A liquid mixing station

Abstract

There is provided a liquid mixing station, comprising a storage vessel for storing mixed liquid, two or more liquid sources, at least one pump for pumping liquid from the liquid sources to the storage vessel, a controller for controlling the at least one pump, and a transceiver connected to the controller, wherein the controller is configured to retrieve weather forecast data from a remote weather forecasting service via the transceiver, to calculate a mix ratio of the liquids from the liquid sources based on the weather forecast data, and to control the at least one pump to pump quantities of liquid from the liquid sources into the storage vessel, the quantities corresponding to the calculated mix ratio.

Description

[0001] A LIQUID MIXING STATION

[0002] FIELD OF THE INVENTION

[0003] The present invention relates to a liquid mixing station, for example for mixing a teat dip, which may be applied to a teat of an animal after milking.

[0004] BACKGROUND OF THE INVENTION

[0005] Milking an animal typically includes inserting a teat of the animal into a teat cup which applies a vacuum to assist in extraction of milk. After milking, a teat dip liquid is typically applied to the teat, and the teat dip typically comprises disinfectants and emollients to protect the teat from infection and to keep the skin of the teat in good condition. If teats fall into poor condition, then infections such as Mastitis can result, sometimes leading to the death of the animal. Keeping the teats in good condition is therefore of utmost importance.

[0006] Each animal only requires a small quantity of teat dip at each milking, however teat dip is typically mixed by a distributor or manufacturer in advance, and shipped to farms in bulk. It is possible to order teat dips with higher or lower concentrations or ratios of active ingredients to suit the farmer’s requirements, however since large quantities are typically delivered to farms in bulk, the mix cannot be changed on a day-to-day basis.

[0007] Since a large proportion of the teat dip is simply water, if the teat dip could be mixed on-site at the farm then only the other ingredients would need to be shipped and a large proportion of the delivery costs could be avoided. The mix can also be more easily altered since smaller quantities can be made up than those usually delivered to farms.

[0008] WO 2011 / 059477 A2 discloses a mixing manifold for mixing up teat dip at the farm, to reduce delivery costs. This means that teat dip can be made in smaller quantities at the desired concentration and mix ratio, however the problem still exists that teat dip has to be made in advance of its actual use. Therefore the mixstill may not match the ideal concentration and mix ratio, which continuously varies based on the current environmental conditions.

[0009] Mixing only upon demand rather than in advance is not practical, due to the time to mix the teat dip, the small quantity of teat dip that is required for each instance of teat dipping, and the large number of instances of teat dipping. A typical farm may have at least 200 dairy cows, each with four teats to be milked and teat dipped twice a day, which adds up to 1600 instances of teat dipping per day.

[0010] It is therefore an object of the invention to improve on the known art.

[0011] SUMMARY OF THE INVENTION

[0012] According to the invention, there is provided a liquid mixing station as defined in claim 1. The liquid mixing station comprises a storage vessel, two or more liquid sources, at least one pump for pumping liquid from the liquid sources to the storage vessel, a controller for controlling the at least one pump, and a transceiver connected to the controller, wherein the controller is configured to retrieve weather forecast data from a remote weather forecasting service via the transceiver, to calculate a mix ratio of the liquids from the liquid sources based on the weather forecast data, and to control the at least one pump to pump quantities of liquid from the liquid sources into the storage vessel, the quantities corresponding to the calculated mix ratio.

[0013] The invention therefore proposes gathering information on what the weather conditions will be in the future, so that when the liquids are mixed, typically 1 to 3 days before its use, the mix can be tailored to the predicted weather conditions at the time of use. Thus, even although the mix is made in advance and stored in the storage vessel, it corresponds well to the weather conditions when it is used, and the problems of mixing on demand are avoided.

[0014] The liquid mixing station may find application in various fields, however is particularly advantageous for mixing of teat dip. For example, the liquid sourcesmay comprise a source of disinfectant and a source of emollient, the disinfectant for protecting against bacterial infections and the emollient for conditioning the skin of the teat. The liquid sources may also comprise a source of solvent such as water, for diluting the disinfectant and emollient to a required ratio. Thus, there may be three or more liquid sources, and the liquid mixing station may be a teat dip station configured to mix teat dip. The mixing of the liquids may take place within one or more liquid manifolds delivering the liquids to the storage vessel, or may take place in the storage vessel itself.

[0015] If the weather forecast data shows that the humidity is expected to drop significantly in two days, then the proportion of emollient in the mix may be increased to provide additional protection against teat skin cracking. If the temperature is expected to drop below a certain level during the time that the teat dip is expected to be used, then the proportion of disinfectant in the mix may be increased since the teats may take longer to dry after milking and bacteria may have longer to grow on the skin.

[0016] The controller may be configured to select a period of the weather forecast data that is to be taken into account when calculating the mix ratio, and wherein the period is selected based on the time duration between successive mixing cycles. Thus, if newly mixed liquid in the storage vessel normally needs to be refilled with a new mixing cycle after 36 hours, then the controller may look at the next 36 hours of weather forecast data to calculate the mix ratio for the next mixing cycle.

[0017] The controller may average the retrieved weather forecast data over a window of time and use the averaged data to calculate the mix ratio. Alternatively, the controller may use the most extreme data point within the window of time as a basis for calculating the mix ratio. The window of time may correspond to the period of time over which the mixed liquid is expected to be delivered from the storage vessel to the teats of the animals, corresponding to the length of time between successive mixing cycles.The quantities of the liquids pumped by the at least one pump may be sufficient to fill the storage vessel to a fill level. For example, the storage vessel may comprise a fill level sensor for detecting when the storage vessel has been filled to the fill level, and a depletion level sensor for detecting when the storage vessel has been emptied down to a depletion level where it needs to be refilled again. The liquid sensors may be connected to the controller to signal to the controller when liquids need to be drawn from the liquid sources and pumped to the storage vessel.

