Transport discharge material flow regulation device and method

Abstract

A bulk material flow regulator configured to regulate material flow from a transport vehicle includes a frame bounded by a perimeter. The perimeter can include a material transport space disposed in a bottom volume of the frame, a material storage space disposed in a top volume of the frame, and a material flow regulation space disposed between the material transport space and the material storage space. A transport unloading platform can be coupled to the frame for supporting a transport vehicle with a material hopper. A plurality of baffles can be disposed within the material flow regulation space. The baffles can be configured to allow horizontal material movement within the material transport space while impeding horizontal material movement in the material storage space.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to bulk material transportation and more specifically to unloading bulk material from hopper cars, such as hopper rail cars and hopper dumpster trucks.

2. Related Art

Bulk material, such as coal, mineral ore, gravel, and the like, is often transported in large hoppers on railcars or trucks. These hopper type vehicles are very efficient since they can be loaded and unloaded quickly, and can transport very large quantities of bulk material. However, while these vehicles can usually dump the material relatively quickly, moving the material away from the dump site is generally a much slower process. Consequently, dumping or discharging the bulk material from the hopper car is often slowed by the limited ability to move the material away from the hopper as it is discharged. Several different types of unloading systems have been developed to solve the problems of unloading such hopper type cars.

One type of unloading system uses a bridge disposed over a large hole. In this system, the hopper car can be driven onto the bridge and the material can be discharged while the hopper is over the hole. The bulk material can fall through holes in the bridge into the hole below. One advantage of this type of system is that the unloading time of the hopper car is only limited by how fast the bulk material can fall through the hopper gates. However, this unloading system requires significant and expensive excavation which results in extensive down time and loss of productivity of the unloading station during installation. Additionally, ground water contamination, environmental permits, and expense of finding bypass transport facilities during installation are also problems for these systems.

Other unloading systems use mobile conveyor belts that can be positioned underneath the hopper car between the hopper gates and the ground. These conveyors capture the bulk material as it falls from the hopper and transport the bulk material from under the hopper car. These mobile conveyor systems don't require expensive and lengthy excavation; however, they take longer to offload the bulk material because the conveyor belt can only transport the amount of bulk material that will fit between the bottom of the hopper gate and the top of the conveyor belt.

Another kind of unloading system lifts and tilts the hopper to dump the bulk material out of the top of the hopper. While the discharge time for these systems is comparable to the pit systems, large complex equipment is needed to lift and tilt the hopper car. Additionally, time is lost in securing and prepping the hopper car for the lift and tilt operation.

Still another type of unloading system couples large pipes to the hopper and forces the bulk material contents from the hopper with suction and/or pressurized air. Such pneumatic unloaders are not as fast as gravity drop systems and have complicated hook ups that take additional time to connect.

SUMMARY OF THE INVENTION

It has been recognized that it would be advantageous to develop a method and device for rapidly unloading a hopper type bulk material transport that minimizes excavation and downtime of transport facilities during installation. In addition, it has been recognized that it would be advantageous to develop a method and device to rapidly unloading a hopper type bulk material transport that provides for access to facilitate servicing and preventive maintenance. Furthermore, it has been recognized that it would be advantageous to develop a method and device for reducing horizontal movement of offloaded material still in contact with the transport vehicle while permitting horizontal movement of offloaded material below the transport vehicle.

The invention provides a bulk material unloading station configured to rapidly receive and transfer the contents of a bulk material transport vehicle. The unloading station can include an unloading platform that can be alignable with an existing thoroughfare at an approximate ground level. A frame can disposed about the unloading platform, and can define a material flow control space for controlling the containment and flow rate of material unloaded from the bulk material transport vehicle. The material flow control space can have an upper containment portion that can be disposed above the unloading platform. The upper containment portion can contain an overflow of bulk material as the bulk material is unloaded on the unloading station. The material flow regulation space can also have a lower material flow regulation space disposed below the unloading platform. The material flow regulation space can control the flow rate of bulk material unloading onto the unloading platform and can minimize the transference of horizontal or shear forces from a lower portion of material to an upper portion of material. A conveyor system can be operably associated with the lower material flow regulation space, and can operate to horizontally move a lower portion of the bulk material.

The present invention includes a bulk material flow regulator configured to regulate material flow from a transport vehicle. The material flow regulator can include a frame bounded by a perimeter defining a material transport space disposed in a bottom volume of the frame, a temporary material storage space disposed in a top volume of the frame above the product flow regulation space, and a product flow regulation space disposed between the material transport space and the temporary material storage space. The frame can be one stationary means for receiving and transporting material off-loaded from a transport vehicle. The material flow regulator can also include a transport unloading platform that can be coupled to the frame for supporting a transport vehicle with a material hopper.

In another aspect, the present invention includes a plurality of baffles that can be disposed within the material flow regulation space extending transverse to the longitudinal axis of the frame. A portion of the plurality of baffles can be oriented parallel to the longitudinal axis of the flow regulation space. Advantageously, the baffles can allow horizontal material movement within the material transport space while impeding horizontal material movement in the temporary material storage space.

In yet another aspect, the present invention provides for a conveyor system that can be disposed within the material transport space. The conveyor system can include a plurality of conveyor belts extending parallel to the longitudinal axis of the frame an offloading conveyor belt extending transverse to the longitudinal axis of the frame configured to transport material from the material transport space out of the frame. A plurality of drive wheels, idler wheels and tensioner wheels can be used to drive and tension the conveyor belts.

In yet another aspect, the present invention includes a pair of rail lines that can be disposed above the material flow regulation space. The pair of rail lines can be alignable within an existing rail line extending parallel to the frame along a longitudinal axis of the frame, and positioned above the material flow regulation space. The rail lines can be supported by a vertical support structure extending parallel to the frame along the longitudinal axis of the frame and extending downward to the bottom of the frame and coupled to the frame.

