Patent Application
20150321860
1. Background of the Invention
This invention relates to manufacture of plastic articles and more particularly relates to pneumatic conveyance and processing of plastic resin pellets prior to molding or extrusion of those pellets into a finished or semi-finished plastic product.
2. Description of the Prior Art
In facilities that fabricate plastic products by molding or extrusion, it is common to use “vacuum systems” to pneumatically convey pellets of thermoplastic resin, prior to molding or extrusion of those pellets into a finished or semi-finished product, from a central storage point to each of the many compression or injection plastic molding machines or plastic extruders scattered throughout the facility. Individual loaders, which are referred to as “integral” loaders because they contain their own vacuum motor and generate their own vacuum, can be used for conveying plastic resin pellets short distances, typically 20 feet or less. When the plastic resin pellets are purchased in 50 pound bags, 200 pound drums, or 1,000 pound containers commonly referred to as “Gaylords”, these bags, drums, and/or containers can be placed close to the molding press or extruder and small integral loaders can be used to convey the plastic resin pellets from the storage bag, drum, or container to the molding press or extruder.
In this patent application, injection and compression molding presses and extruders are collectively referred to as “process machines.”
Another approach for conveying plastic resin pellets from a storage location to a process machine, which approach is often used in larger facilities, is to install a central vacuum pump or even several vacuum pumps, connected by common vacuum lines to multiple “receivers.” (Receivers are loaders which lack integral power units. A receiver is shown in U.S. Pat. No. 6,089,794, the entire disclosure of which is hereby incorporated by reference)
Vacuum pumps connected to the vacuum lines draw vacuum, namely air pressure slightly below atmospheric, as the vacuum pump sucks air through the “vacuum” line. The suction moves large quantities of air which carry pellets of thermoplastic resin through the “vacuum” line. An alternative is to use positive pressure produced by a blower or the exhaust side of a vacuum pump. With such an approach, the positive pressure results in a movement of substantial amounts of air which may be used to carry plastic resin pellets.
In practice, vacuum pumps are preferred and vacuum lines are desirable in part because power requirements to create the required vacuum necessary to carry plastic resin pellets through the lines are lower than the power requirements if the plastic resin pellets are pushed through the lines by a blower or the exhaust side of a vacuum pump. When vacuum is used, the static pressure within the line may be not much less than atmospheric; when positive pressure is used, the dynamic pressure of the air flowing through the line must be relatively high in order to move adequate amounts of plastic resin pellets.
Receiver-based central loading systems for granular resin typically have one vacuum pump connected to many receivers. When a receiver calls for material, the pump starts, and that single receiver is loaded. Loading is done one receiver at a time.
If several receivers call for material simultaneously, too much air is dumped into the system and the conveying vacuum drops to the point of not conveying correctly.
Some systems use larger diameter vacuum lines as vacuum reservoirs. In such a case, the vacuum pump keeps running to hold a high vacuum level in the large capacity vacuum line network. In that case, when a receiver calls for material, the required vacuum is available. Also, several receivers can call for material at the same time as a large reserve of vacuum is available. However, if too many receivers come on line at the same time, then the vacuum will drop too much. Or if one of the receivers is not pulling material, and just air, the resulting greatly increased volume of air is a problem.
As used herein, and in light of the foregoing explanation, the terms “vacuum pump” and “blower” are used interchangeably.
When one or more central vacuum pumps are connected to multiple receivers, a receiver is located over each temporary storage hopper, in which the plastic resin pellets are temporarily stored before being molded or extruded, and a temporary storage hopper is associated with each process machine.
In prior art systems, each receiver is connected by a control wire to a central control system. The control system works by selectively opening a vacuum valve located in each receiver, allowing one or several vacuum pumps to sequence drawing “vacuum”, i.e. below atmospheric pressure air, to carry the pellets among and to multiple receivers as individual ones of the receivers, positioned over individual hoppers associated with the individual process machines, require additional plastic resin pellets. The receiver for a given hopper-process machine combination is actuated by opening the vacuum valve located in or near the receiver, causing the receiver to feed plastic resin pellets by gravity into the hopper from where the pellets may be fed by gravity downward into the associated process machine.
Large, high capacity industrial vacuum pumps are reliable and are suited to heavy duty industrial use. Use of large high capacity vacuum pumps allows long conveying distances for the plastic resin pellets. Currently available large capacity vacuum pumps permit plastic resin pellets to be conveyed over distances of 200 feet or more using vacuum drawn by the pump. Use of such high capacity vacuum pumps results in a big rush of below atmospheric pressure air through the line, carrying the plastic resin pellets over a long distance.
