WO2008134007A1

WO2008134007A1 - Material and energy distribution system

Info

Publication number: WO2008134007A1
Application number: PCT/US2008/005379
Authority: WO
Inventors: Lawrence M. Levenstein; Eric A. Williams; Robert D. Thibodeau
Original assignee: C.H.& I. Technologies, Inc.
Priority date: 2007-04-24
Filing date: 2008-04-24
Publication date: 2008-11-06

Abstract

This invention distributes energy that distributes material. This energy (electrical, hydraulic, and/or pneumatic) is distributed to material displacement devices. These displacement devices convert this distributed energy into hydraulic energy to transfer material through material piping sections. These displacement devices and piping sections may be parallel, series, and/or in a network. Instrumentation and controls are integrated with these displacement devices and piping sections.

Description

MATERIAL AND ENERGY DISTRIBUTION SYSTEM

BACKGROUND OF THE INVENTION

The present invention is directed to a system and method that distributes energy for distributing material to displacement devices, and more particularly to displacement devices that convert distributed energy into hydraulic energy to transfer material through a material piping network. The contents of U.S. Non-Provisional Patent Application Serial No. 11/584,932, filed October 21, 2006; and U.S. Patent No. 5,435,468 are each hereby incorporated herein by reference.

Prior known material and energy management systems have encountered difficulty transferring from a containment vessel certain thick, viscous fluids, liquids and other types of materials that may resist pumping and that can be damaging to pumping apparatus. As used herein, a fluid is a substance that is capable of flowing and that changes its shape at a steady rate when acted upon by a force tending to change its shape. Certain materials, while normally not considered to be fluids, also can be made to flow under certain conditions, for example, soft solids and semi-solids. Vast quantities of fluids are used in transportation, manufacturing, farming, mining, and industry. Thick fluids, viscous fluids, semi-solid fluids, visco-elastic products, pastes, gels and other fluid materials that are not easy to dispense from fluid sources (for example, pressure vessels, open containers, supply lines, etc.) comprise a sizable portion of the fluids utilized. These fluids include thick and/or viscous chemicals and other such materials, for example, lubricating greases, adhesives, sealants and mastics. The ability to transport these materials from one place to another, for example, from a container to a manufacturing or processing site, and in a manner that protects the quality of the material, is of vital importance.

Various components of fluid delivery systems are known, but are typically configured with heavy-duty pumps and are not integrated with a material delivery system having process controls and /or a computer interface capability. The contents of U.S. Patent Nos. 4,783,366; 5,373,221 ; 5,418,040; 5,524,797; 6,062,492; 6,253,799; 6,364,218; 6,540,105; 6,726,773; 6,814,310; 6,840,404; and 6,861,100 are each hereby incorporated herein in their entirety by reference. A refillable material transfer system may be configured to move highly viscous fluids from a vessel to a point of use. Such a material transfer system may be configured to dispense only the required amount of material without waste, which is especially important when chemicals are not easily handled and cannot be manually removed easily or safely from the vessel. Preferably, such a material transfer system would reduce or eliminate costs and expenses attendant to using drums, kegs and pails, as well as the waste of material associated with most existing systems. Because certain chemicals are sensitive to contamination of one form or another, such a material transfer system may be sealed, protect product quality, allow sampling without opening the container to contamination and permit proper attribution of product quality problems to either the supplier or the user. A refillable material transfer system may further be configured to use low cost components and provide a non-mechanical (no moving parts), non-pulsating solution for dispensing and transferring thick fluids and other such materials.

Accordingly, what has been needed and heretofore unavailable is a material and energy distribution system and method that overcome the deficiencies of existing configurations. The present invention disclosed herein satisfies these and other needs.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGURE 1 is a schematic representation of the material and energy distribution system of the present invention.

FIG. 2 is a description and depiction of a hydrohoist suitable for use with the system and method of the present invention.

FIG. 3 is a description and depiction of a low-cycle chamber feeder suitable for use with the system and method of the present invention.

FIG. 4 is a description and depiction of a various accumulators suitable for use with the system and method of the present invention.

FIG. 5 is a side plan view of an intelligent material transfer subsystem of the present invention having a plurality of sensors and transmitters located on a material vessel. FIG. 6 is a side plan view of the intelligent material transfer subsystem of FIG. 5, wherein the instrumentation has been adapted for connection to a computer, microprocessor or other data processing system.

FIG. 7 is a block diagram representation of an intelligent material transfer subsystem of the present invention.

FIG. 8 is a schematic representation of an intelligent material transfer subsystem of the present invention.

FIG. 9 is a front plan view in partial cross-section of an intelligent material transfer subsystem of the present invention having a plurality of discrete control systems shown in schematic representations.

FIG. 10 is a front plan view in partial cross-section of an intelligent material transfer subsystem of the present invention having a plurality of control systems integrated with a computer control system shown in schematic representations.