The present invention also provides for a method for unloading the contents of a bulk material transport vehicle on a bulk material unloading station formed as an integrated, single unit for quick installation including aligning an unloading platform of the unloading station with an existing transport vehicle thoroughfare. A bulk material transport vehicle can be positioned on the unloading platform. The contents of the bulk material transport vehicle can be released so that a part of the bulk material contents of the transport vehicle fall into a plurality of baffles disposed at least partially below the unloading platform while a residual part of the bulk material remains in the transport vehicle. A horizontal conveyor disposed below the plurality of baffles can be engaged to remove the bulk material falling through the plurality of baffles to allow horizontal material movement on the conveyor while each of the plurality of baffles impedes horizontal material movement in the transport vehicle.

Additional features and advantages of the invention will be apparent from the detailed description which follows, taken in conjunction with the accompanying drawings, which together illustrate, by way of example, features of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a bulk material unloading station in accordance with an embodiment of the present invention, shown with a bulk material transport vehicle on an unloading platform;

FIG. 2 is a front view of the unloading station of FIG. 1, shown in without the transport vehicle;

FIG. 3 is cross section front view of the unloading station of FIG. 1;

FIG. 4 is a side view of the unloading station of FIG. 1;

FIG. 5 is a cross section side view of the unloading station of FIG. 1;

FIG. 6 is a top view of the unloading station of FIG. 1;

FIG. 7 is a bottom view of the unloading station of FIG. 1;

FIG. 8 is a cross section view of a transport vehicle positioned on the unloading station of FIG. 1;

FIG. 9 is a top cross section view of a conveyor system of the unloading station of FIG. 1;

FIG. 10 is a cross section side view of a conveyor system of the unloading station of FIG. 1;

FIG. 11 is a partial cross section side view of the conveyor system of FIG. 8; and

FIGS. 12 a-12d illustrate a method for unloading a bulk material transport vehicle on the unloading station of FIG. 1 in accordance with an embodiment of the present invention.

FIG. 13 a is a partial cross section front view of the unloading station of FIG. 1 showing an example of the baffle structure;

FIG. 13 b is a top view of a portion of a middle section of a baffle structure without an inverted V member;

FIG. 14 a is a partial cross section front view of the unloading station of FIG. 1 showing another example of the baffle structure;

FIG. 14 b is a top view of a portion of a middle section of a baffle structure without an inverted V member;

FIG. 15 a is a top view of the unloading station of FIG. 1 showing the baffle inside of the unloading station with hatching on the apertures of the middle section;

FIG. 15 b is a top view of a complete middle section of a baffle structure with hatching on the inverted V members of the baffle structure.

FIG. 16 is a perspective view of the unloading station of FIG. 1 showing the baffle inside of the unloading station; and

FIG. 17 is a perspective view of the unloading station of FIG. 1 showing the baffle inside of the unloading station with hatching on the transverse inverted V members of the baffle structure/

DETAILED DESCRIPTION

Reference will now be made to the exemplary embodiments illustrated in the drawings, and specific language will be used herein to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Alterations and further modifications of the inventive features illustrated herein, and additional applications of the principles of the inventions as illustrated herein, which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention.

The embodiments of the present invention described herein generally provide for an unloading station for unloading bulk material from belly-dump, hopper style, bulk material, transport vehicle such as a railcar, semi tractor-trailer, or the like. The unloading station can be formed as an integrated, single unit that can be transported and installed without additional fabrication to the unloading station at the installation site. The unloading station can be installed and positioned in-line with an existing transport vehicle thoroughfare, such as an existing rail line or roadway. The unloading station can also be partially positioned below the grade of the existing thoroughfare in a relatively shallow below-ground, or below grade, excavation or hole. The excavation can be sufficiently deep to house or contain the unloading station yet sufficiently shallow so as to not require lateral supporting structure on the walls of the excavation.

Thus, in one aspect the excavation can have a depth of less than approximately 6 feet. The unloading station can have a hopper with a material storage space disposed substantially above ground, a material flow regulation space disposed at least partially below ground, and an unloading platform disposed substantially between the material storage space and the material flow regulation space. The unloading station can also have a material transfer space disposed below the ground level under the hopper. The material transfer space can include a conveyor system to transport material away from the unloading station. Together, the hopper and the material transfer space, including the conveyor system, can be formed as an integrated, single structure that is transportable as a single unit and that can be quickly installed into an existing transport vehicle thoroughfare.

In use, a transport vehicle can be positioned on the unloading platform and bulk material in the transport vehicle can be released into the hopper of the unloading station. A lower portion of material dumped from the transport vehicle can gravity feed into and through the material flow regulation space to the conveyor system in the material transfer space. The conveyor system can move the lower portion of bulk material while an upper portion of bulk material remains in and above the material flow regulation space. The conveyor system can move the lower portion of bulk material horizontally parallel to a longitudinal axis of the transport vehicle toward a location below the center of the transport vehicle. The conveyor system can also move the bulk material horizontally and transversely from the location below the center of the transport vehicle a location away from the transport vehicle.

As illustrated in FIGS. 1-7, a bulk material unloading station, indicated generally at 10, in accordance with an embodiment of the present invention is shown for use in rapidly unloading and transferring the contents of a bulk material transport vehicle 12, such as a belly-dump, hopper style railcar, truck, trailer, semi-trailer or the like. The unloading station 10 can include a hopper, indicated generally at 40. The hopper 40 can include a material storage space, indicated generally at 50 (FIG. 3), disposed above the ground level 14, a material flow regulation space, indicated generally at 60, disposed at least partially below the ground level, and an unloading platform 30 disposed substantially between the material storage space and the material flow regulation space. The unloading station can also include a material transfer space, indicated generally at 90, disposed below the ground level 14 and under the hopper 40.