Operators of plastic manufacturing facilities prefer to buy plastic resin pellets in bulk, in rail cars or tanker trucks. Bulk purchases result in cost savings. Plastic resin pellets delivered in bulk are typically pumped into large silos for storage. In a large manufacturing facility, the distance from a plastic resin pellet storage silo to a process machine may be several hundred feet, or more. Accordingly, when plastic resin pellets are purchased in bulk, a central vacuum-powered conveying system, powered by one or more large, high capacity industrial vacuum pumps, is a necessity.
Typically, large central plastic resin pellet conveying systems have one or more vacuum pumps, each typically from 5 to 20 horsepower. These central systems include central control connected by wire to each receiver associated with each process machine in the facility. Typically eight, sixteen, thirty-two or sixty-four receivers, each associated with a process machine, may be connected to and served by the central plastic resin pellet vacuum conveying system. Of course, the higher the number of receivers served by the system, the higher the cost.
A factor to be considered in designing such a system is the speed of the plastic resin pellets as they flow through a conduit as the plastic resin pellets are carried by the moving air stream drawn by the vacuum pump. If air flow is too slow, the plastic resin pellets fall out of the air stream, lie on the bottom of the conduit, and there is risk of clogging the conduit. If air flow is too fast, the plastic resin pellets can skid along the conduit surface. In such case, harder, more brittle plastic resin pellets are damaged, resulting in dust within the conduit, which when drawn into the vacuum pump can damage the vacuum pump and render the system inoperative. Softer plastic resin pellets heat up and can melt from friction resulting from contact with the conduit interior surface. This results in “angel hair”—long, wispy-thin strands of plastic film which eventually clog the conduit and cause the system to shut down.
For these reasons, pneumatic plastic resin pellet conveying systems must be designed to produce desired, reasonable conveying speeds for the plastic resin pellets.
Conveying speed of the plastic resin pellets is most often controlled by controlling air flow, measured in cubic feet per minute, and varying the desired and designed cubic feet per minute based on conduit diameter, with a larger diameter conduit requiring more cubic feet per minute of air flow to maintain proper air flow speed through the conduit. Controlling air flow, measured in cubic feet per minute, is done by properly specifying the vacuum pump by capacity and, in some cases, by varying speed of the vacuum pump as the vacuum pump draws the air in a “vacuum” condition through the conduit, carrying plastic resin pellets in the moving, below atmospheric pressure air. Controlling cubic feet per minute of air flow is an indirect way of controlling plastic resin pellet speed as the plastic resin pellets flow through a conduit of a given diameter.
Typically, a 2 inch diameter conduit requires about 60 cubic feet per minute of air flow for typical plastic resin pellets. A 2½ inch diameter conduit typically requires 100 cubic feet per minute of air flow for typical plastic resin pellets. To achieve these desired air flow volumes, the designer must carefully match the horsepower of a vacuum pump, which has a given cubic feet of air per minute rating, to a selected size conduit, taking into consideration the average distance the plastic resin pellets must be conveyed through the conduit from a storage silo to a receiver or loader. If this results in selection of a 5 horsepower blower/vacuum pump, then a given facility may require several such blowers/vacuum pumps, with each blower/vacuum pump supplying only a selected number of receivers.
A single plastic resin molding or extruding facility might theoretically require a 20 horsepower blower and the corresponding cubic feet per minute capability for the conveyance provided by the blower to meet the total conveying requirements for plastic resin pellets throughout the facility. However, a single 20 horsepower blower would result in far too high a conveying speed for the plastic resin pellets through any reasonable size conduit. As a result, the conveying system for the plastic resin pellets in a large facility is necessarily divided and powered by 3 or 4 smaller blowers, resulting in 3 or 4 different, separate systems for conveyance of plastic resin pellets. Sometimes several blowers are connected to a single set of receivers, with one or more of the extra blowers turning “on” only when required to furnish the required extra cubic feet per minute of air flow. This is controlled by a central station monitoring all receivers and all blowers, with the central station being programmed to maintain all of the hoppers associated with the process machines in a full condition, wherever those hoppers are located throughout the facility.
Even with careful planning and design, results achieved by such pneumatic plastic resin pellet conveying systems are not consistent. Air flow speed and cubic feet per minute capacity of blowers often vary and are outside of selected design and specification values.
The instant invention provides an improvement to known pneumatic plastic resin pellet conveying systems, reducing the costs of those systems while providing more consistent control of air speed and delivered cubic feet per minute of air for individual receivers. The invention facilitates easy expansion of the pneumatic plastic resin pellet conveying system as the system grows. Such expandable systems are made feasible in part by the air flow limiter disclosed herein, which is also disclosed and claimed in pending U.S. patent application Ser. No. 14/185,016 and in part by the novel receivers as disclosed and claimed in this application.
