Grain dryer sampling system

Abstract

A grain sampling mechanism 208 operatively connected to a wall 112 of a heating column 110 of a grain dryer 102 includes a sampler housing 210 having an opening 212 configured to receive grain 204 as the grain drops down the heating column 110. The sampler housing is pivotally mounted about a pivot axis 214 and a biasing mechanism 216 provides a biasing force that positions the sampler housing in a first condition where the opening extends into the heating column. When an amount of grain collected in the sampler housing reaches a sufficient quantity to overcome the biasing force, the collected grain causes the sampler housing to pivot to a second condition in which the opening is blocked such that a fixed sample of grain is contained within the sampler housing. A sensor 206 senses a moisture parameter of the fixed sample of grain collected in the sampler housing.

Description

GRAIN DRYER SAMPLING SYSTEMBACKGROUND OF THE INVENTIONField of Invention

[0001] This disclosure relates generally to agricultural grain dryers, and more particularly to sampling systems for grain dryers.Description of Related Art

[0002] Grains such as wheat, corn, soybean, and other agricultural products such as nuts, often need to be dried after harvesting to achieve a moisture content adequate for inhibiting microbial growth during storage and preserve the value of the stored product. Agricultural dryers most commonly referred to as grain dryers, allow farmers to start harvesting earlier at higher moisture levels and dry the products in bins to a more optimal moisture content, increasing yields and improving profits. This allows the farmer to minimize weather risks, reduce dry matter loses, and reduce head shatter loss. Drying typically involves the reduction of moisture from about 17-30% w / w to values between 8 and 15% w / w, depending on the product involved.

[0003] Drying the product includes directing an air flow through a heater to heat the air and then directing the heated airflow through a bin storing the grain. Various methods of drying grain are well-known in the art. Cross-flow dryers provide airflow in a direction perpendicular to the flow of the grain through the dryer. Many cross-flow dryers utilize perforated screens to hold the grain in columns while allowing air to pass through the grain. Commonly assigned U.S. Patent Application No. 17 / 020,284 entitled “Vacuum Cooled Grain Dryer” discloses features of a grain dryer that has adjustable bypass air inlets leading to a cooling section of the dryer.

[0004] To ensure that the grain is properly processed and stored so as to maintain optimal quality of the grain, it is desirable to sample the grain and assess the conditions during the drying process. Sensors are used to monitor the grain sample so that the grain can be dried to a desired moisture level without overheating the grain, which could cause damage to the grain.BRIEF SUMMARY

[0005] In one aspect, the invention is directed to a grain sampling mechanism operatively connected to a wall of a heating column of a grain dryer. The grain sampling mechanism includes a sampler housing having an opening configured to receive grain as the grain drops down the heating column. The sampler housing is pivotally mounted about a pivot axis and a biasing mechanism is configured to provide a biasing force that positions the sampler housing in a first condition where the opening extends into the heating column such that the sampler housing receives a portion of the grain dropping down the heating column. When an amount of grain collected in the sampler housing reaches a sufficient quantity to overcome the biasing force of the biasing mechanism, the collected grain causes the sampler housing to pivot about the pivot axis to a second condition in which the opening is blocked from receiving any further grain from the heating column such that a fixed sample of grain is contained within the sampler housing. The grain sampling mechanism includes a sensor configured to sense a moisture parameter of the fixed sample of grain collected in the sampler housing.

[0006] In one aspect, the grain sampling mechanism further includes a locking mechanism that locks the sampler housings in the second condition and a return passage operatively connected to the sampler housing that is in communication with the wall. The return passage comprises a blocking member configured to keep the grain collected in the sampler housing from entering the return passage while the sensor is sensing the parameters of the fixed sample of grain.

[0007] This summary is provided to introduce concepts in simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features or essential features of the disclosed or claimed subject matter and is not intended to describe each disclosed embodiment or every implementation of the disclosed or claimed subject matter. Specifically, features disclosed herein with respect to one embodiment may be equally applicable to another. Further, this summary is not intended to be used as an aid in determining the scope of the claimed subject matter. Many other novel advantages, features, and relationships will become apparent as this description proceeds. The figures and the description that follow more particularly exemplify illustrative embodiments.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0008] To easily identify the discussion of any particular element or act, the most significant digit or digits in a reference number refer to the figure number in which that element is first introduced.

