GB2588700A

GB2588700A - Controller for bulk solid handling equipment

Info

Publication number: GB2588700A
Application number: GB2005544.8A
Authority: GB
Inventors: John Ghislain Francois Podevyn Michel; Hollings Craig
Original assignee: Spiroflow Ltd
Current assignee: Spiroflow Ltd
Priority date: 2020-04-16
Filing date: 2020-04-16
Publication date: 2021-05-05
Anticipated expiration: 2040-04-16
Also published as: GB2588700B; GB202005544D0

Abstract

A controller for 1100 the motor of bulk solid handling equipment (Figs 1 & 4) receives a signal 1110 associated with power supplied to the motor when rotating at a base speed. Controller 1100 determines if this is within a predetermined range 1120 and if not then causes at least two temporary changes in electric motor speed 1130; either increasing or decreasing the speed accordingly by between 2-15%. Once allowed to return to the base speed, controller 1100 redetermines with the predetermined range 1140, 1150 and if this is then outside the range inducing vibration 1160 of the equipment or part thereof. An associated piece of equipment, method and associated computer program are also disclosed.

Description

TITLE

Controller for bulk solid handling equipment

TECHNOLOGICAL FIELD

Embodiments of the present disclosure relate to a controller for bulk solid handling equipment. Some relate to a controller for improving the efficiency of bulk solid handling equipment.

BACKGROUND

Dry bulk solids, such as powder and/or granular materials, are often transferred from a bulk bag using bulk solid handling equipment. The handling of bulk solids can include for instance conveying the bulk solids, moving the bulk solids, or agitating the bulk solids.

Occasionally, this bulk solid handling equipment can perform inefficiently, due to for instance foreign materials in the bulk solids, or flow problems. The flow problems could include bridging, ratholing, a blockage in a conveyor, or the bulk solid becoming too fluidised. Some examples of bulk solid handling equipment are provided below.

Figs. 1 to 3 illustrate an example screw conveying apparatus 100 for conveying bulk solids, such as powders and/or granular material. The example screw conveying apparatus 100 includes an enclosed conduit for receiving the bulk solids, which in this example is in the form of a flexible tube 110. The flexibility of the tube 110 means that the materials can be conveyed at various angles, and around obstacles. The flexible tube 110 may be made from rubber or a plastics material.

A conveyor 120 in the form of a helical coil is located in the flexible tube 110. The helical coil 120 provides a conveying surface, which is best shown in Fig. 3. The helical coil 120 defines a channel 122 extending therethrough. The helical coil 120 may be flexible, and may be made from spring steel or stainless steel.

The example screw conveying apparatus 100 includes a motor 130 configured to urge the conveyor 120, thereby causing the conveyor 120 to move within the flexible tube 110. In this example, the motor 130 is an electric motor. In use, the motor 130 rotates the helical coil 120 within the flexible tube 110, thereby urging the bulk solids through the tube 110.

In the example of Figs. 1 to 3 the example screw conveying apparatus 100 includes an inlet assembly 150 for guiding the bulk solids into the flexible tube 110. The inlet assembly 150 includes a hopper.

The example screw conveying apparatus 100 includes a rotor 140 for urging the conveyor 120. The rotor 140 is driven by the motor 130. In the example illustrated in Figs. 1 to 3, the rotor 140 is in the form of a drive shaft 140, which couples to the helical coil 120 to cause the helical coil 120 to rotate within the flexible tube 110.

As shown in Figs. 1 & 2, a housing 160 is provided at the opposite end of the flexible tube 110 to the inlet assembly 140. The housing 160 may be made from mild steel or stainless steel. In this example, the drive shaft 140 and one end of the helical coil 120 are positioned within the housing 160. The housing 160 includes an outlet 162 for the bulk solids to exit the example screw conveying apparatus 100. The outlet 162 directs the bulk solids to a desired location. The outlet 162 extends from a substantially cylindrical body 166 of the housing 160. The housing 160 may include a further outlet 164, which extends from the body 166 of the housing 160 in a different direction to the outlet 162, to enable the bulk solids to exit the example screw conveying apparatus 100 when the housing 160 is in a different orientation.

A first mounting flange 168 for use in fastening the housing 160 to the flexible tube 110 is provided on the body 166 of the housing 160. A second mounting flange 169 for use in fastening the housing to the motor 130 is provided on the opposite end of the body 166 to the first mounting flange 168.

A problem with the example screw conveying apparatus 100 of Figs. 1 to 3 is that the efficiency of the apparatus 100 can be impacted by for instance blockages, the bulk solid being too fluidised, or foreign materials within the conduit.

Figs. 4 and 5 illustrate an example disc conveying apparatus 200 for conveying bulk solids, such as powders and/or granular material. The example disc conveying apparatus 200 includes an enclosed conduit for receiving the bulk solids, which in this example is in the form of a rigid pipe 210. The rigid pipe 210 may be made from steel.

A conveyor 220 in the form of a plurality of discs is located in the rigid pipe 210. The discs 220 provide a conveying surface, which is best shown in Fig. 4. The discs 220 are each mounted to a line 222, along the length of the line 222. The line 222 may be attached to the centre of the discs 220. The line may for instance be in the form of a rope, a cable, or a chain.

As shown in Fig. 4, the example disc conveying apparatus 200 includes an inlet assembly 250 for guiding the bulk solids into the rigid pipe 210.

The example disc conveying apparatus 200 includes a motor (not shown) configured to urge the conveyor 220, thereby causing the conveyor 220 to move within the rigid pipe 210. In this example, the motor is an electric motor. In use, the motor urges the line 222 or the discs 220 to pull the line 222 and discs 220 through the rigid pipe 210, thereby urging the bulk solids through the rigid pipe 210.