The material storage space 50 (FIG. 3) can be defined by an upper portion 42 of the hopper 40. The upper portion 42 can be substantially above ground level and also substantially above the unloading platform 30. The upper portion 42 can extend longitudinally along each side of the station 10 and can have sidewalls 44 (FIGS. 4 & 5) that can extend above the ground level. The sidewalls 44 can be sized and shaped to contain overflow dust and particles of bulk material, and to keep the bulk material within the unloading station 10 as the bulk material is unloaded or dumped from the transport vehicle 12.

It will be appreciated that many bulk materials, such as sand, gravel, dirt, and the like are aggregate in nature and have particles of varying size and shape. As these bulk or aggregate materials are unloaded or dumped from a transport vehicle, the smaller particles can be expelled away from the sides of the transport vehicle by the force of the bulk material dropping from the transport vehicle hopper. Thus, the side walls 44 of the material storage space 50 can help to reduce the expulsion of bulk material from the site of the unloading station 10, and can contain bulk material dust and other small particles within the confines of the unloading station 10. Advantageously, containing the bulk material during unloading provides a more efficient transfer since less bulk material is lost from the load carried by the transport vehicle. Additionally, less clean up is required after unloading a transport vehicle since most of the bulk material is contained within the unloading station.

The material storage space 50 can be fabricated from metal beams and metal sheeting that can be fastened or welded together to form the sidewalls 44. The sidewalls 44 can be coupled together by transverse members 46. The transverse members 46 can span the lateral width of the unloading station 10 and can provide support structure for the unloading platform 30. The transverse members 46 can be supporting structural members, as commonly used and known in the art, such as metal beams, tubing, or the like.

The a material flow regulation space 60 can be disposed at least partially below the ground level and under the material storage space 50. The material flow regulation space 60 can regulate the flow rate of the bulk material moving out of the material storage space 50 and the transport vehicle 12. The material flow regulation space 60 can also minimize the transference of momentum related forces within the bulk material during the unloading process as the bulk material is moved by the unloading station 10.

For example, as illustrated in FIG. 8, the material flow regulation space 60 can minimize the transference of horizontal, momentum related forces, indicated as arrows 66, from a lower, unloaded portion 14b of bulk material to an upper portion 14c of bulk material remaining in the material storage space 50. The lower portion 14b of bulk material 14a can be the portion of bulk material that gravity feeds first from the hopper 16 of the transport vehicle 12, through the unloading platform 30, and into the hopper 40 of the unloading station 10. The upper portion 14c of bulk material 14a can be the portion of bulk material above or on top of the first or lower portion 14b to fall through the platform 30. The upper portion 14c can remain partially contained within the hopper 16 of the transport vehicle 12, while the lower portion 14b is moved by the material transfer space 90. Thus, the material flow regulation space 60 can restrict horizontal momentum related forces in portions 14c of the bulk material remaining in the transport vehicle 12 and near the transport vehicle hopper gates 18 so that only vertical gravity related forces, indicated by arrow 68, can significantly act on the remaining bulk material in the transport vehicle 12.

In one aspect, the material flow regulation space 60 can have a deflection grating or baffle system, indicated generally at 200, that can have a plurality of through holes with inclined walls so that as material moves out of the transport vehicle 12 and into the baffles, the sloped or inclined walls can reduce the velocity of bulk material as the bulk material falls by the force of gravity 68 from the transport vehicle 12. The sloped walls can also direct the flow of the bulk material to a conveyor system 80 in the material transfer space 90.

Additionally, the size of the apertures can vary along the longitudinal length of the baffle system 200 in order to regulate the longitudinal flow rate from the transport vehicle 12 to the conveyor system 80 as described in greater detail in related U.S. Provisional Patent Application No. 60/810,290, filed on Jun. 2, 2006, which is herein incorporated by reference in its entirety for all purposes. In this way, the material flow regulation space 50 can provide a relatively even flow of material from the transport vehicle along the longitudinal length of the transport vehicle. Advantageously, controlling the longitudinal flow rate in this manner can minimize the transfer of horizontal momentum related forces on material remaining in the material storage area 50 and the transport vehicle 12.

It will be appreciated that since the bulk material 14a is dumped by the belly dump of the transport vehicle hopper 16 into a pile, any attempted movement of the lower portion 14b of the bulk material will also attempt to move the upper portion 14c of the bulk material. Rapid movement of the upper portion 14c remaining in the hopper 16 of the transport vehicle 12 can apply shear forces against the hopper 16 of the transport vehicle 12 and the gates 18 to the belly dump opening 20. These shear forces can damage the hopper 16 or gates 18.

Advantageously, as discussed above, the material flow regulation space 60 controls both the flow rate of bulk material from the transport vehicle hopper 16 as well as the transference of horizontal momentum related forces from the lower portion 14b of the pile of bulk material 14a to the upper portion 14c. Thus, the baffle system 200 can absorb or nullify horizontal movement related forces from the lower portion 14b of the pile by restricting horizontal movement of bulk material in and above the baffle. In this way, shear forces from the movement of the bulk material against the transport car hopper 16 and belly-dump gates 18 can be minimized so as to protect the gates from damage.

Returning to FIGS. 1-7, the bulk material unloading station 10 can include an unloading platform 30 disposed in the hopper 40 substantially between the material storage space 50 and the material flow regulation space 60. The unloading platform 30 can be positioned at approximately ground level 14, and can function as a bridge extending over the below ground portions of the unloading station 10. The unloading platform 30 can be alignable with an existing transport vehicle thoroughfare, such as a rail line or roadway so as to allow a transport vehicle traveling on the thoroughfare to move easily onto and off of the unloading platform.