FIG. 11 is a side plan view of a refillable material transfer subsystem of the present invention integrated with a pump system, an applicator apparatus and a computer control system shown in a schematic representation.

FIG. 12 is a side plan view of a refillable material transfer subsystem of the present invention integrated with at least one applicator apparatus and a computer control system shown in a schematic representation.

FIG. 13 is a block diagram representation of several configurations of material transfer systems in accordance with the present invention.

FIG. 14 is a schematic representation of a pumpless material dispensing system in accordance with the present invention.

FIGS. 15A and 15B are block diagrams of a prior art material dispensing system and a pumpless material dispensing system of the present invention.

FIG. 16 is a prior art integral servo dispensing system suitable for use with the pumpless material dispensing system of FIG. 14. SUMMARY OF THE INVENTION

As shown in the drawings for purposes of illustration, the present invention uses lower-pressure and lower-cost material displacement devices and material piping sections, having integral instrumentation and controls, to transfer materials indefinite lengths at lower costs. In one embodiment, the system and method of the present invention is intended to replace current systems that use relatively higher-pressure components, higher-cost components and/or higher cost methods to transfer viscous and/or elastic fluids. The system and method of the present invention distributes energy (electrical, hydraulic, and/or pneumatic) that distributes such fluids to material displacement devices and to material applicators. The material displacement devices configured in the system of the present invention convert distributed energy into hydraulic energy to transfer the material through material piping sections. Such material displacement devices and material piping may be in parallel, in series and/or in a network. Instrumentation and controls may be integrated with the material displacement devices and piping sections configured in the system of the present invention.

In numerous automotive manufacturing plants and other facilities, higher-pressure higher-cost pumps and piping transfer viscous and/or elastic fluids, such as Liquid Applied Sound Deadener (LASD), from containers to applicators. Many of these pumps are steel or stainless steel piston pumps (available from Graco, Inc., Minneapolis, Minnesota), some with a 34:1 ratio (100 psig compressed air delivers up to 3,400 psig LASD). Double Extra Strong Schedule 160 steel or stainless steel piping is required for the pressures associated with such pumps. There are limited distances that these type of pumps can transfer LASD and other viscous and/or elastic fluids. These limited distances, often significantly less than one thousand feet, are based on the pressure capacities of these pumps.

Although such pumps are often installed in parallel to increase the flow capacities, the pumps are seldom installed in series to increase the pressure capacities. If the pumps are installed in series, then the pumps are vulnerable to stalling in mid-stroke and fail to operate. If the pumps are installed in series with atmospheric break tanks, then the pumps and the storage tanks are vulnerable to fouling (for example, from dried out and cured LASD from tank air exchange/venting) and may fail to operate properly. In some of facilities that use such viscous and/or elastic fluids, the material must be moved distances that exceed the distances that it can be reasonably pumped. In these plants, the material containers must be transported with higher-cost labor (personnel) operating higher-cost equipment (material handling equipment, lift trucks).

Turning now to the drawings, in which like reference numerals represent like or corresponding aspects of the drawings, and with particular reference to FIG. 1, the material and energy distribution system 1000 of the present invention is configured for moving material an indefinite length. Such material may be transported via a tank truck and tank trailer 1100 or provided by and/or stored in material semi-bulk containers on a trailer 1200 (see also FIG. 13). The material may be transferred from the tank truck to the semi-bulk containers and/or to a bulk material vessel 1300. In addition, the material may be transferred from the tank truck, semi-bulk containers or bulk vessels to a semi-bulk refillable material transfer system 1510 (see also FIGS. 5-6, 9-10). Material is transferred from the bulk vessel and/or semi-bulk refillable material transfer system through low pressure, low cost piping 1400. The bulk vessel and semi-bulk vessels may be configured with instrumentation and controls (I & C) and have separate energy sources.

Material is moved through the low pressure piping 1400 by a series of material in-line accumulators 1600 that also may be provided with separate energy sources and instrumentation and controls (see also FIGS. 2-4). The piping and material in-line accumulators may be fed to a material metering device 1700 that provides the material to an applicator 1810 (see also FIGS. 14-16). Alternatively, material may be transferred from the bulk vessel 1300 and semi-bulk refillable material transfer system 1500 through the low pressure piping 1400 and material in-line accumulator to a refillable material transfer system 1520 that may be connected directly to a material applicator 1820 (FIGS. 1 1-15) and may have one or more additional material in-line accumulators between the refillable material transfer system and the material applicator.

Referring again to FIG. 1 , material is transferred to applicators through a system configured from a network of parallel and series lower-cost, lower-pressure material displacement devices and material piping sections. A tank truck, tank trailer, and semi-bulk on a trailer may supply material to this system. The material displacement devices may be bulk vessel, semi-bulk refillable material transfer system, refillable material transfer system, and material inline accumulators. This system of the present invention is configured to distribute energy, for example, but not limited to, electrical, hydraulic and pneumatic energy. This system supplies material to a material applicator, and a material applicator with a material metering device (shot meter). One aspect of the system of the present invention is the enablement of reliable operation of its material displacement devices in series. Another aspect is the integrated instrumentation and controls (I & C).