The example disc conveying apparatus 200 includes a rotor 240 for urging the conveyor 220. The rotor 240 is driven by the motor. In the example of Fig. 5, the rotor 240 is in the form of a sprocket 240 for engaging with at least one of the line 222 or the discs 220. The sprocket 240 includes one or more recesses 242, with each recess 242 being configured to locate a disc 220. The sprocket 240 is rotatably engageable with the line 222 or discs 220 to pull the line 222 and discs 220 through the enclosed rigid pipe 210.

A housing 260 is provided in the example disc conveying apparatus 200, which locates the sprocket 240. The housing 260 may include an outlet 262 for the bulk solids, to direct the bulk solids to a desired location.

A problem with the example disc conveying apparatus 200 of Figs. 4 and 5 is that the efficiency of the apparatus can be impacted by for instance blockages, the bulk solid being too fluidised, or foreign materials within the conduit.

Fig. 6 illustrates an example bulk bag discharger 300. Bulk bag dischargers are configured to discharge the contents of a bulk bag in a controlled manner. The contents of a bulk bag could be for instance discharged into the conveyors described herein.

The example bulk bag discharger 300 includes a support frame 310 for a bulk bag 320, a flow regulator (mostly hidden in Fig. 6) for regulating the flow from the bulk bag 320, and a hopper 340 for receiving the bulk solids from the bulk bag 320. The hopper 340 is tapered, and narrows down to an outlet 342. In use, the bulk bag 320 is mounted to the support frame 310 above the hopper 340. The bag 320 is opened, and the flow regulator regulates the flow of solids into the hopper 340. The bulk solids then exit from the outlet 342 of the hopper into for instance a conveyor or a container.

An agitator (not shown) is mounted in the hopper 340 adjacent to the outlet 342. A motor (also not shown), which powers the agitator, is included in the example bulk bag discharger 300. The agitator is configured to break up compacted bulk solids to improve the flowability of the bulk solids. In this example, the agitator is provided by a plurality of fingers mounted to a central rotor. The motor rotates the rotor, causing the fingers to dislodge the bulk solids.

A problem with the bulk bag discharger 300 of Fig. 6 is that the efficiency of the apparatus can be impacted by for instance blockages or bridging of the bulk solids. Bridging of bulk solids occurs when the solids interlock or bond together to build an arch above the outlet of the hopper 340, which prevents any further flow of the bulk solids through the outlet.

BRIEF SUMMARY

According to various, but not necessarily all, embodiments there is provided a controller comprising means for: receiving a signal indicating a value of an electrical parameter associated with power supplied to an electric motor of bulk solid handling equipment, which is rotating at a base speed; determining whether the value of the electrical parameter is within a predetermined range; based on a determination that the value of the electrical parameter is outside of the predetermined range, causing one or more temporary changes in the speed of the electric motor; once the one or more temporary changes in the speed have ceased and the electric motor has returned to its base speed, receiving a further signal indicating a further value of the electrical parameter; determining whether the further value of the electrical parameter is within the predetermined range; and based on a determination that the further value of the electrical parameter is outside of the predetermined range, causing a vibrator of the bulk solid handling equipment to vibrate.

According to various, but not necessarily all, embodiments there is provided a controller comprising means for: receiving a signal indicating a value of an electrical parameter associated with power supplied to an electric motor of bulk solid handling equipment, which is rotating at a base speed; determining whether the value of the electrical parameter is within a predetermined range; based on a determination that the value of the electrical parameter is outside of the predetermined range, causing two or more temporary changes in the speed of the electric motor, including: causing the speed of the electric motor to temporarily increase relative to the base speed, and causing the speed of the electric motor to temporarily decrease relative to the base speed; once the two or more temporary changes in the speed have ceased and the electric motor has returned to its base speed, receiving a further signal indicating a further value of the electrical parameter; determining whether the further value of the electrical parameter is within the predetermined range; and based on a determination that the further value of the electrical parameter is outside of the predetermined range, causing a vibrator of the bulk solid handling equipment to vibrate.

The causing the two or more temporary changes in the speed of the electric motor may comprise causing the speed of the electric motor to temporarily decrease relative to the base speed after the temporary increase in the speed of the motor.

At least one of the temporary changes in the speed of the electric motor may be a change in speed of at least 2% relative to the base speed. At least one of the temporary changes in the speed of the electric motor may be a change in speed of 2 to 15% relative to the base speed. At least one of the temporary changes in the speed of the electric motor may be a change in speed of 2 to 8% relative to the base speed.

The electrical parameter may be the current supplied to the motor.

The predetermined range may be within ±10% of a predetermined expected value for the electrical parameter.

According to various, but not necessarily all, embodiments there is provided an apparatus for handling bulk solids, the apparatus comprising: a controller according to any of the preceding paragraphs; a device for moving the bulk solids; a vibrator configured to vibrate at least a portion of the apparatus; and an electric motor for powering the device.

The device for moving the bulk solids may be a conveyor or an agitator.

The apparatus may further include an enclosed conduit, and the device may be a conveyor locatable inside the enclosed conduit, the conveyor being configured to urge bulk solids through the enclosed conduit when powered by the motor.

The vibrator may be located adjacent to an inlet or an outlet of the apparatus.

The enclosed conduit comprises a flexible tube. The conveyor may comprise a helical coil.

The conveyor may be provided by a plurality of discs. The plurality of discs may be mounted to a line.

The apparatus may include a hopper. The device may be an agitator configured to maintain the bulk solids in a free-flowing state.

According to various, but not necessarily all, embodiments there is provided a system comprising one or more of the apparatuses of any of the preceding paragraphs, wherein the system further includes one or more upstream or downstream processing 30 units.

