WO2000018217A1

WO2000018217A1 - Central dairy system control cabinet

Info

Publication number: WO2000018217A1
Application number: PCT/US1999/021986
Authority: WO
Inventors: Kevin Keeffe; Brion Gompper
Original assignee: Babson Brothers Co
Current assignee: Babson Brothers Co
Priority date: 1998-09-29
Filing date: 1999-09-22
Publication date: 2000-04-06
Anticipated expiration: 2001-03-29
Also published as: AU1440800A

Abstract

A dairy system control cabinet for housing a number of system controls that is convenient, inexpensive, and easily maintained.

Description

CENTRAL DAIRY SYSTEM CONTROL CABINET

FIELD AND BACKGROUND OF THE INVENTION

This invention relates generally to control cabinets for dairy systems and particularly to a central control cabinet that services a number of dairy operating systems, reduces installation and maintenance costs, simplifies trouble-shooting, enhances safety, and interfaces with a central activity-based controller for enhanced dairy efficiency and production.

Dairies are complex physical plants having many individual dairy systems, including milking equipment, vacuum pumps and controls, pipelines, milk storage, milk chillers, clean-in-place wash systems, chemical dispensers, feeding systems, sort gates, and heating, ventilation and air conditioning systems, among other things. Many of the systems in a dairy are operated at remote locations from one another, including being in separate buildings, different elevations, and different environmental exposures. Because all dairies are unique, with different herd sizes, physical layout, milk productions, climates, etc., individual dairy systems tend to be stand-alone units that are serviced and controlled at separate control cabinets or panels. Even similar systems at a single dairy have separate control panels because each system is sold, operated, and maintained as a separate system operating independently of other systems in the dairy. To install each system, separate control panels are wired at the dairy to interact with the system to which the control panel is dedicated. Trouble shooting, start-up, and coordination with other systems is done in the dairy at relatively high labor rates and under adverse conditions.

To maintain and operate the varied dairy system components scattered about the dairy, a dairy operator travels from one dairy location to another to activate controls on control panels at each location. Each system tends to have a unique control panel and controls that must be understood for efficient maintenance. Further, data supplied to operators at the individual control panels must be periodically monitored and/or collected. Thus, even when no maintenance is required, regular trips to disparate locations throughout the dairy to simply collect data are necessary to calculate dairy production and efficiencies. This is inconvenient, inefficient, and increases the probability of operator error.

Moreover, where the dairy system controls are scattered about the dairy, it is difficult to adjust the controls to react to various situations and/or problems. Because the systems are interrelated, when one system is adjusted, other dairy system controls must also be adjusted. For example, changing the number of milkings per day in a dairy can require adjustment and re-adjustment of all other dairy systems. To manually adjust controls of each dairy system, at numerous locations in the dairy, and then monitor data at each location requires excessive time and energy, in addition to an intimate working knowledge of each dairy system.

Control box construction tends to be unique to the intended environment of its installation. Consequently, each control cabinet has unique seals, gaskets, connections, locking mechanisms, power supplies, and materials of construction. As a result, even routine maintenance requires a selection of dedicated replacement parts that is unique to each control panel in a dairy. Since most dairies have more than a dozen panels in each a burdensome number of replacement parts must be kept on hand, or makeshift repairs using incompatible parts or components might be attempted.

Thus, there is needed a control cabinet that houses and services a variety of dairy systems, reduces field installation and maintenance times, reduces power supply requirements, is safe to maintain and operate, reduces the variety of boxes and replacement parts necessary to service the boxes, minimize the types of controls that are used, reduces the number of data collection points in the dairy, and is not difficult to adjust for varying dairy conditions.

SUMMARY OF THE INVENTION The present invention overcomes the shortcomings of prior art dairy system control panels by providing a centralized dairy system control panel that houses the controls for a number of dairy systems in a single location. The present invention is particularly useful in pre-manufactured dairies that are engineered, assembled, and tested at a remote location and then installed at the dairy site with a minimum of field assembly and trouble-shooting required. The central dairy system control cabinet in accordance with the present invention can be remotely controlled by an activity-based controller so that the necessary operator interaction is accessible via system control dials and buttons that are uniform in operation and appearance and lighted or audible to alert operators of dairy system conditions. Further, dairy system data is presented in concise formats.

