or the like is upon one another, rather than harder materials. As such, damage to the material can be reduced. In certain exemplary embodiments, the diameter of the opening may be adjustable, as by means well known in the art for adjusting the diameter of an opening or aperture, as is known in the art. 
         [0037]    Further, in use, the material may be flowing into the bowl at a variable rate, such that the bowl may have a variable amount of material over time. In certain situations, the bowl is also configured to allow for “overflows,” so as to further provent clogging while maintaining the slowing effect of the flow regulator. 
         [0038]    In these embodiments, this “overflow” may cause the material to slow down and/or uniformly fall out of the bowl, for example to the flow unit below (as shown in  FIG. 6 ) by way of openings  120 A,  120 B,  120 C between the frustoconical region  102  and the outer tube  116 , thus yielding improved measurement accuracy. As the material comes in contact with other material, rather than metal or other rigid material, the flow regulator also causes less damage to the individual units of the material, and when the rate of flow reduces, the bowl  102  can continue to function as previously described. 
         [0039]    A principle aim for the utilization of this frustoconical shape is so as to optimize the size of the opening  104  or openings. Otherwise, the material may flow out of the bowl too quickly and the bowl will not fill properly. Likewise, the opening cannot be too small, thus causing plugging of the opening by the material. Thus, in certain embodiments, the size of the opening may be adjustable. 
         [0040]    In certain further embodiments, the frustoconical embodiments of the flow regulator can be used independently from the flow meter, wherein the flowable material is falling from a great height, or traveling at a high speed such as coming off of a conveyor, so as to provide similar reduction in damage to the flowable material and control of the flow rate. 
         [0041]    Exemplary embodiments of the described devices, systems and methods also provide other advantages, such as being dust-free, quieter in operation, lighter, durable, causing less impact damage to the flow-through material, and fully backwards compatible or otherwise retrofittable with existing systems. 
         [0042]    While multiple embodiments are disclosed, still other embodiments of exemplary embodiments will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. As will be realized, the invention is capable of modifications in various obvious aspects, all without departing from the spirit and scope of exemplary embodiments. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive. 
         [0043]    Although exemplary embodiments has been described with reference to preferred embodiments, persons skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.