According to various, but not necessarily all, embodiments there is provided a method of controlling bulk solid handling equipment, the method comprising: receiving a signal indicating a value of an electrical parameter associated with power supplied to an electric motor of bulk solid handling equipment, which is rotating at a base speed; determining whether the value of the electrical parameter is within a predetermined range; based on a determination that the value of the electrical parameter is outside of the predetermined range, causing one or more temporary changes in the speed of the electric motor; once the one or more temporary changes in the speed have ceased and the electric motor has returned to its base speed, receiving a further signal indicating a further value of the electrical parameter; determining whether the further value of the electrical parameter is within the predetermined range; and based on a determination that the further value of the electrical parameter is outside of the predetermined range, causing a vibrator of the bulk solid handling equipment to vibrate.

According to various, but not necessarily all, embodiments there is provided a method of controlling bulk solid handling equipment, the method comprising: receiving a signal indicating a value of an electrical parameter associated with power supplied to an electric motor of bulk solid handling equipment, which is rotating at a base speed; determining whether the value of the electrical parameter is within a predetermined range; based on a determination that the value of the electrical parameter is outside of the predetermined range, causing two or more temporary changes in the speed of the electric motor, including: causing the speed of the electric motor to temporarily increase relative to the base speed, and causing the speed of the electric motor to temporarily decrease relative to the base speed; once the two or more temporary changes in the speed have ceased, receiving a further signal indicating a further value of the electrical parameter; determining whether the further value of the electrical parameter is within the predetermined range; and based on a determination that the further value of the electrical parameter is outside of the predetermined range, causing a vibrator of the bulk solid handling equipment to vibrate.

According to various, but not necessarily all, embodiments there is provided a computer program comprising program instructions for causing an apparatus to perform at least the following: receiving a signal indicating a value of an electrical parameter associated with power supplied to an electric motor of bulk solid handling equipment, which is rotating at a base speed; determining whether the value of the electrical parameter is within a predetermined range; based on a determination that the value of the electrical parameter is outside of the predetermined range, causing one or more temporary changes in the speed of the electric motor; once the one or more temporary changes in the speed have ceased and the electric motor has returned to its base speed, receiving a further signal indicating a further value of the electrical parameter; determining whether the further value of the electrical parameter is within the predetermined range; and based on a determination that the further value of the electrical parameter is outside of the predetermined range, causing a vibrator of the bulk solid handling equipment to vibrate.

According to various, but not necessarily all, embodiments there is provided a computer program comprising program instructions for causing an apparatus to perform at least the following: receiving a signal indicating a value of an electrical parameter associated with power supplied to an electric motor of bulk solid handling equipment, which is rotating at a base speed; determining whether the value of the electrical parameter is within a predetermined range; based on a determination that the value of the electrical parameter is outside of the predetermined range, causing two or more temporary changes in the speed of the electric motor, including: causing the speed of the electric motor to temporarily increase relative to the base speed, and causing the speed of the electric motor to temporarily decrease relative to the base speed; once the two or more temporary changes in the speed have ceased, receiving a further signal indicating a further value of the electrical parameter; determining whether the further value of the electrical parameter is within the predetermined range; and based on a determination that the further value of the electrical parameter is outside of the predetermined range, causing a vibrator of the bulk solid handling equipment to vibrate.

According to various, but not necessarily all, embodiments there is provided a controller comprising: at least one processor; and at least one memory including computer program code, the at least one memory and the computer program code being configured to, with the at least one processor, cause the controller at least to perform: receiving a signal indicating a value of an electrical parameter associated with power supplied to an electric motor of bulk solid handling equipment, which is rotating at a base speed; determining whether the value of the electrical parameter is within a predetermined range; based on a determination that the value of the electrical parameter is outside of the predetermined range, causing one or more temporary changes in the speed of the electric motor; once the one or more temporary changes in the speed have ceased and the electric motor has returned to its base speed, receiving a further signal indicating a further value of the electrical parameter; determining whether the further value of the electrical parameter is within the predetermined range; and based on a determination that the further value of the electrical parameter is outside of the predetermined range, causing a vibrator of the bulk solid handling equipment to vibrate.

According to various, but not necessarily all, embodiments there is provided a controller comprising: at least one processor; and at least one memory including computer program code, the at least one memory and the computer program code being configured to, with the at least one processor, cause the controller at least to perform: receiving a signal indicating a value of an electrical parameter associated with power supplied to an electric motor of bulk solid handling equipment, which is rotating at a base speed; determining whether the value of the electrical parameter is within a predetermined range; based on a determination that the value of the electrical parameter is outside of the predetermined range, causing two or more temporary changes in the speed of the electric motor, including: causing the speed of the electric motor to temporarily increase relative to the base speed, and causing the speed of the electric motor to temporarily decrease relative to the base speed; once the two or more temporary changes in the speed have ceased, receiving a further signal indicating a further value of the electrical parameter; determining whether the further value of the electrical parameter is within the predetermined range; and based on a determination that the further value of the electrical parameter is outside of the predetermined range, causing a vibrator of the bulk solid handling equipment to vibrate.

According to various, but not necessarily all, embodiments there is provided examples as claimed in the appended claims.

BRIEF DESCRIPTION

Some examples will now be described with reference to the accompanying drawings in which: Fig. 1 shows an example screw conveying apparatus; Fig. 2 is a partial cutaway view of the example screw conveying apparatus of Fig. 1; Fig. 3 is a schematic partial cutaway view of part of the example screw conveying apparatus of Fig. 1, showing material passing through the conveying apparatus; Fig. 4 is a partial cutaway side view of an example disc conveying apparatus; Fig. 5 is a partial cutaway side view of part of the example disc conveying apparatus of Fig. 4; Fig. 6 is a side view of an example bulk bag discharger; Fig. 7 illustrates a controller according to the present disclosure, along with an electric motor and a vibrator of bulk solid handling equipment; Fig. 8 shows a method according to the present disclosure; Fig. 9 illustrates a controller according to the present disclosure, a management system according to the present disclosure, and a user device; Fig. 10 is a perspective view of a first apparatus according to the present disclosure; Fig. 11 is a side view of a second apparatus according to the present disclosure; Fig. 12 is a side view of a third apparatus according to the present disclosure; and Fig. 13 is a cross-sectional side view showing a fourth apparatus according to the present disclosure, part of the first apparatus, and a container.