The unloading platform 30 can include a pair of rails 32 or wheel tracks (not shown) in the case the transport vehicle 10 is a semi tractor trailer. The pair of rails 32 or wheel tracks can be coupled to a pair of metal beams 38, such as W sections or I beams. In one aspect, each metal beam 38 can be disposed under one of the rails 32 and can extend longitudinally in the direction of an existing rail line or roadway. The metal beams 38 can be sized and shaped to wholly support a loaded transport vehicle. In the case, I-beams are used reinforcing flanges can be coupled to the I-beam to provide structural support for the weight of the transport vehicle.

The unloading platform 30 can also have an open floor 34, or can have a plurality of apertures 36 through the platform 30 that bulk material can pass through when unloaded or dumped from the transport vehicle 12.

The unloading platform 30 can also be raisable between a raised position and an in-line position. In the raised position, workers and maintenance personnel can have access to the underground portions of the unloading station 10. In the in-line position, the rails 32 or wheel tracks of the unloading platform can be aligned with the rails or roadway of an existing transport vehicle thoroughfare.

The unloading station 10 can also have a material transfer space 90 disposed below the ground level 14 under the hopper 40. The material transfer space 90 can receive bulk material from the material flow regulation space 60 through the baffle or deflector grating 200. The material transfer space can have a conveyor system, indicated generally at 80, to horizontally move bulk material received from the material flow regulation space 60.

The conveyor system 80 can be a system of conveyor belts that can operate to horizontally move the lower portion 14b of the bulk material pile 14a dumped from the transport vehicle 12. The conveyor system 80 can include at least one conveyor belt 82 running longitudinally from a first end 22 of the unloading platform 30 toward a central portion 24 of the unloading platform, and at least one conveyor belt 84 running longitudinally from adjacent a second end 26 of the unloading platform 30 toward a central portion of the unloading platform. In this way, the bulk material dumped from the hopper 16 of the transport vehicle 12 into the unloading station 10 can be moved to a central collection point under the transport vehicle.

In one aspect, the conveyor system 80 can include three longitudinal belts 82a, 82b, and 82c extending from the first end 22 to the central portion 24 of the unloading station, and three corresponding belts 84a, 84b, and 84c running from the second end 26 to the central portion, as shown in FIG. 9. In the case where the conveyor system 80 has three longitudinal belts, the three belts can be aligned side by side, parallel to one another, to substantially cover or cross the lateral width of the unloading station 10. In this way, the conveyor system 80 can maximize the capture and transfer of bulk material falling from the material flow regulation space 60.

Referring to FIGS. 6-7 and 9, a transverse conveyor belt 86 can be disposed under the central portion 24 of the bridge and under the two longitudinal conveyor belts 82 and 84. The transverse conveyor belt 86 can run transverse to the longitudinal axis, indicated by dashed line at 15, of the transport vehicle and can extend across the bridge 20. In one aspect, the transverse conveyor can extend uphill and away from the unloading station in order to move material from below the unloading station to an above ground access point. For example, the transverse conveyor can be a 60 foot continuous belt with a portion below the unloading station 10 and a distal end away from the unloading station. In another aspect, an uphill conveyor belt 88 can be associated with the end 87 of the transverse conveyor belt 86 and can receive material from the transverse conveyor belt 86. The uphill conveyor belt 88 can transport the bulk material up and out of the below ground portions of unloading station 10.

Referring to FIGS. 10-11, the conveyor belts of the conveyor system 80 described above can be continuous belts 98 disposed around a plurality of wheels. The plurality of wheels can include a head wheel 90 disposed at a head end of the continuous belt. The head wheel 90 can tension and direct the motion, or track, of the continuous belt. The plurality of wheels can also include a drive wheel 92 disposed at a central portion of the conveyor. The drive wheel 92 can engage and turn the continuous belt to convey the contents of the hopper car. The continuous belt 98 of the conveyors can form an S-curve around the drive wheel 92 and an idler wheel 94 disposed adjacent the drive wheel. A second idler wheel 96 can stretch and tension the continuous belt 98.

Advantageously, the S-curve, or serpentine configuration of the continuous belt 98 can minimize the vertical height of the conveyor and, thus, can decrease the size of the hole below ground necessary to house the underground portion of the unloading station 10. Additionally, the S-curve more evenly distributes load from the drive wheel throughout the continuous belt and tensions the belt against the weight of the bulk material.

In the case of three longitudinal belts described above, the conveyor system 80 can include a plurality of head wheels 97, as shown in FIG. 9. Each head wheel 97 can be disposed in one of the continuous belts 82a, 82b, 82c, 84a, 84b, or 84c, and each head wheel 97 can independently tension and direct the motion of the continuous belt in which the head wheel is disposed. A common tail wheel 96 can be disposed through all of the plurality of continuous belts. The common tail wheel, or idler wheel 96, can tension all of the belts at a common end.

Returning to FIGS. 1 and 6, a power supply station can supply power to the conveyor system. For example, the power supply station can have diesel motor 120 coupled to hydraulic pumps 122. The hydraulic pumps can supply pressurized hydraulic fluid to hydraulic motors 124 coupled to the drive wheels of the continuous belts in the conveyor system 80. Other types of power supplies, such as electric motors, pneumatic compressors, and the like, can also be used to power the unloading station, as known in the art. Additionally, a controller 126 can be coupled to the power supply and motors so that the entire unloading station 10 can be operated by a single user.

