WO2010025526A1

WO2010025526A1 - A livestock feed delivery system with sensor

Info

Publication number: WO2010025526A1
Application number: PCT/AU2009/001171
Authority: WO
Inventors: Thomas Banhazi; Brian M. Lewis
Original assignee: Pork Crc Limited
Priority date: 2008-09-05
Filing date: 2009-09-04
Publication date: 2010-03-11
Also published as: AU2009290153A1; AU2009290153B2

Abstract

The present invention relates to a feed delivery system in which livestock are supplied with feed from one or more trough feeders. The system includes a feed conveyor for conveying particulate feed to the trough feeders, a plurality of drop tubes extending from the feed conveyor to a position above the trough feeders, and an elevated flow sensor disposed in the path of feed between each drop tube and trough feeder. The flow sensors are adapted to measure the flow rate of feed into each trough feeder upon impact with the flow sensors. The system further includes a means of providing information in connection with individual feeders based on data retrieved from each flow sensor.

Description

A LIVESTOCK FEED DELIVERY SYSTEM WITH SENSOR

The present invention relates to a livestock feed delivery system and, in particular, to a feed delivery system including a solid-flow sensor for measuring the amount of feed entering each feeder in one or more feeder lines during a feed episode. The system is intended for commercial use in piggeries, however, is not intended to be limited to such use.

BACKGROUND OF THE INVENTION

In commercial livestock operations, it is conventional to raise several hundred animals in livestock buildings. An automated feeding system is typically provided to feed the animals and typically includes one or more feed tanks or silos located outside of the livestock buildings. Feed trucks deliver feed to these silos. A conveyor is used to then convey the feed from the bulk feed tank into the livestock building. A plurality of individual feeding bins, referred to herein as feeders, are located inside the livestock building and are automatically supplied feed from the conveyor.

The conveyor is typically in the form of a closed tube in which a helical auger is housed. The auger may either be rotary driven or axially driven to transport the feed through the tube. The feed system also includes drop tubes associated with openings in the conveyor. Each drop tube extends downwardly from an opening in the conveyor tube so that feed is supplied along the conveyor tube to the drop tubes into a plurality of feeders in line with the conveyor tube. Operation of the conveyor functions to successively fill the drop tubes and feeding troughs along the length of the system.

Feeding systems of this type are typically controlled such that after all the feeders in the line are filled with feed, the conveyor is turned off. This defines one feed episode. In a piggery, there will typically be three to four feed episodes per day. This can be accomplished by operating the feed line for a predetermined amount of time calculated to fill all of the feeders. Alternatively, a sensor switch can be used which is operated by a paddle engageable by the feed, the paddle being provided in the last feeder of the feeder line to sense when the last feeder is filled with feed and to shut off the conveyor.

Being able to measure the feed intake of individual animals provides very useful information to farm managers, it allows for more control over the amount of feed delivered, and is an important factor when measuring the efficiency of a particular livestock enterprise. For example, in the case of piggeries, the feed intake of pigs (and the feed conversion efficiency calculated from this) determines to a large extent the profitability of the piggery. Currently, there is no feed delivery system known to the Applicant which effectively measures feed intake of distinct groups of animals.

Currently used manual "spot-check" measurements of feed intake are labour intensive and not practical enough to be incorporated into normal management procedures of a piggery enterprise. Alternative technologies, such as load cells placed under feed silos, can yield useful information about the feed intake of very large groups of animals feeding from the same feed silo. However, this information will not alert farm managers in relation to differences in feed intake between distinct groups of animals. Therefore, the usefulness of such information is very limited.

Load cell based feeders which include load cells under the feeder are expensive, cumbersome and economically prohibitive for production conditions. A piggery environment is extremely dusty and destructive, making existing load cell technology unsuitable for commercial use. In fact, such technology is currently only used for research purposes.

Furthermore, existing feed measurement devices known to the Applicant are not easily retrofitted into existing feed delivery systems. At present, feed delivery systems are required to be completely replaced in order to incorporate such equipment.

It is therefore an object of the present invention to overcome at least some of the aforementioned problems or to provide the public with a useful alternative.