The system of the present invention is configured to feed material forward to the applicators like a closed and pressurized "bucket brigade." The application process is a batch process, and the applicators are either on or off. When the applicators are on, the system feeds material to them from the material displacement device immediately upstream of them. When the applicators are off, the system refills the material displacement devices. These material displacement devices are refilled in sequential batch processes, from upstream, to downstream.

The integrated instrumentation and controls of the system of the present invention refill each material displacement device by de-pressurizing it, closing its outlet valve, opening its inlet valve, refilling it from the material displacement device immediately upstream of it, closing its inlet valve, pressurizing it, and opening its outlet valve. This system's integrated instrumentation and controls include operating logic that manages these batch application and refilling processes. This logic includes a learning mode and anticipation function, and is based on real time operating data and historical operating data. As one example, this logic could anticipate a decrease in the material application and increase in the material refill "window", based on the time of day (real time operating data) and personnel shift change (historical operating data).

Suitable material inline accumulators (for example, but not limited to, positive displacement pumping devices) that may be used with the system and method of the present invention include, but are not limited to: (1) Hydrohoists as shown in FIGS. 2A and 2B — available from Merpro Limited, Scotland, UK

(http://merpro.com/section.php?page=sandhydro) under the trade name "Tore Hydrohoist";

(2) Low-Cycle Changer Feeders as shown in FIG. 3 - available from Hitachi, Ltd (http://www.hitachi.com); and (3) Accumulators as shown in FIG. 4 - available from Hydac

Technology Corp. (http://www.hydacusa.com/accum/accum.htm) and Pulseguard Inc.

(http://www.pulseguard.com). Referring now to FIG. 5, the system of the present invention may include an intelligent automated material transfer system 110 having process instrumentation associated with a refillable material vessel 120 configured in a vertical format; however, horizontal and other configurations may be used. The material vessel includes a main body 150, a top 122, and one or more legs or extensions 170. The main body of the material vessel is configured in a cylindrical format having a lower portion 152 to be connected to the legs 170 and an upper portion to be connected to the top. So as to facilitate removal of the top 122 from the refillable container 120, a lifting mechanism 130 may be configured adjacent the main body 150 of the material vessel. The refillable material transfer system 110 may be further configured with a material inlet and outlet manifold 140 positioned below the main body 150 of the material vessel 120 and adjacent the bottom portion 152 of the vessel.

As shown in FIG. 5, the intelligent material transfer system 110 includes a plurality of sensors and transmitters located on the refillable material vessel 120. For example, on the top of the vessel 122, a volume sensor 210 and transmitter 215 are located between a temperature sensor 220 with transmitter 225 and a pressure sensor 230 with transmitter 235. As will be appreciated by those of ordinary skill in the art, many configurations of the sensors may be employed in such a transfer system. Likewise, the transmitters may include a wireless signal 200, hardwired signal or other connection to a remote receiver. Such transmissions may include radio frequency, microwave, infrared, coaxial, universal serial buss (USB) or other industry standards, such as, but not limited to, relay wiring, twisted pair, Bluetooth and Ethernet.

Various other sensors and transmitters may be included in the intelligent material transfer system 110, such as a flow inlet sensor 270 with transmitter 275 and flow outlet sensor 280 with transmitter 285 positioned in or about the fluid inlet outlet manifold 140 and vessel support device (legs or pedestals) 170. Similarly, the vessel 120 may be connected to a weight sensor 290 and transmitter 295, such as a load cell or similar device at or near the bottom 152 of the vessel. Further, identification devices 240 with transmitters 245, such as a radio frequency identification device (RFID), may be attached to or otherwise associated with the vessel. For purposes of locating such a material vessel, a global positioning system (GPS) device 250 and transmitter 255 may be associated with the automated material transfer system. Additionally, a mechanism for tracking the time that fluid has been retained in the vessel, such as a time sensor 260 with transmitter 265 may be configured with the system. Other timer related events, such as, but not limited to, depressurizing, start and end fill times may be monitored and/or tracked. Further, a sensor may be associated with the lifting mechanism 130 to indicate when the lid has been lifted or removed from the main body of the vessel. Such sensors may be passive or include the ability for intelligence, including operator input, local display and other functions. Alternatively, the sensors may be very simple devices, such as color dots, irreversible moisture indicators, conductivity sensors, pH sensors and the like. Other instrumentation may include devices for measurement and/or monitoring of gas properties and/or material properties.