[0009] FIG. 1 is a perspective view of a grain dryer;

[0010] FIG. 2 illustrates a view of a grain sampling mechanisms in a first condition;

[0011] FIG. 3 illustrates a view of the grain sampling mechanisms in a second condition; and

[0012] FIG. 4 illustrates a view of the grain sampling mechanisms in a third condition.DETAILED DESCRIPTION

[0013] The invention will now be described in the following detailed description with reference to the drawings, wherein preferred embodiments are described in detail to enable practice of the invention. Although the invention is described with reference to these specific preferred embodiments, it will be understood that the invention is not limited to these preferred embodiments. But to the contrary, the invention includes numerous alternatives, modifications and equivalents as will become apparent from consideration of the following detailed description. Many of the fastening, connection, processes and other means and components utilized in this invention are widely known and used in the field of the invention described, and their exact nature or type is not necessary for an understanding and use of the invention by a person skilled in the art, and they will not therefore be discussed in significant detail. Also, any reference herein to the terms "left" or "right" are used as a matter of mere convenience and are determined by standing at the rear of the machine facing in its normal direction of travel. Furthermore, the various components shown or described herein for any specific application of this invention can be varied or altered as anticipated by this invention and the practice of a specific application of any element may already by widely known or used in the art by persons skilled in the art and each will likewise not therefore be discussed in significant detail.

[0014] As used herein, the singular forms following “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. As used herein, the term “may” with respect to a material, structure, feature, or method act indicates that such is contemplated for use in implementation of an embodiment of the disclosure, and such term is used in preference to the more restrictive term “is” so as to avoid any implication that other compatible materials, structures, features, and methods usable in combination therewith shouldor must be excluded. As used herein, the term “configured” refers to a size, shape, material composition, and arrangement of one or more of at least one structure and at least one apparatus facilitating operation of one or more of the structure and the apparatus in a predetermined way.

[0015] As used herein, any relational term, such as “first,” “second,” “top,” “bottom,” “upper,” “lower,” “above,” “beneath,” “side,” etc., is used for clarity and convenience in understanding the disclosure and accompanying drawings, and does not connote or depend on any specific preference or order, except where the context clearly indicates otherwise.

[0016] As used herein, the term “about” used in reference to a given parameter is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the given parameter, as well as variations resulting from manufacturing tolerances, etc.). As used herein, the term “substantially” in reference to a given parameter, property, or condition means and includes to a degree that one skilled in the art would understand that the given parameter, property, or condition is met with a small degree of variance, such as within acceptable manufacturing tolerances. By way of example, depending on the particular parameter, property, or condition that is substantially met, the parameter, property, or condition may be at least 90.0% met, at least 95.0% met, at least 99.0% met, or even at least 99.9% met.

[0017] Referring now to FIGS. 1 and 2, an example grain dryer 102 configured to dry grain has a wet hold section 104 that acts as a receiving area for grain entering the grain dryer 102 through an inlet port 106. The wet hold section 104 is in communication with and distributes grain to a heated drying section 108. Desirably, the heated drying section 108 is formed having a pair of separated heating columns 110. As is known in the art, each heating column 110 may comprise an outer wall 112 of perforate construction and an inner wall 114 also of perforate construction with the inner wall spaced from the outer wall a desired distance so as to form the column of grain to be dried. The illustrated example wet grain to be dried is delivered to the inlet port 106 at the top of the grain dryer 102 and is distributed lengthwise of the dryer and split into two heating columns 110. As is known in the art, one or more fan units either forces or draws heated air into an interior plenum chamber 116 which is then generally uniformly distributed through the perforate inner wall into the heating column 110 to dry the grain. The air with the moisture from the grain is discharged to the atmosphere as it passes through the perforate outer wall 112. After the grain has traveled downwardly through the heating column110, the dried grain is discharged from the bottom of the grain dryer 102. At the bottom of the grain column, a metering discharge mechanism 118 may be provided which is positively driven so as to control the rate at which dried grain is conveyed from the heating column 110. This, in turn, controls the speed and thus the time that the grain is exposed to the drying air within the heating column 110.

[0018] Turning to FIG. 2, the grain dryer 102 has a controller 202 used to direct operation of various components of the grain dryer 102. For example, the controller 202 must control operation of the inlet port 106 supplying wet grain to the grain dryer 102 and the discharge mechanism 118 carrying away dried grain, thus controlling the amount of time grain 204 spends in the heating column 110. The controller 202 must also control the operation of the fan / heater units that control the amount temperature of the air passing through the heating columns 110. The controller 202 desirably monitors at least one sensor 206 located within the grain dryer 102 so as to enable operation of the grain dryer 102 to dry the grain to a desired moisture level without overheating the grain (which could cause damage to the grain), and desirably shuts down operation of the grain dryer 102 in the event certain parameters being monitored by the controller 202 are outside limits established for these parameters corresponding to undesirable operating conditions for the grain dryer 102.

