Patent Document

CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority under 35 U.S.C. 119(e) and 37 C.F.R. 1.78(a)(4) based upon copending U.S. Provisional Application Ser. No. 60/936,064 for Energy Reduction Apparatus For Soiled Textile Sortation System filed Jun. 18, 2007 and the specification of which is incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present apparatus is related to the field of textile sorting machines for use in commercial laundries and the like. More particularly, the present apparatus provides a more energy efficient all suction-based textile flow pathway apparatus that allows for counting and sorting and classifying and dividing textiles into groups prior to the distribution of the textile groups about a laundry operation for further actions thereon. The apparatus further provides selectable control of the amount of suction delivered to the apparatus in response to the amount of usage the system is receiving. 
       BACKGROUND OF THE INVENTION 
       [0003]    The present invention relates to the means for more efficiently transporting soiled textile items into sorting bins with reduced energy consumption and improved laundry load measuring accuracy within commercial laundry operations. These counting and sorting systems are extensively used in commercial laundries associated with the rental of linen—napkins, bar towels, table cloths and the like—to the hotel, uniform, medical and food service industry. Soiled linen counting and sorting systems, in the commercial laundry industry, typically use vacuum air systems to move textiles into sorting bins. These systems have evolved over the years but have used mechanical means to control the vacuum flow. To the extent that soiled linen counting has been employed by commercial linen cleaning operators it has been a system that was highly labor intensive, often error-prone and difficult to manage. Previously, the soiled linen items were first painstakingly separated into types of linen items such as napkins, or bar towels or table cloths then counted into separate small piles on a worktable. 
         [0004]    This labor intensive operation has been replaced by devices that use vacuum motors to provide suction to move a group of like textile items into a temporary storage bin, placed over a moving belt. Such devices generally are similar to the device shown in  FIGS. 9 and 11 . Referring to  FIGS. 9 and 11 , to release the items onto the belt  19  below bin  17  as a sorted pile, the suction to the bin  17  is cut-off to allow gravity to drop the items to the belt  19  below. These systems use a damper or blast gate  80  ( FIG. 9 ), operated by an air cylinder (not shown), to temporarily cut-off the suction flow generated by the fan  82  ( FIG. 9 ) and motor  84  ( FIG. 9 ) until the dump cycle is completed. This method of operation leaves the motor and fan generating the vacuum running during the dump cycle. It also a “dead head” state for the fan so that the fan is without any inflow to the intake. Such a “dead head” state can lead to fan and motor damage over time. Therefore, these previous devices presented the undesirable characteristics of excess noise and excess power consumption. While the blast gate is closed, the motor produces greater noise as the fan wheel cavitates and experiences excess vibration without an inlet source of air. Also, the power consumed in driving the fan wheel while the unit is in dump cycle is simply waste. 
         [0005]    Another previous system used to move textiles from multiple sources to a singular bin of like items is commonly known as a “classifier”. An additional attribute of this type of system is that it measures the amount of textiles in the bin, and determines the precise number of items to be dumped into a wash container to achieve a particular volume for the intended wash wheel or compartment for which it is destined. 
         [0006]    Such “classifier” systems have used three different methods to deliver the textiles to the correct bin. One method uses a vacuum motor or fan to provide suction for an initial lift stage that takes the textile into the tube and lifts it some height. A second stage then employs the exhaust side of the vacuum motor or fan to push the textile down a another tube toward a set of diverting doors. These diverting doors direct the goods to the correct bin. A drawback with this system is the need for high power requirements to generate sufficient suction to operate each tube being operated in the whole of the system. Typically, 15 HP is required for each 6″ diameter sort tube for a six (6) tube system 90 HP would be needed to operate the system. Further, in this type of system it is typical that each tube would have air flow or suction supplied by a separate motor. These multiple motors and fans substantially increase system complexity and noise. 
         [0007]    Another prior “classifier” system design uses multiple sets of motors in a common plenum to create suction for all bins. In this system each tube gets suction from an open connection to one of the bins. In this system design the inlets are vertical in nature and significant power is required to provide enough suction. Typically, 60 HP is required for (8) 4″ tubes. The system is also practically limited to 4″ diameter tubes, whereas 6″ diameter has greater compatibility with larger textile items, such as table tops or bed sheets. 