Referring now to FIG. 6, some of the instrumentation shown in FIG. 5 has been adapted for connection to a computer, microprocessor or other data processing system 300. For example, the volume or level sensor 210 is associated with a computer connection 217, the temperature sensor 220 is associated with a computer connection 227 and the pressure sensor 230 is associated with a computer connection 237. Similarly, the RFID device 240 has a computer connection 247, and the GPS device 250 has a computer connection 257. Likewise, inlet and outlet flow sensors 270 and 280 include computer connections 277 and 287. As described with reference to FIG. 5, any of the sensors (such as system time and material weight) shown therein or described regarding instrumentation suitable for such a material transfer system may be connected to the data processing system 300.

A data processing system 300 of the automated material transfer system 110 may take many configurations suitable for retrieving the data from the various instrumentation, processing of data to provide alarms, time and date information, event information, fault data, financial data, calculation of fluid and other properties associated with the refillable material vessel 120. The computer control system typically will include a processor 310 or similar computing device, a display device 320 and an operator input device 340. The computer system may further include a modem 350 or other connection(s) for integrating the automated material transfer system to a remote monitoring system, an intranet, the Internet or other system. In addition, the automated material transfer system shown in FIGS. 5 and 6 may require a separate power source, such as alternating current (AC) or direct current (DC), for example, local batteries. It will be appreciated by those of ordinary skill in the art that each of the individual instrumentation may have its own internal power source, such as a battery, or may be connected to a central or external power source. As shown in FIG. 7, the processor 310 (FIG. 6) may include diagnostic logic, financial logic, operating logic and wireless logic. The processor may be associated with random access memory (RAM), read only memory (ROM) and other data storage devices. The data processing system may also comprise a more simpler device, such as a data logger with ability to retrieve data stored in such a device with minimal processing capabilities. The data processing system may further include an analog-to-digital (AfD) and/or digital-to- analog (D/ A) interface 360 (FIG. 6), and some instrumentation may connect directly to the processor via USB or other communication devices. It will be appreciated by those of ordinary skill in the art various configurations of the instruments, processors, data logger, memory devices, modems and other devices shown in FIGS. 5 through 8 may be altered to achieve the complexity or simplicity of a desired refϊllable (for example, intelligent and/or portable) material (thick or otherwise) transfer and dispensing system in accordance with the present invention.

Referring now to FIG. 8, various configurations of a microprocessor based distributed data acquisition system 300 may be implemented in accordance with the present invention. For example, the microprocessor 310 may be configured with a display device 320, input/output device 340 and printer 370. Various configurations of the input/output device, such as a keyboard, keypad, touch screen, personal device assistant (PDA) and other electronic and mechanical devices are contemplated by the present invention. Likewise, the operator display may be a conventional cathode ray tube (CRT), plasma, liquid crystal diode (LCD), light emitting diode (LED) or other known or yet to be developed operator interface systems that can provide a graphical, textual or other display capability. Likewise, the printer system may be a conventional dot matrix, laser or thermal paper apparatus. The data acquisition system may include electronic storage devices 386, such as removable diskettes, compact disks (CD), digital video disks (DVD), laser disks and other such data storage mediums. The microprocessor may have other storage capabilities, such as read-only memory (ROM) 382 and random access memory (RAM) 384. The microprocessor may have serial (for example, USB) and parallel (for example, RS-232) interface connections 390 for connecting to intranets, the Internet, broadband, cable and other systems. The microprocessor may also be connected to a modem 350 for wireless, phone line, broadband, cable and other connections. The microprocessor 310 and other aspects of the present invention may be configured with external or local alternating current (AC), direct current (DC) or other power supplies (not shown). The microprocessor may also interface with an analog-to-digital (AfO) and digital-to-analog (D/ A) 360 device for interfacing with the various volume, pressure, temperature, flow and other sensors and instrumentation 217, 237, 227, 277, 287, 297, 247, 257 as heretofore described. Alternatively, such devices as the RFID 247 and GPS 257 may connect directly to the microprocessor via a USB or other interface. The microprocessor may also be configured to interface directly with programmable logic controllers (PLC) 512, 522, 532, 552 for regulating pressure, temperature, flow and other process parameters. Alternatively, the microprocessor may connect with the programmable logic controllers or other control devices through the A/D and D/A converter.

Referring now to FIGS. 9-12, the intelligent material transfer system 10 of the present invention may be configured to automate and control a refillable material vessel 20. The refillable material vessel and its compressed gas source can be portable. The control system may also link and communicate with another automated material transfer systems and with other control and information systems. The automated material transfer system includes a control device, database, instrumentation, operator interface, power source, processor, and receiver/transmitter. The processor includes logic for diagnostic, financial, operating, and wireless data. The power source includes portable sources, such as battery and photovoltaic (PV), and the receiver/transmitter includes wireless communication, such as radio frequency (RF). The data includes information from a control system database and another control systems and information systems. The data includes, but is not limited to, alarm information, dates and times, events, faults, financial data, global position, interface identification, system identification, material identification, operator identification, material properties, gas properties, flow rates, pressure, temperature, and volume.