[0019] The grain dryer 102 has one or more grain sampling mechanisms 208 where parameters such as the moisture content of a representative sample or portion of the grain 204 is sensed so the parameter content can be used by the controller 202 for operation of the grain dryer 102. In the illustrated embodiment, the grain sampling mechanism 208 is operatively connected to the outer wall 112 of the heating column 110. The grain sampling mechanism 208 includes a sampler housing 210 having an opening 212 configured to receive grain 204 as the grain drops down the heating column 110. The sampler housing 210 is pivotally mounted about a pivot axis 214 such that in a first condition when the sampler housing 210 is empty of grain 204 as shown in FIG. 2, the sampler housing 210 is pivoted into a position such that the opening 212 extends into the heating column 110 such that the sampler housing 210 receives a portion of the grain 204 passing through the heated drying section 108.

[0020] The grain sampling mechanism 208 has a biasing mechanism 216 configured to position the sampler housing 210. The grain sampling mechanism 208 is biased such that when the sampler housing 210 is empty or substantially free of grain 204, the biasing mechanism 216 causes the sampler housing 210 to pivot about the pivot axis 214 into the first condition. In theillustrated embodiment, the biasing mechanism 216 comprises a biasing weight 218 positioned on or partially filling a portion of an interior volume of the sampler housing 210. The pivot axis 214 of the sampler housing 210 is positioned such that the biasing weight 218 causes the sampler housing 210 to tip into the first condition when the sampler housing 210 is free of grain 204. In the illustrated embodiment, the biasing weight 218 is position in a lower portion of the sampler housing 210 and with a majority of the biasing weight 218 on a side of the pivot axis 214 closest to the heating column 110. Desirably, the pivot axis 214 is offset from a geometric centered point of the sampler housing 210.

[0021] As the grain 204 enters the sampler housing 210 through the opening 212 and begins to fill a grain-collecting volume within the sampler housing 210, a majority of the grain 204 collects in the sampler housing 210 on a side of the pivot axis 214 opposite the heating column 110. When the amount of the grain 204 collecting in the sampler housing 210 reaches a sufficient quantity such that the weight of the grain 204 within the grain-collecting volume of the sampler housing 210 is sufficient to overcome the biasing force caused by the biasing weight 218, gravity causes the sampler housing 210 to pivot to a second condition as shown in FIG. 3. In the second condition, the sampler housing 210 moves to a position such that the opening 212 is no longer exposed to the flow of grain 204 in the heating column 110. Accordingly, in the second condition a fixed sample of grain 204 is contained within the sampler housing 210. Desirably, when the amount of the grain 204 collecting in the sampler housing 210 is sufficient for the intended sample, the sampler housing 210 quickly flips from the first condition to the second condition. In one embodiment, it takes less than a second for the sampler housing 210 to flip from the first condition to the second condition. The biasing weight 218 may include a fixed portion necessary to return the sampler housing 210 to the first condition when the sampler housing 210 is empty and may also include a selectable portion configured to be added or removed to allow calibration of the amount of grain that is necessary to tilt the sampler housing 210 to the second condition.

[0022] In the illustrated embodiment, when the sampler housing 210 moves to the second condition, the sampler housing 210 activates a limit switch 302. The limit switch 302 may activate a locking mechanism 304 that locks the sampler housings 210 in the second condition. In one example, the locking mechanism 304 may be an electromagnet configured to hold the sampler housing 210 in the desired position. Other locking mechanisms 304 configured to keep the sampler housing 210 from pivoting back to the first condition, such as a turn screw or thelike, may be used using sound engineering judgment. Additionally, when the limit switch 302 is activated, the controller 202 causes the sensor 206 to sense parameters, such as moisture content, of the sample of grain 204 and output a signal indicative of the sensed parameters. As is known, the signal produced by the sensor 206 is received by the controller 202 and may be converted to a percentage moisture content of the grain 204 to be used for operating the grain dryer 102.

[0023] Turning now to FIG. 4, a return passage 402 is operatively connected to the sampler housing 210 that is in communication with the outer wall 112 of the heating column 110. The return passage 402 comprises a blocking member 404 such as a rotatable or pivotable access member such as a ball or a door configured to keep the grain 204 that has collected in the sampler housing 210 from entering the return passage 402 while the sensor 206 is sensing the parameters of the sample. When sensor 206 completes its readings, the grain sampling mechanism 208 operates in a third condition in which the controller 202 may control the blocking member 404 with a release mechanism 406 that opens the return passage 402 to allow the grain 204 that has been collected in the sampler housing 210 to return back to the heating column 110. When the sampler housing 210 is empty, the blocking member 404 is reset so that the sampler housing 210 is ready to receive the next sample.