Repair of system controls is simplified by a cental dairy system control cabinet that includes: a single main power control button that shuts power to all systems; and a control power cut-off that enables monitoring of a dairy system while cutting off any output from the controller that would otherwise cause the system to operate. Safety is enhanced by including these shut-offs and, in addition by including an automatic main power cut-off switch that is activated when there is unauthorized access to the cabinet.

Because many controls are in a single control cabinet, there can be a vast reduction in maintenance costs as compared to the use of smaller dedicated control cabinets for each of the numerous dairy systems. In this manner, costs are reduced and protection of the controls from the dairy environment is improved.

Further, the box is constructed such that controls in the same cabinet are compatible with each other and other electrical components in the vicinity. Further, power supplies for the controls can be reduced in number and still provide a redundancy that permits "hot swappable" changes in power supply. Using such a centralized dairy system control cabinet results in the system controls being usable as intelligent remote terminal units that are simply connected to a dairy system activity-based controller with a simple multi-cable twist connection. Once connected, the activity-based controller "finds" the dairy systems in the central cabinet and activates each in a sequence, frequency, and mode that can be changed from the remote activity-based controller. Each individual system control and/or intelligent remote terminal unit, can comprise programmable logic controllers, programmable computer boards, or other programmable devices that vary controls for a particular dairy function and may be controlled by a central activity-based controller. BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is a block diagram illustrating the interaction between a dairy system control network and a central dairy system control panel in accordance with the present invention.

Fig. 2 is a schematic elevational drawing of the interior of a central dairy system control cabinet and the back side of an access door in accordance with the present invention.

Fig. 3 is a schematic elevational side view of a control cabinet and the front side of the access door of Fig. 2, in accordance with the present invention. DETAILED DESCRD7TION OF THE DRAWINGS In the following detailed description, the same reference numeral will be used to identify the same or similar parts as illustrated in each of the figures. Illustrated generally in Fig. 1 is a dairy control system 20 in accordance with the present invention having a central control cabinet 22 sub-divided into a power filter 24 and a plurality of dairy system controls 26, an activity-based controller 28 in communication with the system controls 26, a utility power supply 30 in communication with the power filter 24, and a plurality of sensors 32 and actuators

34 in the dairy that are in communication with individual system controls 26, and that monitor and control dairy operations.

An optional secondary dairy system control cabinet 36 is provided for housing a plurality of controls at a second location, preferably remote from the central control cabinet 22. The secondary control cabinet 36 includes a power filter 38 and at least one system control 40.

The dairy control system 20 is unique to the given dairy in which it is installed. It may monitor and control any number of dairy systems and/or operations including: milking, milker detachers, milk chilling and storage, milk diagnostics, clean-in-place wash systems, chemical dispensers, data processing, fuzzy logic optimization software, feed systems, sort gates, system warnings, and any number of other systems that are optimally included in the system for management by the activity-based controller 28.

The activity-based controller 28 is preferably at a location remote from the central control cabinet 22, but the activity-based controller 28 can be mounted in the cabinet 22 or be incorporated with one or more of the system controls 26. While it is preferred that an activity-based controller be utilized in the present invention and be in communication with one or more of the system controls 26, the use of such a controller is not necessary. In such a situation, the system controls 26 will be in communication with the sensors 32 and actuators 36.

The central control cabinet 22, preferably conforms to N.E.M.A. 4x specifications or the equivalent to ensure protection for the system controls 26 from the dairy environment. The power filter 24 is the direct link between the system controls 26 and the utility power supply 30. It can include surge protectors, circuit breakers 27, and other components for preventing any damage to the system controls 26 resulting from lightning strikes, surges, brown outs or other electromagnetic disturbances. These circuit breakers 27 can also be interactive and signal a dairy operator of fault conditions.

The system controls 26 are housed in the central control cabinet 22 and are dedicated to any of the above-mentioned dairy systems. There may be, and preferably are some redundancies in the controls 26 so that removal from service of one control

26 need not remove its corresponding dairy system from service.