[0018] Once the storage vessel has been emptied to the depletion level of the depletion level sensor, there may still be a significant quantity of liquid in the storage tank. Thus, if any problems occur with the liquid mixing station then there is sufficient mixed liquid in the storage tank to provide time to sort the problem out, before the mixed liquid runs out entirely. Since there is normally a significant quantity of mixed liquid in the storage vessel when a new mixing cycle begins, the controller may be configured to calculate the mix ratio based on the mix ratio that was used in the previous mixing cycle and the volume of mixed liquid that is currently in the storage vessel at that previous mix ratio. For example, if the previous mixed liquid included X% of disinfectant, and the next batch of mixed liquid is to include Y% of disinfectant where Y is greater than X, then the mix ratio of disinfectant to be pumped to the storage vessel may be set at Z%, where Z is greater than Y by an amount corresponding to the ratio of volumes between the mixed liquid before and after the new mixing cycle takes place. Then, once the new mixing cycle has taken place the mixed liquid will include Y% of disinfectant.

[0019] The calculation of the mix ratio may comprise the controller adjusting the mix ratio based on the mix ratios that have been applied during the preceding days. To cope with challenging weather conditions, the proportion of disinfectant may be increased and the proportion of emollient may also be increased by reducing the proportion of water, however the presence of more emollient results in a reduction in the effectiveness of the disinfectant. Therefore, if a high proportion of emollient has been applied for multiple days based on poor weather conditions, then a mix with a high proportion of disinfectant and a low proportion of emollient may be produced to significantly reduce bacterial activity on the teats,before returning to a high proportion of disinfectant and emollient for the next mix based on the poor weather conditions. Thus, the controller may be configured to record the mix ratio of each mixing cycle, and when the mix ratios for a number of preceding days all have a high proportion of emollient, the proportion of emollient may be greatly reduced for the next mixing cycle.

[0020] The controller may be programmable by a remote computer via the transceiver, to define the mix ratios that will be applied under a selection of respective forecasted weather conditions. For example, the remote computer may be a smartphone running an app, and the app may be used to define or adjust the mix ratios that are to be applied for a variety of different weather conditions. The transceiver may for example comprise a cellular telecommunications transceiver having a SIM, a transceiver for connecting to a local wireless network having an Internet connection, and / or a transceiver for communicating through direct wireless links such as Bluetooth®.

[0021] It is also possible that the weather forecasting data could be retrieved by the remote computing device and that a remote controller could be implemented on the remote computing device. The remote controller may calculate the mix ratio based on the forecasted weather data at the geographic location of the mixing station, and send the calculated mix ratio to the controller of the mixing station.

[0022] The geographic location of the mixing station may be programmed into the controller during installation of the mixing station, however the mixing station may comprise a position determination system for receiving satellite or cellular base station signals to determine the geographical location of the mixing station automatically. For example, the position determination system may receive global navigation satellite signals from systems such as GPS or Galileo, or may receive cellular system signals from a cellular network that a SIM of the transceiver is registered with.

[0023] The controller may be configured to only retrieve weather forecast data that is relevant to the geographic location of the mixing station, to reduce the volume of data transferred, or may filter the retrieved weather forecast data toselect only the weather forecast data that is relevant to the geographic location of the mixing station. Then the controller may calculate the mix ratio based on the weather forecast data for the geographical location of the mixing station.

[0024] The liquid mixing station may comprise a housing supporting the liquid sources, the pump, and the storage vessel. All of the components of the mixing station may be present together with one another on or within the housing, allowing easy installation of the mixing station by mounting the housing to a wall of a building.

[0025] The first and second ones of the liquid sources may comprise respective source containers in which the corresponding liquids are held. For example, the first source container may comprise disinfectant and the second source container may comprise emollient. The source containers may be enclosed inside of the housing.

[0026] Further liquid sources may also be present, and may also be implemented as further source containers enclosed within the housing. For example, further liquid sources could hold teat dip ingredients such as pH buffers, surfactants, wetting agents, colorants and / or thickeners.

[0027] The storage vessel may be mounted to a side of the housing, and may be transparent and visible from outside of the housing, so that a farmer can visually monitor the level of mixed liquid inside the housing. A third one of the liquid sources may comprise a source vessel that mounted to an opposite side of the housing from the side of the housing where the storage vessel is mounted.

[0028] The third liquid source may be a source of water, and the third liquid source may be in the form of the source vessel, but could simply be an inlet to a water supply in alternate embodiments.

[0029] DETAILED DESCRIPTION

[0030] Embodiments of the invention will now be described by way of non-limitingexample only and with reference to the accompanying drawings, in which:

[0031] Fig. 1 shows a schematic perspective diagram of a liquid mixing station according to an embodiment of the invention, including a housing with source and storage vessels mounted on opposing sides of the housing to one another;

[0032] Fig. 2 shows a schematic perspective diagram of the liquid mixing station of Fig. 1 with a front door opened to show various internal components;

[0033] Fig. 3 shows a schematic side elevational diagram of the liquid mixing station of Fig. 1, with the front door removed and the source and storage vessels shown as transparent;

[0034] Fig. 4 shows a schematic diagram of various liquid connections to and within the liquid mixing station of Fig. 1 ;

[0035] Fig. 5 shows a flow diagram of a method implemented by the liquid mixing station of Fig. 1 ;

[0036] Fig. 6 shows a schematic diagram of an apparatus comprising the liquid mixing station of Fig. 1 and bulk containers for liquids connected to the liquid mixing station; and

[0037] Fig. 7 shows a schematic diagram of a pump forming part of the liquid mixing station of Fig. 1.

[0038] The figures are not to scale, and same or similar reference signs denote same or similar features.

[0039] Fig. 1 shows a liquid mixing station 100 in accordance with an embodiment of the invention. The liquid mixing station may comprise a housing 50 having a top panel 51, a left side panel 52, right side panel 53, and front door 55. The housing 50 may also have a rear panel 50a opposite from the front door 55, and a bottom panel 54 (see Fig. 2) opposite from the top panel 51. In this embodiment the housing 50 is generally rectangular, although other shapes of housing could alternatively be implemented.