Together the hopper 40 and the material transfer space 90 can form the unloading station 10 as an integrated structure that is transportable and installable as a single unit. Advantageously, the integrated structure of the unloading station 10 can be relatively compact, thereby reducing the distance, indicated as D in FIG. 3, between the uppermost surface of the wheel paths 38 and a lowermost surface of the material transfer space 90. For example, the unloading station can have a distance D of less than approximately 50 inches. In this way, the total height of a corresponding excavation below the grade of the thoroughfare can be minimized, thereby reducing construction and installation time.

Additionally, the integrated structure of the unloading station 10 can facilitate quick installation into an existing transport vehicle thoroughfare. In this way, the bulk material unloading station 10 can be an integrated, modular unit that can be fabricated and shipped as a complete or single unit to the location the station 10 will be inserted into an existing rail line or roadway.

It is a particular advantage of the present invention that the unloading station 10 can be fabricated as an integrated structure and transported as a single unit. It will be appreciated that such a fabrication process speeds up the installation time of the device since additional fabrication need not be performed at the installation site. In contrast, other unloading stations are often assembled at the site of installation and require significant down time of the rail line or roadway. Thus, the unloading station of the present invention provides significant savings with respect to excavation, construction, fabrication, and down-time of existing facilities.

As noted above, the unloading station 10 can be at least partially contained within a hole or excavation in the ground, or below the grade of an existing transport vehicle thoroughfare, such as a rail line or roadway. Specifically, the bulk material unloading station 10 can be positioned in an excavation 70 with a total below ground depth less than approximately the combined height of the material flow regulation space 60 and the material transfer space 90. In one aspect, the below grade or below ground portion of the unloading station 10 can have a depth of less than approximately 72 inches. In another aspect, the below grade portion of the station can have a depth of less than approximately 50 inches. In yet another aspect, the total below grade portion of the station can have a depth of 42 and ⅝ inches where the grade is measured from the transport vehicle thoroughfare, rail line, or roadway.

It is another particular advantage of the present invention that the total below grade or below ground portion of the unloading station 10 is relatively shallow. Because the bulk material unloading station 10 has such a shallow below ground depth, the unloading station 10 can be positioned in line with an existing thoroughfare with a total below ground depth sufficiently shallow so as to not require lateral supports in the corresponding excavation. It will be appreciated that typical gravity feed dump stations require a total depth sufficient to contain an entire transfer vehicle load. In some cases these holes must be up to 20 feet deep or more. While this type of system enables quick unloading times, these dump stations also require significant and expensive excavation and support structure to maintain the walls of the excavation. Unfortunately, such large excavations and construction of the corresponding support structure usually result in lengthy down time for an existing rail line or roadway. In contrast, the unloading station 10 of the present invention only requires a relatively shallow excavation and correspondingly short installation time since such a shallow excavation does not require any additional construction to laterally support the walls of the excavation.

Another advantage of using a shallow excavation with the unloading station of the present invention is that the width of the excavation can also be smaller than a typical below ground unloading station. It will be appreciated that a conveyor moving bulk material from a below ground excavation to an above ground deposit point must have an incline angle sufficiently shallow so as to prevent bulk material from sliding off or back down the conveyor. Consequently, the length of the below ground portion of the conveyor must be sufficiently long so as to accommodate the required angle. Thus, the excavation must be large enough to accommodate the below ground length of the conveyor. In contrast, the shallow depth of the unloading station of the present invention allows the conveyor to rise from the below ground portion immediately adjacent the unloading station, and excavation along the sides of the unloading station can thus be minimized, or in some instances may not be required at all. Thus, the unloading station of the present invention reduces the depth and width of excavation needed, thereby reducing down time of the transport vehicle thoroughfare during installation.

In use, a transport vehicle 12 can be moved onto the unloading station 30 with the hopper 16 of the transport vehicle positioned over the unloading platform. The hopper gates 20 on the transport vehicle hopper 16 can then be opened and the contents of the transport hopper 16 can fall from through the unloading platform 30 and into the material flow regulation space 60. The material flow regulation space 60 can slow the fall of the bulk material and can direct the bulk material onto the longitudinal conveyor belts 82 and 84 below the material flow regulation space. The longitudinal conveyor belts 82 and 84 can be engaged to horizontally move the lower portion 14b of the bulk material 14a parallel to the longitudinal axis 15 of the transport vehicle 12 to a central region under the vehicle. The bulk material can then fall from the longitudinal belts 82 and 84 onto the transverse belt 86 and the transverse belt can move the bulk material out from under the transport vehicle 12. Thus, the hopper 40 can receive the lower portion 14b of the contents of the bulk material transport vehicle 12 and direct the lower portion 14b of the bulk material pile 14a to the conveyor system 80 that can remove the lower portion 14b of the bulk material pile from the hopper 40 so the hopper 40 can receive additional bulk material from the upper portion 14c of the bulk material pile 14a. Thus, the hopper 40 and the conveyor system 80 can operate together to continuously empty, or drain, the contents of the bulk material transport vehicle 12.

In this way, the unloading station 10 of the present invention can rapidly empty and remove the contents of the hopper 16 of a transport vehicle 12. For example, in one aspect, the flow rate for transferring material from the transport vehicle can be approximately 1 ton per second, or approximately 100 tons per 100 seconds. Thus, the entire contents of the transport vehicle can be rapidly removed by the unloading station 10 of the present invention.

Returning to FIG. 3, the unloading station can also have a plurality of jacks 100 extending from the metal beams 38 to a ground or support surface in the hole. The plurality of jacks 100 can raise the unloading station 10 to allow access for maintenance personnel in the material flow regulation space and to the conveyor system. In one aspect the unloading station 10 can have a jack 100 on each end of each of the pair of metal beams 38 for a total of 4 jacks. The jacks 100 can raise the unloading station 10 up to a height greater than approximately 24 inches. It will be appreciated that the jacks 100 can be raised by common power sources known in the art, such as hydraulic, pneumatic, or electric motors and cylinders. The jacks 100 can also lower and align the rails 32 or roadway with the existing rail lines or roadway to ensure a smooth transition from the existing transport vehicle thoroughfare to the unloading station 10. The jacks can be locked into a position by a lock pin 113 or other locking devices as known in the art. The jacks can be powered by the power supply and operated by the controller 126 described above.

