FIELD OF THE DISCLOSURE
This invention relates to improvements for handling, storing, aerating and discharging dry bulk materials, such as feed and grain, from flat-bottom and hopper bottom storage silos.
BACKGROUND
For the last hundred plus years, storage bins and silos with flat-bottom floors have been used to store free flowing granular material, such as grain, salt, and sugar. In order to discharge the granular material out of the silo more effectively, many designs have been implemented with the flat-bottom floors of the storage bins and silos. The vast majority of these designs include the use of an exposed sweep auger for emptying the grain. Because one or more workers are usually needed to be inside the silo to carry out the unloading process while the exposed sweep auger is operating, the process of discharging the grain from the silo becomes dangerous.
Some prior art has used pneumatically movable flexible membranes to discharge the grain from the silo, such as a single flexible cup-shaped bag surrounding a central discharge opening. However, by only using a single bag to convey the grain within the silo, high pressure of air is maintained against the entire surface area of the cup-shaped bag during the unloading process, including a section of the bag not exposed to a load of bulk material. Consequently, a fully inflated segment of the bag forms during the initial stage of inflation and grows within the silo before full inflation of the bag is achieved. The fully inflated section creates an improper load balance along the surface of the bag, which places significant stresses on the silo wall, the exposed liner, and the clamp bar assemblies. These stresses may cause the silo wall to be pulled inward and seams on the liner to tear and rupture. Ultimately, the clamp bar assembly becomes bent and pulled away from the mounting surface along the silo wall, resulting in a leaky joint.
The inflated sections of the bag not exposed to bulk material also form folds between the segments of the liner during the initial stage of inflation. These folds trap the free flowing granular material, thereby hindering the flow of the granular material. As a result, the single flexible cup-shaped bag is not able to completely cleanout the granular material. Furthermore, a single bag design is difficult to be implemented in larger-sized silos, such as silos having diameters over 18 feet, because as the outer perimeter of the bag increases with respect to the diameter of the central discharge hole, the bag tends to fold, wrinkle and form a strong vacuum between the liner of the bag and the silo floor during deflation. The folding and wrinkling makes the liner return to the silo wall in an aligned manner virtually impossible.
Accordingly, there is a need for a discharge system that is scalable for larger-sized silos without the need for a sweep auger to convey the granular material.
SUMMARY
The present invention provides a flexible liner system for a silo receiving and storing granular materials, in which the flexible liner system includes a first flexible inflate liner and a second flexible inflate liner placed in the silo and aligned respectively against a silo wall and a silo floor. The first inflate liner and the second inflate liner are separated from each other by a central trough that extends completely across or substantially completely across the silo floor. Silo clamp bar assemblies and secure one edge of the inflate liners, respectively, against the silo wall. Another edge of the first inflate liner and the second inflate liner, respectively, are secured to or adjacent to a respective edge of the central trough formed by a conveyor assembly, thereby dividing the grain silo into two liner air compartments. The conveyor assembly includes conveyor housings and an auger installed in between the housings in the center of grain silo. However, other types of conveyors may may be implemented with the conveyor aeration assembly, including an air slide, a belt, and a chain.
Each inflate liner is configured to be inflated to form an inflated wall extending parallel to the central trough, in which the inflated wall pushes the granular material toward the central trough without a segment of the liner becoming fully inflated. After unloading the granular material to the trough, the flexible liner system includes a liner return system configured to return each inflate liner back toward the wall and floor of the silo, thereby allowing the silo to be loaded with a second load of granular material without the need of workers entering the storage silo to untangle and pull the liner back to the wall.
By moving in the form of an inflated wall that runs parallel to the central trough, the flexible liner system is able to maintain equal loading when pushing the granular material toward the central trough, thereby improving the flowing conditions of the granular material and reducing stress on the silo wall and liner components. Furthermore, by separating two inflate liners with a central trough comprising multiple collection wells, the flexible liner system is scalable to larger silos compared to the other flexible membrane systems of the prior art.
Other features and characteristics of the subject matter of this disclosure, as well as the methods of operation, functions of related elements of structure and the combination of parts, and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated herein and form part of the specification, illustrate various embodiments of the subject matter of this disclosure. In the drawings, like reference numbers indicate identical or functionally similar elements.
