Automated Wand System

Abstract

A system comprising a plurality of wands, suction and pneumatic valves, pneumatic cylinders, a vacuum and tilt sensors, and a programmable logic controller configured to read input signals from the vacuum and tilt sensors and send output signals controlling the pneumatic valves and cylinders, which open and close the vacuum valves regulating suctioning of the wands to achieve uniform and maximum depletion of pelletized material from a bulk container.

1 . A system, comprising: a plurality of wands, vacuum valves, a vacuum sensor, and a PLC; the system is in electrical communication with a power source;
 the vacuum sensor provides input signals to the PLC; the PLC sends output signals, which signals open and close the vacuum valves regulating suctioning of the wands.   
     
     
         2 . A system, comprising: a plurality of wands, vacuum valves, pneumatic cylinders, pneumatic valves, a vacuum sensor, tilt sensors, and a PLC; the system is in electrical communication with a power source;
 the vacuum and tilt sensors provide input signals to the PLC; the PLC sends output signals activating the pneumatic valves controlling compressed air into the pneumatic cylinders, which open and close the vacuum valves regulating suctioning of the wands.   
     
     
         3 . The system in  claim 2 , wherein when the system is placed inside a bulk container and is connected to a vacuum loader hose, and when the vacuum loader hose is turned on, the vacuum sensor sends an input signal to the PLC; the PLC reads the input signals of the vacuum sensor and the tilt sensors, then the PLC sends output signals to the pneumatic valves controlling the pneumatic cylinders to open and close the vacuum valves, which control suction through the wands, so that the system levels itself inside the bulk container. 
     
     
         4 . The system in  claim 3 , wherein each of the wands have first and second ends; wherein the shape of the wands as well as the gauge thickness of the wand material are sized to provide structural strength, so that the plurality of wands are capable of supporting the weight of the entire system; wherein each wand is substantially s shaped; and wherein the wand first ends contain anti-plug loops, and the wand second ends are connected to the vacuum valves. 
     
     
         5 . The system in  claim 4 , wherein the cross sectional area of the wand first ends are coplanar, thereby constituting the system plane; when the system plane is parallel to the horizontal plane the system is level, thereby constituting the level system plane. 
     
     
         6 . The system in  claim 5 , wherein each wand second end is connected to a separate vacuum valve. 
     
     
         7 . The system in  claim 6 , wherein the system is placed in a bulk container with the wand first ends placed substantially on top of the pelletized material; and wherein the wand first ends are spaced apart to achieve uniform and maximum depletion of pelletized material in the bulk container when the system plane is level. 
     
     
         8 . The system in  claim 7 , wherein when the system plane is unlevel, at least one wand first end is below the system level plane and at least another wand first end is above the system level plane. 
     
     
         9 . The system in  claim 8 , wherein when the system plane is unlevel, the tilt sensors send input signals to the PLC, which in turn sends output signals to the pneumatic valves, closing vacuum valves to wands whose first ends extend below the level system plane and keeping fully open vacuum valves to wands whose first ends are above the level system plane. 
     
     
         10 . The system in  claim 9 , wherein a wand first end comprises an area of suction, which is the maximum lateral range of suction of the wand first end when the system is level. 
     
     
         11 . The system in  claim 10 , wherein the plurality of wands consist of 9 wands, comprising 1 inner wand, and 8 outer wands, all wands equally spaced apart, such that when the system is placed level inside in the middle of a 4′×4′×4′ bulk container full of pelletized material, the area of suction of the wand first ends extend equidistant between adjacent wand first ends, and the area of suction of the outer wands extend to the container walls. 
     
     
         12 . The system in  claim 11 , wherein the first end of the inner wand is equidistant to the first end of the outer wands, such that when the system is unlevel, at least one outer wand first end extends below the system level plane about the inner wand first end and at least another outer wand first end is above the system level plane about the inner wand first end. 
     
     
         13 . The system in  claim 12 , wherein when the system is unlevel, the angle between the system plane and level system plane about the inner wand first end constitutes the angle of tilt of the system; and wherein when a wand first end is below the system level plane, the angle of tilt of that wand first end is negative, and when a wand first end is above the system level plane, the angle of tilt of said wand is positive. 
     