One advantage of housing the controls 26 in this manner is the ability to install, wire, test and assemble a number of dairy system controls in the factory to ensure operational controls in the dairy and to reduce field installation, testing, and trouble-shooting, which can be time consuming and expensive. This arrangement is particularly advantageous in prefabricated modular dairies, but it also provides numerous advantages in older dairies as will be apparent below.

A plurality of the system controls 26 are preferably remote terminal units that are monitored and activated by the activity-based controller 28 for synchronized and efficient dairy system operation. A "remote terminal unit" as used herein is a programmable dairy system control that can be, but need not be, in communication with the activity-based controller 28. However, one or more non-programmable system controls can also be used in accordance with the present invention. The activity-based controller 28 can also collect data from the system controls 26 and use the data to optimize related dairy systems or simply compile data for ready access by a dairy operator.

As stated above, where remote terminal units are used, as one or more of the system controls 26, those units are programmable themselves to control and monitor functions that are specific to the corresponding dairy system. The remote terminal units may include fuzzy logic software that improves efficiency of the particular system. Preferably the remote terminal units include: programmable logic controllers, embedded controls, or single board computers.

Also preferably, the systems controls 26 are hardwired to a single coupler, such as a twist-coupler, that allows easy and accurate installation with the activity- based controller 28 and/or to sensors 32 and actuators 34 via a data and transmission line 35 or via wireless communications. The convenience of maintenance and trouble shooting with centrally housed system controls 26 is apparent when compared to the randomly housed and located system controls of the prior art. With the present invention, a dairy operator visits a single location for maintenance, control, and data collection from various systems. Further, housing numerous system controls 26 in a single control cabinet 22 permits factory certification of emissions and susceptibility ("EMC") compatibility of the various system controls 26 before problems can arise in the dairy.

Figs. 2 and 3 illustrate additional details and advantages of the central control cabinet 22. The cabinet 22 includes a plurality of walls 50, a top 52, and a bottom 54 that together define an interior space 56. The power filter 24 is preferably mounted in the top of the interior space 56 and the system controls 26 are preferably mounted along the walls 50 in the interior space 56.

A power supply 60 is advantageously mounted in the bottom of the cabinet interior 56 for converting AC to DC power. Preferably, the power supply 60 is redundant to permit replacement ("hot swappable") and repair without shutting down the entire dairy system. Although redundant, the power supply 60 is more economical than having numerous power supplies scattered around a dairy in stand-alone control panels. Likewise, there may be redundancy in individual system controls 26, but there is considerable benefit in that redundancy in avoiding system shut-down by converting to stand-by controls, such as in vacuum pulsation controls.

The centralized arrangement of the cabinet 22 and system controls 26 permits safer maintenance and operation. The cabinet 22 includes a main power cut-off 62 (Fig. 3) that cuts AC power from the utility power supply 30 to the power filter 24. The main power cut-off may be a single button 62 on an access door 70 or it may be an automatic switch 66 having one stationary terminal 68 and one door-mounted terminal 69 that cuts main power when the access door 70 is opened by unauthorized personnel. One power outlet (not illustrated) can be mounted inside the cabinet 22 and kept "live" even when main power is cut, to provide power for tools and diagnostic equipment. In addition to main power cut-off 62, there is provided control power cut-off that may be one or more buttons 76 on the access door 70 or mounted on the interior of door 70. Control power cut-off 76 does not cut electrical power to the controls 26. Rather, the control power cut-off 76 cuts output from a system control 26 to its respective dairy system sensors 32 and actuators 34. This arrangement permits cycling of the system controls 26 for diagnostic purposes without a resulting activation of the dairy system. This isolation of controls from system is a useful tool that permits trouble-shooting of numerous system controls from a single location without affecting overall dairy operations. The control cut-off 76 preferably is implemented through switching of control relays and/or a rack of control contacts (not illustrated). The access door 70 is preferably a single door, but a number of doors can be used. Appropriate seals and door connectors are used to protect the cabinet interior 56 form the dairy environment. Preferably, a tool (not illustrated) is necessary to open the access door 70, to limit access by unauthorized or unskilled personnel. A simple battery of machine screws can serve this purpose, but other closure means may be used within the scope of the present invention.