In another one of its inventive aspects, this invention provides a receiver for use in a pneumatic granular resin delivery system for receiving and temporarily holding granular resin material until needed by a process machine. The receiver includes a vessel having an input port for receipt of pneumatically conveyed granular resin material, an outlet port for discharge of the granular resin material held in the vessel, and a second outlet port for escape of pneumatic conveying air. The receiver preferably further includes a sensor for detecting level of granular resin material in the vessel, and opening the input port for receipt of granular resin material when the detected level of granular resin material is low. The receiver further includes a second sensor for detecting level of vacuum in a pneumatic resin conveyance conduit connected to the inlet port and overriding the opening of the inlet port when vacuum level in the conduit is below a preselected level.
The air flow limiter that is the subject of U.S. patent application Ser. No. 14/185,016, filed 20 Feb. 2014, prevents excessive air from entering a resin conveying vacuum based system.
Many large central systems often have too much capacity and result in conveying material at too great a velocity. The flow limiter that is the subject of the '016 application also eliminates that issue as flow in cubic feet per minute (CFM) is held to correct levels.
With these flow limiters in place at each receiver, or at least at most of the receivers, and in any event at critical postures in the system, new design approaches are feasible.
Use of air flow limiters make it much more likely that multiple receivers can load successfully at the same time.
If a conventional receiver is pulling resin material from a container that has run dry of material, and the receiver now is just sucking air, this is not so damaging to a central vacuum reserve system when the receiver has an air flow limiter associated with it.
With use of air flow limiters as disclosed herein and the receivers as newly disclosed and claimed in this patent application, the central control system, which heretofore has been used to tell each receiver when it can load, can be eliminated.
In another one of its inventive aspects, this invention provides a variable speed drive for the vacuum pump in a granular resin material pneumatic delivery system. Use of a variable speed drive on the vacuum pump, together with self-regulating receivers of the type disclosed herein, and air flow limiters of the type disclosed herein, allow the fabrication and operation of vacuum powered resin loading systems without any central control, thereby substantially reducing costs and increasing reliability of pneumatically-powered granular plastic resin material delivery systems.
With the flow limiter, the vacuum pump(s) can be controlled to hold a certain level of vacuum. Using a variable frequency drive control to vary vacuum pump speed, one can speed up or slow down the vacuum pump as required, based on a vacuum level reading at or near the vacuum pump.
At each of the new receivers in accordance with the invention as disclosed herein, the opening of a vacuum valve connection to the main vacuum reservoir line is based on two criteria: The usual and heretofore only criteria is when a low material lever is detected, and there is a consequent need to load. The second criteria, namely that the vacuum level is high enough to work as sensed by the individual receiver, may also be used. This second criteria prevents too many receivers from coming on line at the same time, which previously has been a problem.
This system requires no central control. No network of wiring is required throughout the plant. Vacuum pump speed is held to a correct speed to meet vacuum loading requirements and multiple receivers can operate at the same time.
By adding a flow limiter of the type disclosed herein to every receiver or at least to most of the receivers, and in any event at critical postures in the system, plant operators can limit air flow in cubic feet per minute to a value that is ideal for that particular receiver, considering conduit diameter and distance over which the plastic resin pellets must be conveyed through that conduit. If such a flow limiter is combined with a receiver of the type disclosed and claimed herein, plant operators can be eliminated since system is self-regulating and no central control is required.
In one of its many aspects, this invention provides a self-regulating vacuum powered system for delivery of granular plastic resin material to a plurality of plastic resin material processing machines. In this aspect, this invention includes a plurality of receivers, a plurality of air flow limiters, with at least some of the air flow limiters being operatively associated with a receiver. A vacuum pump draws granular resin material through a conveying conduit under vacuum. The conveying conduit is connected to a supply of granular resin material, to the air flow limiters, and to the receivers. Most desirably, an air flow limiter is associated with each receiver.
Further desirably, a variable speed drive is connected to the vacuum pump to allow variation of the vacuum pump speed according to selected parameters.
This aspect of the invention preferably further includes a plurality of vacuum level detectors each connected to a receiver for detecting vacuum level in the conveying conduit immediately upstream of a connected receiver.
In yet another one of its aspects, this invention provides vacuum powered apparatus for delivery of granular plastic resin material to a plurality of plastic resin material processing machines, where the apparatus includes a resin conveying conduit, a plurality of receivers, a plurality of air flow limiters, with each of the air flow limiters being connected to the conduit downstream of an associated receiver, with each of the receivers being connected to an associated air flow limiter, and with the apparatus further including a vacuum pump for drawing granular resin material through the conveying conduit under vacuum, where the conveying conduit is connected to a supply of granular resin material, to the receivers and to the air flow limiters.