In another aspect, the unloading station 10 can have a pair of lifting jacks and a pair of safety locking jacks. The lifting jacks can lift the unloading station as described above, and the locking jacks can extend from the lifted unloading station to a ground surface. The locking jacks can be locked in the extended position to prevent the unloading station from lowering back into the excavation. Such locking jacks can be advantageous when using hydraulic lifting jacks because the hydraulic system can be turned off for servicing when the unloading station is in the lifted position. Thus, the locking jacks can maintain the unloading station in the lifted position even when the hydraulic system and hydraulic jacks are turned off.

As illustrated in FIGS. 12a-d, the present invention also provides for a method for unloading the bulk material contents 14 of a bulk material transport vehicle 12 including aligning an unloading platform 30 with an existing transport vehicle thoroughfare 110. A bulk material transport vehicle 12 can be positioned on the unloading platform 30, as shown in FIG. 12a. The contents 14 of the bulk material transport vehicle 12 can be released so that a lower part 14b of the contents fall into a hopper 40 of the unloading station 10 while a residual part of the bulk material remains in the transport vehicle, as shown in FIG. 12b. A conveyor system having a plurality of conveyor belts can be engaged to remove the lower portion of the bulk material contents from the hopper so the hopper can receive additional bulk material from the transport vehicle above, as shown in FIGS. 12c-12d.

Additionally, the present invention also provides for a method for servicing a bulk material unloading station including engaging a plurality of jacks to raise the unloading station from a shallow underground position and expose a material flow regulation space and material transfer space, including a conveyor. The material flow regulation space and conveyor can be serviced with the unloading station in the raised position. The plurality of jacks can be lowered to lower the unloading station into a shallow underground position with a top surface of an unloading platform aligned and coplanar with an existing transport vehicle thoroughfare.

The step of engaging the jacks can include actuating a power supply and power transfer system such as hydraulic actuators and pumps, pneumatic compressors, electric motors, and the like.

The present invention also provides for a method for installing a bulk material unloading station including removing a section of a transport vehicle thoroughfare, such as a rail line or roadway. A relatively shallow excavation or hole less than approximately 6 feet can be excavated in the removed section of the thoroughfare. An unloading station having an integrated hopper and material transfer space can be placed in the excavation. The hopper can include a material storage space and a material flow regulation space. A top surface of an unloading platform in the hopper can be aligned with remaining existing sections of the thoroughfare so a bulk material transport vehicle can smoothly move from the thoroughfare to the unloading station.

Referring generally to FIGS. 13a, 13b, 14a, and 14b, the baffle system 200 can be configured transverse to the longitudinal axis of the unloading platform 30 occupying the material flow regulation space 60. Furthermore, the baffles 200 can be configured to allow horizontal material movement within the material transfer space and horizontal and vertical material movement within the material flow regulation space 60 while impeding horizontal material movement in the material containment space 50. The baffles can be configured further to reduce stagnation of aggregate material flowing through the baffles at potential material flow stagnation points 210.

Referring specifically to FIG. 13a, which shows a cross section of the unloading station, the baffle structure 200 can be include plurality of inverted V members 224 and inwardly sloping members 225 aligned parallel to the longitudinal axis of the unloading platform. FIGS. 15a and 15b also show the inverted V members 224 and inwardly sloping members configured parallel to the longitudinal axis of the unloading platform. A perspective view of the inverted V members and inwardly sloping members is also shown in FIG. 16.

Referring generally to FIGS. 13b, 14b, 15a, and 15b, the baffles can be configured to define a plurality of apertures at the bottom of the baffle structure 220. The apertures may gradually taper from a middle portion of the unloading platform 245 toward a terminal portion of the unloading platform 246 along the longitudinal axis of the platform. The configuration defines a larger aperture toward the middle portion of the platform 221 and a smaller aperture 222 toward the terminal portion of the platform for optimizing material flow through the baffle structure 200 towards the direction of the transverse belt of the conveyor system 86.

The members of the baffle system 200 act together to protect the belts on the conveyor system from excessive loading stresses as well as to redirect and regulate material flow from the transport vehicle such that transference of forces from a lower portion of the pile of bulk material from an upper portion of the pile of bulk material are minimized during bulk material transport. FIGS. 15a and 15b illustrate the tapering of the apertures in the middle section of the baffle structure while the lateral sections of the baffle structure show apertures 220 which do not vary in width. The variation of aperture width may change depending on each specific unloading platform design.

Thus, in one aspect, the present invention includes a bulk material flow regulator such as the bulk material unloading station 10 that is configured to regulate material flow from a transport vehicle 12. The material flow regulator can include a frame 300 bounded by a perimeter defining a material transfer space 90 disposed in a bottom volume of the frame, a material storage space 50 disposed in a top volume of the frame, and a material flow regulation space 60 disposed between the material transfer space and the material storage space. A portion of the frame 300 can be above ground and the remaining portion of the frame can be below ground with a total depth below ground no greater than approximately 72 inches. The frame can be one stationary means for receiving and transporting material off-loaded from a transport vehicle.

The material flow regulator can also include a transport unloading platform 30 that can be coupled to the frame 300 for supporting a transport vehicle with a material hopper.