SUMMARY OF THE INVENTION

Therefore, in one form of the invention there is proposed a A flow sensor for a feed delivery system characterised in that said sensor is adapted for placement in a delivery path of feed into a feeder whereby said feed impacts the sensor, said sensor having a load cell including neans to measure the flow rate of the feed during a feed episode. The skilled addressee would ^•ealise that a weight reading for each feeder in a line of feeders in a livestock building can be generated by data from the sensor.

Preferably said flow sensor further includes a valve moveable between an open position n which feed is allowed to pass and a closed position in which feed is prevented from passing. In preference said flow sensor further includes a control means into which predetermined data is entered, said control means adapted to receive flow rate data from said sensor and operate said valve in accordance with said predetermined data.

Preferably said predetermined data relates to the weight of feed requires in the feeder.

Preferably said flow sensor includes an upright cylindrical body which houses said load cell, and an impact member supported above the body and being magnetically coupled to the load cells so that when feed impacts the cone, a flow rate signal is registered by the load cell.

In preference said feed is particulate feed.

In a further form of the invention there is proposed a feed delivery system for a livestock building including a plurality of feeders, said feed delivery system characterised by: a conveying means for supplying feed to a plurality of drop tubes associated with each feeder; a flow sensor adapted to be placed in the feed path between each drop tube and feeder, said feed adapted to impact the sensor which is configured to record the feed flow rate during a feed episode; and a means of providing information in connection with individual feeders based on data retrieved from said flow sensor.

Preferably said information includes the weight of feed present in each feeder.

In preference said flow sensor includes an upright cylindrical body which houses load cells, and an impact cone supported above the body and being magnetically coupled to the load cells so that when feed impacts the cone, a flow rate signal is registered.

Preferably said system further includes a control means adapted to control one or more components of the system in accordance with data retrieved from said flow sensor.

In preference said one or more controlled components includes the conveying means.

In preference said one or more controlled components includes a valve in said feed line upstream of said sensor and moveable between an open position in which feed is allowed to pass and a closed position in which feed is prevented from passing.

Preferably each feeder includes a proximity sensor adapted to detect when the feeder is full. In preference said system further includes a control means adapted to control one or more components of the system in accordance with data retrieved from said flow sensor.

Preferably said one or more controlled components includes the conveying means.

Preferably said conveyor means includes an auger disposed within a conveyor tube for conveying feed in one direction.

In preference said auger is driven by a drive motor.

In a still further form of the invention there is proposed a feed delivery system in which livestock are supplied with feed from one or more trough feeders, said feed delivery system including: a feed conveyor for conveying particulate feed to the trough feeders, said feed conveyor comprising a conveyor tube extending along a feed line conveyor path to said trough feeders, a plurality of drop tubes extending from said feed conveyor to a position above said trough feeders, an elevated flow sensor disposed in the path of the feed between each drop tube and trough feeder, said flow sensors adapted to measure the flow rate of feed into each trough feeder upon impact with the flow sensors, and a means of providing information in connection with individual feeders based on data retrieved from each flow sensor.

In preference each flow sensor includes an upright cylindrical body which houses load cells, and an impact cone supported above the body and being magnetically coupled to the load cells so that when the particulate feed impacts the cone, a flow rate signal is registered.

Preferably each flow sensor includes an outer housing between which said particulate feed passes after impacting with the cone, said outer housing adapted to be fitted to said drop tubes.

BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an implementation of the invention and, together with the description, serve to explain the advantages and principles of the invention. In the drawings:

Figure 1 illustrates a side elevation view of a livestock building, a bulk feed silo located outside the building, and a feed delivery system in accordance with the present invention;

Figure 2 illustrates an exploded perspective view of the measurement component of the feed delivery system of Figure 1, including a flow rate sensor positioned between each drop tube and its associated feeder, and proximity sensors located at the top of each feeder;

Figure 3 illustrates a perspective, cutaway view of the measurement component of the feed delivery system of Figure 1, including a flow rate sensor positioned between each drop tube and its associated feeder, and proximity sensors located at the top of each feeder;

Figure 4 illustrates an enlarged perspective view of the flow rate sensor of Figures 2-3;

Figure 5 illustrates an enlarged perspective view of the flow rate sensor of Figures 2-3 including a dust cover; and

Figure 6 illustrates a side cross-sectional view of a flow rate sensor in accordance with a preferred embodiment of the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following detailed description of the invention refers to the accompanying drawings. Although the description includes exemplary embodiments, other embodiments are possible, and changes may be made to the embodiments described without departing from the spirit and scope of the invention. Wherever possible, the same reference numbers will be used throughout the drawings and the following description to refer to the same and like parts.