In yet another one of its aspects, this invention provides vacuum powered apparatus for delivery of granular plastic resin material to a plurality of plastic resin material processing machines where the apparatus includes a first resin conveying conduit, a plurality of receivers connected to the first resin conveying conduit, a plurality of air flow limiters, each of the air flow limiters being connected to an associated receiver downstream thereof. The apparatus yet further includes a second resin conveying conduit of a size different from the first resin conveying conduit. The apparatus yet further includes a plurality of receivers connected to the second resin conveying conduit and a plurality of air flow limiters, each of the air flow limiters being connected to an associated receiver downstream thereof, and further being connected to the second conveying conduit. A vacuum pump is connected to the first and second resin conveying conduits.
In yet another one of its aspects, this invention provides a receiver for use in a pneumatic granular resin delivery system. The receiver serves to receive and temporarily hold granular resin material until needed by a process machine. The receiver includes vessel having an input port for receipt of pneumatically conveyed granular resin material, an outlet port for discharge of the granular resin material held in the vessel, and an outlet port for escape of the conveying air. The receiver further includes a sensor for detecting level of granular resin material in the vessel and opening the input port for receipt of granular resin material when detected level of granular resin material in the vessel is low. The receiver yet further includes a sensor for detecting level of vacuum in a pneumatic resin conveyance conduit connected to the input port and overriding the opening of the input port when the vacuum level in the pneumatic resin conveyance conduit is below a pre-selected level.
In still another one of its aspects, this invention provides a method for pneumatically conveying granular resin material from a supply thereof through a conduit to a plurality of receivers for temporary storage of the resin material prior to molding or extrusion thereof, where the conveying is effectuated by drawing vacuum into conduit by operation of a vacuum pump. In this method, the invention comprises the improvement of varying the vacuum pump speed in response to sensed vacuum level in the conduit proximate to the pump.
In yet another one of its aspects, the invention relates to a method for pneumatically conveying granular resin material from a supply thereof through a conduit to a plurality of receivers for temporary storage of the resin material prior to molding or extrusion, where the pneumatic conveyance is performed by drawing vacuum in the conduit by operation of the vacuum pump. In this method, the invention resides in the improvement comprising limiting air flow downstream of a receiver to a maximum value to be drawn by the vacuum pump and varying the vacuum pump speed in response to sensed vacuum level in the conduit at a position downstream of the location where air flow is being limited.
Use of the air flow limiter and receiver in accordance with this invention allows pneumatic plastic resin pellet conveying systems to utilize a single large high horsepower vacuum pump. In accordance with the invention, each receiver in a facility is preferably fitted with a flow limiter so the flow for each receiver in cubic feet per minute flow is self-limiting. The invention eliminates the need to size vacuum pumps or blowers to a specific material conduit size or conveyance distance. The flow limiter, together with the disclosed receiver, permits operators to run a very large vacuum pump or blower at a speed that will maintain a desired high level of vacuum throughout the entire vacuum or pneumatic plastic resin pellet conveying system.
Using larger than standard diameter vacuum conduits allows a significant vacuum reserve to exist in the plastic resin pellet conveying system, without the need for a vacuum reserve tank. Larger diameter conduits also mean there is little loss of vacuum over long distances, even at the most distant receiver to which plastic resin pellets are supplied by the system. A variable frequency drive control varies the speed of the single large high horsepower vacuum pump to hold vacuum within a desired range. This saves energy when demand is low and vacuum is at the high end of a desired range. In this aspect of the invention at least one vacuum sensor provides input to control a variable frequency drive, varying the speed of the vacuum pump or blower.
With the flow limiter facilitating use of high horsepower vacuum pumps or blowers, designers utilizing the invention can now design to load multiple receivers at the same time without fear of dropping vacuum levels too low in portions of the pneumatic or vacuum plastic resin pellet conveying system.
In the plastic resin pellet conveying system aspect of the invention, no central control system is required. With the flow limiter, each receiver controls its own operation and is not wired to any central control facility. When the level of plastic resin pellets in a particular receiver associated with a specific process machine falls to a sufficiently low level, the receiver level sensor tells the receiver to load. Coupled to the receiver level sensor is a receiver vacuum supply sensor, which confirms that sufficient vacuum is available to load the receiver. If too many other receivers are currently loading, and the sensed vacuum level for that particular receiver is below the threshold for effective loading, then the receiver will wait until the vacuum reading rises. When available system vacuum is sufficient to assure adequate flow of plastic resin pellets into that receiver, the vacuum sensor causes the receiver vacuum valve to open, connecting the receiver to the conduit carrying the plastic resin pellets, and the receiver loads.
In accordance with one aspect of the invention, each receiver acts on its own information. Use of the high horsepower vacuum pump means that multiple receivers can load simultaneously. Because no central control computer system is required, the cost of a central control system and the cost of running control wires throughout a plastic facility are eliminated.