[0024] With the sampler housing 210 empty and when it is desired to collect another sample, the locking mechanism 304 is released. Without the locking mechanism 304 holding the empty sampler housing 210 in the second condition, the biasing mechanism 216 causes the sampler housing 210 flip about the pivot axis 214 back to the first position. Desirably it is only once the blocking member 404 is closed and the grain sampling mechanism 208 ready for a new sample does the locking mechanism 304 release the sampler housing 210 to return back to the first position. The grain sampling mechanism 208 may operate in loop as set forth above to repeatedly collect samples of grain 204 to ensure desired operation of the grain dryer 102.

[0025] The foregoing has broadly outlined some of the more pertinent aspects and features of the present invention. These should be construed to be merely illustrative of some of the more prominent features and applications of the invention. Other beneficial results can be obtained by applying the disclosed information in a different manner or by modifying the disclosed embodiments. Accordingly, other aspects and a more comprehensive understanding of the invention may be obtained by referring to the detailed description of the exemplary embodiments taken in conjunction with the accompanying drawings.

Claims

CLAIMSWhat is claimed is:

1. A grain sampling mechanism 208 operatively connected to a wall 112 of a heating column 110 of a grain dryer 102, the grain sampling mechanism comprising: a sampler housing 210 having an opening 212 configured to receive grain 204 as the grain drops down the heating column 110, wherein the sampler housing is pivotally mounted about a pivot axis 214; a biasing mechanism 216 configured to provide a biasing force that positions the sampler housing in a first condition where the opening extends into the heating column such that the sampler housing receives a portion of the grain dropping down the heating column, and wherein when an amount of grain collected in the sampler housing reaches a sufficient quantity to overcome the biasing force of the biasing mechanism, the collected grain causes the sampler housing to pivot about the pivot axis to a second condition in which the opening is blocked from receiving any further grain from the heating column such that a fixed sample of grain is contained within the sampler housing; and a sensor 206 configured to sense a moisture parameter of the fixed sample of grain collected in the sampler housing.

2. The grain sampling mechanism of claim 1 wherein the grain sampling mechanism is biased such that when the sampler housing is free of grain, the biasing mechanism causes the sampler housing to pivot about the pivot axis into the first condition.

3. The grain sampling mechanism of claim 2 wherein the biasing mechanism comprises a biasing weight positioned on the sampler housing.

4. The grain sampling mechanism of claim 3 wherein the pivot axis of the sampler housing is positioned such that the biasing weight causes the sampler housing to tip into the first condition when the sampler housing is free of grain.

5. The grain sampling mechanism of claim 4 wherein the biasing weight is position in a lower portion of the sampler housing and with a majority of the biasing weight on a side of the pivot axis closest to the heating column.

6. The grain sampling mechanism of claim 4 wherein as the grain enters the sampler housing through the opening, a majority of the grain collects in the sampler housing on a side of the pivot axis opposite the heating column.

7. The grain sampling mechanism of claim 4 wherein gravity causes the sampler housing to pivot to the second condition when a sufficient amount of grain has collected in the sampler housing.

8. The grain sampling mechanism of claim 4 wherein the pivot axis is offset from a geometric centered point of the sampler housing.

9. The grain sampling mechanism of claim 4 wherein the biasing weight includes a fixed portion necessary to return the sampler housing to the first condition when the sampler housing is empty, and includes a selectable portion configured to be added or removed to allow calibration of the amount of grain that is necessary to pivot the sampler housing to the second condition.

10. The grain sampling mechanism of claim 1 or 4 further comprising a controller 202, wherein one or more parameters of the grain is sensed by the sensor and used by the controller for operation of the grain dryer.

11. The grain sampling mechanism of claim 10 further comprising a limit switch, wherein when the sampler housing moves to the second condition, the sampler housing activates the limit switch, and when the limit switch is activated, the controller causes the sensor to sense parameters and output a signal indicative of the sensed parameters.

12. The grain sampling mechanism of any one of claims 1, 4 or 11 further comprising a locking mechanism 304, wherein the locking mechanism locks the sampler housings in the second condition.

13. The grain sampling mechanism of claim 12 wherein the locking mechanism is an electromagnet configured to hold the sampler housing in the second condition.

14. The grain sampling mechanism of claim 1 or 4 further comprising a return passage 402 operatively connected to the sampler housing that is in communication with the wall.

15. The grain sampling mechanism of claim 14 wherein the return passage comprises a blocking member 404 configured to keep the grain collected in the sampler housing from entering the return passage while the sensor is sensing the parameters of the fixed sample of grain.

16. The grain sampling mechanism of claim 15, wherein when the sensor completes its readings, a controller 202 operates a release mechanism 406 to open the blocking member 404 and allow the fixed sample of grain collected in the sampler housing to return back to the heating column through the return passage.

17. The grain sampling mechanism of claim 16, wherein when the sampler housing is empty the controller releases a locking mechanism, and the biasing mechanism causes the sampler housing to pivot about the pivot axis back to the first position.

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