[0040] The front door 55 may be connected to the left side 52 with hinges, and may comprise a locking mechanism 55a to hold the front door 55 closed. A source vessel 1 may be mounted to the left side 52 of the housing, and a storage vessel 4may be mounted to the right side 53 of the housing. In use, the liquid mixing station is typically wall-mounted, for example by fixing the rear panel 50a to a wall at a convenient height.

[0041] Fig. 2 shows a perspective view of the liquid mixing station 100 with the front door 55 hinged open, allowing various components inside of the housing 50 to be seen. The liquid mixing station may have a transceiver 57 mounted on the rear side of the front panel 55, and the transceiver may have one or more antenna 57a for wireless communicating with external networks. For example, the transceiver 57 may include a SIM card for connecting to a cellular telecommunications network, or may connect to local wireless network having an Internet connection, and / or through direct wireless links such as Bluetooth®, or any other known wireless communication methods.

[0042] The transceiver 57 may connect to a cloud-based server computer 120 via the Internet, and access a weather forecasting service provided by the server computer 120, for retrieval of weather forecast data. The transceiver 57 may also connect to a remote computer 122, which may for example be a smartphone device. In some embodiments, the transceiver 57 may retrieve the weather forecast data from the server computer 120 via the remote computer 122.

[0043] The liquid mixing station may also have a controller 56 mounted on the rear side of the front panel 55 and connected to the transceiver 57. The controller 56 may monitor and / or control various functions of the liquid mixing station 100, typically via electrical wires (not shown for clarity) that cross from the front door 55 to the left side panel 52 at a front edge of the left side panel 52. The controller 56 may record the geographic location of the liquid mixing station, for example in a memory of the controller. The geographic location may be programmed into the memory of the liquid mixing station, or the liquid mixing station may utilise satellite or cellular base station signals from the transceiver to determine the geographical location of the mixing station.

[0044] The housing 50 may enclose a pump 5 and two liquid sources in the form of first and second source containers 2 and 3. The source containers 2 and 3 may beused to store two different types of liquid to be mixed with one another, for example disinfectant and emollient. The source containers 2 and 3 may be held within the housing 50 at a same height as one another, as shown.

[0045] The pump 5 may be used to pump the liquids from the source vessel 1 and from the source containers 2 and 3 into the storage vessel 4, to mix the liquids together. Typically the source vessel 1 is used to store water, which dilutes the disinfectant and emollient liquids so they can be held in the source containers 2 and 3 in a more concentrated form. The storage vessel 4 comprises a overflow 47 in case of a malfunction that pumps excessive liquids into the storage vessel. The overflow 47 may be on the right side of the storage vessel 4, so that any liquid exiting through it is clearly visible and will alert the farmer to the malfunction.

[0046] The source containers 2 and 3 may be the same as one another, and may each include a sensing arrangement of one or more sensors to detect the level of the liquid stored inside of them. Each source container may include a depletion level sensor 39, a fill level sensor 40 and an emergency level sensor 41. The depletion level sensor 39, fill level sensor 40 and emergency level sensor 41 may be float sensors that sense when the liquid level in the source container is above or below the sensor. Accordingly, the depletion level sensor 39 may be at a depletion level within the source container, the fill level sensor 41 may be at a fill level within the source container, above the depletion level sensor 39, and the emergency level sensor 41 may be at an emergency level within the source container, above both the depletion and fill level sensors 39 and 40.

[0047] The depletion level sensor 39, fill level sensor 40 and emergency level sensor 41 may all be connected to a header connector 46, and the header connector 46 may be connected to the controller 56 via a cable (not shown in Figs). Thus, the controller 56 may monitor the level of the liquid in each source container using the depletion level sensor 39, fill level sensor 40 and emergency level sensor 41.

[0048] The source containers 2 and 3 may also each include a vacuum sensor 45 for detecting a level of vacuum inside the source container. The vacuum sensor 45may be connected to the header connecter 46, and so the header connector 46 may also provide information on any vacuum inside the source containers to the controller 56.

[0049] The source containers 2 and 3 may each include an outlet port 42, an inlet port 43, and a vacuum port 44. The outlet port 42 may be at the top of the source container and include a straw inside the source container that reaches down to near the base of the source container, allowing liquid to be drawn from the source container via the outlet port. The inlet port 43 may also be at the top of the source container and allows liquid to be added to the source container. The vacuum port 44 is may be at the top of the source container, so that no liquid will flow out of the source container through the port 44 when a vacuum is applied. The liquid may be drawn into the source container via the inlet port 43, by applying a vacuum inside the source container using the vacuum port 44.

[0050] Fig. 3 shows a more comprehensive view of the components inside the housing 50 of the liquid mixing station 100, with the front door 55 removed and the source and storage vessels 1 and 4 made transparent so their internals are visible. The components are connected by various liquid pipes, as shown schematically in Fig. 4.

[0051] Referring to Fig. 3, the source vessel 1 may comprise a float valve 26 for inletting liquid into the source vessel. The float valve 26 may be connected to a pipe leading to one of several connections 37 at the bottom panel 54 of the housing. That connection 37 may for example be connected to a mains water supply pipe, and so water from the mains water supply 111 (see Fig. 4) may be delivered into the source vessel 1 under control of the float valve 26. The float valve 26 may comprise a float 27 which falls and rises with the liquid level in the source vessel 1 , respectively opening and closing the float valve to maintain the level of the liquid in the source vessel 1.

[0052] The source vessel 1 may also comprise an emergency level sensor 32 beneath the float valve 26. The emergency level sensor may comprise a small float that is pivotally connected to a base, as shown, and the float will pivot up ordown depending on the liquid level. The level sensors 39, 40 and 41 of the source containers 2 and 3 may be the same type of sensor as the emergency level sensor 32. The emergency level sensor 32 may detect when the level of liquid inside the source vessel falls below the emergency level sensor, corresponding to an emergency level. The emergency level sensor 32 may be connected to the controller 56 and the controller 56 may sound an alarm and / or issue a notification to the remote computer 122 if the liquid falls below the emergency level, signifying that a malfunction has occurred.

