cu») United States 2) Patent Application Publication co) Pub. No.: US 2017/0100754 Al oy oy fo) 3) en @ (60) Nelson coUuNTE DUAL WHIP-HEAD DEVICE FOR FRAGMENTING SOLIDIFIED BULK MATERIALS IN +» Mankato, MN Applicant: Pheumat Systems, ws) Inventor: Gregory Wallace Nelson, Mankato, MNS) Assignee: Pneumat Systems, Ine. Mankato, MN ws) Appl. Nos 15/169,182 Filed: May 31, 2016 Related U.S. Application Data Provisional application No. 62/288,825, filed on Oct. 8, 2015 US 20171 1 00754, (43) Pub. Date: Apr. 13, 2017 Publication Classification (1) Inte OSB 9/087 (2006.01) BRC 2102 (2006.01), (2005.01), BOSE 9/087 (2013.01); BARC 13/28 Go13.01); Bore 21402 2013.01): BoC 2013/2816 (201301), on ABSTRACT A device to fragment solidified bulk: material is disclosed Te device comprises a hydatlie motor a stationary assem- bly and rotating assemblies, wherein the rotating assemblies inclides, a rotational upper whip mount assembly adapted to rotate ina digcction, a rotational mide assembly perimeter adapted to rotate in the same direction as the rotational upper ‘whip mount assembly, and a rotational lower whip mount assembly adapted t0-totate ina disction opposite the rolational direction of the upper whip mount and middle perimeter assemblies, and a plurality of fils configured to Fracture hardened, solidified bulk material while Balancing the torque forces to more accurately Keep the dal whip- head head ina desired location when operationally engaged ‘with the bulk materia L 501 503 hs J 503,Patent Application Publication Apr. 13,2017 Sheet 1 of 5 US 2017/0100754 Al Spe, 134. oe 131 \," 103. ve uo 105 14 135 117 119 t i Se 124 120 0 122 FIG. 1US 2017/0100754 AI Patent Application Publication Apr. 13, 2017 Sheet 2 of S (NK iM h ko IM] VEAY \V WA ey 202" a) = ENN | J 205 FIG. 2Patent Application Publication Apr. 13,2017 Sheet 3 of 5 US 2017/0100754 AlPatent Application Publication Apr. 13,2017 Sheet 4 of 5. US 2017/0100754 Al Ge Se ® S ZZ 402 401 403 FIG. 4Patent Application Publication Apr. 13,2017 Sheet Sof 5 US 2017/0100754 Al 503 503 4 a = FIG. 5US 2017/0100754 Al COUNTER-ROTATIONAL DUAL WHIP-IEAD DEVICE. FOR FRAGMENTING SOLIDIFIED BULK MATERIALS IN ‘CONTAINMENT VESSELS BACKGROUND OF THE INVENTION 0001) [0002] The present invention relates to fragmenting sol fied ulk materials to facilitate the flow and removal of sich materials from containment vessels, including bins, silos, hoppers and other tansport vessels 10003] 2. Description of the Prior Art 10004) Bulk materials eft undisturbed in a containment vessel like a bin or silo tend to setle, compress, and ‘eventually solidify into a hard, amalgamated solid that is ‘iffcult to remove from the vesel, This happens frequeatly at cement manvfactaring plants. When soch bull material ‘nist be removed from the containment vessel, o increase its storage capacity for example, manual labor is offen used to Jragment and remove the material, Using picks and shovels insuch an environment is ime consuming and increases the potential for personal injury. 10005) ‘To solve this problem, the applicant invented the BinWhip® system, which used a pueumatcally-powered ‘leaning head and Als that was lowered into the contain= ment vessel to fragment the solidified material instead of ‘sing human labor. The applicant later switched oa hyra- Tically-powered system, While effective, both the pneumatic and hydraulic systems used a cleaning head that rotated in ‘one direction only. But because the BinWhip® represented fast improvement over human labor others i the industry ‘copied applicant's pneumate and hydraulic unidirectional systems. Thus, the curent state of fragmentation systems that employ rotating fils to fragment solidified bulk mate- Fials uses @ unidirectional cleaning head configured to spin in either a clockwise or counterclockwise direction, but hot simultaneously. [0006] | Whether pneumatically or hydraulically driven, the ‘leaning head of sch systems require a hose system to carry the pressurized fluid a motor system, which is typically housed within or proximate the cleaning head, The reactive torque that results from the ails striking the solidified rmaleral, however. puts significant rotational forees on the hose connecting the power unit 10 the cleaning head. As rotational speeds increase to achieve greater striking force (Ge, inereasing the rotational speed ofthe cleaning head and ‘ails to increase the impoet forces onthe solidified material) the