The present invention relates to a feed delivery system 10 for use in a livestock building 12. The feed delivery system 10 is shown in Figure 1, and includes a feed conveyor 14 for conveying feed 16 from an outdoor silo 18 to a plurality of feeders 20 disposed in a line or a plurality of lines within the livestock building 14. In the case of piggeries, the building 14 is typically of a size to house twenty to eighty pigs, and the feed 16 is in the form of a pelleted feed. The feed conveyor 14 comprises a conveyor tube 22 having a plurality of outlet openings 24 therein for attaching drop tubes 26 thereto for supplying feed to the individual feeders 28 there below.

The feed conveyor 14 has an auger 25 disposed within the conveyor tube 22, generally in the form of an open helical coil-like member having flights based on equal intervals therealong. The auger 25 is preferably a flexible centreless auger so as to enable it to readily go around corners and accommodate changes in elevation. An electric drive motor (not shown) is preferably used for driving the auger, and is typically located at the end of the conveyor line.

The feed silo 18 is shown located outside the livestock building 14. The silo 18 has a raised tank body 30 with a downwardly converging outlet section 32. At the bottom end of this outlet section 32 is an outlet boot 34 which is connected to the feed conveyor 14.

Each feeder 20 includes a round container 36 positioned below a cylindrical feed bin 38 which includes a bottom valve 40 that can be opened and closed manually. The operation of the feeder 20 will not be described in any great detail here, and it is to be understood that any other suitable feeder could be used. For example, if the present invention were applied to livestock other than pigs, the feeder 20 would be configured differently.

The feed delivery system 10 of the present invention is designed to be retrofitted into feed supply systems of the type described above. The system 10 includes a measurement component in the form of sensors 42 and 44, and a control component in the form of a control unit (not shown).

The control unit can be in the form of any suitable controller that is capable of receiving and processing signals from the two sensors, and which is also programmable to control operation of the feed conveyor drive motor (not shown) and other components which will be later described. In preference, the control unit is associated with a farm computer (no shown) at a remote location, including a display screen and software which enable it to display data from the sensors, and allow users to input data.

The first sensor 42 is a cylindrical solid-flow sensor which is sealed inside a metal housing 46 for measuring the flow rate of feed 16 falling down the drop tube 26. The sensor 42 and its housing 46 is adapted to be fitted in the feed delivery line between the drop tube 26 and the feeder 20. This is shown most clearly in Figures 2-3. In particular, the metal housing 46 includes an upper inlet end 48 configured to engage the bottom of the drop tube 26, a cylindrical body 50, and a lower outlet end 52 configured to engage the top of the feeder 20. The housing 46 downwardly diverges from the inlet end 48 to the cylindrical body 50, and then downwardly converges from the cylindrical body 50 to the outlet end 52.

The solid-flow sensor 42 is in the form of a load cell cylinder. The sensor 42 includes an impact plate or cone 54 which levitates above the head of the cylinder 42 and is held horizontally by guides and bearings (not shown). The impact cone 54 includes an internal magnet (not shown), and there is also a stationery magnet (not shown) inside the cylinder which floats on the load cell (not shown). The magnets are configured to repel each other so that when the cone 54 moved downwardly when impacted by feed, the cylinder magnet is repelled downwardly and thereby provides a force on the load cell with reference to a base plate inside the cylinder. A flow rate signal is transmitted through wire 56 to the control unit for processing. The load cell is safely contained within the cylinder 42 to protect the sensitive load cell under harsh, dusty operating conditions. The metal housing 46 also contributes to sealing in the sensitive sensor components. It is to be understood that the means by which the impact plate 54 is supported and held horizontally is not intended to be limited to the embodiment described.

