CONCRETE MATERIAL DISPENSING SYSTEM

• US 20110166689A1
• Filed: 02/26/2011
• Published: 07/07/2011
• Est. Priority Date: 05/23/2008
• Status: Active Grant

• Current Assignee: Amtec Meter & Controls, Inc.
• Original Assignee: Amtec Meter & Controls, Inc.
• Inventors: Alden, Kevin Odell, Smelquist, Ken
• Granted Patent: US 9,678,496 B2
• Time in Patent Office: Days
• US Class Current: 700/108
• CPC Class Codes: B28C 7/0418 control systems therefor
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G05B 19/0421 Multiprocessor system
• CPC Class Codes: G05B 19/0426 Programming the control sequence
• CPC Class Codes: G05B 19/4185 characterised by the network communication
• CPC Class Codes: G05B 2219/25428 Field device
• CPC Class Codes: G05B 2219/33273 DCS distributed, decentralised controlsystem, multiprocessor
• CPC Class Codes: G05B 23/0275 Fault isolation and identification, e.g. classify fault; estimate cause or root of failure
• CPC Class Codes: G05D 7/0617 specially adapted for fluid materials
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y02P 90/80 Management or planning

Abstract

A control system for a concrete plant adds intelligent capabilities in the concrete plant that may enhance safety, localize control of the concrete plant, and assist with troubleshooting. The control system may also enhance accuracy for determining an amount of mixed concrete dispensed, or amounts of concrete ingredients to dispense, and may eliminate the need for equipment used to verify the amount of mixed concrete or concrete ingredients dispensed.

Claims

1. A distributed system for controlling and monitoring operations for a concrete plant comprising:

a field box communicating with a concrete plant batch panel, wherein the field box receives batch panel command signals from the batch panel and translates the batch panel command signals to control signals;

concrete plant equipment communicating with the field box, wherein the field box controls operation of the equipment using the control signals; and

one or more sensors associated with the equipment and communicating with the field box, wherein the one or more sensors generate operating signals based on a state of the equipment and transmit the operating signals to the field box.

2. A distributed system for controlling and monitoring operations for a concrete plant according to claim 1, further comprising:

the field box controlling operation of the equipment using the control signals and the operating signals.

3. A distributed system for controlling and monitoring operations for a concrete plant according to claim 2, wherein:

the field box shuts off the equipment based on successful completion of a control signal or based on operating signals that indicate errors or faulty operation of the equipment.

4. A distributed system for controlling and monitoring operations for a concrete plant according to claim 1, wherein:

the field box translates and transmits the operating signals to the batch panel.

5. A distributed system for controlling and monitoring operations for a concrete plant according to claim 1, further comprising:

a batch computer communicating with the field box;

wherein the field box translates and transmits the operating signals to the batch computer; and

the batch computer is programmed to create operational records for the equipment based on the operating signals.

6. A distributed system for controlling and monitoring operations for a concrete plant according to claim 5, wherein:

the concrete plant equipment includes admixture dispensing equipment.

7. A distributed system for controlling and monitoring operations for a concrete plant according to claim 6, wherein:

the admixture dispensing equipment includes a tank and a pump and a flow meter associated with and in fluid communication with the tank; and

the field box is associated with the tank, the field box communicating with the associated pump and flow meter to send control signals to the associated pump and flow meter and receive operating signals from the associated pump and flow meter.

8. A distributed system for controlling and monitoring operations for a concrete plant according to claim 7, wherein:

the flow meter associated with the tank tracks a running total of a volume of fluid that passes out of the associated tank and through the flow meter and the flow meter transmits to the associated field box signals indicating the running total of fluid that has flowed through the flow meter;

the tank includes an associated liquid level sensor that generates signals indicating how much liquid is in the tank and the liquid level sensor transmits the signals indicating how much liquid is in the tank to the field box associated with the tank;

the associated field box transmits signals containing information about the running total of fluid that has flowed from the tank and the liquid level in the tank to the batch computer; and

the batch computer is further programmed to,

monitor a total amount of fluid removed from the tank;

monitor a total amount of fluid in the tank;

compare the total amount of fluid removed against a previous total amount of fluid removed on a periodic basis having a time period to determine the amount of fluid removed from the tank during the time period;

compare the total amount of fluid in the tank against a previous total amount of fluid in the tank on a periodic basis having the time period to determine a change in the fluid amount;

determine a rate of consumption of the fluid in the tank based on the determined amount of fluid removed from the tank and on the time period;

for the tank, determine the amount of fluid added during the time period based on the determined amount of fluid removed during the time period and the determined change in the fluid amount; and

schedule delivery for fluids to the tank based on the determined rate of consumption and the determined amount of fluid added for the tank.

9. A distributed system for controlling and monitoring operations for a concrete plant according to claim 7, wherein the field box is programmed to receive metering pulses from the flow meter and the field box is further programmed to transmit metering pulses to the batch panel at a set rate regardless of the rate at which metering pulses are received from the flow meter.

10. A distributed system for controlling and monitoring operations for a concrete plant according to claim 9, wherein the field box is further programmed to transmit metering pulses to the batch panel at or below the set rate regardless of the rate at which metering pulses are received from the flow meter.

11. A distributed system for controlling and monitoring operations for a concrete plant according to claim 9, wherein the field box is further programmed to aggregate metering pulses from the flow meter before transmitting metering pulses to the batch panel.

12. A distributed system for controlling and monitoring operations for a concrete plant according to claim 9, wherein the field box is further programmed to shape the metering pulses received from the flow meter before transmitting the metering pulses to the batch panel.

13. A distributed system for controlling and monitoring operations for a concrete plant according to claim 1, wherein the field box is programmed to receive input indicating a technician serviced at least one of the concrete plant equipment communicating with the field box.