         [0008]    Yet another system uses a blowing motor to simply push the goods down a tube toward a set of diverting dampers. These dampers then direct the goods to the bin. This system is limited in application as there is no provision to lift and take away the textiles, that is, the textiles must be dropped via gravity or some other mechanism into the tube. 
         [0009]    There for it would be a benefit if a textile sorting and distribution system were available that reduced the number of motors and fans needed to cause flow of the textile through a pathway and into sorting bins. 
         [0010]    It would be another benefit if such a textile sorting and distribution system were available that could avoid the need to cause “dead head” states in the motor and fan thereby reducing the wear and tear on the motors and fans providing the flow of the textile through a pathway and into sorting bins, 
         [0011]    Yet another benefit would be attained if such a textile sorting and distribution system were available that could selectably adjust the motor and fan energy requirements and amount of generated suction or air flow generated by the fan to match the number of sorting tubes being employed at any determined time. 
         [0012]    Still another benefit would be attained if such a textile sorting and distribution system were available that could avoid the need to start and stop the vacuum or air flow or suction to permit the unloading of textile items from the sorting bins. 
         [0013]    These objects and advantages and others will become apparent from the following detailed description of the embodiments read in conjunction with the accompanying drawings. The detailed description and drawings are merely illustrative of the present invention rather than limiting, the scope of the present invention being defined by the appended claims and equivalents thereof. 
       SUMMARY OF THE INVENTION 
       [0014]    The first counting/sorting portion of the system does not use the damper or blast gate  80  ( FIG. 9 ) method for controlling vacuum to the bin. A variable frequency drive unit (VFD)  62  ( FIG. 10 ) having a brake  25  ( FIG. 10 ) is used to quickly start and stop the motor  26  to control vacuum generated by fan  24 . When the dump cycle from the sorting bin is initiated, the VFD shuts down the motor very quickly to eliminate all suction and allow the goods to drop. The braking mechanism  25  is employed to stop the motor even more quickly. This allows the system to save electrical power while the system is in dump mode. Also, the system controls the motor so that during non-sorting operations (when textiles are not actively being delivered) the motor is off, unlike previous systems where the motor was more or less operating continuously for an entire work shift. During this downtime, the laundry is spared from unnecessary noise as well. When counting/sorting resumes, the motor is ramped up to speed with a gradual curve, to avoid large current inrush, which could trigger “Demand” charges by some electric utility providers. 
         [0015]    The second, “classifier” portion of the system overcomes the high power requirements of previous systems. The system uses the vacuum side of the motor(s) for all bins, but has unique design advantages. In order for a bin to create suction, but not self-plug the inlet with the textiles themselves, prior systems required either large internal volumes, or baffles that restricted flow, thus increasing power requirements. The present sorting system uses a cyclonic principle in which the textile goods, or workpiece, enter a cone-shaped bin at high velocity. In the cone-shaped bin the workpiece travels in a spiraling motion whereupon the velocity is dissipated and the workpiece falls to the bottom of the bin away from the suction inlet. 
         [0016]    A further aspect of the device is the use of diverter tubes which send the goods to the respective bins. In the prior art, diverters were either simple damper doors that directed goods to fall one way or the other, due to simple deflection. Or, in vacuum based systems, a blast gate at the inlet of the bin was used. In the blast gate example, the bypass line would remain open. This caused an undesirable problem: “blow-by”, where the goods would not slow and direct to the desired bin, but coast on past the inlet. To compensate, holes at the end of the suction line would need to be left open, to create a small amount of “back suction”, to ensure air and the goods would flow into the gate. The diverters of the present embodiment create a true two-state switch. When no workpiece is in a particular tube as indicated by the operator selection and the counting software, the tube is devoid of suction. When the tube is selected, it then is actively connected to, and only to, one sorting bin and suction is thereby applied to the tube. There is no open path to bypass. 
         [0017]    Another aspect of the device is the angle of the inlet to the cyclonic bins. The cyclonic sorting bins are inverted cones which receive the sorted textile workpieces. In the prior art, the inlets required an upward, against gravity, path to the bin. Also, the previous path was a 180 degree turn from upward to downward motion into the bin. 