The flow limiter does several things to make such systems in accordance with the invention possible. By limiting cubic feet per minute of flow that is required, there is no limit on the horsepower of the control pump. The risk of a too high a conveyance speed of the plastic resin pellets through the conduit is eliminated. Additionally, if the main supply of plastic resin pellets being essentially exhausted, the empty conduit of the conveying system would manually convey a substantial amount of air, which normally would drop the vacuum reserve of the entire pneumatic conveying system very rapidly. But with the flow limiter present in the system, together with receivers of the type disclosed and claimed herein present in the system, such dumping of air into the conveying conduit is substantially reduced, if not eliminated. Further contributing to minimized air dump into the vacuum conduit is the receiver's ability to detect vacuum system failure or absence of material to be loaded, thereby stopping further load cycles and sounding an alarm.
In the preferred air flow limiter, the limiter has but a single moving part, a valve, which relies on two opposing forces, namely gravity in one direction and lift created by air flow in the opposite direction. Because the preferred air flow limiter uses gravity, orientation of the air flow limiter is critical. Air flow must be upward, essentially vertically through the air flow limiter, to counter the downward force of gravity.
The air flow limiter is desirably in the form of a tube with an air flow actuated valve within the tube. In a “no flow” condition, gravity holds the valve closed. However, as air flow through the limiter reaches a pre-selected design value, flow of air over and against a sail-like plate lifts an internal free floating valve, which shuts off air flow through the air flow limiter if the free floating valve rises sufficiently to contact a stop located within the tube.
By adjusting the size and/or shape of the “sail”, and the weight of the free floating valve, desired air flow can be regulated very closely. Gravity as a force in one direction means the opening force is constant over the full range of motion of the valve device. (A spring, if one were used, would provide a variable force. However, use of gravity in the preferred flow limiter eliminates that variable).
In the preferred flow limiter, at the desired design cubic feet per minute of air flow, the valve opens as it lifts. The valve would continue moving upwardly except for the fact that the valve reaches a point of air flow restriction, where the valve holds air flow steady at the desired design value. If the valve moves further upwardly towards a “closed” position, this reduces air flow, causing the valve to drop. If the valve drops below the control level, this allows more air flow and consequently the valve rises. As a result, the valve reaches the desired design valve equilibrium control point instantly and accurately.
Known air flow shutoffs are subject to “vacuum pull”, causing them to shut off completely once air begins to flow. This is because in known shutoffs, vacuum pull of the vacuum pump is always present. However in the preferred flow limiter as disclosed herein, a short vertical tube closes against a flat horizontal surface. In this preferred flow limiter, air flow is directed through the center of the short tube and escapes over the top edge of the short tube and then around open edges of a flat shutoff surface. A flat, desirably triangular or star-shaped partial plate is positioned in the air flow below and connected to the short tube. This plate acts as the sail in the air flow and will, at the designed desired cubic feet per minute air flow rate, provide enough lift to raise the short tube against the shutoff plate.
At shut off, with vacuum above the flat shutoff surface and air pressure below the flat shutoff surface, most of the air pressure forces are against the walls of the short tube. Those forces are radially outwardly directed, namely they are horizontal, and do not exert vertical force that would make the movable portion of the valve, namely the short tube, move in a vertical direction.
The surface of the end of the short tube at the short tube edge is a horizontal surface and can provide a small vertical force. For this reason, the preferred flow limiter uses a very thin wall short tube to minimize the horizontal surface area of the short tube.
In the preferred flow limiter, air flow rate in cubic feet per minute can be adjusted by adding or subtracting weight from the floating valve, or by adjusting the surface area of the sail, or by adjusting the size or shape of the sail in the air flow.
Accordingly, the preferred air flow limiter has a vertically oriented tube, a pair of open-ended telescoping tubular internal segments within the tube, with an outer tubular segment being fixed and the other being slidably moveable along the fixed segment in the axial direction. A plate extends partially across the interior of the vertically oriented tube and is positioned for contacting the moveable one of the telescoping tubular segments and limiting travel of the moveable telescoping tubular segment, with the plate covering the upper, open end of the moveable telescoping tubular segment upon contact therewith. A sail is positioned in the vertically oriented tube below the telescoping segments, a strut connects the sail and the moveable telescoping tubular segment, and a baffle is positioned to direct upward air flow within the tube through the telescoping tubular segments, where the moveable telescoping tubular segment moves vertically within the tube unitarily with the sail responsively to air flow upwardly through the tube against the sail.
The tubular segments are preferably cylindrical; the surface of the plate contacted by the moveable tubular segment is preferably planar; the portion of the moveable tubular segment contacting the plate surface is preferably annular.
In a variation of terminology (but not of structure), a surface of the plate contacted by the moveable tubular segment is flat, the tubular segments are cylindrical and the circular edge of the tubular segment contacting the plate service is annular and normal to the axis of the tubular segment.