[0053] The source vessel 1 may comprise an outlet 33 for outletting liquid from the source vessel 1 , and the outlet 33 may be beneath the emergency level sensor 32 so the emergency is signalled before the liquid has fallen so far as to interrupt supply to liquid to the outlet 33. The outlet 33 is connected to a valve arrangement 6 via a pipe 11 , also as seen in Fig. 4.

[0054] The valve arrangement 6 comprises multiple valves which are controlled by the controller 56 and which direct the flow of liquids through the liquid mixing station 100. Referring to Fig. 4, the liquids to be mixed are first drawn into the source containers (header tanks) 2 and 3, from bulk containers in bulk storage 112 and 113. The bulk containers are separate from the liquid mixing station, and are typically positioned beneath the liquid mixing station, and connected to the liquid mixing station at connections 37.

[0055] Two bulk containers at bulk storage 112 may be connected to two connections 37, and the liquid mixing station may comprise two pipes 16 and 17 that lead from those connections 37 to a valve block 6a of the valve arrangement 6. The valve block 6a may also be connected to the inlet port 43 of the source container 2 via a pipe 18, and the valve block 6a may open and close passageways from the pipes 16 and 17 to the pipe 18 under control of the controller 56, to allow delivery of liquid from the bulk storage 112 to the source container 2.

[0056] Similarly, two bulk containers at bulk storage 113 may be connected to two connections 37, and the liquid mixing station may comprise two pipes 21 and 22that lead from those connections 37 to a valve block 6b of the valve arrangement 6. The valve block 6b may also be connected to the inlet port 43 of the source container 3 via a pipe 23, and the valve block 6b may open and close passageways from the pipes 21 and 22 to the pipe 23 under control of the controller 56, to allow delivery of liquid from the bulk storage 113 to the source container 2.

[0057] The liquids may be drawn along the pipes 16, 17, 18 and 12, 22, 23 by vacuums inside of the source containers 2 and 3, the vacuums being applied via the vacuum ports 44 of the source containers. The vacuums are generated by vacuum generators 7 and 8, and the vacuum generators are driven by compressed air, as will now be explained in more detail.

[0058] The liquid mixing station may comprise an air valve block 29, which may be connected to an air supply 110 of compressed air via the connections 37. The air valve block 29 may comprise a first air filter 28, and second air filter 30, and a silencer 31. The first air filter may be a relatively coarse air filter, for example a 5 micron filter, and the second air filter may be a relatively fine air filter connected to the output of the coarse air filter, for example a 0.1 micron filter. The silencer serves to reduce any noise generated by the flow of the compressed air.

[0059] The air valve block 29 may also comprise an air valve for opening and closing a passageway for compressed air, the passageway leading to the valve arrangement 6 via a pipe, more specifically leading to a valve block 6c of the valve arrangement 6 via the pipe. The air valve may be connected to the controller 56, and the controller 56 may control the air valve to open and close as required. The air valve block 29 and the valve block 6c may together constitute an air valve arrangement.

[0060] The valve block 6c may be connected to the vacuum generator 7 by a pipe 19, and also connected to the vacuum generator 8 via a pipe 24. The valve block 6c may open and close passageways from the air valve block 29 to pipes 19 and 24 under control of the controller 56, to allow delivery of compressed air from the compressed air supply 110 to the vacuum generators 7 and 8. Each vacuumgenerator may comprise a passageway for compressed air and a venturi hole which opens into that passageway to generate a vacuum. The vacuum generated by vacuum generator 7 may be supplied to the vacuum port 44 of the source container 2 by a pipe 20, and the vacuum generated by vacuum generator 6 may be supplied to the vacuum port 44 of the source container 3 by a pipe 25.

[0061] When the source container 2 becomes depleted of liquid to the depletion level, the depletion level sensor 39 of the source container 2 may indicate to the controller 56 that the liquid has fallen to the depletion level. In response to that indication, the controller 56 may open a valve in valve block 6a to open a passageway either along pipes 16 and 18 or 17 and 18, and open a valve in valve block 6c to open a passageway from the air valve block 29 to the vacuum generator 7. Compressed air may enter the vacuum generator 7 and a vacuum may be applied along the pipe 20 and into the source container 2 via the vacuum port 44 of the source container 2. The vacuum may suck liquid from the bulk storage 112 along the pipes 16 or 17, into pipe 18, and into the source container 2. The level of liquid in the source container 2 may rise, until the fill level sensor 40 of the source container 2 indicates to the controller 56 that the liquid has reached the fill level. In response to that indication, the controller may close the valve in the valve block 6c to shut off the compressed air to the vacuum generator 7 so that vacuum is no longer supplied to the source container 2 and no further liquid is drawn from the bulk storage 112, and the controller may also close the valve in valve block 6a to close the passageway either along pipes 16 and 18 or 17 and 18.

[0062] If the level of the liquid in the source container 2 continues to rise further for any reason, for example due to a malfunction of the fill lever sensor 40, then when the liquid level reaches the emergency level the emergency level sensor 41 of the source container 2 may indicate this to the controller 56 and the controller 56 may sound an alarm and / or issue a notification to the remote computer 122, signifying that a malfunction has occurred. The controller 56 may also close the valve in the valve block 6c to shut off the compressed air to the vacuum generator 7, and close the valve in valve block 6a to close the passageway either along pipes 16 and 18 or 17 and 18.Similarly, when the source container 3 becomes depleted of liquid to the depletion level, the depletion level sensor 39 of the source container 3 may indicate to the controller 56 that the liquid has fallen to the depletion level. In response to that indication, the controller 56 may open a valve in valve block 6b to open a passageway either along pipes 21 and 23 or 22 and 23, and open a valve in valve block 6c to open a passageway from the air valve block 29 to the vacuum generator 8. Compressed air may enter the vacuum generator 8 and a vacuum may be applied along the pipe 25 and into the source container 3 via the vacuum port 44 of the source container 3. The vacuum may suck liquid from the bulk storage 113 along the pipes 21 or 22, into pipe 23, and into the source container 3. The level of liquid in the source container 3 may rise, until the fill level sensor 40 of the source container 3 indicates to the controller 56 that the liquid has reached the fill level. In response to that indication, the controller may close the valve in the valve block 6c to shut off the compressed air to the vacuum generator 8 so that vacuum is no longer supplied to the source container 3 and no further liquid is drawn from the bulk storage 113, and the controller may also close the valve in valve block 6a to close the passageway either along pipes 16 and 18 or 17 and 18.