DETAILED DESCRIPTION

Embodiments of the disclosure relate to a controller 1010 for controlling bulk solid handling equipment including an electric motor 1020 and a vibrator 1030, as illustrated in Fig. 7. The vibrator 1030 may be in the form of a vibrator pad mounted to the equipment.

The controller 1010 is operationally coupled to each of the electric motor 1020 and the vibrator 1030. Any number or combination of intervening elements can exist between the controller 1010 and the electric motor 1020 or the vibrator 1030 (including no intervening elements).

The controller 1010 is configured to receive a signal indicating a value of an electrical parameter associated with power supplied to the electric motor 1020. The electrical parameter may be measured by an electronic measuring device (not shown), which in this example forms part of the motor 1020. In other examples, the electronic measuring device may be separate from the motor 1020. In some examples, the signal is sent from the motor 1020 to the controller 1010, which is represented by arrow 1082 of Fig. 7.

The controller 1010 is able to send a signal to the motor 1020 to cause a change in the speed of the motor 1020, which is represented by arrow 1084 of Fig. 7. The controller 1010 is able to send a signal to the vibrator 1030 to cause the vibrator 1030 to vibrate, which is represented by arrow 1086 in Fig. 7. In some examples, the vibrator and/or the motor may send operational data to the controller 1010, such as data indicating the speed of the motor 1020, or data indicating whether the vibrator 1030 is on or off.

Implementation of the controller 1010 may be as controller circuitry. The controller 1010 may be implemented in hardware alone, have certain aspects in software including firmware alone or can be a combination of hardware and software (including firmware).

The controller 1010 may be implemented using instructions that enable hardware functionality, for example, by using executable instructions of a computer program 1016 in a general-purpose or special-purpose processor 1012 that may be stored on a computer readable storage medium (disk, memory etc.) to be executed by such a processor 1012.

The processor 1012 is configured to read from and write to the memory 1014. The processor 1012 may also comprise an output interface via which data and/or commands are output by the processor 1012 and an input interface via which data and/or commands are input to the processor 1012.

The memory 1014 stores a computer program 1016 comprising computer program instructions (computer program code) that controls the operation of the controller 1010 when loaded into the processor 1012. The computer program instructions, of the computer program 1016, provide the logic and routines that enables the controller 1010 to perform the method illustrated in Fig. 8. The processor 1012 by reading the memory 1014 is able to load and execute the computer program 1016.

The computer program 1016 may arrive at the controller 1010 via any suitable delivery mechanism 1050, as shown in Fig. 7. The delivery mechanism 1050 may be, for example, a machine readable medium, a computer-readable medium, a non-transitory computer-readable storage medium, a computer program product, a memory device, a record medium such as a Compact Disc Read-Only Memory (CD-ROM) or a Digital Versatile Disc (DVD) or a solid state memory, an article of manufacture that comprises or tangibly embodies the computer program 1016.

In some examples, the controller 1010 comprises at least one transceiver that is under control of the processor 1012. The at least one transceiver may comprise any suitable means for receiving and/or transmitting information. The delivery mechanism may be a signal configured to reliably transfer the computer program 1016. The controller 1010 may propagate or transmit the computer program 1016 as a computer data signal.

The at least one transceiver may comprise one or more transmitters and/or receivers. The at least one transceiver may enable a wireless connection between the controller 1010 and the motor and/or vibrator of the bulk solid handling equipment. The wireless connection could be via short-range radio communications such as VVi-Fi or Bluetooth, for example, or over long-range cellular radio links or any other suitable type connection.

In some examples the controller 1010 is an electronic device. The controller 1010 may be an electronic communications device such as a personal computer. The controller 1010 may be a portable electronic communications device such as a handheld electronic communications device or a wearable electronic communications device. The controller 1010, may be configured for mobile cellular communication. The controller 1010 may be a smartphone, a smartwatch, or another type of portable personal computer.

Fig. 8 illustrates an example of a method 1100 carried out by the controller 1010. The method improves the efficiency of bulk solid handling equipment, such as for instance any of the bulk solid handling equipment described herein that includes a motor and a vibrator.

Before operation of the bulk solid handling equipment, a base speed of the motor of the bulk solid handling equipment is set. The base speed is the standard (non-zero) operating speed of motor for a particular application, which could be set automatically or by an operator. The speed of the motor increases to the base speed after initiation of the motor. The base speed of the motor of the bulk solid handling equipment will be set depending on the type of equipment and the type of bulk solid being handled. For instance, a more delicate bulk solid would generally require a lower base speed than a more robust bulk solid, in order to prevent unnecessary damage to the solids being handled. In use, the actual speed of the motor may vary within a small margin of error relative to the base speed.

At block 1110, the controller 1010 receives a signal indicating a value of an electrical parameter associated with power supplied to an electric motor rotating at a base speed. The electrical parameter is measured whilst the motor is rotating at its base speed. The electrical parameter is measured by an electronic measuring device, which may form part of the motor. The signal is sent from the electronic measuring device to the controller 1010, and could be sent via a wired connection and/or a wireless connection. The electrical parameter may be, for instance, the current that is supplied to the motor to cause it to rotate at its base speed, the potential difference (voltage) applied to the motor to cause it to operate at the base speed, or the power consumed by the motor when operating at the base speed.