The control systems of the present invention allow a refillable material vessel to be a fully automated portable system. The control system may be self-powered, self-controlled and constantly linked with other control systems and information systems. The control system can initiate communication with another control system and/or information system, such as those for filling, transporting, inventorying, transferring, monitoring and controlling refillable material vessels and other containers. Example communications include, "Container #1 OK.", and "Help! I'm LASD Container #1, its noon, 1-27-05, and I'm empty, cold, and lost at GM in Warren, MI!".

The high levels of automation and communication of the present invention were previously unavailable with commercial refillable material transfer system technology. The control system and its components are preferably small and light, including miniature electronic components, relative to the refillable material transfer system, to be portable. The control system components preferably have a low cost and low energy consumption, including miniature electronic components, to be practical. Currently available devices may perform the various functions of the control system. The high levels of automation and communication for the control system of the present invention convert the refillable material vessel into a fully automated portable system.

Referring now to FIG. 9, the intelligent material transfer system 10 includes a vessel 20 having a force transfer device 90 contained within a fluid space 40 and gas space 80. The vessel further includes a false bottom 50 so as to constrain the material 42. The force transfer device further includes a tangential element 95 and stabilizers 96. Fluid may be transferred into and out of the container via a manifold 45, having inlet piping 48 and outlet piping 46. In accordance with the present invention, various control systems may be associated with the automated material transfer system. For example, a pressure control system 510 may be associated with the upper portion of the vessel having a pressure control device 512, such as a programmable logic controller (PLC), connected to a pressure sensor 514 located within or on the vessel. The pressure control device is operably connected to a gas (two way) valve 518 configured in the top or lid of the vessel.

Similarly, a temperature control system 520 may be associated with the lower portion of the vessel 20. The temperature control system may include a temperature controller 522, such as a PLC or other control device, operably connected to a temperature sensor 524 located within the fluid manifold 45 or otherwise positioned to sense an appropriate portion of the fluids temperature. The temperature controller is further operably connected to a heat transfer (heating and/or cooling) coil 526 or other mechanism for imparting thermal, kinetic or other energy to the fluid. The temperature controller may be connected to one or more temperature sensors located proximate the heating coil, in the material inlet conduit 48, the material outlet conduit 46 or any other desired location within the material manifold 45. The pressure and temperature control systems of the automated material transfer system 10 of the present invention may include local operator interfaces, such as displays and keyboard inputs for monitoring the pressure and temperature, as well as providing control set points and other data or alarm points to the controllers. Likewise, the controllers may include operator alarms, shut off mechanisms and other features known to those of ordinary skill in the art.

The intelligent material transfer system 10 of the present invention may include other control devices, such as programmable logic controllers and programmable recording controllers (PRC) to control various aspects of the material transfer system regarding sensors as shown in FIGS. 5 and 6. For example, an inlet flow control system 530 may be associated with the fluid (material) inlet manifold 48. The inlet flow controller may include a control device 532 associated with a flow sensor 534 positioned within the inlet piping or other conduit. The flow controller also is operably connected to an inlet flow valve 536. Similarly, a flow outlet controller 540 may be associated with the outlet manifold 46. The outlet controller may include a flow control unit 542 operably connected to a flow sensor 544 and flow outlet valve 546 positioned within the outlet piping or other conduit. In accordance with the present invention, the flow controllers may include operator input devices or interfaces for connecting to configuration devices. Likewise, the flow controllers may include visual displays of the flow sensor information, as well as alarms and other data or processed information.

The material transfer vessel 20 may be further configured with a high level sensor system 560 and a low level sensor system 570. The level sensor systems may be configured with sensors or switches 562, 572 and alarm indicators or displays 564, 574. The high and low level sensors may be operably connected to the flow inlet and flow outlet controllers 532, 542 so as to provide high fluid level and low fluid level shut off capabilities. For example, during a fill cycle, the inlet flow controller 532 may be configured to close the inlet flow control valve 536 when the high level sensor 560 detects that the force transfer element 90 has come into contact or otherwise activated the high level switch 562. At that time or alternatively, the high level sensor may activate the visual and/or audible high level alarm 564. Likewise, the outlet flow control unit 542 may be configured to close the flow outlet valve 546 when the vessel is in operation and the force transfer device 90 contacts or otherwise activates the low level switch 572. The low level system 570 may be configured to send a signal to the flow outlet controller and/or activate the alarm 574. In addition, a volume or level sensor 550 may be configured with an output 552 that may be integrated into the flow control systems for feed forward, feed back, shut off or other functions to be integrated into the flow controllers.