[0063] If the level of the liquid in the source container 2 continues to rise further for any reason, for example due to a malfunction of the fill lever sensor 40, then when the liquid level reaches the emergency level the emergency level sensor 41 of the source container 3 may indicate this to the controller 56 and the controller 56 may sound an alarm and / or issue a notification to the remote computer 122, signifying that a malfunction has occurred. The controller 56 may also close the valve in the valve block 6c to shut off the compressed air to the vacuum generator 7, and close the valve in valve block 6a to close the passageway either along pipes 16 and 18 or 17 and 18.

[0064] The controller 56 may control the valve block 6c to only send the compressed air to one of the vacuum generators 7 and 8 at a time, so that each vacuum generator will always receive the same pressure of compressed air as the other vacuum generator(s), and the vacuum generators will all be consistent withone another in their operation. The pressure level of the compressed air may for example be about 3 bar (300 kPa), and the level of vacuum generated by each vacuum generator may for example be around 60 kPa below atmospheric pressure.

[0065] The schematic diagram of Fig. 6 shows an apparatus 200 comprising the liquid mixing station 100 and four bulk containers 140, 141, 145 and 146 that are connected to the liquid mixing station 100 by respective pipes 16a, 17a, 21a and 22a. The liquid mixing station 100 may be mounted on a wall of a building, and the bulk containers may be standing on the floor beneath the liquid mixing station, to provide the bulk storage 112 and 113.

[0066] Specifically, the bulk storage 112 may comprise a bulk container 140 and a further bulk container 141. A pipe 16a may be connected from the bulk container 140 to the connection 37 of the pipe 16. A pipe 17a may be connected from the bulk container 140 to the connection 37 of the pipe 17. The bulk storage 113 may comprise a first additional bulk container 145 and a second additional bulk container 146. A pipe 21a may be connected from the bulk first additional container 145 to the connection 37 of the pipe 21. A pipe 22a may be connected from the second additional bulk container 146 to the connection 37 of the pipe 22. Each of the pipes 16a, 17a, 21a and 22a may comprise an opening at the bottom of the corresponding bulk container.

[0067] Initially the bulk containers 140 and 141 may be both filled with a first liquid, for example concentrated disinfectant, and the bulk containers 145 and 146 may be both filled with a second liquid, for example concentrated emollient. The liquid mixing station may draw liquid from only one of the bulk containers in each bulk storage at a time, and when the liquid in that bulk container is exhausted, liquid can be drawn from the other bulk container instead whilst the exhausted bulk container is being replaced.

[0068] The following discussion considers the source container 2 and the bulk storage 112, but is equally applicable to the source container 3 and the bulk storage 113. The controller 56 may be configured to draw the liquid from the bulkcontainer 140 into the source container 2, by controlling the valves in the valve blocks 6b and 6c as described further above to supply a vacuum into the source container 2 via the vacuum ports 44. Once the vacuum generator 7 is activated, the level of vacuum inside the source container 2 begins to rise, and liquid from the bulk container 140 will be sucked up through the pipe 16a, through the valve block 6a and into the inlet port 43 of the source container 2.

[0069] The lower the level of the liquid inside the bulk container 140, the higher the level of the vacuum inside the source container 2 may rise before the liquid will enter the source container 2 and begin to arrest the rise in vacuum. The level of vacuum inside the source container 2 is sensed by the vacuum sensor 45, and indicated to the controller 56 via the header connector 46. The controller 56 may therefore determine the level of the liquid inside the bulk container 140 based on the vacuum sensor 45.

[0070] The controller may be configured to measure the level of vacuum after a delay period of time from activating the vacuum generator so the measurement is taken whilst the liquid is flowing into the source container and the vacuum is at a stable level.

[0071] The controller 56 may monitor the rate of consumption of the liquid from the bulk container 140 based on the measurements taken by the vacuum sensor 45, or based on how frequently the liquid in the source container 2 is replenished, and use this to estimate how much longer the bulk container will last for before it is exhausted of liquid. The estimated time until exhaustion may be compared to a threshold period of time set by the famer via the computing device 122, and a notification of imminent exhaustion may be issued once the estimated time until exhaustion falls beneath the threshold period of time.

[0072] Once the liquid in the bulk container 140 becomes exhausted, if the bulk container 140 is open to the atmosphere then air will rush into the pipe 16a instead of liquid and the vacuum inside the source container 2 will drop dramatically, to beneath an empty threshold level. The vacuum sensor 45 indicates this drop to the controller 56, and in response to this indication the controller determines the bulkcontainer 140 is exhausted. The empty threshold level may for example be 15 kPa below atmospheric pressure, and so if the vacuum drops to only 10 kPa below atmospheric pressure for example, then the controller determines the bulk container 140 is exhausted. Alternatively, if the bulk container 140 is not open to the atmosphere, for example if the bulk container is sealed around the pipe 16a and is made of a flexible material that collapses as the liquid is withdrawn from it, then when all the liquid has been sucked out of the bulk container 140 and no further liquid / gas can be drawn, the vacuum inside the source container 2 will rise dramatically. The vacuum sensor 45 indicates this rise to the controller 56, and in response to this indication the controller determines the bulk container 140 is exhausted.

[0073] Once the controller 56 determines that the bulk container 140 is exhausted, the controller 56 controls the valve block 6b to close the passageway from the pipe 16 to the pipe 18, and instead open the passageway from the pipe 17 to the pipe 18, so that liquid can be drawn from the further bulk container 141 via the pipe 17a instead of the bulk container 140, and the bulk container 140 can be replaced or replenished. The controller may issue a notification to inform the farmer that the bulk container 140 is ready to be replaced or replenished. The liquid may be drawn from the further bulk container 141 until the controller 56 determines the further bulk container 141 has been exhausted, whereupon the controller 56 may switch back to drawing the liquid from the replaced / replenished bulk container 140.