FIG. 1 is a side section view of the Grain Silo divided into liner air compartments;
FIG. 2 is a side section view of the Grain Silo with Inflate Liner starting to Inflate;
FIG. 3 is a side section view of the Grain Silo with Inflate Line continues to inflate;
FIG. 4 is a side section view of the Grain Silo with Inflate Liner continues to inflate;
FIG. 5 is a side section view of the Grain Silo with final unload of Liner;
FIG. 6 is a side section view of the Grain Silo with all grain emptied on Inflate Liner;
FIG. 7 is a side section view of the Grain Silo with Inflate Liner starting to Inflate;
FIG. 8 is a side section view of the Grain Silo with Inflate Line continues to inflate;
FIG. 9 is a side section view of the Grain Silo with both liners completely unloading;
FIG. 10 is a top section view of the Silo showing a stage of unloading dry material;
FIG. 11 is a side section view of the Grain Silo showing the return line system;
FIG. 12 is a side section view of the Grain Silo showing the return line system;
FIG. 13 is a side section view of the Grain Silo showing the return line system;
FIG. 14 is a side section view of the Grain Silo showing the return line system;
FIG. 15 is a side view of the Conveyor Assembly according to one embodiment of the present invention;
FIG. 16 is a top view of the Conveyor Assembly according to one embodiment of the present invention;
FIG. 17 is a side section view of the Air Compartments according to one embodiment of the present invention;
FIG. 18 is a side view of the Conveyor Assembly according to one embodiment of the present invention;
FIG. 19 is a top view of the Grain Silo prior to unloading;
FIG. 20 is a top view of the Grain Silo starting to unload;
FIG. 21 is a top view of the Grain Silo unloading;
FIG. 22 is a top view of the Grain Silo unloading;
FIG. 23 is a front view of the Inflate Liner Wall according to one embodiment of the present invention;
FIG. 24 is a top view of the Inflate Liner Floor according to one embodiment of the present invention;
FIG. 25 is a sectional top view of the liner floor and trough according to one embodiment of the present invention;
FIG. 26 is a top view of the Liner Wall according to one embodiment of the present invention;
FIG. 27 is a section view of the Clamp Bar Assembly according to one embodiment of the present invention;
FIG. 28 is a section view of the Clamp Bar Assembly according to one embodiment of the present invention;
FIG. 29 is a section view of the Conveyor Housing and Aeration Deck according to one embodiment of the present invention;
FIG. 30 is a section view of the Air Manifold for Aeration Tube according to one embodiment of the present invention;
FIG. 31 is a top view of the Aeration Tube Arrangement within the Grain Silo according to one embodiment of the present invention;
FIG. 32 is a top view of the Aeration Tube Arrangement within the Grain Silo according to one embodiment of the present invention;
FIG. 33 is a side view of the Grain Silo with a Clamp Bar Assembly according to one embodiment of the present invention.
FIG. 34 is a top view of inflate liner floor panel according to one embodiment of the present invention.
DETAILED DESCRIPTION
While aspects of the subject matter of the present disclosure may be embodied in a variety of forms, the following description and accompanying drawings are merely intended to disclose some of these forms as specific examples of the subject matter. Accordingly, the subject matter of this disclosure is not intended to be limited to the forms or embodiments so described and illustrated.
Unless defined otherwise, all terms of art, notations and other technical terms or terminology used herein have the same meaning as is commonly understood by one of ordinary skill in the art to which this disclosure belongs. All patents, applications, published applications and other publications referred to herein are incorporated by reference in their entirety. If a definition set set forth in this section is contrary to or otherwise inconsistent with a definition set forth in the patents, applications, published applications, and other publications that are herein incorporated by reference, the definition set forth in this section prevails over the definition that is incorporated herein by reference.
FIGS. 1 to 9 are side section views of a grain silo 17 incorporating a flexible liner system according to an example embodiment of the present invention. The flexible liner system is adapted to align within an interior surface of a storage bin, such as a grain silo, to move dry bulk material to and through a centrally located conveyor and aerate the dry bulk material while being stored in the storage bin. The grain silo 17 according to the example embodiment comprises a silo floor 22 resting on a foundation 19 and a silo roof 21 displaced above the silo floor 22 with a silo wall 20 extending in between to define cylindrical shaped storage space for grain 39.
In FIG. 1, the flexible liner system according to one embodiment generally includes a first flexible inflate liner 38a and a second flexible inflate liner 38b placed in the grain silo 17 and aligned respectively against the silo wall 20 and the silo floor 22. The first inflate liner 38a and the second inflate liner 38b are separated from each other by a central trough that extends completely across or substantially completely across the silo floor 22. Silo clamp bar assemblies 31a and 31b secure one edge of the inflate liners 38a and 38b, respectively, against the silo wall 20. Another edge of the first inflate liner 38a and the second inflate liner 38b, respectively, are secured to an respective edge of the central trough formed by a conveyor aeration assembly 37, thereby dividing the grain silo 17 into two liner air compartments 30a and 30b. The conveyor aeration assembly 37 includes conveyor housings 23a and 23b and an auger 26 installed in between the housings 23a, 23b on the foundation 19 in the center of grain silo 17. However, other types of conveyors may be implemented with the conveyor aeration assembly, including an air slide, a belt, and a chain, without departing from the scope of the present invention. As shown, the silo wall 20 and foundation 19 are integral in providing the support and air tightness for liners 38a and 38b to be inflated under low air pressure.
At the beginning of the unloading process, a center well of the auger 26 is opened to receive free flowing grain moved simply by gravity. During this initial stage of the unloading process, the inflate liners 38a, 38b are at rest. However, the free flowing of grain 39a comes to a stop when the grain 39a remains in the silo 19 at an angle of repose. Then, as shown in FIG. 2, the inflate liner 38a begins inflating via liner inflation port 34c causing grain 39a to begin rolling past its angle of repose so that it will flow and flood auger 26 for unloading. Typically during the grain unloading process, inflate liners 38a and 38b are not operated at the same time but rather sequentially where inflate liner 38a is operated first.