Referring now to FIG. 10, an automated computer control system 600 may be associated with the intelligent material transfer system 10. The computer control system includes a main computer controller 610, such as a microprocessor or other device for processing input data and providing output data. The computer control system may include ROM, RAM or other memory storage devices for maintaining data and processed information. The control system also includes a user interface 620, which may provide a graphical display, keyboard and other mechanisms for operator output and input. The system may be further configured with Internet, serial and parallel connections for integration into networks and communication with other control devices. For example, the pressure controller 512 may include an output 515 that is operably connected to the computer controller 610. The connection may be through an analog-to-digital interface (not shown), cabling, wiring or other suitable interface device. Similarly, the temperature controller 522, flow input controller 532 and flow output controller 542 may each include outputs 525, 535, 545 to regulate their respective process apparatus, such as flow valves. Each of the controller outputs 515, 525, 535, 545 may be operably connected to the computer controller. Similarly, volume sensor 550, high level sensor 560 and low level sensor 570 may be connected to the computer controller. The output from the computer controller 650 may be connected to the pressure controller, temperature controller and flow controllers to provide set points and other control or process information.

As shown in FIG. 7, the computer control system may include a processor with diagnostic logic, financial logic, operating logic, wireless logic and other processing systems for different levels of sophistication of computer control and data acquisition. The computer control system may also include a database having alarms, date information, events data, fault data, financial data and material properties such as flow rate, temperature, pressure volume as well as position information, identification, material properties, operator identification and other system and process variables. The computer control system will probably require an external power source, but may be self contained with battery or other AC/DC power sources. The computer system may also include a wireless modem or other device for connection into an intranet or internet system. The operator interface may be a graphical user interface or other digital display device. Analog controllers, recorders and display devices may be also associated with the computer control system of the present invention.

Referring now to FIG. 11, integrated material transfer and dispensing system 110 is configured with an automated control system 700 having a PLC, PRC, computer controller or other computer processing system 710. The material vessel 120 and fluid outlet manifold 140 are configured to feed through a pumping system 730 and/or an applicator system 740. Inputs to the process control system 710 may be configured as shown in FIGS. 9 and 10, and may include, but are not limited to, any instrumentation shown in FIGS. 5 and 6. Likewise, any other process control variables required for control of the pumping system 730 and/or application system 740 may be included as inputs to and outputs from the process controller 710.

The integrated material control system 110 may be further configured with a fluid control valve 720 associated with the fluid inlet and outlet manifold 140. The computer controller 710 may be associated with the base and pedestal 170 of the vessel 120, or may be located remotely and operably connected to the instrumentation and control devices. Piping or conduits from the outlet of the fluid vessel 120 may be connected to the pumping system 730 and/or application system 740 by a variety of mechanisms. For example, the pipes or conduits 145 from the fluid vessel may be connected via a manifold 732 or directly to one or more pumps 734. Instrumentation such as from a pressure and/or flow sensor 736 may be fed back to the control system 710. Similarly, the control system may be connected to pump motor drive or controller 738 to operate the pumping mechanisms. Additional pipes or conduits 147 may provide fluid communication between the pumping system 730 and the application system 740. As shown in FIG. 12, the automated material transfer system 110, which may be configured as heretofore described regarding FIG. 11 , may be connected directly to one or more applicators 740 via conduits or pipes 148, 149 without the need for intermediary pumps.

Such integrated material transfer systems may be used for providing oils, greases, mastics, sealants, elastomers and other materials such as liquid sound deadeners. Such materials may include, but are not limited to, thick fluids, viscous fluids, semi-solid fluids, visco-elastic products, pastes, gels and other fluid materials that are not easy to dispense. The fluid pumping system may include booster pumps in series or in parallel for the manifold. In addition, the applicator may include its own booster pumps or other drive mechanisms in addition to the pumping system 730. The applicator system may further include metering devices and local control devices that contain instrumentation that may be integrated into the computer control system 710 of the present invention.

As shown in FIG. 13, the material transfer systems may be the same size or of different sizes. In addition, compound material transfer subsystems may be configured such that two or more vessels of different sizes may be connected in series to obtain efficiencies as a first larger vessel (having a force transfer device of a first aspect ratio) feeds one or more second smaller vessels that may have force transfer devices with different aspect ratios than the larger vessel. The material transfer subsystems may feed pumps and/or directly feed material to a device such as a robotic sprayer (applicator) or "shot meter." Likewise, multiple vessels may be in fluid communication with one or more material (fluid) manifolds that are connected to one or more pumps and applicators. Each automated material transfer system may be externally fed by larger material transfer systems, such as those on the back of a railcar or truck.

Referring to FIG. 131, the system of the present invention may be configured to store and transport semi-solids fluids and/or liquids, such as Adhesive Sealants and Mastics (ASM). The system may be configured with transportable bulk (600 gallon) and intermediate bulk (300 gallon) containers that are mobile, transportable, stationary and cleanable. The containers be configured with a sophisticated follower device (force transfer element). The system may be relatively sophisticated, being pumpless, simple and smart with significant automation and intelligence. The system may be configured for use with a trailer truck to transport material to and from the user's site and to and from fluid providers and with multiple intermediate bulk containers at the user's site, in an environmentally controlled cabinet. The system may further be configured with bulk storage so as to transfer material to intermediate bulk containers, and configured to transfer ASM directly to the point of application.