[0074] The controller 56 may be configured to draw the liquid for the source container 3 via the pipes 21a and 22a, by switching between the first additional bulk container 145 and the second additional bulk container 146 as they become exhausted, in the same manner as it switches between the bulk container 140 and further bulk container 141. The volume of each bulk container may be at least five times greater than the volume of each source container, so that each source container can be refilled multiple times from the bulk container before the bulk container requires replacement or replenishment.

[0075] The arrangement shown in Fig. 6 may be expanded to add further pipes running parallel to the pipes 16a, 17a, 21a and 22a, and that each have a furtheropening part-way down each bulk container, at a depletion level of the liquid inside the bulk container. For example, a further pipe may run parallel to the pipe 16a and be slightly shorter than the pipe 16a so that it has an opening in the bulk container 140 intermediate of the top and bottom of the bulk container, corresponding to a depletion level. The valve block 6a may be configured to open a further passageway from the further pipe to the inlet port 43 under control of the controller. The controller may determine the liquid has dropped to the depletion level once air rushes into the opening of the further pipe and causes the sensed vacuum to drop below a depletion level threshold. The depletion level threshold may for example be 15 kPa below atmospheric pressure. A notification that the bulk container 140 is at the depletion level, for example half empty, may then be issued to the farmer, for example by sending the notification to the remote computer 122 via the transceiver 57. The controller may then switch the valve block 6a to close the further passageway from the further pipe and to open the passageway from the pipe 16a, to allow the remaining liquid to be drawn from the bulk container 140.

[0076] The storage vessel 4 may store liquids that have been pumped from the source vessel 1 , source container 2 and source container 3 into the storage vessel 4 by the pump 5. As shown in Fig. 3, the storage vessel 4 may comprise an emergency level sensor 35, a depletion level sensor 34 and a fill level sensor 34a. The depletion level sensor 34, fill level sensor 34a and emergency level sensor 35 may be float sensors that sense when the liquid level in the storage container is above or below the sensor. Accordingly, the depletion level sensor 34 may be at a depletion level within the storage vessel 44, the fill level sensor 34a may be at a fill level within the storage vessel 44, above the depletion level sensor 34, and the emergency level sensor 35 may be at an emergency level within the storage vessel 44, beneath both the depletion and fill level sensors 34 and 34a.

[0077] The depletion level sensor 34, fill level sensor 34a and emergency level sensor 35 may all be connected to the controller 56 via a cable(s) (not shown in Figs). Thus, the controller 56 may monitor the level of the liquid in the storage vessel 4 using the depletion level sensor 39, fill level sensor 40 and emergency level sensor 41.The storage vessel 4 may comprise an inlet 38 for liquids pumped from the source vessel 1 , source container 2 and / or source container 3. The inlet 38 may be positioned to eject the liquids into the storage vessel 4 near the bottom of the storage vessel 1 , for example beneath the depletion sensor 34 or the emergency level sensor 35, so the liquids will be ejected into the existing liquid already in the storage vessel and create turbulence within the existing liquid.

[0078] The storage vessel 4 may comprise an outlet 36 for the liquid stored in the storage vessel. The outlet 36 may be at the bottom of the storage vessel, and may for example be connected to onward piping and control systems to control when the liquids are delivered for the end purpose, such as teat dipping. Once enough liquid has been outlet from the storage vessel for the level of liquid inside the storage vessel to fall to the depletion level, the depletion level sensor 34 indicates this to the controller 56. In response to that indication, the controller 56 may begin a mixing cycle to replenish the liquid stored in the storage vessel back up to the fill level, using liquid from the source vessel 1, the source container 2 and / or the source container 3.

[0079] The liquid mixing station may comprise a pipe 11 that is connected from the outlet 33 of the source vessel 1 to a valve block 6d of the valve arrangement 6, a pipe 9 that is connected from the outlet port 42 of the source container 2 to the valve block 6d, and a pipe 10 that is connected from the outlet port 42 of the source container 3 to the valve block 6d. The valve block 6d may also be connected to the pump 5 via a pipe 12, and the valve block 6d may be configured to open and close a first passageway leading from the pipe 9 to the pipe 12, a second passageway leading from the pipe 10 to the pipe 12, and a third passageway leading from the pipe 11 to the pipe 12. The valve block 6d may be connected to the controller 56, and the controller 56 may select which one of those passageways the valve block 6d opens at any given time. The controller 56 and / or valve block 6d may be configured to only allow one of those passageways to be open at a time.The pipe 12 may be connected from the valve block 6d to an inlet of the pump 5. The pump 5 may have an outlet connected to a pipe 13, and the pipe 13 may lead from the outlet of the pump 5 to the inlet 38 of the storage vessel 4. The pump 5 may be controlled by the controller 56 to pump liquid from the valve block 6d into the storage vessel 4, when the controller 56 receives the indication from the depletion level sensor 34 that the level of liquid in the storage vessel 4 has fallen to or below the depletion level, or receives the indication from the emergency level sensor 35 that the level of liquid in the storage vessel 4 has fallen to or below the emergency level.

[0080] For example, the pump 5 may be a diaphragm pump as shown in Fig. 7. The diaphragm pump may comprise a diaphragm 134 that moves within a pump chamber 130, and a piston 132 that moves within an air chamber 131. The diaphragm 134 may be connected to the piston by a pump shaft 133, so that the diaphragm and piston move in unison within the pump and air chambers, respectively.

[0081] The pump 5 may comprise a first air inlet 14a for connecting to the pipe 14, and a second air inlet 15a for connecting to the pipe 15. The first and second air inlets 14a and 15a may receive compressed air from the valve block 6c via the pipes 14 and 15, respectively. The pump 5 may also comprise a liquid inlet 12a for connecting to the pipe 12 and receiving liquid from one of the liquid sources via the valve block 6d, and may also comprise a liquid outlet 13a for connecting to the pipe 13 and sending liquid from the pump 5 to the storge vessel 4.