Additionally, a plurality of baffles or baffle system 200 can be disposed within the material flow regulation space 60 extending transverse to the longitudinal axis of the frame. A portion of the plurality of baffles can be oriented parallel to the longitudinal axis of the flow regulation space, as shown in FIG. 13b. Advantageously, the baffles 200 can allow horizontal material movement within the material transfer space 90 while impeding horizontal material movement in the material storage space 50.

The plurality of baffles 200 can also define a plurality of apertures 221 and 222 at the bottom of the frame 300. The apertures 221 and 222 can gradually taper from a middle portion of the frame toward a terminal portion of the frame along the longitudinal axis of the material flow regulation space 60. In this way, the baffles 200 can define a larger aperture toward the middle portion of the frame and a smaller aperture toward the terminal portion of the frame. Moreover, the plurality of baffles can include substantially vertical members 223, inverted V members 224, and inwardly sloping members 225. The plurality of baffles is one means for regulating the flow of an aggregate material from a transport vehicle.

Advantageously, the various sizing of the apertures 221 and 222 combined with the orientation of the various members 223, 224, and 225 allows aggregate material to fall through the baffle system 200 faster in a middle portion of the frame and slower near the terminal or end portions of the frame. In this way, an unloading transport vehicle 12 can be moved or can continue moving while dumping the aggregate material and the plurality of baffles and various sized apertures can allow horizontal material movement within the material transfer space 60 while impeding horizontal material movement in the material storage space 50.

Additionally, a conveyor system 80, as described above and shown in FIGS. 1-9 can be disposed within the material transfer space. The conveyor system 80 can include a plurality of conveyor belts 82 and 84 (FIG. 9) extending parallel to the longitudinal axis of the frame an offloading conveyor belt extending transverse to the longitudinal axis of the frame configured to transport material from the material transfer space out of the frame. A plurality of drive wheels, idler wheels and tensioner wheels can be used to drive and tension the conveyor belts. The conveyor system is one means for conveying an aggregate material from a bulk material unloading station. Additionally, the drive wheels, idler wheels and tensioner wheels are one means for adjusting tensile forces of the conveyor means.

Additionally, a pair of rail lines 32, as described above and shown in FIGS. 1-9, can be disposed above the material flow regulation space 60. The pair of rail lines 32 can be alignable within an existing rail line extending parallel to the frame 300 along a longitudinal axis of the frame, and positioned above the material flow regulation space. The rail lines 32 can be supported by a vertical support structure, such as an I beam 38 (FIG. 1) extending parallel to the frame along the longitudinal axis of the frame and extending downward to the bottom of the frame and coupled to the frame.

Referring to FIGS. 13b, 14b, 15a, and 15b, another example of a bulk material unloading system is shown, wherein the baffle structure 200 may be configured to be coupled to an adjoined baffle structure 200 at the substantially vertical members 223 of the baffle structure for convenient shipping and on site assembly. FIGS. 13b and 14b illustrate a top view of a middle section of the baffle structure without an inverted V member. The terminal members of the baffle structure are substantially vertical members 223. As shown in FIGS. 15a and 15b, the terminal members can be butted against each other to form coupled vertical member 223a. FIGS. 15a and 15b show one example of a baffle structure comprising four individual baffle structures joined at three substantially vertical members 223a to form one integrated baffle structure. Specifically, FIG. 14a illustrates a baffle structure positioned within the unloading station with a middle member and two lateral members. FIG. 15b shows an example of a middle member outside of the unloading station.

In an additional embodiment, referring generally to FIG. 17, the inverted V members 224 of the baffle structure 200 may also be configured transverse to the longitudinal axis of the platform to optimize material flow through the baffle structure.

The present invention also provides for a method for unloading the contents of a bulk material transport vehicle on a bulk material unloading station formed as an integrated, single unit for quick installation including aligning an unloading platform of the unloading station with an existing transport vehicle thoroughfare. A bulk material transport vehicle can be positioned on the unloading platform. The contents of the bulk material transport vehicle can be released so that a part of the bulk material contents of the transport vehicle fall into a plurality of baffles disposed at least partially below the unloading platform while a residual part of the bulk material remains in the transport vehicle. A horizontal conveyor disposed below the plurality of baffles can be engaged to remove the bulk material falling through the plurality of baffles to allow horizontal material movement on the conveyor while each of the plurality of baffles impedes horizontal material movement in the transport vehicle.

It is to be understood that the above-referenced arrangements are only illustrative of the application for the principles of the present invention. Numerous modifications and alternative arrangements can be devised without departing from the spirit and scope of the present invention. While the present invention has been shown in the drawings and fully described above with particularity and detail in connection with what is presently deemed to be the most practical and preferred embodiment(s) of the invention, it will be apparent to those of ordinary skill in the art that numerous modifications can be made without departing from the principles and concepts of the invention as set forth herein.

Claims

1. A bulk material flow regulator configured to regulate material flow from a transfer vehicle, comprising: a) a frame bounded by a perimeter defining: i) a material transfer space disposed in a bottom volume of the frame; ii) a material storage space disposed in a top volume of the frame; and iii) a material flow regulation space disposed between the material transfer space and the material storage space; b) a transfer unloading platform coupled to the frame for supporting a transfer vehicle with a material hopper; and c) a plurality of baffles disposed within the material flow regulation space extending transverse to a longitudinal axis of the frame, the baffles being further configured to allow horizontal material movement within the material transfer space while impeding horizontal material movement in the material storage space.

2. An apparatus as in claim 1, further comprising a conveyor system disposed within the material transfer space.

3. An apparatus as in claim 1, wherein a portion of the plurality of baffles are configured parallel to the longitudinal axis of the flow regulation space.

4. An apparatus as in claim 1, wherein a portion of the frame is above ground and the remaining portion of the frame is below ground with a total depth below ground no greater than approximately 72 inches.