The access door 70 also serves as a convenient controller interface location via buttons, dials, levers, screens, etc., although any cabinet exterior surfaces serves the benefit of controller interface without requiring access to the cabinet interior 56. Suitable operator interfaces include a main power button 64, control power button 78, a clean-in-place pipeline control panel 80, a milk cooling thermostat control 82, an intermediate milk receiver control 84, stall controls 86, bulk tank controls 88, pump out 90, pulsation controls 92, and DC power controls 94, although, as stated above, numerous other system controls can be interfaced with such buttons, etc. Preferably, the buttons are lighted or activate audible signals to indicate to operators various system status issues, such as operation, failure, adjustments, and so on.

The foregoing detailed description of the invention is provided for clearness of understanding only and no unnecessary limitations therefrom should be read into the following claims.

Claims

1. A central dairy control system comprising: a cabinet defining an interior space; an access door for sealing the interior space; and a plurality of dairy system controls, each dedicated to a particular dairy system and mounted in the cabinet interior space.

2. The central dairy control system of claim 1, wherein the cabinet complies with N.E.M. A. 4x standards.

3. The central dairy control system of claim 1, wherein the access door includes a plurality of dairy system controllers in communication with corresponding remote terminal units.

4. The central dairy control system of claim 3, wherein at least one of the dairy system controllers is a lighted button.

5. The central dairy control system of claim 1, wherein the access door includes a main power cut-off mounted thereon.

6. The central dairy control system of claim 1, wherein the access door includes at least one control power cut-off mounted thereon.

7. The central dairy control system of claim 1, wherein the access door comprises: a main power cut-off activated when the access door is opened.

8. The central dairy control system of claim 1, wherein at least one of the dairy system controls is a remote terminal unit.

9. The central dairy control system of claim 8, wherein at least one of the remote terminal units is a programmable data processor.

10. The central dairy control system of claim 8, wherein at least one remote terminal unit includes an activity-based controller interface.

11. The central dairy control system of claim 8, wherein a plurality of the remote terminal units include an activity-based controller quick-connect.

12. The central dairy control system of claim 8, and further comprising: a redundant power supply electrically coupled to the dairy system controls.

13. The central dairy control system of claim 1, and further comprising: a second cabinet defining an interior space; an access door for sealing the second cabinet interior space; and a plurality of dairy system controls, each dedicated to a particular dairy system and mounted in the second cabinet interior space.

14. A central dairy control system comprising: a cabinet defining an interior space; an access door for sealing the interior space; and a plurality of remote terminal units, each dedicated to a particular dairy system and mounted in the cabinet interior space.

15. The central dairy control system of claim 14, wherein the cabinet complies with N.E.M. A. 4x standards.

16. The central dairy control system of claim 14, wherein the access door includes a plurality of dairy system controllers in communication with corresponding remote terminal units.

17. The central dairy control system of claim 16, wherein at least one of the dairy system controllers is a lighted button.

18. The central dairy control system of claim 14, wherein the access door includes a main power cut-off mounted thereon.

19. The central dairy control system of claim 14, wherein the access door includes at least one control power cut-off mounted thereon.

20. The central dairy control system of claim 14, wherein the access door comprises: a main power cut-off activated when the access door is opened.

21. The central dairy control system of claim 14, wherein at least one of the remote terminal units is a programmable data processor.

22. The central dairy control system of claim 14, wherein at least one remote terminal unit includes an activity-based controller interface.

23. The central dairy control system of claim 14, wherein a plurality of the remote terminal units include an activity-based controller quick-connect.

24. The central dairy control system of claim 14, and further comprising: a redundant power supply electrically coupled to the dairy system controls.

25. The central dairy control system of claim 14, and further comprising: a second cabinet defining an interior space; an access door for sealing the second cabinet interior space; and a plurality of dairy system controls, each dedicated to a particular dairy system and mounted in the second cabinet interior space.