[0082] The liquid inlet 12a may comprise a check valve V12 that only allows flow of liquid into the pump 5, and the liquid outlet 13a may comprise a check valve V13 that only allows flow of liquid out of the pump 5. Fig. 7 shows the pump in a state where the diaphragm 134 is moving upwardly in the pump chamber 130 to pump liquid out of the liquid outlet 13a, and so the check valve V13 is open and the check valve V12 is closed. When the diaphragm 134 moves downwardly, the check valve V12 opens to suck liquid from the pipe 12 into the pump chamber 130, and the check valve V13 closes.The diaphragm 134 may be driven to move by the piston that is connected to the diaphragm by the pump shaft 133. When compressed air is inlet into the air chamber 131 via only the first air inlet 14a, the piston and diaphragm and driven downwardly as viewed in Fig. 7, and when compressed air is inlet into the air chamber 131 via only the second air inlet 15a, the piston and diaphragm are driven upwardly as viewed in Fig. 7.

[0083] The controller 56 may be configured to control the valve block 6c to open and close passageways from the air valve 29 to the pipes 14 and 15, to drive the piston 132 and therefore the diaphragm 134, to pump liquid from the liquid inlet 12a to the liquid outlet 13a. For example the controller may repeatedly switch the valve block 6c between applying compressed air to pipe 14 and applying compressed air to pipe 15, to move the diaphragm back and forth at a desired frequency, corresponding to the speed of the pump. Various other constructions of diaphragm pumps are known in the art and could alternatively be used.

[0084] Since the diaphragm of the pump 5 is driven by compressed air, the amount of time required for the diaphragm to move to its full extent under the pressure exerted by the compressed air will depend on the viscosity of the liquid being pump. The diaphragm must be moved to its full extent to accurately judge the amount of liquid that is pumped by each stroke of the diaphragm. Therefore, the liquid mixing station may comprise one or more temperature sensors connected to the controller 56, to make allowance for higher liquid viscosities when the temperature is low. Specifically, the lower the measured temperature, the lower the frequency that the controller 56 will switch the valve block 6c at, so that more time is provided for the diaphragm to reach its full extent under the pressure of the compressed air and the pump runs more slowly. Thus, the diaphragm pump may be a variable speed diaphragm pump. The temperature sensors may for example comprise a temperature sensor 135 (see Fig. 2) that measures the temperature of the liquid inside the source container 2, and reports the temperature to the controller 56 via the header connector 46.The controller 56 may be configured to pump liquid into the storage vessel 4 using the pump 5, and may be configured to draw that liquid from the source vessel 1 , the source container 2 and the source container 3 in sequence.

[0085] For example, the controller 56 may control the valve block 6d to open the passageway from the source vessel 1 to the pump 5, thereby closing the passageways from the source containers 2 and 3 to the pump 5, and to control the valve block 6c to move the diaphragm of the pump 5 a first number of times, to pump a first quantity of liquid from the source vessel 1 into the storage vessel 1.

[0086] The controller 56 may then control the valve block 6d to open the passageway from the source container 2 to the pump 5, thereby closing the passageways from the source vessel 1 and the source container 3 to the pump 5, and to control the valve block 6c to move the diaphragm of the pump a second number of times, to pump a second quantity of liquid from the source container 2 into the storage vessel 1.

[0087] The controller 56 may then control the valve block 6d to open the passageway from the source container 3 to the pump 5, thereby closing the passageways from the source vessel 1 and the source container 2 to the pump 5, and to control the valve block 6c to move the diaphragm of the pump a third number of times, to pump a third quantity of liquid from the source container 2 into the storage vessel 1 , completing the sequence.

[0088] The sequence may be repeated multiple times, such that each of the first, second and third quantities are relatively small compared to the size of the storage vessel. Repeating the sequence multiple times helps provide a well-mixed liquid in the source container. Once the level of the liquid in the source container reaches the fill level, the fill lever sensor 34a indicates this to the controller 56, and the controller 56 ceases to drive the pump diaphragm anymore using the valve block 6c, to cease pumping of liquid.

[0089] The ratio between the first, second and third quantities of liquid may be referred to as a mix ratio, and differing mix ratios provide the liquid in the storagevessel with differing characteristics. For example, to provide a weaker solution with good teat-conditioning properties the first quantity (corresponding to water from the source vessel 1) may be 20 units in volume, the second quantity (corresponding to disinfectant from the source container 2) may be 1 unit in volume, and the third quantity (corresponding to emollient from the source container 3) may be 2 units in volume, or to summarise, a mix ratio of 20:1:2. To provide a stronger solution with high disinfecting properties, the first quantity may be 15 units in volume, the second quantity may be 2 units in volume and the third quantity may be 1 unit in volume, or to summarise a mix ratio of 15:2:1.

[0090] In use, as shown in Fig. 5 the controller 56 may be configured to retrieve the weather forecast data from the cloud-based server computer 120 using the transceiver 57, in a first step 125. The weather forecast data may be retrieved for the geographic location of the liquid mixing station, based on a geographic location stored in a memory of the controller or based on satellite / cellular signals received via the transceiver. Then, in a second step 126 the controller 56 may determine the mix ratio of the liquids based on the weather forecast, and in a third step 127 the controller may drive the pump 5 to pump quantities of liquids corresponding to the mix ratio into the storage vessel.

[0091] The controller typically comprises at least one memory and at least one processor. The memory may store a mapping scheme between the forecasted weather and the mix ratio, for example if the weather forecast data shows that the humidity is expected to fall beneath a certain level then the mapping scheme may dictate a certain increase in the proportion of emollient to be included in the mix, to provide additional protection against teat skin cracking. If the temperature is expected to drop below a certain level, then the mapping scheme may dictate a certain increase in the proportion of disinfectant in the mix since the teats may take longer to dry after milking and bacteria may have longer to grow on the skin. . If the windspeed is expected to increase above a certain level, then the mapping scheme may dictate a certain increase in the proportion of emollient in the mix to counteract the increased drying of the teats due to the wind.A mapping scheme may be defined or adjusted by a farmer using the remote computer 122, and the remote computer 122 may send the mapping scheme to the controller 56 via a network and the transceiver 57, to provide the system with flexibility and allow some user customisation. Optionally, the remove computer 122 may be a smartphone running an app associated with the liquid mixing station, and which may allow the farmer to program how the liquid mixing station is to operate. The controller 56 may also send statistics on the usage and mix radios of the liquids to the server computer and / or the remote computer 122 via the transceiver 57, for monitoring purposes.