     
         14 . The system in  claim 13 , wherein the system comprises a vacuum valve housing, containing the vacuum valves, a plenum, a vacuum loader hose connection, bottom and top surfaces, a box-shaped compartment forming the plenum with a plurality of spaced apart ports in the bottom surface, and a plurality of apertures in the top surface; the second ends of the wands attach to the ports, such that when a vacuum loader hose is connected to the vacuum loader hose connection and turned on with the vacuum valves open, the pelletized material is suctioned through the wands into the plenum, and into the vacuum loader hose. 
     
     
         15 . The system in  claim 14 , wherein each vacuum valve has a valve stopper; wherein the pneumatic valves are controlled by solenoids; and wherein each pneumatic cylinder includes a cylinder rod, each pneumatic cylinder is connected to a separate pneumatic valve, each cylinder rod is inserted in a separate aperture in the top surface of the vacuum valve housing and is connected to at least one vacuum valve, each vacuum valve's valve stopper is aligned with a separate vacuum port, such that filling each of the cylinders with compressed air forces the connected cylinder rod to push the connected valve stopper inside and closing the vacuum port aligned therewith, preventing suctioning through the wand connected thereto. 
     
     
         16 . The system in  claim 15 , wherein each cylinder rod is connected to two vacuum valves. 
     
     
         17 . The system in  claim 16 , wherein the vacuum sensor detects when the vacuum loader hose is turned on by measuring the vacuum pressure in the vacuum valve housing. 
     
     
         18 . The system in  claim 17 , wherein the tilt sensors detect when the system is level by measuring the angle of tilt of the system; and wherein each tilt sensor is capable of detecting the tilt angle of at least one wand first end. 
     
     
         19 . The system in  claim 18 , wherein the tilt sensors send on or off, input signals to the PLC;
 wherein a tilt sensor sends an off input signal to the PLC if the tilt sensor detects a negative angle of tilt of a wand first end; wherein a tilt sensor sends an on input signal to the PLC if the tilt sensor detects a positive angle of tilt of a wand first end; wherein the PLC will send an output signal to a pneumatic valve energizing the solenoid to fill the connected pneumatic cylinder with compressed air and in turn closing the connected vacuum valve, thereby preventing suctioning in the connected wand whose angle of tilt is negative; and wherein the PLC will send an output signal to a pneumatic valve de-energizing the solenoid to withdraw compressed air from the connected pneumatic cylinder and in turn opening the connected vacuum valve, thereby allowing suctioning in the connected wand whose angle of tilt is positive.   
     
     
         20 . The system in  claim 19 , wherein the system plane comprises axis one and axis two; axis one extends through the first end of the inner wand and through the first ends of two outer wands on opposite sides of the inner wand; axis two is perpendicular to axis one and extends through the first end of the inner wand and through the first ends of two outer wands on opposite sides of the inner wand. 
     
     
         21 . The system in  claim 20 , wherein the system includes a NEMA enclosure, comprising a bottom surface parallel to the system plane, and containing the pneumatic valves, vacuum sensor, tilt sensors, the PLC, and other electrical components; the NEMA enclosure being bracketed to the vacuum valve housing and in electrical communication with a power source. 
     
     
         22 . The system in  claim 21 , wherein four tilt sensors are placed on the bottom surface of the NEMA enclosure, paired and spaced apart along axis one and two, such that if a tilt sensor detects a negative tilt angle, its pair will detect an equal and opposite tilt angle. 
     
     
         23 . The system in  claim 22 , wherein to maintain a pressure differential in the plenum, maximizing the flow of material through the plenum into the vacuum loader hose, the negative pressure at the vacuum loader hose connection is approximately the same as the pressure at the open ports. 
     
     
         24 . The system in  claim 23 , wherein to achieve the pressure differential in the plenum, the negative pressure in the vacuum loader house is −7.5 in Hg (−3.7 psi), having a Flow of 100 ft 3 /min. 
     
     
         25 . The system in  claim 24 , wherein only one port is open at any one time. 
     
     
         26 . The system in  claim 25 , wherein if a tilt sensor detects a positive tilt angle, the PLC sends a sequencing output signal to open and close the vacuum valves one at a time in a clockwise sequence of the outer wands, starting with the vacuum valve connected to the outer wand whose first end is aligned with the same axis as said tilt sensor, and opening and closing the inner wand last. 
     