         [0018]    One present embodiment has a gradually downward path of the receiving arm into the cyclonic bin. This reduces the suction requirement to move the textile goods. The inlet angle of the receiving arm to the sorting bin, is generally in a tangential alignment to the side of the cone. This is the beginning of the circular vortex path of the textile item within the sorting bin during which the textile item falls out of the suction path and drops toward the conical sorting bin apex. 
         [0019]    Another aspect of the cyclonic vortex bin is the suction motor control. Similar to the conventional bin previously described, the motor can be controlled by a variable frequency drive unit (VFD). The benefits of stopped operation when there is no suction demand, and gradual start-stop of the motor for avoiding utility (“Demand”) charges are realized. The system also uses a monitoring control to determine the number of suction tubes in operation. When fewer tubes are in operation, the operational rate of the motor can be correspondingly reduced, saving energy and optimizing the suction necessary. When the number of tubes in use is larger, or at maximum for the system size, the flow rate can be increased, optimizing the necessary suction. Thus the required energy can be matched to the suction needed. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0020]    Preferred embodiments of the invention, illustrative of the best modes in which the applicant has contemplated applying the principles, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims. 
           [0021]      FIG. 1  is a perspective view of an embodiment of the apparatus  10  showing the interconnection of the various components of an embodiment of the apparatus having a sorting table  12  at a first end of the apparatus and a motor  26  and a fan  24  operated said motor at a second end of said apparatus; 
           [0022]      FIG. 2  is a side elevation view of a diverter  22  with the side panel of the diverter housing removed to show diversion tubes  36  and  40  which are selectably positionable between a first position  38   a  and a second position  38   b  to connect either diversion tube  36  or  40  to inlet  23 . 
           [0023]      FIG. 3  is a side and front view of the diverter  22  of  FIG. 2  with the side panel of the diverter housing removed and with receiving arm  32  included to show diversion tube  36  in position  38   a  to deliver textile items into receiving arm  32  from inlet  23 ; 
           [0024]      FIG. 4  is a front and bottom perspective view of a portion of an embodiment of the apparatus showing the sorting bins  14  having cones  21  and the cylindrical extension extending from the cone and an holding bin  20  at the apical end of the cone  21 ; 
           [0025]      FIG. 5  is a view of the apparatus control panel  59  showing the housing for variable frequency drive control  62  for motor  26  and the housing for computer controller  60  for the apparatus  10 ; 
           [0026]      FIG. 6  is shows the processing unit  60   a  of the computer controller  60 ; 
           [0027]      FIG. 7  shows an interior view of variable frequency drive control  62  for apparatus  10 ; 
           [0028]      FIG. 8  shows the receiving arms  32  connected to the sorting bins  14  and shows with an Arrow “A” the active position in which vacuum or suction is provided to the tube  18  to draw a textile or workpiece into the receiving arm  32  and shows an Arrow “B” indicating the non-active in which a textile or workpiece passes through a diverter  22  on the way to another diverter  22  and receiving arm  32  of different sorting bin  14  and the figure shows that when a series of diverters  22  all are in the “B” position that no vacuum or no suction is provided to the tube  18  of the apparatus thereby saving the energy of providing suction to that particular tube  18 . 
           [0029]      FIG. 9  a prior art counter/sorter having a dump or blast gate  80  to interrupt the suction being generated by fan  82  and motor  84 . 
           [0030]      FIG. 10  shows an embodiment of a counter/sorter having the dump or blast gate  80  eliminated and the interruption of the suction being generated by fan  82  and motor  84  being governed by use of a variable frequency drive control  62  and a brake  25 ; and 
           [0031]      FIG. 11  shows a side elevation view of a sorting table and flowtubes leading to a counter/sorter of  FIG. 10  that is governed by use of a variable frequency drive control  62  and a brake  25  and in which the variable frequency drive control is a Powerflex 40 240VAC 22B-B017N104 and the brake is a AK-R2-030P1K2 brake resistor manufactured by the Allen Bradley division of Rockwell Automation of Milwaukee, Wis. 
       
    
    
     DETAILED DESCRIPTION 
       [0032]    As required, detailed embodiments of the present inventions are disclosed herein; however, it is to be understood that the disclosed embodiments 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 to variously employ the present invention in virtually any appropriately detailed structure. 