The cylinder includes a tripod stand 57 including three legs connected at one end to the base of the cylinder, and at their free ends to the metal housing 46 to thereby elevate the cylinder 42 in mid-air inside the housing 46. Therefore, feed entering the housing from the drop tube 26 enters through the inlet 48, impacts the cone 54 and is thereby diverted to the sides of the cylinder 42, and then exits the housing 46 through outlet 52.

The skilled addressee would realise that once a flow rate signal is measured, the weight of feed delivered, in kilograms for example, can quite easily be calculated. This is achieved using a signal processor in the control unit (not shown).

The second sensor 44 forming part of the measurement component of the system 10 is a proximity sensor located at the top of the feed bin 38 for sensing when the feeder is full. When the proximity sensor 44 senses that the feeder has reached a maximum level, a signal is sent to the control unit through wire 58. A control valve 60 is also located adjacent each opening 24 of the feed conveyor 14 in the drop tube 26. In the embodiment shown, this is in the form of a butterfly type valve 62 which is rotatable between an open position allowing feed 16 to enter, and a closed position stopping feed 16 from entering. The control valve 60 is connected to and operable by the control unit (not shown) through wire 64.

The control valve 60 could be operated under a number of different circumstances. For example, it could be made to shut off when a particular weight has been recorded by sensor 42, or it could be shut off when sensor 44 senses that the feeder is full. Then, when sensor 42 detects that the weight is not at a predetermined level, or sensor 44 or perhaps even a low level sensor (not shown) detects that feed is required, the control unit opens the control valve 62 ready for the next feed episode. It is to be understood that the control valve 60 need not necessarily be positioned right at the top of the drop tube 26, and that it could equally well form part of the sensing unit 42 just above the impact cone. The control unit could also be incorporated into the flow rate sensor 42 so that it receive data from the load cell and operates the valve in real time.

Figure 4 illustrates an enlarged view of the flow rate sensor 42, and Figure 5 illustrates the same sensor 42 including a dust cover 66. The dust cover is preferably always used during operation to reduce frictional resistance or potential dust build-up on the bearings supporting the impact cone's movement.

To summarise, when a feed episode is initiated, feed 16 is adapted to be transported from the silo 18, up through the feed conveyor 14, and is dropped into each drop tube 26 sequentially. When a predetermined weight is recorded in each feeder, or when the proximity sensor 44 senses a maximum level, the control valve 60 closes and so feed is then transported further along the line to the next drop tube, and so on until the final feeder is full. Once the feed particles 16 have dropped into each feeder, they collide with the impact member 54 of sensor 42. The feed sensor 42 recognises the feed episode and begins producing a measurement signal which is registered by the associated control unit (not shown). Therefore, the amount of feed deposited into each feeder 20 in each feeding episode can be monitored and controlled.

The recorded information can then be used at the farm manager's discretion. For example, he or she may view the information relating to each feeder, which may correspond with a distinct group of animals, and then operate the feed conveyor drive motor (not shown) in the way they see fit. Alternatively, the control unit (not shown) could be programmed to automatically operate the feed conveyor 14 and control valve 60 in accordance with the measured data.

During field testing of the present invention, it has been found that the accuracy of the measured weight of feed to each feeder is within ±5% of the actual weight. Changed humidity conditions and diet composition did not affect the readings. The skilled addressee would realise that the feed delivery system 10 of the present invention therefore provides:

• a system which can be used in a commercial environment for providing accurate feedback to farm managers regarding the feeding characteristics of distinct groups of animals;

• a system which tracks and records the number of feed batches weighed, the average flow rate, the batch weight and the total weight;

• a system which may be easily retrofitted into feed distribution systems of existing livestock farms;

• a system that can be used under harsh environmental conditions, and which requires minimal maintenance; and

• a system that is able to offer highly repeatable weight measurements into each feeder at an accuracy of ±5%.

Further advantages and improvements may very well be made to the present invention without deviating from its scope. Although the invention has been shown and described in what is conceived to be the most practical and preferred embodiment, it is recognized that departures may be made therefrom within the scope and spirit of the invention, which is not to be limited to the details disclosed herein but is to be accorded the full scope of the claims so as to embrace any and all equivalent devices and apparatus.

In any claims that follow and in the summary of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprising" is used in the sense of "including", i.e. the features specified may be associated with further features in various embodiments of the invention.