5. An apparatus as in claim 1, wherein the plurality of baffles are configured to define a plurality of apertures at the bottom of the frame.

6. An apparatus as in claim 5, wherein at least one of the apertures gradually tapers from a middle portion of the frame toward a terminal portion of the frame along the longitudinal axis of the flow regulation space defining a larger aperture toward the middle portion of the frame and a smaller aperture toward the terminal portion of the frame.

7. An apparatus as in claim 1, wherein the plurality of baffles is configured to be removably coupled to an adjoining plurality of baffles.

8. An apparatus as in claim 1, wherein the plurality of baffles comprises substantially vertical members, inverted V members, and inwardly sloping members.

9. An aggregate material unloading apparatus having a flow regulator configured to regulate aggregate material flow from a rapid discharge transfer vehicle, comprising: a) a substantially rectangular frame bounded by a perimeter and having a total height no greater than approximately 72 inches, the frame defining: i) a material transfer space disposed in a bottom volume of the frame; ii) a material storage space disposed in a top volume of the frame; and iii) a material flow regulation space disposed between the material transfer space and the material storage space; b) a pair of rail lines disposed above the material flow regulation space, alignable within an existing rail line extending parallel to the frame along a longitudinal axis of the frame, and positioned above the material flow regulation space, the rail lines being supported by a vertical support structure extending parallel to the frame along the longitudinal axis of the frame and extending downward to the bottom of the frame and coupled to the frame; c) a conveyor system disposed within the material transfer space, and including a plurality of conveyor belts extending parallel to the longitudinal axis of the frame an offloading conveyor belt extending transverse to the longitudinal axis of the frame configured to transfer material from the material transfer space out of the frame; and g) a plurality of baffles disposed within the material flow regulation space extending transverse to the longitudinal axis of the frame, the baffles being further configured to allow horizontal material movement within the material transfer space while impeding horizontal material movement in the material storage space.

10. An apparatus as in claim 9, wherein the baffled structure includes a plurality of substantially vertical members, inverted V members, and inwardly sloping members.

11. An apparatus as in claim 9, wherein the plurality of baffles is configured to be removably coupled to an adjoining plurality of baffles.

12. An apparatus as in claim 9, wherein the plurality of baffles are configured to define a plurality of apertures at the bottom of the frame wherein a portion of the plurality of apertures are parallel to the longitudinal axis of the frame and the remaining portion of the plurality of apertures are transverse to the longitudinal axis of the frame.

13. An apparatus as in claim 12, wherein at least one of the plurality of apertures is configured parallel to the longitudinal axis of the frame gradually tapers from a middle portion of the frame to a terminal end of the frame along the longitudinal axis of the frame defining a larger aperture toward the middle portion of the frame and a smaller aperture toward the terminal end of the frame.

14. A method for unloading the contents of a bulk material transfer vehicle on a bulk material unloading station formed as an integrated, single unit for quick installation, comprising: a) aligning an unloading platform of the unloading station with an existing transfer vehicle thoroughfare; b) positioning a bulk material transfer vehicle on the unloading platform; c) releasing the contents of the bulk material transfer vehicle so that a part of the bulk material contents of the transfer vehicle fall into a plurality of baffles disposed at least partially below the unloading platform while a residual part of the bulk material remains in the transfer vehicle; and d) engaging a horizontal conveyor disposed below the plurality of baffles to remove the bulk material falling through the plurality of baffles to allow horizontal material movement on the conveyor while each of the plurality of baffles impedes horizontal material movement in the transfer vehicle.

15. A method as in claim 14, wherein the transfer vehicle is a railcar.

16. A method as in claim 14, the unloading platform, comprising: a) a frame bounded by a perimeter defining a material transfer space, a material storage space, and a product flow regulation space, wherein the material transfer space occupies a bottom volume of the frame, the product flow regulation space occupies a middle volume of the frame, and the material storage space occupies a top volume of the frame, the frame being no greater than approximately 72 inches in height; b) a pair of rail lines configured alignable with an existing rail line extending parallel to the frame along the longitudinal axis of the frame and positioned above the material flow regulation space, the rail lines supported by a vertical support structure extending parallel to the frame along the longitudinal axis of the frame and extending downward to the bottom of the frame, and c) a conveyor system disposed within the material transfer space.

17. An apparatus as in claim 14, wherein the plurality of baffles includes a plurality of substantially vertical members, inverted V members, and inwardly sloping members.

18. A system for regulating material flow from a transfer vehicle to a shallow in-ground conveyor system comprising: a) a stationary means for receiving and transferring material off-loaded from a transfer vehicle, the means for receiving being no more than approximately 72 inches in height; and b) a means for regulating flow of an aggregate material positioned in the means for receiving, the means for regulating flow including substantially vertical members, inverted V members, and inwardly sloping members configured to allow horizontal movement of material below the means for regulating flow while impeding horizontal movement of material above the means for regulating flow.

19. A system as in claim 18, the means for receiving comprising: a) a frame bounded by a perimeter defining: i) a material transfer space disposed in a bottom volume of the frame; ii) a material storage space disposed in a top volume of the frame; and iii) a material flow regulation space disposed between the material transfer space and the material storage space; b) a transfer unloading platform coupled to the frame for supporting a transfer vehicle with a material hopper; and b) a pair of rail lines configured alignable with an existing rail line extending parallel to the frame along the longitudinal axis of the frame and positioned above the material flow regulation space, the rail lines supported by a vertical support structure extending parallel to the frame along the longitudinal axis of the frame and extending downward to the bottom of the frame; and c) a means for conveying an aggregate material disposed within the material transfer space for transferring material from the material transfer space to the center of the frame and out of the frame thereafter.

20. A system as in claim 18, further comprising a means for adjusting tensile forces of the conveyor means.