Referring to FIG. 13 J: Multiple refillable material transfer systems may be configured on a cargo truck and cargo trailer. The configuration of these multiple systems may be independent configurations (for example, independent systems, and independent instrumentation and controls), combined configurations (for example, integrated systems, and integrated systems and controls), and various hybrid configurations (for example, independent systems, and integrated instrumentation and controls). In one anticipated embodiment of a hybrid configuration for bulk transport of a single material (for example, automotive LASD), twenty refillable material transfer systems, each system four feet length by four feet width, would be on a cargo trailer that is forty feet length by eight feet width. In this configuration, the compressed gas piping would be manifolded together (integrated), the material piping would be manifolded together (integrated), and the instrumentation and controls would be integrated. However, in this configuration, each of these twenty refillable material transfer systems would be operated independently (hybrid). A common material inventory control methodology, FIFO (First In First Out), may be accomplished by independently and sequentially filling and emptying the refillable material transfer systems. In another anticipated embodiment of a hybrid configuration for semi-bulk transport of multiple materials (for example, automotive epoxy resin, automotive epoxy hardener, automotive sealant, and automotive structural adhesive), four refillable material transfer systems, each system four feet length by four feet width, would be on a cargo truck, with a bed sixteen feet length by eight feet width. In this configuration, the compressed gas piping would be manifolded together (integrated), and the instrumentation and controls would be integrated. However, in this configuration, the material piping would be separate. A common material delivery methodology, "milk runs", may be accomplished by independently filling and emptying the refillable material transfer systems.

Referring now to FIG. 14, the pumpless material dispensing system 2000 of the present invention includes an automated material transfer system 110, a metering device system 800 and a robotic material dispenser system 900. The automated material transfer system 110 is configured with a control system 700 having a PLC, PRC, computer controller or other computer processing system 710. Inputs to the process control system 710 may include, but are not limited to, any instrumentation shown in FIGS. 14 and 16. The automated material control system may be further configured with a fluid control valve 720 associated with the fluid inlet and outlet manifold 140. The computer controller 710 may be associated with the base and pedestal 170 of the vessel 120, or may be located remotely and operably connected to the instrumentation and control devices. The automated material transfer system may be configured for providing oils, greases, mastics, sealants, elastomers and other materials such as liquid sound deadeners. Such materials may include, but are not limited to, thick fluids, viscous fluids, semi-solid fluids, visco-elastic products, pastes, gels and other fluid materials that are not easy to dispense. The computer control system 710 may be configured to interface with the metering device system 800 and the robotic material dispenser system 900 the of the present invention.

The automated material transfer system 110 may be configured with a pressure sensor 230 that may be connected as an input to the process controller 710. The process controller may include an output control signal 1780 for regulating a flow control valve 780 interposed between the material vessel 120 and a pressurized gas (or other fluid) input conduit (pipe, line) 790. The automated material transfer system further includes an inlet conduit (pipe, line) 148 and an outlet conduit (pipe, line) 146. The outlet manifold 140 is in fluid communication with a material transfer conduit (pipe, line) 145 having instrumentation, such as a flow sensor 740 and a pressure sensor 745, operably connected to the process controller, which regulates the material outlet control valve 720. The material transfer conduit 145 is in fluid communication with a material transfer manifold (conduit, pipe, line) 750 that is in fluid communication with the metering device system 800.

The metering device system 800 includes a metering device 810, for example, a shotmeter, a mastic regulator, or other suitable other flow element, such as a differential pressure device (orifice, venturi), a displacement device (gear, piston), a magnetic device ("mag meter"), an ultrasonic device (Doppler), a mass based device (Coriolis, MICRO MOTION), or a device configured for solids (progressive cavity, screw). The function of the metering device is to provide material 75 (FIG. 10) to the robotic material dispenser system 900 through a material transfer conduit (pipe, line) 850. The metering device system may further include an input manifold 812, an output manifold 814 and a material plunger 816 that are in fluid communication with the material transfer conduits and manifolds 145, 750, 850 leading from the automated material transfer system 110 to the robotic material dispenser system 900.

Referring now to FIGS. 15A and 15B, prior art dispensing systems for thick, viscous fluids and other such materials include a container or refillable material transfer subsystem, a pump, a metering device and an applicator. Such prior art systems may have metering devices with significant flow restrictions in their inlet and/or outlet, and may be configured with actuation for their dispense stroke only. Such systems require significant energy from pumps to transfer material through the metering device inlet and/or outlet restrictions to actuate the metering devices during their refill cycles. As shown in FIG. 15B, the pumpless material dispensing system of the present invention substantially eliminates the flow restrictions in the inlet and outlet of the metering device, and may add actuation for the refill stroke of the metering device. The system of the present invention decreases the energy required to transfer material through the metering device to the applicator. The metering device may be further configured with improvements, including inlet and outlet components having increased flow capacity and components for actuation in the refill stroke. The material dispensing system of the present invention does not require a pump, is simpler, has fewer components and requires less space than prior art dispensing systems. The system of the present invention includes lower-cost lower-pressure components upstream of the metering device, and costs less to purchase, install, operate and maintain.

