Feed bin monitoring system and method
A bin monitoring system functions both as a device for lifting the bin and as a weighing system for monitoring or measuring the level of feed in a feed bin. Various embodiments having a suspended load cell and methods of retrofitting the bin monitoring system to existing bins are provided. Further, the accuracy provided by various embodiments enables one to accurately predict when the feed bin will be empty. Thus, the feed mill can be aware of anticipated needs days in advance, allowing the feed mill to better optimize its scheduling and deliveries.
1. A bin monitoring system useable with a bin having a weight and a plurality of bin legs that support the bin above a foundation, the bin monitoring system comprising:
a frame configured to be securable to the foundation adjacent a bin leg;
a load cell having upper and lower ends;
the upper end of the load cell being moveably mounted to the frame to allow the load cell to be raised and lowered relative to the frame; and
a mechanical connector attached to the lower end of the load cell and attachable to the adjacent bin leg to raise the adjacent bin leg above the foundation and apply the bin weight to the lower end of the load cell when the load cell is raised.
2. The bin monitoring system of claim 1 , wherein the load cell is an S-type load cell.
3. The bin monitoring system of claim 1 , wherein:
the load cell includes a first threaded aperture and a first threaded bolt;
the frame includes a bore adjacent the first threaded aperture; and
the first threaded bolt extending through the bore and threadably engaging the first threaded aperture in the load cell to secure the load cell to the frame and to lift and support the load cell when the first threaded bolt is rotated.
4. The bin monitoring system of claim 3 , wherein the frame has an A-frame configuration with a top and a pair of legs, the bore being at the top of the frame and the legs of the A-frame attachable to the foundation.
5. The bin monitoring system of claim 1 , wherein the mechanical connector includes a second threaded bolt and the load cell includes a second threaded aperture to receive the second threaded bolt.
6. The bin monitoring system of claim 5 , wherein the second threaded bolt is arranged to lift and support the mechanical connector when the second threaded bolt is rotated.
7. The bin monitoring system of claim 1 , wherein the bin monitoring system is arranged and configured such that, in operation, the load cell is in tension.
8. The bin monitoring system of claim 1 , further comprising a limiting mechanism to limit upward movement of the mechanical connector with respect to the frame.
9. A bin monitoring system useable with a bin having a weight and a plurality of bin legs that support the bin above a foundation, each bin leg having a bottom, the bin monitoring system comprising:
a frame configured to be securable to the foundation adjacent a bin leg;
a load cell having first and second ends, one of the load cell ends being carried by the frame;
a mechanical connector attached to the uncarried end of the load cell and attachable to the adjacent bin leg to carry the weight of the adjacent bin leg and apply the weight of the adjacent bin leg to the load cell;
wherein the load cell is positioned on the frame at a location higher than the bottom of the adjacent bin leg and the weight of the bin leg is applied to the lower end of the load cell.
10. The bin monitoring system of claim 9 , wherein the load cell is an S-type load cell.
11. The bin monitoring system of claim 9 , wherein:
the load cell includes a first threaded aperture and a first threaded bolt;
the frame includes a bore adjacent the first threaded aperture; and
the first threaded bolt extending through the bore and threadably engaging the first threaded aperture in the load cell to secure the load cell to the frame and to lift and support the load cell when the first threaded bolt is rotated.
12. The bin monitoring system of claim 11 , wherein the frame has an A-frame configuration with a top and a pair of legs, the bore being at the top of the frame and the legs of the A-frame attachable to the foundation.
13. The bin monitoring system of claim 9 , wherein the mechanical connector includes a second threaded bolt and the load cell includes a second threaded aperture to receive the second threaded bolt.
14. The bin monitoring system of claim 13 , wherein the second threaded bolt is arranged to lift and support the mechanical connector when the second threaded bolt is rotated.
15. The bin monitoring system of claim 9 , wherein the bin monitoring system is arranged and configured such that, in operation, the load cell is in tension.
16. The bin monitoring system of claim 9 , further comprising a limiting mechanism to limit upward movement of the mechanical connector with respect to the frame.
17. A bin monitoring system useable with a bin having a weight and a plurality of bin legs that support the bin above a foundation, the bin monitoring system comprising:
a frame configured to be securable to the foundation adjacent a bin leg;
a load cell having upper and lower ends; and
a mechanical connector attachable to the adjacent bin leg and constructed and arranged to carry the weight of the bin;
wherein the upper end of the load cell is movably mounted to the frame;
wherein the lower end of the load cell being is movably mounted to the mechanical connector to raise and lower the mechanical connector relative to the frame; and
wherein the mechanical connector applies the weight of the bin to the load cell when said one of the mechanical connector or the load cell is raised relative to the frame to suspend the adjacent bin leg above the foundation.
18. The bin monitoring system of claim 17 , wherein the load cell is an S-type load cell.
19. The bin monitoring system of claim 17 , wherein:
the load cell includes a first threaded aperture and a first threaded bolt;
the frame includes a bore adjacent the first threaded aperture; and
the first threaded bolt extending through the bore and threadably engaging the first threaded aperture in the load cell to secure the load cell to the frame and to lift and support the load cell when the first threaded bolt is rotated.
20. The bin monitoring system of claim 19 , wherein the frame has an A-frame configuration with a top and a pair of legs, the bore being at the top of the frame and the legs of the A-frame attachable to the foundation.
21. The bin monitoring system of claim 17 , wherein the mechanical connector includes a second threaded bolt and the load cell includes a second threaded aperture to receive the second threaded bolt.
22. The bin monitoring system of claim 21 , wherein the second threaded bolt is arranged to lift and support the mechanical connector when the second threaded bolt is rotated.
23. The bin monitoring system of claim 17 , wherein the bin monitoring system is arranged and configured such that, in operation, the load cell is in tension.
24. The bin monitoring system of claim 17 , further comprising a limiting mechanism to limit upward movement of the mechanical connector with respect to the frame.
25. A method for retrofitting bin monitoring systems to a heavy storage bin having a multiplicity of supporting bin legs already attached to a foundation and having conveyor pipes attached to the bin for moving the content of the bin to or from the bin while avoiding damage to the bin or disruption of the conveyor pipes during retrofitting, comprising the steps of:
providing a multiplicity of bin monitoring systems with a said system for each bin leg, each system comprising;
a frame configured to be securable to the foundation;
a load cell configured to measure a weight of the bin and having upper and lower ends with the upper end supported by the frame; wherein the load cell is secured to the bin leg;
a connector connected to the lower end of the load cell and connectable with a bin leg such that the weight of the bin leg is applied to the lower end of the load cell; and
a lifting mechanism for raising the connector relative to the frame in order to lift the bin leg;
detaching the multiplicity of bin legs from the foundation;
operatively attaching a connector to each bin leg of the storage bin;
operatively positioning a frame and load cell adjacent each bin leg and aligning a frame with each bin leg;
actuating each of the lifting mechanisms to raise the bin leg to which it is attached an amount of height insufficient to damage the bin or disrupt the conveyor pipes and causing the weight of the bin to be entirely carried by the frame while applying the weight at each bin leg to the load cell of the monitoring system adjacent that bin leg; and attaching the frame of the bin monitoring system associated with each bin leg to the foundation.