The current supplied to the motor varies to some extent during normal use, to provide more/less power to the motor, thereby enabling the motor to maintain the base speed.

The change in current supplied to the motor could be caused by differing amounts of material passing through the equipment at a given time. If the change in the current supplied is relatively small, this suggests that the equipment is operating normally and no action is required. More extreme changes in the current value could be caused by blockages in the bulk solid handling equipment, or for instance where the bulk solid in the form of a powder becomes too fluidised to be efficiently conveyed. A significant change in the electrical parameter is therefore indicative of a problem in the bulk solid handling equipment.

At block 1120, the controller 1010 determines whether the value of the electrical parameter is within a predetermined range. In some examples, the predetermined range is set manually by an operator. In other examples, the predetermined range is automatically generated based on a predetermined expected value for the electrical parameter. The automatically generated predetermined range may be within ±10% of the predetermined expected value for the electrical parameter.

The predetermined expected value of the electrical parameter could be generated automatically, or be based on a user input. The predetermined expected value could be generated automatically based on the base speed that has been set for the motor, by using a lookup table to identify an expected value of the electrical parameter based on the particular base speed. The lookup table may include an expected value for the electrical parameter that corresponds to that base speed. Alternatively, the predetermined expected value could be automatically determined using an average of previous recorded values of the electrical parameter when the motor is operating at the particular base speed For example, the motor may be a 415V electric motor, and the expected value of the current supplied to the motor may be set automatically at 1.6A when a particular base speed is set by a user. In this example, a current value of around 1.6A enables the motor to rotate at the base speed set by the user during normal operation. The predetermined range is then automatically generated based on the expected current value as 1.44A -1.76A, which is a range of ±10% of the predetermined expected value.

At block 1130, the controller 1010 causes one or more temporary changes in the speed of the electric motor relative to the base speed, based on a determination that the value of the electrical parameter is outside of the predetermined range. This change in speed of the motor could refluidise the bulk solid or unblock the equipment, thereby increasing the efficiency of the equipment. In some examples, at least one of the temporary changes in the speed of the electric motor is a change in speed of at least 2% relative to the base speed. Preferably, at least one of the temporary changes in the speed of the electric motor is a change in speed of 2% to 15% relative to the base speed. Most preferably, at least one of the temporary changes in the speed of the electric motor is a change in speed of 2 to 8% relative to the base speed. The temporary change in speed of the motor could be for instance a temporary increase or a temporary decrease in the speed of the motor of 5% relative to the base speed. In some examples, the temporary change in speed relative to the base speed lasts for between 1 to 10 seconds, then the motor returns to its base speed.

For example, the bulk solid handling equipment may be a flexible screw conveyor with a motor operating at 800 rpm. If the value of the electrical parameter falls outside of the predetermined range, the controller 1010 could cause the motor speed to increase to 840 rpm for 5 seconds, or decrease to 760 rpm for 5 seconds.

In some examples, the controller 1010 causes two or more temporary changes in the speed of the electric motor relative to the base speed, based on a determination that the value of the electrical parameter is outside of the predetermined range. The causing the two or more temporary changes in the speed of the motor includes: causing the speed of the electric motor to temporarily increase relative to the base speed; and causing the speed of the electric motor to temporarily decrease relative to the base speed. In some examples, the method comprises causing the speed of the motor to operate at the base speed for a period of time between the first temporary change in speed and the second temporary change in speed. In one example, the of aperiod of time is 2 seconds. During this period of time, the torque being applied is reduced relative to when a transition is occurring between the increased/decreased speeds, thereby extending the operating life of the motor and equipment. In some embodiments, a further determination as to whether the value of the electrical parameter is outside of the predetermined range may be carried out before proceeding with the second temporary change in speed, to ascertain whether this second temporary change in speed is necessary. If a determination is made that the value of the electrical parameter remains outside of the predetermined range after the first temporary change in speed, the controller 1010 causes the motor to proceed to the second temporary change in speed. If a determination is made that the value of the electrical parameter is inside of the predetermined range after the first temporary change in speed, the method may comprise causing the motor to return to or remain at the base speed, and not proceed with the second temporary change in speed.

The causing two or more temporary changes in the speed of the electric motor may comprise causing the speed of the electric motor to temporarily decrease relative to the base speed after the temporary increase in the speed of the motor. For example, the bulk solid handling equipment may be a flexible screw conveyor operating at 800 rpm. If the value of the electrical parameter falls outside of the predetermined range, the controller 1010 could cause the motor speed to increase to 840rpm for 5 seconds, operate at the base speed for 2 seconds, and then decrease to 760 rpm for 5 seconds. The advantage of first increasing the speed of the motor, rather than first decreasing the speed of the motor, is that the likelihood of causing a blockage in the bulk solid handling equipment is reduced. If the speed of the motor is decreased first, this could defluidise the bulk solids and cause a complete blockage of the equipment.

At block 1140, the controller 1010 receives a further signal indicating a further value of the electrical parameter, once the one, two or more temporary changes in the speed have ceased and the electric motor has returned to its base speed. The further signal is sent from the electronic measuring device to the controller 1010, which could be sent via a wired connection and/or a wireless connection.

At block 1150, the controller 1010 determines whether the further value of the electrical parameter is within the predetermined range. The predetermined range is the same as the predetermined range of block 1120.

At block 1160, the controller 1010 causes a vibrator of the bulk solid handling equipment to vibrate, based on a determination in block 1150 that the further value of the electrical parameter is again outside of the predetermined range. Where the one or more temporary changes in speed have not fully resolved the problem in the bulk solid handling equipment, which could be for instance a blockage, the vibration offers a further opportunity to solve the problem by loosening the bulk solids. For example, the vibration could dislodge bulk solids that are trapped in the equipment.