The preferred air flow limiter may be viewed as consisting of a vertical oriented tube, a tubular segment within the tube, which segment is moveable in the axial direction, a plate extending at least partially across the interior of the tube for contacting the movable tubular segment and defining a limit of travel of the moveable tubular segment, a sail positioned in the tube below the moveable tubular segment and being moveable vertically within the tube, a strut connecting the tubular segment and the sail, and a baffle connected to and located within the tube defining a lower limit of travel of the moveable tubular segment upon contact of the strut with an upper extremity of the baffle. The moveable tubular segment is in sliding telescoping engagement with the tubular portion of the baffle, directing upward air flow within the tube, the moveable tubular segment being moveable unitarily with the sail in response to upward air flow through the tube contacting the sail.
The preferred air flow limiter may be considered as having a vertically oriented tube with a sail assembly positioned in the tube and moveable therewithin responsively to air flow through the tube, to regulate air flow through the tube and to stop air flow thorough the tube upon air flow exceeding a preselected value.
In one of its aspects, this invention places two or more air flow limiters in the resin conveying system at key locations so that smaller, preferably 1.5 inch lines can be used for air flow for auxiliary devices, in addition to the conventional 2 inch lines for the main resin conveyance. This permits the desired commodity, such as color pellets or some other additive, to be conveyed by air controlled by traveling through a lower size fixed air flow limiter and hence functioning to deliver granular resin material to a receiver or to deliver an additive to that receiver.
This use of multiple flow limiters to allow different line sizes in the same resin conveying system is an important aspect of this invention. Such use of multiple flow limiters, allowing use of different sized conveyance lines, facilitates greater flexibility with consequent cost savings for the purchaser of the resin conveying system.
Referring to the drawings in general and to
Each receiver 102A, 102B is depicted as having a resin discharge conduit 108 at the bottom thereof for discharge of resin when needed from the associated receiver. Resin is discharged upon demand by a process machine requiring additional resin to continue manufacture of molded or extruded plastic parts. Receivers 102A and 102B are preferably all identical.
As depicted schematically in
Air drawn under vacuum by vacuum pump 112 leaves from each receiver 102 laterally via a side air vacuum discharge conduit designated 110A or 110B. Each receiver air discharge conduit 110A, 110B leads initially to an air flow limiter 30. Air as vacuum leaving a receiver 102A, 102B, after passing through an air flow limiter 30, travels on through the associated receiver discharge conduit 110A, 110B, with discharge conduits 110A and 110B joining as illustrated at the right side of
Vacuum pump 112 is desirably equipped with a variable frequency drive unit 114, allowing precise control of vacuum pump 112.
Each receiver 102 is desirably of the type shown schematically in
In the embodiment illustrated in
Air flow limiters 30 are all preferably identical. Air flow limiter 30-1 is desirably of larger size and hence of larger capacity than air flow limiters 30. However, air flow limiter 30-1 is preferably of the same design as air flow limiters 30, as disclosed above.
Still referring to the drawings and to
Similarly to the apparatus illustrated in
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As depicted schematically in
Similarly to the arrangement shown in
Vacuum pump 112, similarly to vacuum pump 112 illustrated in
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Similarly to the apparatus illustrated in
Referring to
Similarly to
As depicted schematically in
Air drawn under vacuum by vacuum pump 112 from each receiver departs that receiver, either 102A or 102B, laterally via a side air as vacuum discharge conduit designated 110A or 110B or 110X. Side air discharge conduits 110A and 110B discharge air as vacuum from an associated receiver 108 initially through an air limiter 30, if an air limiter 30 is present. Air as vacuum leaving a receiver 102A or 102B either through air discharge conduit 110A or 110B, after passing through an associated air flow limiter 30 if present, travels on through the receiver air discharge conduits 110A or 110B to a point of juncture therebetween, and from there through air flow limiter 30-3 to vacuum pump 112.
In the embodiment illustrated in
Similarly to the apparatus depicted in
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Similarly to the configuration illustrated in
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Further respecting the configuration illustrated in
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In
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Since a given process, whether extrusion or molding, may require different amounts of granular plastic resin material from supply 104 and granular plastic resin material, or additive materials, or solid colorants from supply 116, material from supply 104 and material from supply 116 travel through separate conveyance conduits which have been numbered 106A and 118 in
Similarly to the configurations illustrated in
Similarly to
Unlike the apparatus illustrated in
Since some receivers 102A, 102B illustrated in
Further respecting the configuration of the apparatus shown schematically in
Also similarly to the other configurations of the apparatus embodying the invention, in
Referring to
Referring to
Receiver 200 preferably includes a material inlet conduit designated 204 and a material outlet conduit designated 206 in
Receiver 200 further preferably includes a receiver material level sensor 202 for sensing the level of material within receiver 200 and providing a suitable signal when the material reaches a low enough level that replenishment of material in receiver 200 is required.