         [0033]    First referring to  FIG. 1 , a perspective top and right side view of the overall apparatus  10  is shown. The structure of the apparatus  10  will now be described in the sequence that a textile article or workpiece  11  would take in passing through the apparatus  10 . The soiled textile is first deposited onto a soil counting table or work table  12  where an operator sorts the workpiece from other textile workpieces and determines which sorting bin  14  the particular selected textile should be directed toward. The operator (not shown) then examines the options presented on operator selection panel  16  to select the proper sorting bin  14  to which the textile is to be deposited. Operator selection panel  16  provides, in this embodiment, three possible sorting bin  14  selections for each of flow tubes  18   a ,  18   b . In the embodiment shown in  FIG. 1 , three sorting bins  14  are presented in general linear array, and each sorting bin  14  is provide with a collection bin  20  which resides at the bottom of a cyclonic cone  21 . A suitable touch screen display for use as operator selection panel  16  is the model ELO ET1537L-80WA-1-G manufactured by Elo TouchSystems, Inc. of Menlo Park, Calif. and which is controlled by computer controller  60 . 
         [0034]    The operator at work table  12  retrieves a textile item or a workpiece such as a napkin from a pile of pieces to be sorted on work table  12  and then examines the options on screen  16  to determine the bin selection for the item selected. The operator then makes the selection on selection panel  16  for either of flow tubes  18   a ,  18   b  into which the operator will deposit the workpiece. When the operator selects the particular sorting bin  14  into which the workpiece is to be deposited, the series of diverters  22  which are set in sequential fashion along the length of flow tubes  18   a ,  18   b  are switched to permit the workpiece that is introduced into a flow tube  18   a ,  18   b  to be deposited into the correct sorting bin  14  that the operator selected on selection panel  16 . The specific operation of diverters  22  will be discussed hereinafter. 
         [0035]    When the textile or workpiece  11  is introduced into flow tube  18   a ,  18   b , it is pulled through flow tube  18   a ,  18   b  by the suction of a reduced pressure which is created in flow tube  18   a ,  18   b , and the system in general, by vacuum fan  24  which is operator by motor  26 . Motor  26  is provided with a variable-frequency drive, the operation of which and the effect on the apparatus  10  will be described hereinafter. 
         [0036]    The operation of fan  24  by motor  26  generates an air flow, or vacuum air flow as it is commonly referred, within vacuum connection tube  28  which is connected to vacuum distribution duct  30 . The low pressure created by vacuum fan  24  is thereby communicated to the remainder of the system including cyclonic cones  21  and receiving arms  32  which are attached to cyclonic cone  21 . In this manner, a directional air flow is created throughout the entirety of apparatus  10  which permits the operator at work table  12  to rapidly direct selected textile workpieces through either of flow tubes  18   a ,  18   b  and into the plurality of sorting bins  14 . The operator can, through proper switching of diverters  22  at selection panel  16 , select the proper sorting bin  14  for the workpiece  11 . The processing unit controller  60  of the apparatus  10  then automatically orients the sequence of diverters  22  on the selected flow tube  18   a ,  18   b  to result in the depositing of the workpiece  11  into the selected sorting bin  14  once the workpiece is introduced into the mouth  34  of the selected flow tube  18   a ,  18   b . For the embodiment shown in  FIG. 1 , a suitable fan is Model HDAF or HDBI manufactured by Cincinnati Fan and Ventilator Company, Inc., of Mason, Ohio. For the embodiment shown in  FIGS. 10 and 11 , a suitable fan is Model PB-14 manufactured by Cincinnati Fan and Ventilator Company, Inc., of Mason, Ohio. 
         [0037]    Referring now to  FIG. 2 , the operation of the diverters  22  will be described. Each diverter  22  is comprised of a housing which contains, generally, a diversion tube  36 ,  40  that can be selectably positioned between a first exit position  38   a  and a second exit position  38   b  to achieve the selection of a path of travel of a workpiece  11  through the apparatus. This selection of the diversion tube positions is made by the operator at panel  16  and allows the operator to select a pathway through tubes  18  that will lead a workpiece  11  to the particular sorting bin  14  into which the workpiece  11  is to be placed. In a preferred embodiment, two diversion tubes  36  and  40  are used together and shift position in tandem between a first exit position  38   a  and a second exit position  38   b  to direct the path taken by textile articles or workpieces  11  through the apparatus to reach the operated selected sorting bin  14 . It can be appreciated that additional selectable diversion tube positions could be added to the diverter  22  in an alternate embodiment. 