In some embodiments, the above method 1100 may be repeated until a determination is made that the value of the electrical parameter is inside the predetermined range. If no determination is made that the value of the electrical parameter is inside the predetermined range after the method 1100 has been performed a predefined number of times (e.g. three), the repetition of the method 1100 may cease.

In some embodiments, the controller 1010 is connected to a plurality of bulk solid handling apparatuses via a wired or wireless connection. The controller 1010 may carry out the method 1100 on a single one, more than one, or all of the plurality of bulk solid handling apparatuses at a given time.

In some embodiments, the controller 1010 sends diagnostic information to a management system 1200, as illustrated by the arrow 1102 in Fig. 9. The management 35 system 1200 may be a cloud-based management system. The management system 1200 may be configured to receive diagnostic information from a plurality of controllers 1010. If the diagnostic information indicates that the value of the electrical parameter is outside of the predetermined range, the management system 1200 may send an alert (illustrated by the arrow 1104 in Fig. 9) to a user device 1300, such as a mobile phone, a personal computer or a tablet. The alert may for instance be in the form of a notification, a text message, a voice call or an email.

In some embodiments, if the diagnostic information indicates that the method steps 1100 to 1600 of Fig. 11 have been completed, and that the value of the electrical parameter remains outside of the predetermined range, the management system 1200 may send an alert to a user device 1300, such as a mobile phone, a personal computer or a tablet. The alert may for instance be in the form of a notification, a text message, a voice call or an email. This alert highlights a problem with the bulk solid handling equipment, and triggers the user to remediate the problem and thus improve the efficiency of the equipment. In other embodiments, an alert may be sent to a user device 1300 if the diagnostic information indicates that the method 1100 has been repeated a predefined number of times (e.g. three), and that the value of the electrical parameter remains outside of the predetermined range.

Some examples of bulk solid handling equipment where the above method could be applied are provided in Figs. 10 to 13, and these are described below. Furthermore, the method could also be applied to the example equipment 100, 200, 300 of Figs. 1 to 6, if the example equipment 100, 200, 300 included a vibrator and a controller 1010.

Fig. 10 illustrates a first apparatus 400. The first apparatus 400 is similar to the example screw conveying apparatus 100, but includes a vibrator 470 adjacent to the inlet assembly 450 of the first apparatus 400. In this example, the vibrator 470 is in the form of a vibrator pad.

The illustration of the first apparatus 400 in Fig. 10 shows a different length of flexible tube 410 relative to the example screw conveying apparatus 100 in Fig. 1, but in practice any length or dimension of tube could be used in the first apparatus 400. Also, while the first apparatus 400 is not shown as including a hopper at the inlet assembly 450, it could in some examples.

The vibration of the vibrator 470 can dislodge bulk solids around the inlet assembly 450 of the first apparatus 400, thereby preventing or removing blockages. This enables the apparatus 400 to operate more efficiently and convey a greater amount of material in a given period of time.

In this example, the controller 1010 (not shown in Fig. 10) is remote from the first apparatus 400, and is configured to connect to the motor 430 and the vibrator 470 of the first apparatus 400 via a wired and/or wireless connection. In other examples the controller 1010 may be provided in, on, or adjacent to, the first apparatus 400.

The controller 1010 improves the efficiency of the first apparatus 400, using the method 1100 described herein. For example, if a blockage arises in the apparatus 400 and the bulk solid becomes defluidised, this may cause the current supplied to the motor 430 to increase, in order to maintain the base speed of the motor 430. Using the method 1100 described herein, this spike in the current value may trigger the controller 1010 to cause the motor 430 to speed up (thereby speeding up the conveyor) and refluidise the bulk solids. This could remove the blockage and return the equipment to normal operation. If the change in speed of the motor 430 does not resolve the issue, the vibration of the vibrator 470 may be enough to refluidise the solids and return the equipment 400 to normal operation.

Fig. 11 shows a second apparatus 500. The second apparatus 500 is similar to the example disc conveying apparatus 200, but additionally includes a vibrator 570, which in this example is in the form of a vibrator pad. The vibrator 570 is mounted adjacent to the inlet assembly 550 of the second apparatus 500.

In this example, the controller 1010 (not shown) is remote from the second apparatus 500, and is configured to connect to the motor 530 and the vibrator 570 of the second apparatus 500 via a wired and/or wireless connection. In other examples the controller 1010 may be provided in, on, or adjacent to, the second apparatus 500.

The controller 1010 improves the efficiency of the second apparatus 500, using the method 1100 described herein. For example, if a blockage arises in the second apparatus 500 and the bulk solid becomes defluidised, this may cause the current supplied to the motor 530 to increase, in order to maintain the base speed of the motor 530. Using the method 1100 described herein, this spike in the current value may trigger the controller 1010 to cause the motor 530 to speed up (thereby speeding up the conveyor) and refluidise the bulk solids. This could remove the blockage and return the equipment to normal operation. If the change in speed of the motor 530 does not resolve the issue, the vibration of the vibrator 570 may refluidise the solids and return the equipment 500 to normal operation.

Fig. 12 illustrates a third apparatus 600. The third apparatus 600 is similar to the second apparatus 500 in that it is also a disc conveying apparatus, but the third apparatus 600 includes a differently shaped rigid pipe 610 relative to the example disc conveying apparatus 200 and the second apparatus 500. The third apparatus 600 includes a vibrator 670 mounted to the inlet assembly 650.