Receiver 200 further preferably includes a vacuum level sensor 214 positioned in material inlet conduit 204, just upstream of material inlet valve 212. Vacuum level sensor 214 determines when the level of vacuum in the pneumatic conveying system, which is connected to material inlet conduit 204, is excessively low for receiver 200 to draw granular material through material inlet conduit 204 in response to the vacuum drawn by a vacuum pump acting through pneumatic outlet conduit 208.
Receiver 200 as illustrated in
With reference to
Referring to the drawings in general and to
As illustrated in
As best shown in
The upper portion of baffle 52, defining fixed internal tubular segment 44, is adapted for sliding telescopic engagement with, and movement therealong by, movable tubular segment 42. Fixed to movable tubular segment 42 is a first strut 48 which preferably extends transversally across the upper portion of movable tubular segment 42 and is preferably secured on either end to movable tubular segment 42, as illustrated in
Movable sail 34 is preferably planar and positioned fixedly on second strut 50 to remain perpendicular with respect to the axis of vertically oriented outer tube 32. Movable sail 34 is preferably of generally triangular configuration, as best illustrated in
Movable sail 34 is positioned within generally vertically oriented outer tube 32 so that rectangular extremities 76 are closely adjacent to but do not contact the inner surface of vertically oriented outer tube 32, so long as sail 34 moves vertically up and down within vertically oriented external tube 32. The rectangular shape of extremities 76 with their outwardly facing planar surface assures minimal friction and consequent minimal resistance to movement of movable sail 34 in the event one of rectangular extremities 76 contacts the interior surface of vertically oriented tube 32, should sail 34 for some reason move laterally or otherwise and become skew to the vertical axis of tube 32.
Movable internal tubular segment 42 is telescopically movable, unitarily with sail 34, relative to and along fixed internal tubular segment 44. A lower limit of movement of movable tubular segment 42 is illustrated in
When air is flowing through air flow limiter 30, as illustrated generally in
If air flow upwardly through air flow limiter 30 reaches an extreme value, above an acceptable level of operation of the system of which air flow limiter 30 is a part, the excessive force (resulting from the high volume air flow contacting sail 34) pushes sail 34 upwardly to the point that upper annular edge 78 of movable internal tubular segment 42 contacts plate 46. In this condition, which is illustrated in
Once air flow stops through vertically oriented outer tube 32, gravity pulling downwardly on sail 34, connected movable internal tubular segment 42, and first and second struts 48, 50, causes these parts, which may be connected together and fabricated as a single integral assembly as shown in
With the self-regulating characteristic of air flow limiter 30, the assembly consisting of movable internal tubular segment 42, first and second struts 48, 50 and sail 34 may oscillate somewhat about the position at which the desired air flow is supplied, as the blower or vacuum pump driving or drawing air through flow limiter 30 varies in output of cubic feet per minute of air blown or drawn.
Desirably, ends of first strut 48, which is depicted as being horizontally disposed in the drawings, are mounted in movable tubular segment 42 in movable fashion such that first strut 48 can move slightly, rotationally, relative to movable internal segment 42. This is to provide a small amount of “play” in the event movable sail 34 and second strut 50, which is vertically oriented and connected to movable sail 34, become skew with respect to the vertical axis of vertically oriented exterior tube 32. Should this occur, the movable characteristic of first strut 48, being slightly rotatable relative to movable internal tubular segment 42, effectively precludes movable internal tubular segment 42 from binding with respect to fixed internal tubular segment 44 and thereby being restricted from what would otherwise be freely telescoping movement of movable internal tubular segment 42 relative to fixed internal tubular segment 44.
Desirably first strut 48 is rotatable relative to movable internal tubular segment 42, to provide maximum freedom of vertical motion of movable internal tubular segment 42 in the event movable sail 34 becomes skew to the axis of vertically oriented exterior tube 32, with consequent frictional force restricting vertical movement of movable sail 34.
Baffle 52 preferably includes two portions, the upper portion preferably being defined by fixed internal tubular segment 44 and a lower portion preferably being defined by conical portion 66 of baffle 52. A lower edge of baffle 52 is circular and is designated 84 in the drawings. Circular edge 84 fits closely against the annular interior wall of vertically oriented exterior tube 32 so that all air passing upwardly through air flow limiter 30, namely through vertically oriented exterior tube 32, is constrained to flow through the interior of baffle 52. The tight fitting of the circular lower edge of baffle 52 against the interior wall of vertically oriented exterior tube 32 forces all air entering flow limiter 30 from the bottom to flow through the interior of baffle 52, flowing upwardly through lower conical portion 66 of baffle 52. The air then flows further upwardly through the interior of fixed internal tubular segment 44. Thereafter, if movable internal tubular segment 42 is spaced away from flow limiting horizontal plate 46, air flows along the surface of movable internal tubular segment 42, passing the upper annular edge 78 of movable internal tubular segment 42; air then flows around the space between edge 82 of flow limiting horizontal plate 46 and the interior annular wall of vertically oriented exterior tube 32. The air then flows out of air flow limiter 30 via open outlet end 56 formed in end cap 60.