         [0038]    Referring now to  FIGS. 2 and 3 , diverters  22  have a single inlet position  23  used by both diversion tubes  36 ,  40  to receive a workpiece  11  from tube  18  that leads to inlet  23 . Diverters  22  have two exit positions  38   a ,  38   b . Only one exit position ever is active and this depends on which of diversion tubes  36  or  40  is in position to receive a workpiece from inlet  23 . A first exit position  38   a  sends the workpiece  11  into receiving arm  32  and into a particular sorting bin  14  which was selected for the workpiece  11  by the operator at selection panel  16 . A second position  38   b  sends the workpiece  11  past receiving arm  32  ( FIG. 3 ) and onto a different diverter  22  or to another pathway. In operation of a preferred embodiment of the apparatus, the operator makes the desired pathway selection at selection panel  16 . A means for shifting  27  ( FIG. 2 ) diversion tubes  36 ,  40 , such as a pneumatic cylinder, is activated by the operator&#39;s selection and diversion tubes  36 ,  40  shift up or down, in tandem, to position either the inlet end of diversion tube  36  or the inlet end of diversion tube  40  in front of inlet  23  of diverter  22  ( FIG. 2 ). This selectable positioning allows the workpiece  11  introduced into the flow tube  18  by the operator to be directed into one of two paths by diverter  22 . 
         [0039]    If the inlet end of diversion tube  36  is positioned in front of inlet  23  then the workpiece  11  will be directed through diversion tube  36  and sent out first exit position  38   a  to send the workpiece  11  into receiving arm  32  (shown in fragmentary view in  FIG. 3 ). If the inlet end of diversion tube  40  is positioned in front of inlet  23  then the workpiece  11  will be directed through diversion tube  40  and sent out second exit position  38   b  to send the workpiece  11  into a different diverter  22  and different receiving arm  32  or into another pathway. 
         [0040]    As may be observed by inspecting  FIG. 3  and  FIG. 1 , in apparatus  10 , each receiving arm  32  is connected to one of sorting bins  14  and to a diverter  22  for each tube  18  that is intended to direct workpieces  11  to a particular sorting bin  14 . The workpiece, upon entering receiving arm  32 , travels down receiving arm  32  and into the selected sorting bin  14  which the operator previously selected at selection panel  16 . It further will be appreciated that the selectable shifting, or selectable movement of the diversion tubes  36  and  40  within diverter  22  can be mechanically operated by a number of alternate means. A means for shifting  27  ( FIG. 2 ) may be comprised of a pneumatically or hydraulically motivated arm or piston or a solenoid can be employed by those skilled in the art to achieve the movement of diversion tubes  36  and  40  between the first and second positions  38   a ,  38   b  for the selectable repositioning of diversion tubes  36  and  40 . Alternatively, a motorized gear mechanism could be employed to shift the diversion tubes  36  and  40  to orient the desired diversion tube  36  or  40  inlet in front of inlet  23 . 
         [0041]    Referring now to  FIG. 8  the features of diverters  22  will be further discussed. As is shown in  FIG. 8  receiving arms  32  are connected to sorting bins  14  and diverters  22 . The selectable shifting of diversion tubes  36 ,  40  within diverters  22  is indicated by arrows as providing two pathways. When diversion tube  36  is in use the pathway shown by Arrow “A” is the active position and vacuum or suction is provided to the tube  36 , and in turn also to the associated tube  18 . This application of suction draws the textile or workpiece  11  through diversion tube  36  from the associated tube  18  and into the receiving arm  32 . When a diversion tube  40  is in use the pathway shown by Arrow “B” is the active position. In this position a textile or workpiece  11  passes through diverter  22  on the way to another diverter  22  and receiving arm  32  of different sorting bin  14 . Also, when all of the diversion tubes  40  of a flow tube  18  all are in the Arrow “B” position no vacuum or no suction is provided to the particular tube  18  of the apparatus as the tube  18  then has no connection to the vacuum or suction source which is provided by a connection to on of receiving arms  32 . This ability to selectably eliminate the application of vacuum or suction to a particular tube  18  provides an energy savings by the apparatus. 