tarque forces on the cleaning head and attached hose system also inerease, Under conditions when the bulk mate- rial is resistant to fragmentation, like with cement for ‘example, increasing the rotational speed beyond 400 RPM, Jor example, can eause the hose system to twist an coil back ‘on itself, potentially damaging the hose system and increas jing the risk of personal injury or property damage. Conse- ‘quently, the hose system’s resistance tothe torque ereated by the mlating cleaning head and Asils limits the speed and ‘ellciency of unidirectional single head cleaning systems. [0007] ‘Thus, there i a need fora system that ean signifi cantly the efficiency of fragmenting hardened, solidified bull materials to assist in their emaoval from containment vessels. The disclosure herein accomplishes that objective. 1, Field of the Invention Apr. 13, 2017 [BRIEF SUMMARY OF THE INVENTION 0008} ‘The device disclosed herein is designed to facilitate the removal of hardened, solidified bulk material Irom containment vessels, ineluding transport vehicles, The device is part ofa system that includes a hydraulic power unit, which is operably connected to manifold system, whieh in tum is operably connected to a hose system comprising a hose rel and hoses, which ix atfachable to 2 ‘mount assembly atachable to a boom assembly including a safety anchor that is configured to stabilize the hoses. The counter sotational dual whip-head head is attachable to the hose assembly and further comprises a stationary eonnecton asseably to operably connect the hose system to atleast one hydraulic motor, rotational upper whip mount assembly a middle assemibly-the perimeter of which rotates in the same dircction a the rotational upper whip mount assembly ‘and a rotational lower whip mount assembly rotating in the ‘opposite direction of the upper whip mount and middle asseublies, wherein the dual Whip head device is configured ‘long a Verical axis. The middle assembly further comprises 4 stationary inner core comprising at least one hydraulie ‘motor and a east one in-line pearbox, The gearbox ineludes a set of beveled gears—an upper and lower beveled gear ‘which are configured in sepamte horizontal planes and are ‘operationally connected 10 each other by a plurality of pinion gears that rotate around a horizontal axis. The hydraulic motor directly drives the upper beveled gear This in tum causes the pinion geury fo rotate about horizoatal axis 90 degrees from the vertical axis of the hydraulic motor fand gearbox. When the upper beveled gear is putin ro ‘ional movement by the hydraule motor, the pinion gears, being engaged wit both the upper and lower beveled gears transfers an oppositexiretion rotational foree and move- to the lower beveled gear, which ia tum dives aa per drive plate and an upper whip mount assembly in 3 ‘ational direction opposite the upper beveled gear. The pinion gears are fixed into position in the body of the gearbox so they supply rotation transfer only between the ‘upper and lower beveled gears. The lower beveled gear drives the upper drive plate, the perimeter of the middle assembly, and the upper whip mount assembly ina rotational novemient opposite the rotational movement of the lower ‘whip mount assembly and the upper beveled gear. {0009} Two concentric shafts extend ont the bottom of the ‘gearbox. The first sli an ner solid shaft has operably tsonnected tothe upper beveled gear. The second sha is @ hollow shall that is operably connected 10 the lower beveled {gear and mtstes in the opposite dircction around the inner shaft A set of needle bearings separates the counter-otating shafts to minimize any fiction between them as they rotate A keyless coupler is attachable on the outer shaft and is ‘operably conneeted to an upper drive plate, whieh in tum is ‘operably connected to platy of stand-o rods mounted ‘on the upper drive plate that rotate around the outside ofthe gearbox and hydraulie motor and that conneet to and drive the rotating perimeter ofthe mille and upper whip monnt assemblies ofthe dual whip-head, [0010] A stationary connection assembly serves as the junction for the hydravlic supply and retum lines dt, fcnneet the hycraulie moor on one sce an the hydraulic hoses on the other side. The dial whip-head (counter rotational) can now be used in a very similar manner as a ‘rational single head (uni-ottional, but wih a number of surprising advantages.US 2017/0100754 Al [0011] First, the countersotationsl configuration of the ‘dual whip-head balances the tomue forces oa the hydraulic hose, which allows greater rotational speeds and keeps the ‘dual whip-heud in place and prevents it fom ‘walking’ ‘across the surface of the bulk material in response to Titional forces hetween the rotating perimeter of the middle assembly andor fails and the bulk material. This balancing of tongue forces allows for more precise position- ing of the dual whip-head. The use of counter-rtational dual ‘whip-heads essentially doubles the fragmentation power af the system. The counter-otational configuration of the insta! disclosure also allows for fragmentation of stratified layers and ledges of bulk material that single-head systems find challenging beeause of the single operational plane of singl-head systems 10012] The invention can be biter understood by refer ‘ence 1 the following deawings, wherca 0013] FIG. 1 is an exploded view of an embodiment of the countersotstional dsl whip-head for fragmenting solidified bulk mates in containment vessel {0014} FIG. 2s a vansparent view of an embodiment of 2 gearbox of the counteroltional dial Whiphead for fragmenting sliied bulk materials in consinment ves sel W015] FIG. 3 is a perspective view of a patlly ‘assembled counterroatonal dal whip-head for fragment- ing solidified bulk materials in containment vessel 10016] FIG. 4 is a perspective view of a patslly ‘ssembled eounterroatonal dial whip-head for fragment- ing solidified bulk materials in containment vessels 10017) FIG. $5 perspective view ofa fly assembled ‘ountersottonal dl whip-head for fraenting solidified bulk materials in eonsinmint vessels DETAILED DESCRIPTION 10018] In the following detailed description, reference is made othe accompanying drawings that form a part hereof, ‘and ia which are shown by way of illsiraion specifi ‘embodiments or examples. ‘These embodiments may be ‘combined, other embodiments may be utilized, and struc tural, logical, and procedural changes may be made without departing from the spirit and scope of the present invention, The following detailed description is, therefore, not 10 be taken ia a limiting sense, and the scape of the present invention is defined by the appended claims and their ‘equivalents 10019] As disclosed in FIG. 1, an embodiment of a cou terrolational whip head includes at least two bolts 101 that secure a stationary upper receiver 102 to a stationary lower receiver 107, Straddling a rotating upper whip mount 103 ‘are a seal 103 and radial bearing 106 tht allow the upper Whip mount 105 to rotate under the power transfered by & hycaulcally-powered gearbox 118 0 a plurality of rotating drive stand-off rads 119 that are opembly connected to the Upper whip mount 108 by a plurality of bolts 104, Fils 131 are attachable a the upper whip mount 108 via. a plurality of adapter elevs's 134. The Mails 131 are secured othe adapter clevis’s 134 by 2 plurality of nuts 132 and bolts 133 10020] The plurality’ of rotating deve stand-off rods 119 fre further secured to an upper drive plate 120 with » plurality of bolts 121. A plurality of fragmentation collars Apr. 13, 2017 117 may be secured to the stand-off rods 119. The combined structure of these components serve to stabilize and unify the rotating middle section $02 of the whip head S01, Whea the pluniity of fragmentation collars 117 are secured between the upper whip mount 107 and the upper drive plate 120 by stacking the fragmentation collars 147 over the stand-off rods 119, they comprise a rotating perimeter ofthe ‘idle assembly. [0021] A plurality oPholts Ode aso connee the stationary lower receiver 107 to the housing of the hydaulically~ powered gearbox 118 via a plurality of shorter length stand-off rods 110. Pressurized! hydraulic uid is transfered ino and out of the hydraulic motor 114, through a hydraulic ‘uid conduit system comprising « plurality of hydraulic ‘Mush fitings 108, which are connectable to a pressurized hydraulic hid source,» pluality of hydraulic adaers 109, ‘a plicality of upper elbow fitings 111, a plurality of hydean. lic pipes 112, anda plurality of lower elbow fittings 113. The lower elbow fitings 113 are, in tun, direetly connected 10 the hydraulie motor 114. The hydraulic motor 114 is secured to the gearbox case 200 witha plurality of bolts 115 and ck washers 116. The hydraulic motor 114, when pot in rot ‘ional movement by the flow of the