Claims

1. A flow sensor for a feed delivery system characterised in that said sensor is adapted for placement in a delivery path of feed into a feeder whereby said feed impacts the sensor, said sensor having a load cell including means to measure the flow rate of the feed during a feed episode.

2. A flow sensor as characterised in claim 1 wherein said flow sensor further includes a valve moveable between an open position in which feed is allowed to pass and a closed position in which feed is prevented from passing.

3. A flow sensor as characterised in claim 2 wherein said flow sensor further includes a control means into which predetermined data is entered, said control means adapted to receive flow rate data from said sensor and operate said valve in accordance with said predetermined data.

4. A flow sensor as characterised in claim 3 wherein said predetermined data relates to the weight of feed requires in the feeder.

5. A flow sensor as characterised in any one of the above claims wherein said flow sensor includes an upright cylindrical body which houses said load cell, and an impact member supported above the body and being magnetically coupled to the load cells so that when feed impacts the cone, a flow rate signal is registered by the load cell.

6. A flow sensor as characterised in any one of the above claims wherein said feed is particulate feed.

7. A feed delivery system for a livestock building including a plurality of feeders, said feed delivery system characterised by: a conveying means for supplying feed to a plurality of drop tubes associated with each feeder; a flow sensor adapted to be placed in the feed path between each drop tube and feeder, said feed adapted to impact the sensor which is configured to record the feed flow rate during a feed episode; and a means of providing information in connection with individual feeders based on data retrieved from said flow sensor.

8. A feed delivery system as characterised in claim 7 wherein said information includes the weight of feed present in each feeder.

9. A feed delivery system as characterised in claim 7 or claim 8 wherein said flow sensor includes an upright cylindrical body which houses load cells, and an impact cone supported above the body and being magnetically coupled to the load cells so that when feed impacts the cone, a flow rate signal is registered.

10. A feed delivery system as characterised in claim 9 wherein said system further includes a control means adapted to control one or more components of the system in accordance with data retrieved from said flow sensor.

11. A feed delivery system as characterised in claim 10 wherein said one or more controlled components includes the conveying means.

12. A feed delivery system as characterised in claim 10 or claim 11 wherein said one or more controlled components includes a valve in said feed line upstream of said sensor and moveable between an open position in which feed is allowed to pass and a closed position in which feed is prevented from passing.

13. A feed delivery system as characterised in claim 7 or claim 8 wherein each feeder includes a proximity sensor adapted to detect when the feeder is full.

14. A feed delivery system as characterised in claim 13 wherein said system further includes a control means adapted to control one or more components of the system in accordance with data retrieved from said flow sensor.

15. A feed delivery system as characterised in claim 14 wherein said one or more controlled components includes the conveying means.

16. A feed delivery system as characterised in claim 14 or claim 15 wherein said one or more controlled components includes a valve in said feed line upstream of said sensor and moveable between an open position in which feed is allowed to pass and a closed position in which feed is prevented from passing.

17. A feed delivery system as characterised in any one of claims 7-16 wherein said conveyor means includes an auger disposed within a conveyor tube for conveying feed in one direction.

18. A feed delivery system as characterised in claim 17 wherein said auger is driven by a drive motor.

19. A feed delivery system in which livestock are supplied with feed from one or more trough feeders, said feed delivery system including: a feed conveyor for conveying particulate feed to the trough feeders, said feed conveyor comprising a conveyor tube extending along a feed line conveyor path to said trough feeders, a plurality of drop tubes extending from said feed conveyor to a position above said trough feeders, an elevated flow sensor disposed in the path of the feed between each drop tube and trough feeder, said flow sensors adapted to measure the flow rate of feed into each trough feeder upon impact with the flow sensors, and a means of providing information in connection with individual feeders based on data retrieved from each flow sensor.

20. A feed delivery system as characterised in claim 19 wherein each flow sensor includes an upright cylindrical body which houses load cells, and an impact cone supported above the body and being magnetically coupled to the load cells so that when the particulate feed impacts the cone, a flow rate signal is registered.

21. A feed delivery system as characterised in claim 20 wherein each flow sensor includes an outer housing between which said particulate feed passes after impacting with the cone, said outer housing adapted to be fitted to said drop tubes.