Silo content monitoring system
A silo content monitoring system ( 100 ) for a silo ( 102 ) fitted with a rotatable discharge auger ( 114, 118 ). The system has a strain gauge ( 150 ) affixed to at least one of the support struts ( 124 ) supporting the silo shell ( 104 ) above the ground. The strain gauge output ( 1500 ) is proportional to the compressive strain in the said silo strut ( 124 ), and is used to obtain an estimate of the silo's weight, and hence the weight of the silo's content, by subtracting a tare value. The system also has a motion sensor ( 152 ), which detects rotation of the discharge auger ( 118 ). A central processor of the system calculates: during a night time interval, an overnight silo content weight measurement ( 1502 ) based on the strain gauge ( 150 ) readings; and during a daytime interval, an estimated dispensed weight by subtracting a certain weight for each rotation or part-rotation of the auger ( 118 ). By doing this, the system ( 100 ) is able to display, on a read-out device ( 158 ), a dead reckoning silo content weight estimate ( 174 ), which is the overnight silo content weight measurement, minus the estimated dispensed weight since the last overnight silo content weight measurement.
1 . A silo content monitoring system for a silo,
the silo comprising: a shell; a hopper; an outlet aperture located at or towards the base of the hopper; a discharge tube connected to the outlet aperture; a rotatable auger located within the discharge tube; and a plurality of support struts for supporting the shell, hopper, and outlet aperture above ground level,
the silo content monitoring system comprising:
a strain gauge affixed to at least one of the support struts;
a motion sensor adapted to detect rotation of the auger relative to the discharge tube; and
central processing unit comprising: a calculating means; a real-time clock; an input/output interface connected to the strain gauge, the motion sensor and to a read-out device, wherein
the central processing unit is adapted to:
in operation, during a night time interval, to monitor an output of the strain gauge to ascertain an overall weight of the silo, subtract a tare weight from the overall weight to obtain an overnight silo content weight measurement;
in operation, during a daytime interval, to monitor an output of the motion sensor and for each rotation or part-rotation of the auger, calculate an estimated dispensed weight; and
in operation, to output, via the read-out device, a subtractive silo content weight estimate being the overnight silo content weight measurement, minus the estimated dispensed weight.
2 . The silo content monitoring system of claim 1 , comprising a strain gauge affixed to more than one of the support struts, the overnight silo content weight measurement being based on a function of the outputs of the strain gauges.
3 . The silo content monitoring system of claim 2 , wherein the function comprises a geometric mean or an arithmetic mean.
4 . The silo content monitoring system of claim 1 , wherein the motion sensor comprises an encoder affixed to a drive shaft of the auger and/or to a rotor of a motor driving the auger.
5 . The silo content monitoring system of claim 1 , wherein the motion sensor comprises a current sensor connected to a power cable of a motor driving the auger.
6 . The silo content monitoring system of claim 1 , wherein the motion sensor comprises an induction sensor adapted to detect the rotation of the auger within the discharge tube.
7 . The silo content monitoring system of claim 1 , wherein the night time interval is a period of a 24-hour day commencing at or after sunset and ending before or at sunrise, and the daytime interval is a reminder of the 24-hour period.
8 . The silo content monitoring system of claim 7 , wherein the start and end of the night time interval are fixed programmable, or user-inputted, times within the 24-hour period.
9 . The silo content monitoring system of claim 7 , wherein the start time and end time of the night time interval are dynamic variables based on actual sunset and sunset times for a given location of the silo.
10 . The silo content monitoring system of claim 1 , wherein the central processing unit is further adapted, in use, to recalibrate the estimated dispensed weight per rotation or part-rotation of the auger by:
ascertaining a difference between the overnight silo content weight measurement on a first day and the overnight silo content weight measurement on a second day;
ascertaining the number of rotations or part-rotations of the auger between the first day and the second day;
dividing the overnight silo content weight measurement difference by the number of rotations or part-rotations of the auger to obtain a calibrated value of the weight dispensed per rotation or part-rotation of the auger; and
using the calibrated value of the weight dispensed per rotation or part-rotation of the auger in future subtractive silo content weight estimates.
11 . The silo content monitoring system of claim 10 , wherein the first day and the second day are between 1 and 5 days apart.
12 . The silo content monitoring system of claim 10 , wherein the recalibration is repeated at intervals so as to obtain a rolling average of the calibrated value of the weight dispensed per rotation or part-rotation of the auger.
13 . The silo content monitoring system of any of claim 10 , wherein the rolling average is reset if the overnight silo content weight measurement on a given day is greater than the overnight silo content weight measurement on a preceding day.
14 . The silo content monitoring system of claim 1 , wherein the read-out device comprises a dial, screen, digital display, or LED bar graph visually indicating the subtractive silo content weight estimate.
15 . The silo content monitoring system of claim 1 , wherein the read-out device comprises a wireless transceiver adapted in use, to output a signal indicative of the subtractive silo content weight estimate, which signal can be interpreted and viewed by a user via a web-based portal, or via an app of a smartphone or tablet computing device.
16 . The silo content monitoring system of claim 15 , wherein a GUI of the web-based portal or app presents a log of silo content use and replenishment metrics and events.
17 . The silo content monitoring system of claim 15 , wherein the signal indicative of the subtractive silo content weight estimate is receivable by a supplier who can schedule a replenishment of the silo contents based on an instantaneous subtractive silo content weight estimate or a predicted future subtractive silo content weight estimate.
18 . A silo content monitoring kit for a silo comprising:
a shell;
a hopper;
an outlet aperture located at or towards the base of the hopper;
a discharge tube connected to the outlet aperture;
a rotatable auger located within the discharge tube; and
a plurality of support struts for supporting the shell, hopper, and outlet aperture above ground level,
the silo content monitoring kit comprising:
a strain gauge and a set of fixings for retrofitting the strain gauge to a support strut of the silo;
a motion sensor and a set of fixings or connections for retrofitting to the discharge tube of the silo so as to monitor movement of the auger;
a read-out device;
a central processing unit with a calculating means, a real-time clock, and an input/output interface connected to the strain gauge, the motion sensor and the read-out device; and
a wiring harness for connecting the strain gauge, motion sensor and read-out device to the central processing unit, which when fitted to the silo is configured such that:
during a night time interval, the central processing unit is adapted to monitor an output of the strain gauge to ascertain an overall weight of the silo, subtract a tare weight from the overall weight to obtain an overnight silo content weight measurement;
during a daytime interval, the central processing unit is adapted to monitor an output of the motion sensor and for each rotation or part-rotation of the auger, calculate an estimated dispensed weight; and
the central processing unit is adapted to output, via the read-out device, a subtractive silo content weight estimate being the overnight silo content weight measurement, minus the estimated dispensed weight.
19 . The silo content monitoring kit of claim 18 , further comprising any one or more of the group consisting of: a mains power adapter; a mobile telephony interface; a wireless local area network interface; a short-range wireless interface; and a firmware dongle.