pressurized hydaul ‘uid, transfers rotational foree to an eneased gearbox 118 200. The bolts 101, stationary upper receiver 102, bolts 04a, radial hearing 106, stationary lower receiver 107, hydraulic fish fitings 108, hydraulic adapters 109, shorter length stand-off rods 110, upper elbow fitings 14, hydraulic pipes 112, lower elbow fitings 113, hydraulic motor 114, bolls 118 and lock washers 116, and encased gearbox 118 jomprise a stationary, middle assembly [0022] As disclosed in Hg. 2, the encased gearbox 200 includes a set of beveled gears 201 202 configured in separate horizontal planes that are operably connected 10 cach other by a phaality of pinion gears 20% that rotate ‘around 9 horizontal axis. Engaging the hydravlic motor ‘causes the upper bevel gear 201 to cotton its vertical axis, ‘which in tur causes the pinion gears 203 to rotate about & horizontal axis about 90 degrees Irom the vertical axis ofthe motor 114 and gearbox 200. When the upper beveled gear 201 is put in rotational movement by the hydruulic motor 114 the pinion gears 203, being operably engaged with both the upper 201 and lower 202 beveled gear set, transfers an ‘oppositeirection rotational force and movement 10 the lower beveled 202 gear sc. The upper heveled gear set 201 drives an innor solid shaft 208 that drives the lower whip mount 128. The lower beveled gear set 202, being in ‘opposite rotational direction to the upper beveled gear 201, drives an outer hollow shall 205 that drives the rotational perimeter of the middle assembly S02 and the upper whip ‘ron 108 in rotational direction opposite the lower Whip ‘mount 125. [0023] By way of non-fimiting example only, if pressut- ‘ned hydric Mid is introduced into the hydraulic motor 114 so that the motor 114 rotates in a counterclockwise rection, that rotational movement is dieety transferred to the upper beveled gear 201 and the inner sold shaft 204 that ‘ultimately drives the lower whip mouat 125 in the same counterclockwise direction. Accordingly, the upper beveled gear 201, being engaged with the pinion gears 203, causes the lower heveled gear 202 and otter hollow shalt 208 t0 late in a clockwise direction, The upper deve plate 120 is connected to 8 keyless coupler 122 that in tum is operably ‘connected tothe outer hollow shaft 208, Thus, a8 the outerUS 2017/0100754 Al hollow shaft 205 rotates in clockwise direction, that rotational movement is transferred from the keyless coupler 122 to the upper drive plate 120 and the rotating dive sand-off rads 119-10 rotate the perimeter of the middle assembly 502 and upper Whip mount 108 in the same ‘lockiwise direction, The seal 103, bolis, 104, upper whip ‘mount 105, stand-off rods 119, upper drive pate 120, bots 121, and keyless coupler 122 comprise an upper whip mount assembly. 10024] Positioned betwoen the rotating upper drive plate 120and the lower whip mount 128 area hub fora taperlock bushing 123, and a 1-inch per lock bushing 124 that are ‘configurd to allow the lower whip mount 128 to rotate in the same direction as the ianer shal, The lower whip mount 128is connected toa whip mount cover 128 with a plurality ‘of pinions 126 and bolts 130. plurality of fails 1314 may be secured between the loser whip mount 125 and the whip ‘mount caver 128 with a plurality of auts 127 and bolts 129. The tapet-lock bushing ub 123, T-inch taper lock bushing 124, lower whip mount 126, pinions 126 and bolts 130, nuts 127 and bolts 129, and whip mount cover 128 comprise & lower whip mount assembly. [0025] FIG. 3 discloses the major components of the ‘counter-otational whip head, including the upper receiver 301, the upper whip mount 302, and the clevis assembly 4308, including its nuts and bolts 304 for attaching the Mls 1311 the upper whip mount 302. FIG. 3 further discloses the shorter length stand-off rods 308, the rotating drive stand-off rods 306, the upper drive plate 307, and the ‘combined lower whip mount 308 and whip mount cover 309, 10026] FIG. 4 diseloses an embodiment that includes @ middle assembly comprising # plurality of saw-tothes, fagmentation collars 117 401. In this embodiment, the sw-toothed fragmentation collars 117 401 are stacked between the upper drive plate 102 307 and the upper whip mount 105 302 und include « plurality of holes 138 that ‘correspond to the number and spacing ofeach rotating drive Suand-olf rd 119 306, The fragmentation collars 117 401 are sacked, one on top ofthe other, by passing