As shown in FIG. 3, the first inflate liner 38a continues to be inflated, usually under the control of an operator using a remote switch to turn the blower on and off, to gently feed auger 26. For best results and to avoid backups and spill overs, operator will operate inflate liner 38a so that grain 39a is at a relatively shallow level above auger openings without starving it. As shown, in this configuration, silo wall clamp bar assembly 31a is located above the angle of repose of grain 39a at an approximate angle of 45 degrees from silo floor. As inflate liner 38a expands and rolls and pushes grain 39a to auger 26, it rises above silo clamp bar assembly 31a. Here, the inflatable liner 38a does not lift the grain. Instead, the inflatable liner 38a is pushing the grain to the center trough, thereby preventing potential flow problems with the liner and maintaining low air pressure.
In FIG. 4, inflate liner 38a continues to inflate and is at a point in the unloading process that the inflate compartment 30a is about half completed. As the inflation pressure has peaked and now begins to drop, a small load of grain remains on the liner. At this point, other wells along the convey aeration assembly 37 are opened and receiving free flowing grain 39a. The sequential opening of the other wells along the convey aeration assembly 37 enables the first inflate liner 38a to form a shape of an inflated wall that moves parallel with the central trough. By moving in the shape of an inflated wall, the first inflate liner 38a is able to push the grain 39a to the center trough, rather than lifting the grain 39a. FIGS. 5 and 6 show the first inflate liner 38a moving through the final unloading process, whereby all of the grain 39a will be emptied from inflate compartment 30a.
FIGS. 7 and 8 show the second inflate liner 38b moving through the grain 39b unloading process as the first inflate liner 38a continues to inflate. As shown, the first inflate liner 38a may remain inflated to provide a wall or backstop so that grain 39b does not spill over into liner compartment 30a. Liner Inflate blower 109 (not shown) may be made portable and equipped with a check valve, hose, pressure gauge and cam-lock fittings to enable the operator the ability to easily and quickly change from inflate compartments 30a and 30b via liner inflation ports 34c and 34d respectively. FIG. 9 shows both inflate liners 38a and 38b completely inflated after all grain has been emptied from grain silo via auger 26. Other unloading methods may include the use of belt, chain, air slides and pneumatic conveying equipment may be used in place of auger 26.
FIG. 10 shows a top view of the liner inflate compartment 30b during the initial unloading stage, wherein the center well 27c is opened to begin the silo unloading operation. To provide a safe and balanced unloading procedure, the center well 27c is opened while other side wells 27a, 27b, 27d and 27e remain closed. As the silo unloading procedure continues from a gravity discharge to an assisted discharge with inflate liner 38, center well 27c remains open while other wells 27a, 27b, 27d and 27e remain closed causing inflate liner to move inward from silo wall opposite well 27c. Moving inflate liner 38 across from well 27c first ensures the load of grain 39 is balanced evenly and centered on inflate liner 38. Maintaining equal loading and no loading conditions on inflate liner 38 is important so that no uneven pressures and possible unloading problems occurs. To provide safe and efficient unloading, the inflate liner should move as an inflated wall extending parallel with conveyor trough 23a. Once inflate liner 38 moves inward toward the conveyor trough 23a and establishes an inflated wall position, wells 27a, 27b, 27c, 27d and 27e are opened and closed accordingly to keep inflate liner 38 moving as an inflated wall rather than having certain parts balloon outward, which will cause a load imbalance of grain 39 on the inflate liner 38. These load imbalances result in concentrated loads and stresses that could possibly damage the grain silo 17 and the inflate liner 38.
Along with inflating the first inflate liner 38a and the second inflate liner 38b, the liner system provides a liner return system to return a fully inflated liner 38 back to its original position against the silo wall 20 and silo floor 22 during a deflation cycle. FIGS. 11-14 illustrate one embodiment of the liner return system according to present invention. The liner return system includes a liner return weight 43W attached to liner return cord 41 via liner return pulley 42a. By locating the first liner return anchor 43a under clamp bar 31 a few feet away from liner return pulley 42b, liner return weight 43W is able to move up and down freely without rubbing against the silo wall 20. End of liner return cord 41 is connected to the inflate liner 38 by a second liner return anchor 43b. Liner return weight 43W should have a sufficient weight and size to provide enough pulling force to pull the liner while it is airborne, thereby returning the liner to the silo wall 20 after the inflation cycle is completed. Liner return weight 43W can be a piece of steel or a bag filled with sand. Liner return anchor 43b can be 12″ in diameter or larger and made in different shapes and sizes. The liner return cord 41 may consist of a bungee cord, cable or a rope.
FIG. 11 shows a side view of the grain silo 17 during the initial stage of the inflate liner 38a returning back toward silo wall 20 via liner return cord 41. The liner return cord 41 is routed between the first liner return anchor 43a and the second liner return anchor 43b by liner return pulleys 42a that is attached to liner return weight 43W and fixed liner return pulley 42c. Liner return pulley 42c not only pulls the inflate liner 38a back to silo wall 20 but also centers it on the silo floor. One or more liner restraint cords may be used if required.