     
         27 . The system in  claim 24 , wherein when the system is level, the tilt sensors send input signals to the PLC, which PLC sends output signals to the pneumatic valves causing the cylinders to fully open all vacuum valves. 
     
     
         28 . The system in  claim 27 , wherein the plenum comprises a relief valve, and a plenum saturation level, which occurs when the negative pressure at the open ports approximates the negative pressure at the vacuum loader hose connection; and wherein the vacuum sensor detects when the plenum is saturated and sends an input signal to the PLC, which PLC sends output signals closing all ports until the vacuum loader hose has suctioned virtually all of the pelletized material out of the plenum, and which PLC sends an output signal opening the relief valve introducing compensating air into the plenum. 
     
     
         29 . A system, comprising: 9 wands, comprising 1 inner wand, and 8 outer wands, each of the wands have first and second ends; wherein the shape of the wands as well as the gauge thickness of the wand material are sized to provide structural strength, so that the plurality of wands are capable of supporting the weight of the entire system; wherein each wand is substantially s shaped; and wherein the wand first ends contain anti-plug loops;
 the cross sectional area of the wand first ends are coplanar, thereby constituting the system plane; when the system plane is parallel to the horizontal plane the system is level, thereby constituting the level system plane;   a wand first end comprises an area of suction, which is the maximum lateral range of suction of the wand first end when the system is level;   all wands are equally spaced apart, such that when the system is placed level inside in the middle of a 4′×4′×4′ bulk container full of pelletized material, the area of suction of the wand first ends extend equidistant between adjacent wand first ends, and the area of suction of the outer wands extend to the container walls; the first end of the inner wand is equidistant to the first end of the outer wands;   when the system is unlevel, the angle between the system plane and level system plane about the inner wand first end constitutes the angle of tilt of the system; when a wand first end is below the system level plane, the angle of tilt of that wand first end is negative, and when a wand first end is above the system level plane, the angle of tilt of said wand is positive;   a vacuum valve housing, comprising vacuum valves, a plenum, a vacuum loader hose connection, bottom and top surfaces, a plenum with a plurality of spaced apart ports in the bottom surface, and a plurality of apertures in the top surface; the second ends of the wands attach to the ports and to the vacuum valves, such that when a vacuum loader hose is connected to the vacuum loader hose connection and turned on with the vacuum valves open, the pelletized material is suctioned through the wands into the plenum, and into the vacuum loader hose;   tilt sensors, which detect when the system is level; pneumatic valves, pneumatic cylinders, a vacuum valve, and a PLC; a tilt sensor sends an off input signal to the PLC if the tilt sensor detects a negative angle of tilt of a wand first end; a tilt sensor sends an on input signal to the PLC if the tilt sensor detects a positive angle of tilt of a wand first end; the PLC will send an output signal to a pneumatic valve energizing the solenoid to cause the connected pneumatic cylinder to close the connected vacuum valve, thereby preventing suctioning in the connected wand whose angle of tilt is negative; and the PLC will send an output signal to a pneumatic valve de-energizing the solenoid to cause the connected pneumatic cylinder to open the connected vacuum valve, thereby allowing suctioning in the connected wand whose angle of tilt is positive;   to maintain a pressure differential in the plenum, maximizing the flow of material through the plenum into the vacuum loader hose, the negative pressure at the vacuum loader hose connection is approximately the same as the pressure at the open ports;   the plenum comprises a plenum saturation level, which occurs when the negative pressure at the open ports no longer approximate the negative pressure at the vacuum loader hose connection; and wherein the vacuum sensor detects when the plenum is saturated and sends an input signal to the PLC, which PLC sends output signals closing all ports until the vacuum loader hose has suctioned virtually all of the pelletized material out of the plenum.   
     