         [0042]    A particular feature of the apparatus  10  is the use of variable frequency drive control  60  ( FIG. 1 ) to operate the fan motor  25  in providing the suction or air flow with in the flow pathway that is the motive force for moving the textile workpieces  11  through the flow pathway. The flow pathway, generally, comprising tubes  18  and diversion tubes  36 ,  40  and receiving arm  32  and sorting bin  14 . The benefit to the use of the variable frequency drive control is that the fan, and therefore the suction or air flow in the flow pathway, can more rapidly be controlled. The fan  24  ( FIG. 1 ) rapidly can be started and stopped and operated at selectable speeds depending on the number of tubes  18   a ,  18   b , ( FIG. 1 ) being used at any particular time. In this way the apparatus is made more energy efficient and the noise level of the apparatus, and the workplace, can be reduced. In one embodiment, a brake  25  ( FIGS. 10 &amp; 11 ) also is employed on motor  26  to assist in rapidly changing the speed of fan  24 . 
         [0043]    Alternating-current electric motors run at speeds closely determined by the number of poles in the motor and the frequency of the alternating current supply. This is unlike the steam engine, which can be made to run over a range of speeds by adjusting the timing and duration of valves admitting steam to the cylinder. AC motors can be made with several sets of poles, which can be chosen to give one of several different speeds (say, 720/1800 RPM for a 60 Hz motor). The number of different speeds available is limited by the expense of providing multiple sets of windings. If many different speeds or continuously variable speeds are required, other methods are required. Direct-current motors allow for changes of speed by adjusting the shunt field current. Another way of changing speed of a direct current motor is to change the voltage applied to the armature. 
         [0044]    An adjustable speed drive might consist of an electric motor and controller that is used to adjust the motor&#39;s operating speed. The combination of a constant-speed motor and a steplessly adjustable mechanical speed-changing device might also be called an adjustable speed drive. Electronic variable frequency drives are rapidly making older technology redundant. Process control and energy conservation are the two primary reasons for using an adjustable speed drive. Historically, adjustable speed drives were developed for process control, but energy conservation has emerged as an equally important objective. An adjustable speed drive often uses less energy than an alternative fixed speed mode of operation. Fans and pumps are the most common energy saving applications. When a fan is driven by a fixed speed motor, the airflow may sometimes be higher than it needs to be. Airflow can be regulated by using a damper to restrict the flow, but it is more efficient to regulate the airflow by regulating the speed of the motor. Adjustable-frequency drives (AFD) control the speed of either an induction motor or a synchronous motor by adjusting the frequency of the power supplied to the motor. Adjustable frequency drives are also known as variable-frequency drives (VFD). 
         [0045]    A variable frequency drive control is essentially an electronic power conversion circuit. The conversion circuitry first converts the input AC power to DC intermediate power using a rectifier or rectifier bridge. The DC intermediate power is then converted to a quasi-sinusoidal AC power, at the desired frequency using inverter switching circuitry. The motor used in a VFD system is usually a three-phase induction motor. Some types of single-phase motors can be used, but three-phase motors are usually preferred. Various types of synchronous motors offer advantages in some situations, but induction motors are suitable for most purposes and are generally the most economical choice. Motors that are designed for fixed-speed supply voltage operation are often used, but certain enhancements to the standard motor designs offer higher reliability and better VFD performance. 
         [0046]    AC motor characteristics require the applied voltage to be proportionally adjusted whenever the frequency is changed in order to deliver the rated torque. For example, if a motor is designed to operate at 460 volts at 60 Hz, the applied voltage must be reduced to 230 volts when the frequency is reduced to 30 Hz. Thus the ratio of volts per hertz must be regulated to a constant value (460/60=7.67 V/Hz in this case). For optimum performance, some further voltage adjustment may be necessary, but nominally constant volts per hertz is the general rule. This ratio can be changed in order to change the torque delivered by the motor. An embedded microprocessor governs the overall operation of the VFD controller. The main microprocessor programming is in firmware that is inaccessible to the VFD user. However, some degree of configuration programming and parameter adjustment is usually provided so that the user can customize the VFD controller to suit specific motor and driven equipment requirements. In addition to manual control of the motor speed, the controller circuitry for a variable frequency drive may alternatively be controlled by signals from external processes. 