Furthermore, as soon as grain 39a (not shown) is completely emptied from liner air compartment 30a in grain silo 17 using the first inflate liner 38a, the second inflate liner 38b can begin to immediately empty grain 39b from liner air compartment 30b because the inflate liner 38a is immediately pulled back and away from valve 27 and conveyor housing 23a. Return of the inflate liner 38a is activated by the removal of a blower hose with a one way check valve, thereby disconnecting the inflate liner 38a from the inflate blower. Once the blower hose 126 is removed, air may flow out of air outlet (not shown) from liner air compartment 30a. As a result, the first inflate liner 38a is able to float on a cushion of air while the liner restraint cord 41 pulls the first inflate liner 38a back to silo wall 20. This immediate action of liner restraint cord 41 prevents an interruption in the silo unloading process because inflate liner 39b can be operated very quickly.
As shown in FIG. 12, the first inflate liner 38a is pulled about half way back to silo wall 20 by the liner restraint cord 41. The liner restraint cord 41, liner return anchors 43a and 43b, liner return pulleys 42a, 42b and 43c and the liner return weight 43W are concealed between silo wall 20, silo floor 22 and inflate liner 38a. Liner return anchor 43b may be placed on the exterior side of inflate liner and made of a size and shape that can support the load of liner return weight 43W during the inflation and deflation cycles of inflate liner 38a. As the first inflate liner 38a moves back toward the silo wall 20, the liner return weight 43W moves downward along inside of silo wall 20.
FIGS. 13 and 14 show the final stages of the deflation cycle of inflate liner 38a. As counterweight 43W moves downward, the first inflate liner 38a continues to be pulled back to the silo wall 20. In large silos having a diameter of approximately 36′ in diameter, the weight of inflate liner 38a may be 250 pounds or more, and once it falls to silo floor 22 directly after the inflation cycle, the inflate liner 38 will fold and pile up on itself on and near the conveyor housing 23a without the help of liner restraint cord 41. In addition to forming a heavy, tangled and pile of fabric, fabric, a vacuum may form under the inflate liner 38, making it even more difficult to move the inflate liner 38 back into position for silo reloading. Liner Return weight 43W needs to be heavy enough to allow liner restraint cord 41 to pull back the first inflate liner 38a while a cushion of air remains for the first inflate liner 38a to be supported on during the deflation cycle. The liner restraint cord 41 system eliminates a lot of strenuous labor for returning the inflate liner 38a to its proper position on silo floor 22.
As shown in FIG. 14, the first inflate liner 38a is pulled back completely to silo wall 20 as the liner return weight 43W is at or near the level of silo floor 22. During the inflation cycle, as the inflate liner 38a moves away from silo wall 22, the liner restraint cord 41 is pulled by the inflate liner 38 causing liner return weight 43W to rise. Second liner return anchor 43b needs to have sufficient surface area and a proper shape to spread the load produced by the liner return weight 43W so that no significant stress or damage occurs to the inflate liner 38a during the inflation cycle. As the inflate liner 38a is pulled back to silo wall 22, the second inflate liner 38b and the conveyor auger 26 (not shown) are able to function without delay or other interruptions. Consequently, the liner return system reduces the need for bin entry by workers.
FIG. 15 shows an embodiment of the auger 28 incorporated with the liner system according to the present invention. As shown in FIG. 24, auger 26 is secured to conveyor mounts 24a to 24f, which are connected to foundation 19. Conveyor tube 25 is the housing for the auger 26 and equipped with valves 27a to 27e. Valves 27a to 27e are typically controlled (open and closed) on an independent basis, and it is necessary that only center valve 27c is opened first and used until gravity flow of the grain 39 (not shown) ends. Once gravity flow of grain through center valve 27c ends, then valves 27a, 27b, 27d and 27e can be opened. It is important to note that in addition to emptying grain silo 17, inflate liners 38a and 38b (not shown) may also be used to overcome bridging and rat-holing in grain silo 17 before gravity discharge is completed. Here, in this case, the the inflate liners 38a and 38b will push forward directly toward center valve 27c. Valve 27c is the area within grain silo 17 where grain 39 (not shown) is moving and where a possible void may occur.
FIG. 16 shows a top section view of grain silo 17 with the conveyor tube 25 secured in place between conveyor housings 23a and 23b. Preferably, the conveyor tube 25 is equipped with an odd number of valves (27) so that a “center” opening will be used during the unloading process. However, in some cases, especially if there are a large number of valves 27 (and openings used), there may be a plurality of “center” valves used. Under normal installation conditions, inflate liners 38a and 38b may be partially installed in grain silo 17 before the conveyor housings 23a and 23b, the conveyor tube 25, the auger 26, the valves 27a to 27e and the conveyor support mounts 24a to 24f are secured to each other. For new installations, one or more of inflate liners 38a and 38b, silo wall clamp bars assemblies, conveyor housings 23a and 23b, conveyor tube 25, auger 26, conveyor support mounts and other components may be placed and stored on foundation before or during the erection of grain silo 17. For existing silo installations that are to be retrofitted with an embodiment according to the present invention, each silo may be equipped with a silo door 91 (not shown) and man-way openings 32a and 32b (not shown).