The third apparatus 600 includes larger discs (not shown in Fig. 12) relative to the inner diameter of the pipe 610 when compared to the second apparatus 500. The second apparatus 500 therefore has reduced clearance between the discs and the inner surface of the pipe 510. In view of these differences, the third apparatus 600 is configured to run at slower speeds relative to the second apparatus 500, and is designed for gentle material handling and/or for conveying in multiple planes.

In this example, the controller 1010 (not shown) is remote from the third apparatus 600, and is configured to connect to the motor 630 and the vibrator 670 of the third apparatus 600 via a wired and/or wireless connection. In other examples the controller 1010 may be provided in, on, or adjacent to, the third apparatus 600.

The controller 1010 improves the efficiency of the third apparatus 600, using the method 1100 described herein. For example, if a blockage arises in the third apparatus 600 and the bulk solid becomes defluidised, this may cause the current supplied to the motor 630 to increase, in order to maintain the base speed of the motor 630. Using the method 1100 described herein, this spike in the current value may trigger the controller 1010 to cause the motor 630 to speed up (thereby speeding up the conveyor) and refluidise the bulk solids. This could remove the blockage and return the equipment to normal operation. If the change in speed of the motor 630 does not resolve the issue, the vibration of the vibrator 670 may be enough to refluidise the solids and return the equipment 600 to normal operation.

Fig. 13 shows a fourth apparatus 700, the first apparatus 400 and a container 800. In the example of Fig. 10, the fourth apparatus 700 discharges bulk solids into the first apparatus 400, and the first apparatus 400 conveys the material to the container 800.

In other embodiments, the fourth apparatus 700 may discharge the bulk solids directly into a container, or into a different conveyor.

The fourth apparatus 700 is similar to the example bulk bag discharger 300 of Fig. 6, but additionally includes a vibrator 770. In the example of Fig. 13, the vibrator 770 is in the form of a vibrator pad, which is mounted to the hopper 740 of the fourth apparatus 700. The agitator 720 of the fourth apparatus 700 is powered by a motor 730. The agitator 720 and vibrator 770 of the fourth apparatus 700 can each prevent the bridging of bulk solids (such as powders) in the hopper 740.

In this example, the controller 1010 (not shown) is remote from the fourth apparatus 700, and is configured to connect to the motor 730 and the vibrator 770 of the fourth apparatus 700 via a wired and/or wireless connection. In other examples the controller 1010 may be provided in, on, or adjacent to, the fourth apparatus 700.

The controller 1010 improves the efficiency of the fourth apparatus 700, using the method 1100 described herein. For example, if a blockage arises in the fourth apparatus 700 caused by bridging of the solids in the hopper 740, this may trigger the current supplied to the motor 730 to increase, in order to maintain the base speed of the motor 730. Using the method 1100 described herein, this spike in the current value may trigger the controller 1010 to cause the motor 730 to speed up (thereby speeding up the agitator 720) and stop the bridging of the solids. This could remove the bridging problem and return the equipment to normal operation. If the change in speed of the motor 730 does not resolve the issue, the vibration of the vibrator 770 may be enough to refluidise the solids and return the equipment 700 to normal operation.

References to 'computer-readable storage medium', 'control circuitry', 'computer', 'processor' etc. should be understood to encompass not only computers having different architectures such as single/multi-processor architectures and sequential (Von Neumann)/parallel architectures but also specialized circuits such as field-programmable gate arrays (FPGA), application specific circuits (ASIC), signal processing devices and other processing circuitry. References to computer program, instructions, code etc. should be understood to encompass software for a programmable processor or firmware such as, for example, the programmable content of a hardware device whether instructions for a processor, or configuration settings for a fixed-function device, gate array or programmable logic device etc. The blocks illustrated in Fig. 8 may represent steps in a method and/or sections of code in the computer program 1016. The illustration of a particular order to the blocks does not necessarily imply that there is a required or preferred order for the blocks and the order and arrangement of the block may be varied. Furthermore, it may be possible for some blocks to be omitted.

The bulk solid handling apparatuses described herein may form part of a bulk solid handling system. The system may include one or more downstream or upstream processing units. The upstream or downstream processing units could be for instance conveyors, dischargers, lifting equipment or other units for handling bulk solids.

The term 'comprise' is used in this document with an inclusive not an exclusive meaning. That is any reference to X comprising Y indicates that X may comprise only one Y or may comprise more than one Y. If it is intended to use 'comprise' with an exclusive meaning then it will be made clear in the context by referring to "comprising only one.." or by using "consisting".

In this description, reference has been made to various examples. The description of features or functions in relation to an example indicates that those features or functions are present in that example. The use of the term 'example' or 'for example' or 'can' or 'may' in the text denotes, whether explicitly stated or not, that such features or functions are present in at least the described example, whether described as an example or not, and that they can be, but are not necessarily, present in some of or all other examples. Thus 'example', 'for example', 'can' or 'may' refers to a particular instance in a class of examples. A property of the instance can be a property of only that instance or a property of the class or a property of a sub-class of the class that includes some but not all of the instances in the class. It is therefore implicitly disclosed that a feature described with reference to one example but not with reference to another example, can where possible be used in that other example as part of a working combination but does not necessarily have to be used in that other example.

Although examples have been described in the preceding paragraphs with reference to various examples, it should be appreciated that modifications to the examples given can be made without departing from the scope of the claims.

Features described in the preceding description may be used in combinations other than the combinations explicitly described above.

Although functions have been described with reference to certain features, those functions may be performable by other features whether described or not.

Although features have been described with reference to certain examples, those features may also be present in other examples whether described or not.

The term 'a' or the' is used in this document with an inclusive not an exclusive meaning. That is any reference to X comprising a/the Y indicates that X may comprise only one Y or may comprise more than one Y unless the context clearly indicates the contrary. If it is intended to use a' or 'the' with an exclusive meaning then it will be made clear in the context. In some circumstances the use of 'at least one' or one or more' may be used to emphasis an inclusive meaning but the absence of these terms should not be taken to infer any exclusive meaning.