Referring again to FIG. 14, the robotic material dispenser system 900 includes a robot arm 910, an applicator mount 920 disposed at a distal end of the robot arm and a material applicator (dispenser) 930 fixed to the mount. The robot arm extends up from a base 915, and is movable through a number of axes, allowing it to move to the desired position with respect to a part or piece (for example, an automobile door) 960 being coated or treated and to obtain the proper orientation with respect thereto. In the embodiment shown in the FIG. 14, the material applicator 930 is a broad slit nozzle. As those skilled in the art will appreciate, any type of dispensing outlet may be used, depending on the application parameters and the desired configuration of material 75, 975 being applied, for example, spray guns, pin-hole applicators and nozzles, contact and non-contact, air-atomizing and airless, such as cone, flat (fan, slit, slot), and stream (needle, swirl).

A robot controller 1000 controls the position, orientation and speed of movement of the robot arm 910 and all of its elements by one ore more control signals 1900 to the robotic material dispenser system 900. The elements of the robot move with respect to each other and the base end 915 of the robot. The robot controller controls the position and speed of the robot and material applicator 930. In accordance with the present invention, the robot controller also receives input signals and generates output signals to operate the metering device system 800. A material transfer conduit (pipe, line) 950 that is in fluid communication with the material transfer conduit 850 from the metering device system 800 and that is connected to material applicator may include instrumentation, such as a flow sensor 940 and a pressure sensor 945, operably connected to the robot controller.

More specifically, the robot controller 1000 controls the volume of the material 975 being applied to the part 960 by the material dispenser 930. The robot controller may monitor and control the operation of the metering device through a control signal 1800 to the metering device system 800, for example, controlling the position of a piston in a shotmeter. The robot controller may be configured to control the charging and discharging of the material 975 by controlling air valves, pressure regulators, inlet valves and outlet valves (not shown). The robot controller is also linked 1700 to the computer processing system 710 of the control system 700 and the various instrumentation of the automated material transfer system 110 so as to allow feedback and feed forward control of the pressure in the material vessel 120 and the flow and pressure of the material in the conduits 145, 750, 850 and 950 of the pumpless material dispensing system. An alternative embodiment of a metering device system 800 and a robotic material dispenser system 900 having a double acting shotmeter unit and robotic servo control unit is shown in FIG. 16.

Other features and advantages of the present invention will become more apparent from the following detailed description of the invention, when taken in conjunction with the accompanying exemplary drawings. Further modifications and improvements may additionally be made to the material and energy distribution system and methods disclosed herein without departing from the scope of the present invention. Accordingly, it is not intended that the invention be limited by the embodiments disclosed herein.

Claims

We Claim:

1. A material and energy distribution system, comprising: at least one vessel configured for receiving and releasing a material and for receiving energy; a piping assembly in fluid communication with each vessel; at least one in-line material accumulator configured to receive energy and to receive and transmit material within the piping assembly; and at least one material applicator in fluid communication with the piping assembly.

2. The material and energy distribution system of claim 1, wherein at least one in-line material accumulator is a positive displacement device.

3. The material and energy distribution system of claim 1, wherein at least one vessel is configured with a first end having an inlet for a pressurized gas source, a second end having a manifold configured with a material inlet and a material outlet, and a wall disposed between the first end and the second end so as to form a body of the vessel and to form an internal cavity within the vessel

4. The material and energy distribution system of claim 3, wherein the vessel includes a force transfer device disposed within the internal cavity of the body of the vessel.

5. The material and energy distribution system of claim 4, wherein the vessel includes a first pressure sensor and a material outlet control valve, a first material transfer conduit having a first flow sensor and a second pressure sensor, and a first computer control system configured to interface with the first pressure sensor, the second pressure sensor, the first flow sensor and the material outlet control valve.

6. The material and energy distribution system of claim 1, further including a metering device system in fluid communication with the piping assembly and the material applicator.

7. The material and energy distribution system of claim 6, further including a robotic material dispenser system in fluid communication with the metering device system and the material applicator.

8. The material and energy distribution system of claim 1, further including a metering device system in fluid communication with the outlet of a material manifold of at least one vessel, the piping assembly and the material applicator.

9. The material and energy distribution system of claim 8, further including a robotic material dispenser system in fluid communication with the metering device system and the material applicator.

10. A method for distributing material and energy, comprising: configuring at least one vessel for receiving and releasing a material; providing energy to each vessel; providing a piping assembly in fluid communication with each vessel; configuring at least one in-line material accumulator to receive and transmit material within the piping assembly; providing energy to each in-line material accumulator; and connecting at least one material applicator in fluid communication with the piping assembly.

11. A material and energy distribution system in accordance with the specification and drawings herein.

12. A method for distributing material and energy in accordance with the specification and drawings herein.