FIG. 17 shows an end section view of the conveyor aeration assembly 37. The assembly includes air tight and leak proof liner air compartments 30a and 30b defined by silo wall clamp bars assemblies 31a and 31b, conveyor housings 23a and 23b silo wall sections 20a and 20b and silo floor sections 22a and 22b, all as leak proof boundaries. To ensure liner air compartments remain air tight and leak proof, a variety of caulks, coatings, spray foams and gaskets are used in all the intersections between components and the structures that they are secured to in the grain silo 17. As an added measure, one or more flexible liner structures (not shown) such as a sheet of polyethylene film may be laid across silo floor sections 22a and 22b, as well as silo wall sections 20a and 20b. To help with the installation, testing, set up, pressure tests, trouble shooting procedures and repair functions, man-way openings 32a and 32b are provided silo walls 20a and 20b, thereby allowing service people access to the inside of the liner air compartments, as required. Liner inflation ports 34a and 34b are located near door 91 so that a liner inflate blower 109 may be operated via a hand held remote switch by the operator while monitoring the grain silo unloading process. Liner inflation ports 34c and 34d may also be used for inflation but are primarily used for deflation when man-way cover 33a and 33b may need to be removed. As with the other components within liner air inflate compartments, man-way cover may be equipped with gaskets, caulk or other sealing products to ensure an air tight fit.
FIG. 18 illustrates an embodiment of the aeration conveyor assembly 37 having transition hoppers 149a, 149b, 149c, 149d and 149e located between valves 27a, 27b and 27c. As shown, valves 27a, 27b and 27c are located directly on conveyor 25 that provide a low point of entry. As a result, the inflate liners 38a and 38b (not shown) operate at the lowest air pressure required compared to the air pressure that would be required if the top most elevation of transition hoppers 149a to 149f were at the point of entry for the grain to enter the conveyor tube 25. In operation, grain 39 (not shown) flows to valves 27a to 27c during the unloading procedure. It is only at the end of the inflation cycle that the grain remaining behind transition hoppers 149a to 149f is lifted up above the hoppers 149a to 149f, where the grain then flows down trough of transition hoppers 149a to 149f and flows into valves 27a to 27c, respectively. Accordingly, grain that rests on on transition hopper 149a slides into valve 27a at the end of the unloading cycle. Furthermore, grain grain material left on transition hopper 149a will flow into valve 27a. Grain left on transition hoppers 149c and 149d will flow in valve 27b, while grain left on transition hoppers 149e and 149f will flow into valve 27c. Vibrators may be used in conjunction with transition hoppers 149a to 149e 149e to help induce material flow in addition to gravity.
FIGS. 19-22 show an embodiment of the conveyor assembly 37 implementing a plurality of switches 306a-e to activate the valves 27a-e of the auger 26. The plurality of switches 306a-e are employed to maintain the proper balance of load on the liner 38. In FIG. 19, prior to using the first inflate liner 38a for unloading after gravity discharge ends, center valve 27c is opened, while side valves 27a, 27b, 27d and 27e remain closed. The valve switches 306a to 306d are mounted on silo floor 21 (typically cement) and under inflate liner floor 84a. When a load of grain is resting on silo liner floor 84a, its weight will push switches 306a to 306d to a closed position. Once the inflate liner 84a moves past the valve switches 306a to 306d toward the conveyor housing 23, the respective switch 306 will then change positions to activate valve actuators 307a to 307e. Any type of switches may be used and in any position. Valve actuators may be pneumatic cylinders, hydraulic cylinders, linear actuators or other types of motorized devices.
As shown in FIG. 20, the inflation cycle of the first inflate liner 38a begins with the first inflate liner 38a moving away from the silo wall 20. With a load of grain on silo floor 21 and inflate liner floor 84a, valve switches 306a to 306d remain in an unchanged position since the inflate liner 38a began inflating. The inflate liner 38a is moving in parallel with conveyor housing 23, as a relatively straight wall that is even and balanced.
In FIG. 21, the inflate liner 38a continues to push grain toward and into valve. The center part 38aC of inflate liner 38a begins to move ahead of the sides of inflate liner 38a and lose its shape as a relatively straight wall. To counteract the change in shape and to keep inflate liner 38a 38a with a balanced load on it, the valve actuators 307b and 307d are actuated just as the inflate liner floor 84a moves past the valve switches 306b and 306c on the silo floor 21. Accordingly, valves 27b and 27d are respectively opened.
In FIG. 22, switches 306a and 306e are activated, thereby triggering valve actuators 307a and 307e. Ultimately, valves 27a and 27e are set to open. With valves 27a to 27e open, inflate liner 38a begins to straighten out and forms an inflated wall that pushes the remaining grain to the auger 26 (not shown) confined in the conveyor tube 25. If desired, valve 27c may be closed slightly, or completely, as well as valves 27b and or 27d, to cause inflate liner 38a to from more of a straight wall form.
According to one embodiment of the present invention, the liner 38 is constructed out of a polyester fabric that is woven in a rip-stop scrim pattern. The fabric of the liner 38 is further coated with a PVC resin, which allows the liner to protect the grain from moisture. When secured in the grain silo, the inflate liner 38 is divided into an inflate liner wall 85 aligned with the silo wall 20 and an inflate liner floor 84 aligned with the silo floor 22. A liner floor to wall joint 52 is formed between the inflate liner wall 85 and the inflate liner floor 84.