the holes in the collars 135 over the rotating drive stand-off rods 119 306, Until the collars 117 401 are stacked securely between the upper drive plate 102 307 and the upper whip mount 108 302. In such an embodiment, the saw-toothed fragmentation ‘collars 117 401, which are rotating inthe same direction and speed as the upper whip mount 10S 302, provide an increased fragmentation surface that muy be applied upainst the solidified material along with the Hails 131 13ta, 10027] FIG. § discloses a completely assembled counter rotational dual whip-head embodiment 501 that includes sanw-foothed, ragmentation collars $02 chain link Hails $03 ‘on both upper and lower whip mounts. 10028] Tes to be understood that the above description is Intended tobe illustrative and not restrictive. For example, the above-described embodiments and variations may be tied in combination with each other. Many other embod ments will be apparent t0 those of skill inthe art upon reviewing the abowe description. The scope of the invention should, therefore, be determined with reference to the appended claims, along withthe full scope of equivalents 0 ‘which such claims are ented. lathe appended claims, the terms “including” and “in which" are used. as the plain English equivalents of the respective tems “comprising and “wherein.” Apr. 13, 2017 ‘Wiha is claimed is 1. A device to fragment solidified bulk material compet ing: 1a hydnuulie motor a stationary assembly and rating assemblies, wherein the rotating assemblies include a rotational upper whip mount assembly adapted to rotate in a direction, a rotating perimeter of a middle assembly adapted 10 rotate inthe same dircetion a the rotational upper whip ‘mount assembly, and a rotational lower whip mount assembly adapted to rotate in a direction opposite the rotational direction of the upper whip mount and middle perimoter assemblies; and a plurality of is 2. The device of claim 1, wherein the hydraulic motor includes hydraulic fuid comprising food grade mineral ol 3. The device of claim 1, wherein the stationary assembly includes a connection assembly, an upper receiver, a lower rcociver, a radial bearing a hydraulic fi conduit assembly. a hydraulic motor, an encased gearbox assembly, and 3 plurality of shorter length stand-all rods 4. The device of claim 3, wherein the encased gearbox. includes, set of upper aad ower beveled geus, a plurality of pinion gears, an inner solid shaft, and an outer hollow shat '. The device of claim 4, wherein the set of upper and lower beveled gears are configured in separate horizontal planes and are operationally connected to cach other by the plurality of pinion gears that are configured to rotate around ‘horizontal axis about 90 degrees from the vertical axis of the hycraulic motor and the encased gearbox, and whorvin the upper beveled gear drives the inner sold shaft that drives the lower whip mount assembly an the lower heveled gest, being in opposite rotational direction to the upper beveled gear, drives the outer hollow shaft that drives the rotational perimeter of the middle and upper whip mount assemblies 6. The device of claim 3, wherein the hydraulic tuid conduit assembly inclades a plurality of hydraulic flush Tinings, «plurality of hydraulic adapters, a plurality of upper clbow tings, 2 plurality of hydraulic pipes, and a phrality fof lower elbow fittings 7. The device of claim 1, wherein the rotational upper ‘whip mount assembly includes seal, and an upper whip ott. ‘8. The device of claim 1, whercin the rotational middle assembly includes a keyless coupler, an upper dive plate, fad plurality of rotating drive stand-oll rods. 9. The device of claim 8, wherein the rotational middle assembly inclndes a plurality of fragmentation collars, 10, The device of claim 8, wherein the fragmentation collars plurality of ssw-toothed,tragmentation collars, 11. The device of elaim 1, wherein the plurality of fails include materials selected from the group consisting oF steel chain-link, and hardened plastic. 12. The system of claim 1, wherein the solidified bulk vaterial includes material selected from the group consist ing of catalysis, cement, clay, clinker, coal, coarse ore, concentrate, coke, DDGs, feed, fertilize, ly ash, hydrated Jime, gravel, aypsum, minerals, paper pulp, pigments, pla ties, powder, refuge, salt, sand, sawdust, slag, soda ash, soybean meal, taleum powder, wheat middlings, wood chips, and wood pulp.