The presence of a feature (or combination of features) in a claim is a reference to that feature or (combination of features) itself and also to features that achieve substantially the same technical effect (equivalent features). The equivalent features include, for example, features that are variants and achieve substantially the same result in substantially the same way. The equivalent features include, for example, features that perform substantially the same function, in substantially the same way to achieve substantially the same result.

In this description, reference has been made to various examples using adjectives or adjectival phrases to describe characteristics of the examples. Such a description of a characteristic in relation to an example indicates that the characteristic is present in some examples exactly as described and is present in other examples substantially as described.

Whilst endeavoring in the foregoing specification to draw attention to those features believed to be of importance it should be understood that the Applicant may seek protection via the claims in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not emphasis has been placed thereon.

0 I/we claim:

Claims

CLAIMS1. A controller comprising means for: receiving a signal indicating a value of an electrical parameter associated with power supplied to an electric motor of bulk solid handling equipment, which is rotating at a base speed; determining whether the value of the electrical parameter is within a predetermined range; based on a determination that the value of the electrical parameter is outside of the predetermined range, causing two or more temporary changes in the speed of the electric motor, including: causing the speed of the electric motor to temporarily increase relative to the base speed, and causing the speed of the electric motor to temporarily decrease relative to the base speed; once the two or more temporary changes in the speed have ceased and the electric motor has returned to its base speed, receiving a further signal indicating a further value of the electrical parameter; determining whether the further value of the electrical parameter is within the predetermined range; and based on a determination that the further value of the electrical parameter is outside of the predetermined range, causing a vibrator of the bulk solid handling equipment to vibrate.
2. A controller according to claim 1, wherein the causing two or more temporary changes in the speed of the electric motor comprises causing the speed of the electric motor to temporarily decrease relative to the base speed after the temporary increase in the speed of the motor.
3. A controller according to claim 1 or 2, wherein at least one of the temporary changes in the speed of the electric motor is a change in speed of at least 2% relative to the base speed.
4. A controller according to claim 3, wherein at least one of the temporary changes in the speed of the electric motor is a change in speed of 2 to 15% relative to the base speed.
5. A controller according to claim 4, wherein at least one of the temporary changes in the speed of the electric motor is a change in speed of 2 to 8% relative to the base speed.
6. A controller according to any of the preceding claims, wherein the electrical parameter is the current supplied to the motor.
7. A controller according to any of the preceding claims, wherein the predetermined range is within ±10% of a predetermined expected value for the electrical parameter.
8. An apparatus for handling bulk solids, the apparatus comprising: a controller according to any of the preceding claims; a device for moving the bulk solids; a vibrator configured to vibrate at least a portion of the apparatus; and an electric motor for powering the device.
9. An apparatus according to claim 9, wherein the device for moving the bulk solids is a conveyor or an agitator.
10. An apparatus according to claim 8 or 9, wherein the apparatus further includes an enclosed conduit and the device is a conveyor locatable inside the enclosed conduit, the conveyor being configured to urge bulk solids through the enclosed conduit when powered by the motor.
11. The apparatus according to any of claims 8 to 10, wherein the vibrator is located adjacent to an inlet or an outlet of the apparatus.
12. The apparatus according to claim 10, or claim 11 when dependent on claim 10, wherein the enclosed conduit comprises a flexible tube.
13. The apparatus according to claim 10, or claims 11 or 12 when dependent on claim 10, wherein the conveyor comprises a helical coil.
14. The apparatus according to claim 10, or claims 11 or 12 when dependent on claim 10, wherein the conveyor comprises a plurality of discs.
15. The apparatus according to claim 14, wherein the plurality of discs are mounted to a line.
16. The apparatus according to any of claims 8 to 11, wherein the apparatus includes a hopper, and the device is an agitator configured to maintain the bulk solids in a free-flowing state.
17. A system comprising one or more apparatuses as claimed in any of claims 8 to 16, wherein the system further includes one or more downstream or upstream processing units.
18. A method of controlling bulk solid handling equipment, the method comprising: receiving a signal indicating a value of an electrical parameter associated with power supplied to an electric motor of bulk solid handling equipment, which is rotating at a base speed; determining whether the value of the electrical parameter is within a predetermined range; based on a determination that the value of the electrical parameter is outside of the predetermined range, causing two or more temporary changes in the speed of the electric motor, including: causing the speed of the electric motor to temporarily increase relative to the base speed, and causing the speed of the electric motor to temporarily decrease relative to the base speed; once the two or more temporary changes in the speed have ceased, receiving a further signal indicating a further value of the electrical parameter; determining whether the further value of the electrical parameter is within the predetermined range; and based on a determination that the further value of the electrical parameter is outside of the predetermined range, causing a vibrator of the bulk solid handling equipment to vibrate.
19. A computer program comprising program instructions for causing an apparatus to perform at least the following: receiving a signal indicating a value of an electrical parameter associated with power supplied to an electric motor of bulk solid handling equipment, which is rotating at a base speed; determining whether the value of the electrical parameter is within a predetermined range; based on a determination that the value of the electrical parameter is outside of the predetermined range, causing two or more temporary changes in the speed of the electric motor, including: causing the speed of the electric motor to temporarily increase relative to the base speed, and causing the speed of the electric motor to temporarily decrease relative to the base speed; once the two or more temporary changes in the speed have ceased, receiving a further signal indicating a further value of the electrical parameter; determining whether the further value of the electrical parameter is within the predetermined range; and based on a determination that the further value of the electrical parameter is outside of the predetermined range, causing a vibrator of the bulk solid handling equipment to vibrate.