FIG. 23 shows a front view of the inflate liner wall 85 with inflate liner pleats 78a to 78h folded and secured to top edge of inflate liner 38. The linear reserves 80a to 80h (each having an average width of 12″) are formed by inflate liner pleats 78a to 78h, thereby allowing inflate liner panel 85 to expand easily against silo wall 20 without any tension or stress. The number of inflate liner pleat(s) 78 used in inflate liner wall 85 and or inflate liner floor 84 (not shown) may vary according to the size of each grain silo 17. As a result, the liner 38 is able to expand and push the grain toward the central trough at low air pressure, such as between 0.15 PSI and 2 PSI.
Due to the large size and weight of the inflate liner 38a, it is difficult to have inflate liner 38 fit like a glove inside grain silo 39. Accordingly, the inflate liner 38 must be oversized so that the inflate liner 38 is fully supported. Folded and fastened behind clamp bar 56, inflate liner pleat 78 provides the linear liner reserve 80 “slack,” which eliminates stress along the inflate liner wall 85 and inflate liner floor 84 when the grain silo 17 is refilled with grain 39.
According to one illustrated embodiment, FIG. 24 shows a top section view of inflate liner floor 84 equipped with pull strap 75a on its top surface (against grain 39) and pull strap 75b attached to the bottom of the inflate liner floor 84 (against silo floor) to enable workers to grab and then move inflate liner 38. A filter fabric vent 86 is secured to inflate liner floor 84 close to the conveyor edge 82 and roped edge 79 at the approximate center. A section of inflate liner floor 84 is cut out and replaced with filter fabric vent 86. Placed over the top of filter fabric vent 86 is vent cover 87, which is made of inflate panel PVC coated fabric that is non-breathable. Vent cover 87 is approximately 25% to 50% larger than filter fabric vent 86 and is loosely attached at its corners to inflate floor 84 over filter fabric vent 86. Vent cover 87 may or may not be with filter fabric vent 86. Because filter fabric vent 86 is located next to conveyor edge 82 of inflate floor 84, the portion of the liner floor closest to the conveyor edge 82 will be the last section of inflate liner floor 84 to lift up and become vertical at the end of the inflation cycle.
With the load of grain now removed over vent cover 87, filter fabric vent 86 can breathe, thereby allowing the pressurized air within liner air compartment to exist at a lower pressure. Filter fabric vent 86 may have a pressure resistance from approximately 0.01 PSI to 0.15 PSI so that if inflate blower 109 is left on too long, the air pressure inside liner air compartment cannot build past 0.01 to 0.15 PSI, which is considered a low pressure that will not cause any damage to inflate liner 38 or other components. However, if the air pressure were to keep building up to the inflate blower maximum pressure rating of about 3 PSI, certain damage would occur to grain silo 17 and inflate liner 38. Other advantages of using filter fabric vent 86 is less likelihood of failure, controlling grain from entering the liner air compartment 30, and function at the very end of the unloading cycle.
During the manufacturing process to make a complete inflate liner floor 84, inflate liner wall joint 52 in FIG. 24 will be sealed to inflate liner wall joint 52 in FIG. 23. Filter fabric vent vent 86 can be placed on the section of inflate liner floor 84, close to conveyor edge 82, which will be the last part of inflate liner floor 84 to lift up and become vertical next to conveyor edge 82 at the end of the unloading cycle. Inflate liner floor 84 will lift up and empty grain according to the sequence of opening valve(s) 27.
The inflate liner floor 84 further includes aeration tube flexible straps 224a and 224b attached to inflate liner floor 84 through bolts 220a and 220b and washers 221a and 221b. Flexible straps 224a and 224b are equipped with hook-and-loop fastener strips 226a and 226b and hook-and-loop fastener strips 225a and 225b, respectively, so that flexible straps 224a and 224b can be wrapped around aeration tubing (not shown), thereby securing the aeration tubes on the inflate liner floor 84 during the inflation and deflation cycles of inflate liner 38. This type of attachment can be used in a hopper, flat-bottom or sidewall area of inflate liner 38.
FIG. 25 shows a partial top section view of silo 17 according to an embodiment of the present invention. The liner air compartment 30a is defined between the silo wall 20 and the conveyor trough deck 23T, enclosed by the installation of the inflate liner 38a. The edge of the liner 38a defined by the liner floor to wall joint 52 is approximately 1.5 times longer than the inflate liner trough edge 52TE. As a result, this ratio between the length of the liner floor to wall joint 52 and the length of the inflate liner trough edge 52TE allows the inflate liner 38a maintain a balance load without causing excessive folds and wrinkles during the inflation cycle. As the ratio of the inflate liner trough edge 52TE is reduced in comparison with the length of inflate liner floor to wall joint 52, excessive wrinkles and folds can occur to inflate liner floor 84a which can cause emptying problems, added stress on inflate liner 38a, higher inflation pressures (which may cause related damage), as well as cause problems in retracting inflate liner 38a properly to silo wall 20 during the deflation cycle in preparation for reloading silo 17.
FIG. 26 is a top view inflate liner wall 85 with inflate liner panels 77a, 77b and 77c fastened together via seals 96a and 96b respectively. To provide added strength to inflate liner wall, double seal panel 95a is sealed to inflate liner panel 77a and 77b by seals 96c and 96d. A double seal panel 95b is fastened to inflate liner panels 77b and 77c over seal 96b by seals 96e and 96f to provide added strength and support to seal 96b.