         [0047]    Referring now to  FIGS. 5 and 7 , in the present apparatus  10  the variable frequency drive control  62  is employed to selectably change the fan speed and therefore the amount of generated suction in the flow pathway, depending on the number of tubes  18   a ,  18   b  in use. For the apparatus shown in  FIGS. 10 and 11 , a suitable variable frequency drive control  62  is the Powerflex 40 240VAC 22B-B017N104 with a AK-R2-030P1K2 brake resistor manufactured by the Allen Bradley division of Rockwell Automation of Milwaukee, Wis. For the apparatus shown in  FIG. 1  a suitable variable frequency drive control  62  is the DURApulse GS3-2050 manufactured by the Automation Direct of Atlanta, Ga. 
         [0048]    During the operation of the apparatus one or more tubes  18  ( FIG. 4 ) may be in use at anytime. The more tubes in use at a time, the greater the amount of fan suction is required to produce sufficient air flow in tubes  18  to move the textile articles from table  12  to bins  14 . Conversely, when only one or two tubes  18  are in use less suction is required in the apparatus. This variable need is accounted for and provided by the present apparatus with the use of the variable frequency drive control for the fan motor  26  ( FIG. 1 ) that operates fan  24 . 
         [0049]    In particular, when the apparatus has only one (1) or two (2) tubes  18  operating, the variable frequency drive control will operate the fan motor  26  at approximately 54 Hz to produce a slower fan  24  speed and a reduced amount of suction by fan  24 . When the programmable controller  60  determines apparatus  10  has three (3) to four (4) tubes  18  operating, variable frequency drive control  62  is then directed by controller  60  to operate at an increased frequency and variable frequency drive control  62  will operate the fan motor  26  at approximately 58 Hz to produce a greater fan  24  speed and an increased amount of suction by fan  24 . When five (5) to six (6) tubes  18  are in use the variable frequency drive control  60  will operate the fan motor  26  at 60 Hz to produce a sufficient fan  24  speed to provide sufficient suction by fan  24  to operate all six tubes. It will be appreciated that in this manner the energy consumption of motor  26  is reduced and the associated noise level in the plant also is reduced. In prior art apparatus, the motor and fan had only a single operational speed. Therefore, substantial unnecessary suction was generated by the fan when less than all of the apparatus of being used. This also provided unnecessary noise in the plant. 
         [0050]    A programmable logic controller (PLC) or programmable controller  60  ( FIG. 6 ) is provided to control the operation of apparatus  10  including the operator selection panel  16  and the diverters  22  responsive thereto. A suitable programmable logic controller (PLC) or programmable controller  60  is the Micrologix 1100 1763-L16BWA manufactured by the Allen Bradley division of Rockwell Automation of Milwaukee, Wis. 
         [0051]    The variable frequency drive control  62  ( FIG. 7 ) is responsive to the PLC controller detecting the number of tubes  18  in operation at anytime. The controller  60  detects the number of tubes  18  in use. In response to the detected number of operational tubes  18  controller  60  determines the electrical frequency to be supplied to motor  26  by the variable frequency drive control  62 . As previously described, this variation in electrical frequency provided to motor  26  results in a change in fan  24  speed. This change in fan speed can rapidly be altered by the operation of controller  60  and the variable frequency drive control  62  in response to detected changes in the number of tube  18  being used at any moment. This then provides real time response of fan  24  suction generation to the operational demands of the textile cleaning plant and the apparatus  10 . In  FIG. 1 , programmable controller  60  and variable frequency drive control  62  are located new bins  14  on control panel  40 . 
         [0052]    The programmable controller  60  also monitors the counts of textile pieces or work pieces from the sorting stations  12  to determine when to dump the accumulated textile pieces or work pieces from one of the holding bins  20  at the apical end of the cone  21 . 
         [0053]    In the foregoing description, certain terms have been used for brevity, clearness and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirements of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed. Moreover, the description and illustration of the invention is by way of example, and the scope of the invention is not limited to the exact details shown or described. Certain changes may be made in embodying the above invention, and in the construction thereof, without departing from the spirit and scope of the invention. It is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not meant in a limiting sense. 
         [0054]    Having now described the features, discoveries and principles of the invention, the manner in which the inventive apparatus for textile sorting is constructed and used, the characteristics of the construction, and advantageous, new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts and combinations, are set forth in the appended claims. It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.

Technology Category: 6