In an alternate approach, baffle 52 may be constructed from two pieces that fit closely together, with the two pieces being in facing contact in the area where they define fixed internal tubular segment 44, but diverging one from another in the area where they define conical portion 66 of baffle 52. In such embodiment, illustrated in
In another alternate approach, baffle 52 is one piece, preferably molded plastic, as illustrated in
The assembly illustrated in
Flow limiter 30 contains no springs. Flow limiter 30 preferably contains no sensors to provide feedback to a control device; no sensors are needed since because flow limiter 30 is self-regulating. Flow limiter 30 preferably includes a tubular valve, closing against a flat surface, where the tubular valve is defined by movable internal tubular segment 42 closing against flow limiting horizontal plate 46. Movable internal tubular segment 42 is in the form of an open-ended cylinder and is connected to a plate in the form of movable sail 34 to move movable tubular segment 42 against flow limiting horizontal plate 46. Flow limiter 30 uses gravity alone to open the valve defined by the assembly of movable internal tubular segment 42 and movable sail 34 and the connecting structure therebetween.
In the embodiment of the flow limiter illustrated in
Air flow limiter 30 functions equally well with a vacuum pump drawing air through air flow limiter 30 from bottom to top by application of vacuum to outlet end 56, or by air being supplied under positive pressure at inlet end 54 for passage upwardly through air flow limiter 30.
In the course of practice of the invention with any of the granular plastic resin material conveying systems illustrated, different line sizes may be used. While 2½ inch and 1½ inch line sizes respectively are suggested and ordinarily used for the primary resin conveying line and for the auxiliary or additive conveying line respectively, these line sizes may be varied. Also, the flow limiters may or may not each be of the same resistance or size, whether located in the primary resin conveyance line or in the secondary conveyance line, with the flow limiter selected for specific resistance to air flow for the particular line size in which it is located. Moreover, it is within the scope of the invention to use different size flow limiters on the same size primary and/or secondary lines, depending on the particular additive or other material being drawn therethrough (in the case of a secondary line) and depending on the nature and characteristic of the resin being drawn through the primary line.
Most plastic resin processes require the basic material be delivered at 50 times the rate of the additives, such as color concentrate. Virgin (or natural) pellets may have to be loaded at a rate of 1,000 pounds per hour, requiring a 2.5 or 3 inch line size, while color or another additive may only be required to be delivered at a rate of 20 to 40 pounds per hour. A smaller receiver is desirably used for the color or other additive, namely one that only loads perhaps 5 pounds at a time, while the receiver loading the virgin resin material will be large, loading as much as 50 pounds of resin material for each cycle of the process machine. A 2.5 inch line on a 5 pound receiver should not be used. 1 inch line would be the industry standard; use of a 1.5 inch convey line for the color or other additive would be better.
The variable frequency drive motor allows the vacuum pump to operate at different speeds, and therefore at different volume rates, and to pull different vacuum levels depending on preset information about each receiver served or making adjustment based on feedback of vacuum sensors associated with the receivers.
The flow limiter in the main air as vacuum flow line allows an oversized vacuum pump to be used without risk of conveying at excessive velocity. The flow limiters restrict air flow to a preset level. This maintains the desired rate of air flow at the upstream inlet to the system, which is critical for proper conveying for a given size convey line.
In the claims appended hereto, the term “comprising” is to be interpreted as meaning “including, but not limited to” while the phrase “consisting of” is to be interpreted to mean “having only and no more” and while the phrase “consisting essentially of” is to be interpreted to mean the recited elements and those others that do not materially affect the basic and novel characteristic of the claimed invention.
This patent application is a 35 USC 120 continuation-in-part of co-pending patent application U.S. Ser. No. 14/185,016 entitled “Air Flow Regulator”, filed 20 Feb. 2014 and U.S. patent application Ser. No. 14/574,561 entitled “Resin Delivery System with Air Flow Regulator” filed 18 Dec. 2014, with both of these applications having been filed in the name of Stephen B. Maguire. The priority of both applications is claimed under 35 USC 120. This patent application further claims the benefit of the priority of U.S. provisional application Ser. No. 62/027,379 entitled “Central Vacuum Loading System Without Central Control”, filed 22 Jul. 2014 in the name of Stephen B. Maguire. The priority of the '379 application is claimed under 35 USC 119 and 35 USC 120.
| Number | Date | Country | |
|---|---|---|---|
| 62027379 | Jul 2014 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 14185016 | Feb 2014 | US |
| Child | 14804404 | US | |
| Parent | 14574561 | Dec 2014 | US |
| Child | 14185016 | US |