According to one embodiment of the present invention, a clamp bar assembly 31 is employed to mount the liner 38 against the silo wall 20, in which the clamp bar assembly 31 includes a clamp bar mounting plate 54 and a mount bolt stud 57. As shown in FIG. 27, a mount bolt stud 57s is fixed in a mounting plate hole 60 by a permanent thread locker, welding, or etc. Accordingly, a single threaded stud 57S can be used for securing clamp bar mounting plate 54 to silo wall 20, as well as using the same threaded stud 57S for securing clamp bar 56 in place during the inflate liner 38a (not shown) installation. A flexible shield 64 and a sealant 63 are applied between the clamp bar mounting plate 54 and clamp bar 56 to maintain an air-tight seal between the liner 38 and the silo wall 20, ultimately reducing the possibility of the clamp bar loosening or air leaks. The flexible shield 64 may be formed out of a flexible material, such as a polyethylene film. A gasket 61 and 62 is also implemented with the clamp bar assembly 31 to reinforce the seal between the liner 38 and the silo wall 20. Additionally, a clamp bar nut 65 and mount plate washer 55 may also be used to secure the mounting late 54.
FIG. 28 further shows the clamp assembly 31 including an inflate flap 136 and a protective flap 137 to protect the liner from poking against the mounting plate bolt 57 and mounting plate nut 65. As shown FIG. 27, the inflate liner 38 with a roped edge 79 is clamped between the clamp bar mounting plate 54 and clamp bar 56. The inflate flap 136 extends below the clamp bar 5656 by several inches to protect inflate liner 38 from possible damage during the inflation cycle. The protective flap 137 further protects the inflate liner 38, which may be damaged by bottom edge of clamp bar 56 as it inflates.
As shown in FIG. 28, the inflate liner 38 is inflated under pressure during the grain unloading cycle. Consequently, the inflate liner 38 has risen above and around clamp bar 56 and may be pressed against clamp bar bolt 57. The inflate liner flap 136 and protective flap 136 provide the liner 38 protection from rupture, tearing or other damage from clamp bar bolt 57, clamp bar bolt 65 and the bottom corners of clamp bar 56.
In addition to using inflate liners 38a and 38b to unload grain from grain silo 17, the aeration conveyor assembly 37 of the liner system is also able to aerate grain stored in the silo. According to one embodiment of the present invention, FIG. 29 shows a section view of the silo having conveyor housings 23a and 23b, bottom ends of silo wall clamp bar assemblies 31a and 31b, auger housing 25 support mount(s) 25 and aeration deck 28. The conveyor housing 23a functions as an aeration housing conduit 29a that is pressurized with air by an aeration blower 108 connected to an aeration blower port 35a (not shown). Likewise, conveyor housing 23b functions as an aeration housing conduit 23c that is supplied with low pressure air by an aeration blower connected to aeration port 35c. The aeration blower port 35b is equipped between the outer walls of conveyor housings 23a and 23b, where a conveyor tube 25 is located in the aeration housing conduit 29b. If desired, aeration housing conduit can be connected together to act as a single source of aeration or kept separate from one another to provide three distinct source of low pressure air for aeration.
As shown in FIG. 29, the aeration housing conduits 29a, 29b and 29c remain separated from one another and provide three distinct sources of aeration from one or multiple aeration blowers. Aeration housing conduit 29b is supplied with low pressure air (½ PSI) via aeration blower port 35b, which enables grain directly above aeration deck 28 to be aerated in the grain silo. Preferably, the aeration deck 28 runs across the width of grain silo 17 and has openings that coincide with valve(s) 27. Aeration deck 28, which can be made of separate panels for easy removal and cleaning, can also be sloped into hopper shapes to help direct the flow of grain 39 into each valve 27 along conveyor housing 23.
While the aeration deck 28 and aeration housing conduit 29b supply aeration into the center area of grain silo 17, aeration housing conduit 29a is equipped with aeration exhausting couplings 36a and 36c, which may be attached to ancillary aeration fixtures that rest on the surface of inflate liner 38a (not shown). Similarly, aeration housing conduit 29c is equipped with aeration exhaust couplings 36d and 36b. Aeration exhaust couplings 36a and 36b are attached under inflate liner 38a and 38b and pass through inflate liner to fixture on top. Aeration exhaust couplings 36c and 36d connect to aeration fixtures on top of inflate liners 38a and 38b without passing through inflate liners 38a and 38b, providing a simpler operation and securing method. In the case of an inflate liner 38a or 38b (not shown) not falling back into position in the grain silo 17 due to the formation of folds and wrinkles, aeration exhausting couplings that have air tight valves (not shown) may be opened and operated via a blower to provide a burst of air under inflate liner floor 84 to free the liners 38a and 38b from clinging to silo floor by a vacuum condition. Any type of blower, whether aeration blower 108, liner inflate blower 109 or another type of blower may be used.