[0092] The controller 56 may log the amount of time that passes between each mixing cycle, for example based on the average amount of time that it takes for the storage vessel to be depleted from the fill level down to the depletion level. Since the amount of teat dip consumed per day is normally the same from one day to the next, the time duration that the previously mixed liquid lasted for before the depletion sensor was triggered, will be similar to the time that the next batch of mixed liquid will last for. The amount of time the next batch of mixed liquid will last for may be used to define the period of weather forecast data that will be used to calculate the mix ratio.

[0093] The controller 56 may average the forecasted temperature, windspeed and humidity over the period, and calculate the mix ratio to provide the desired mix of liquids in the storage vessel. If the current mix of liquids in the storage vessel is very different to the desired mix of liquids, then the controller may adjust the mix ratio for the next mix cycle based on the volume of liquid in the storage vessel at the current mix ratio, typically the volume of liquid in the storage vessel when the liquid is at the depletion level.

[0094] The controller 56 may record the mix ratio of each mixing cycle, and adjust the mix ratio for the next mixing cycle based on the mix ratios used for the preceding mix cycles, for example so that a mix with high disinfecting properties is mixed at least once in every certain number of days.Whilst the illustrated embodiment only uses a single pump 5, it will be appreciated that the single pump could be replaced with multiple pumps if desired, for example one pump for each one of the source vessel and source containers. The diaphragm pump(s) could be replaced with alternate type(s) of pump(s) if desired.

[0095] Whilst the illustrated embodiment has three liquid sources, corresponding to the source vessel 1 and the source containers 2 and 3, it will be appreciated that additional liquid sources for mixing further ingredients of the teat dip could be added to the embodiment if desired, or one of the liquid sources could be removed from the embodiment leaving only two liquid sources for mixing, such as concentrated teat dip and water.

[0096] The liquids from the liquid sources of the illustrated embodiment are mixed together in the storage vessel as the different liquids are successively pumped into the storage vessel in sequence. However, the liquids could alternatively be pumped along a common manifold at the same time as one another to effect the mixing before the storage vessel, or the storage vessel could comprise a rotatable paddle driven under control of the controller to mix the liquids together.

[0097] Many other variations of the described embodiments falling within the scope of the invention will be apparent to those skilled in the art.

Claims

1. CLAIMS1. A liquid mixing station, comprising a storage vessel for storing mixed liquid, two or more liquid sources, at least one pump for pumping liquid from the liquid sources to the storage vessel, a controller for controlling the at least one pump, and a transceiver connected to the controller, wherein the controller is configured to retrieve weather forecast data from a remote weather forecasting service via the transceiver, to calculate a mix ratio of the liquids from the liquid sources based on the weather forecast data, and to control the at least one pump to pump quantities of liquid from the liquid sources into the storage vessel, the quantities corresponding to the calculated mix ratio.2 The liquid mixing station of claim 1 , wherein the liquid sources comprise a source of disinfectant and a source of emollient.

3. The liquid mixing station of claim 2, wherein the weather forecast data comprises humidity data, and wherein the calculation of the mix ratio comprises increasing a proportion of the emollient in response to a reduction in the forecast humidity data.

4. The liquid mixing station of any preceding claim, wherein the liquid sources comprise a source of water, wherein the weather forecast data comprises temperature data, and wherein the calculation of the mix ratio comprises increasing a proportion of the disinfectant relative to the water in response to a reduction in the forecast temperature data.

5. The liquid mixing station of any preceding claim, wherein the storage vessel comprises one or more sensors for detecting a level of the liquids in the storage vessel, the sensors being connected to the controller.

6. The liquid mixing station of any preceding claim, wherein the controller is configured to select a period of the weather forecast data that is to be taken into account when calculating the mix ratio, and wherein the period is selected based on a time duration between successive mixing cycles.

7. The liquid mixing station of any preceding claim, comprising a housing supporting the liquid sources, the pump, and the storage vessel, wherein the storage vessel is optionally mounted to a side of the housing.

8. The liquid mixing station of any preceding claim, wherein first and second ones of the liquid sources comprise respective source containers in which the corresponding liquids are held.

9. The liquid mixing station of claim 8 when appended to claim 7, wherein the source containers are enclosed inside the housing.

10. The liquid mixing station of claim 7 or any claim dependent thereon, wherein a third one of the liquid sources comprises a source vessel mounted to an opposite side of the housing from the side of the housing where the storage vessel is mounted.

11. The liquid mixing station of any preceding claim, wherein the liquid mixing station is a teat dip mixing station.

12. The liquid mixing station of any preceding claim, wherein the controller is programmable by a remote computer via the transceiver to define the mix ratios that will be applied under a selection of respective forecasted weather conditions.

13. The liquid mixing station of any preceding claim, wherein the calculation of the mix ratio comprises the controller averaging the retrieved weather forecast data over a window of time.

14. The liquid mixing station of any preceding claim, wherein the calculation of the mix ratio comprises the controller adjusting the mix ratio based on the mix ratios used for the mixed liquid that has been outlet during a preceding number of days.

15. The liquid mixing station of any preceding claim, wherein the calculation of the mix ratio comprises the controller adjusting the mix ratio based on the mix ratio that was applied during an immediately preceding mixing cycle and the volume of liquid currently present in the storage vessel.

16. The liquid mixing station of any preceding claim, wherein the controller comprises a position determination system based on satellite or cellular base station signals to determine a geographical location of the mixing station, and wherein the controller is configured to calculate the mix ratio based on the weather forecast data for the determined geographical location.

17. A method for mixing liquids using the mixing station of any preceding claim, the method comprising retrieving weather forecast data from a remote weather forecasting service, calculating a mix ratio of the liquids from the liquid sources based on the weather forecast data, and pumping quantities of liquid from the liquid sources into the storage vessel, the quantities corresponding to the calculated mix ratio.

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