     
         30 . A system, comprising: a plurality of wands, vacuum valves, pneumatic cylinders, pneumatic valves, a vacuum sensor, tilt sensors, and a PLC; the system is in electrical communication with a power source;
 each of the wands have first and second ends; wherein the shape of the wands as well as the gauge thickness of the wand material are sized to provide structural strength, so that the plurality of wands are capable of supporting the weight of the entire system; wherein each wand is substantially s shaped; and wherein the wand first ends contain anti-plug loops, and the wand second ends are connected to the vacuum valves;   the cross sectional area of the wand first ends are coplanar, thereby constituting the system plane; when the system plane is parallel to the horizontal plane the system is level, thereby constituting the level system plane;   a wand first end comprises an area of suction, which is the maximum lateral range of suction of the wand first end when the system is level;   the plurality of wands consist of 9 wands, comprising 1 inner wand, and 8 outer wands, all wands equally spaced apart, such that when the system is placed level inside in the middle of a 4′×4′×4′ bulk container full of pelletized material, the area of suction of the wand first ends extend equidistant between adjacent wand first ends, and the area of suction of the outer wands extend to the container walls;   the first end of the inner wand is equidistant to the first end of the outer wands;   when the system is unlevel, the angle between the system plane and level system plane about the inner wand first end constitutes the angle of tilt of the system; when a wand first end is below the system level plane, the angle of tilt of that wand first end is negative, and when a wand first end is above the system level plane, the angle of tilt of said wand is positive;   a vacuum valve housing, containing the vacuum valves, a plenum, a vacuum loader hose connection, bottom and top surfaces, a plenum with a plurality of spaced apart ports in the bottom surface, and a plurality of apertures in the top surface; the second ends of the wands attach to the ports, such that when a vacuum loader hose is connected to the vacuum loader hose connection and turned on with the vacuum valves open, the pelletized material is suctioned through the wands into the plenum, and into the vacuum loader hose;   each vacuum valve has a valve stopper; the pneumatic valves are controlled by solenoids; and each pneumatic cylinder includes a cylinder rod, each cylinder rod is inserted in a separate aperture in the top surface of the vacuum valve housing and is connected to at least one vacuum valve, each valve's valve stopper is aligned with a separate vacuum port, such that filling each of the cylinders with compressed air forces the connected cylinder rod to push the connected vacuum stopper inside and closing the vacuum port aligned therewith, preventing suctioning through the wand connected thereto; each cylinder rod is connected to two vacuum valves;   the tilt sensors detect when the system is level by measuring the angle of tilt of the system; and wherein each tilt sensor is capable of detecting the tilt angle of at least one wand first end;   a tilt sensor sends an off input signal to the PLC if the tilt sensor detects a negative angle of tilt of a wand first end; a tilt sensor sends an on input signal to the PLC if the tilt sensor detects a positive angle of tilt of a wand first end; the PLC will send an output signal to a pneumatic valve energizing the solenoid to fill the connected pneumatic cylinder with compressed air and in turn closing the connected vacuum valve, thereby preventing suctioning in the connected wand whose angle of tilt is negative; and wherein the PLC will send an output signal to a pneumatic valve de-energizing the solenoid to withdraw compressed air from the connected pneumatic cylinder and in turn opening the connected vacuum valve, thereby allowing suctioning in the connected wand whose angle of tilt is positive;   the system plane comprises axis one and axis two; axis one extends through the first end of the inner wand and through the first ends of two outer wands on opposite sides of the inner wand; axis two is perpendicular to axis one and extends through the first end of the inner wand and through the first ends of two outer wands on opposite sides of the inner wand;   a NEMA enclosure, comprising a bottom surface parallel to the system plane, and containing the pneumatic valves, vacuum sensor, tilt sensors, the PLC, and other electrical components; the NEMA enclosure being bracketed to the vacuum valve housing and in electrical communication with a power source;   four tilt sensors are placed on the bottom surface of the NEMA enclosure, paired and spaced apart along axis one and two, such that if a tilt sensor detects a negative tilt angle, its pair will detect an equal and opposite tilt angle;   to achieve the pressure differential in the plenum, the negative pressure in the vacuum house loader is −7.5 in Hg (−3.7 psi), having a Flow of 100 ft3/min; only one port is open at any one time;   if a tilt sensor detects a positive tilt angle, the PLC sends a sequencing input signal to open and close the vacuum valves one at a time in a clockwise sequence of the outer wands, starting with the vacuum valve connected to the outer wand whose first end is aligned with the same axis as said tilt sensor, and opening and closing the inner wand last.