The aeration tubes may also be equipped with a manifold assembly. As shown in FIG. 30, a liner manifold plate 160 pivots upward by hinge 161a as the inflate liner floor 84 raises off the silo floor 22 during the inflation cycle of grain unloading. To keep air from escaping within liner air compartment 30a, liner manifold conduit 162 is connected between liner manifold valve 161a and liner aeration manifold 159. Liner manifold conduit is typically made of a flexible material such as hose or a PVC coated fabric tube with reinforcements attached so that it remains open and cannot collapse. During the unloading process, aeration blower 108 (not shown) is turned off.
FIGS. 31 and 32 show top views of grain silo 17 with aeration tube(s) 98 fixed to floor areas of inflate liner(s) 38 in different formations, according to several embodiments of the present invention. The purpose of the particular formation of aeration tubes 98 is to ensure aerating the grain in silo 17 beyond the area of the conveyor aeration assembly 37. In FIG. 31, the aeration air in the aeration tubes 98a to 98L is provided by the conveyor aeration assembly 37. As shown in FIG. 32, the aeration air is supplied to aeration tubes 98a to 98e by aeration exhaust coupling 36a connected to an aeration blower port 35a through a man-way opening 32a and matching opening assembly of liner. Also shown are aeration tubes 98f to 98j being supplied with aeration air from aeration blower (not shown) by an aeration blower port 35b connected to the aeration exhaust coupling 36b through wall of grain silo 17 and inflate liner 38 (not shown). One or more aeration blowers may be used with grain silo 17 to provide the necessary aeration to keep grain dry and conditioned properly during storage.
FIG. 33 is a side view of the grain silo 17 with a silo wall clamp bar assembly 31 according to one embodiment of the present invention. The clamp bar assembly 31 is mounted on silo wall 20 near or below angle of repose 88 of the grain 39. As shown, the inflate liner 38 rises above the silo clamp bar assembly 31a so as to roll and push grain as the liner 38 inflates. Mounting the silo wall clamp bar assembly 31a at a lower position creates a smaller air compartment 30a and aligns the clamp bar assembly 31a along the silo wall in a horizontal position. By forming the clamp bar assembly 31a into a horizontal position, a stronger seal is obtained. The horizontal alignment of the clamp bar assembly 31a ensures a stronger seal and reduces the downward pulling forces created when inflate liner 38 is near peak pressure inflation during the unloading process.
To keep inflate liner 38 positioned properly for the filling and unloading cycles in the grain silo 17, the inflate liner is equipped with one or more liner return anchor(s) 43, which secure one or more liner return cord(s) 41 by liner return pulley(s) 42 and one or more counterweight(s) 97. Counterweight(s) 97 may be located inside or outside of grain silo 17. Also, by placing the silo wall clamp bar 31a in a substantially horizontal position, well below the angle of repose 88 of grain 39, installing the inflate liner becomes easier and safer because the installation can be done without the use of lifts, scaffolding and extension ladders.
To provide access within liner air compartment 30a, a man-way opening 32 is installed on the silo wall 20 with a removable and air tight man-way cover 33. The man-way cover 33 may be made of clear Plexiglass and secured to man-way opening 32 by fasteners or a V-Band clamp. A liner inflation port 34c is attached to the silo wall 20 adjacent to a perforated pipe 40 for more efficient distribution of air during the inflation and deflation cycles. Liner return cord 41 may be made of rope, cable or bungee cord.
FIG. 34 is a top view of inflate liner floor panel 84 according to one embodiment of the present invention. The inflate liner floor panel 84 includes inflate liner pleats 80a and 80b and floor to wall joints 52Xa-g formed as a plurality of straight edges. The straight edge design implemented with the floor-to-wall joints 52Xa-g provide stronger and more reliable heat-seals along the edge of the liner. The inflate liner floor panel 84 further comprises an entry panel 317 defining an access opening. The entry panel 317 has a zipper 318 that is opened by a zipper pull tab tab 319. Zipper 318 is also equipped with pull tab 319b (not shown) to provide a means of opening and closing zipper 318 from the bottom side of the liner inflate liner floor 84. An entry flap 322 is secured to inflate liner floor 84 to the side of the entry panel 317 at secured entry flap edge 324 to provide extra support to zipper 318 Consequently, the zipper 318 is not stressed during the inflation inflation process, in which pressure is generated on the inflate liner floor 84. As entry flap 322 is folded over against entry panel 317, an entry flap border 323 comprising hook-and-loop fastener is fastened to entry panel 317 outside the entry flap border 323 to provide added support and relieve pressure on zipper 318 during the inflation process. Zipper 318 may be opened and closed when inflate liner floor 84 is at rest, under vacuum or under pressure. The zipper 318, entry panel 317 and and entry panel cover 320 are located close to the conveyor edge 82, which is last section of the inflate liner floor 84 to lift off silo floor and exposed to very low pressure.
While the subject matter of this disclosure has been described and shown in considerable detail with reference to certain illustrative embodiments, including various combinations and sub-combinations of features, those skilled in the art will readily appreciate other embodiments and variations and modifications thereof as encompassed within the scope of the present disclosure. Moreover, the descriptions of such embodiments, combinations, and sub-combinations is not intended to convey that the claimed subject matter requires features or combinations of features other than those expressly recited in the claims. Accordingly, the scope of this disclosure is intended to include all modifications and variations encompassed within the spirit and scope of the following appended claims.
Patent Grant
10486898
