FIELD OF THE INVENTION

The present invention relates to a quality control system for food stuff and more particularly to a sensor array deployed in a food stuff storage silo for monitoring quality of food stuff inside the storage silo.

BACKGROUND OF THE INVENTION

The storage of raw materials and /or food for livestock and /or in general can be conducted in many ways. In the case of the holding and storage of high quality foods, in a dry, closed and controlled storage area, it is very important to have access to clear, precise and immediate indications regarding the status of the raw material and /or food located in the storage tank. Livestock located in farming / commercial / industrial structures must receive fresh food of high quality and with easy access so as to ensure their optimal development on a physical and mental level under proper health and sanitation conditions. Therefore, it is of utmost importance that the entire storage system, both storing and dispensing the food, will be professional and of high quality, with the ability to command and control the process immediately online. A breakdown in the system and control of the stored food that is dispensed to the animals in a manner that is unhealthy and / or untimely and /or otherwise flawed will lead to a dramatic and /or critical effect on the entire growing process, and more specifically, the quality of the animals themselves.

SUMMARY OF THE INVENTION

According to the present invention there is provided a system for controlling and monitoring a food- stuff storage container and dispensation therefrom, the system including: a sensor cable suspended down a center of the storage container, the sensor cable having sensors configured to provide sensor data regarding the food- stuff in the storage container; a processing unit in electrical communication with the sensor cable, the processing unit configured to receive the sensor data from the sensor cable; a feeder engine configured to control release and conveyance of the food- stuff from the storage container to feeding areas, the feeder engine being in electrical communication with the processing unit and adapted to receive instruction therefrom; and a feeder sensor arrangement configured to monitor the food-stuff received at the feeding areas, the feeder sensor arrangement in electrical communication with the processing unit and adapted to provide monitoring data thereto. According to further features in preferred embodiments of the invention described below the sensor cable includes a cable and the sensors on the cable, each of the sensors is of a type of sensor selected from the group of: image sensors, temperature sensors, humidity sensors, proximity sensors, PH sensors, motion sensors, audio sensors, and weight sensors.

According to still further features in the described preferred embodiments the sensor cable further includes a weight disposed at a distal end thereof. According to further features the weight further includes therein at least one additional sensor.

According to further features the sensors are mounted on the cable or integrated in the cable. According to further features the sensor cable further includes a power and communications line in electrical communication with the sensors and the processing unit, the power and communications line adapted to communicate energy to the sensors and the sensor data from the sensors to the processing unit. According to further features the power and communications line is disposed inside the cable.

According to further features the sensors are disposed on a plurality of printed circuit boards (PCBs) spaced apart along a length of the cable. According to further features at least one of the PCBs houses more than one of the sensors.

According to further features the processing unit is collocated with the storage container. According to further features the processing unit includes a local, secondary computing device and a remote, main computing device, the local secondary computing device configured to be in electrical communication with at least the sensor cable and the remote, main computing device.

According to further features the processing unit is configured to process and analyze the monitoring data. According to further features the processing unit is configured to compare the sensor data regarding the food-stuff in the storage container and the monitoring data.

According to another embodiment there is provided a method for monitoring and controlling storage of food-stuff in a container and dispensation of the food-stuff therefrom, the method including the steps of: receiving, at a processing unit, user input regarding the food-stuff; requesting and receiving, at the processing unit, sensor data from a sensor cable disposed on the container; instructing, by the processing unit, a feeder engine to dispense and convey a portion of the food-stuff from the container to a feeding area; receiving, by the processing unit, monitoring data from a feeder sensor regarding the portion of the food-stuff received a the feeding area.

According to further features the method further includes the step of: comparing the sensor data to the monitoring data. According to further features the method further includes: displaying the sensor data on a system display.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments are herein described, by way of example only, with reference to the accompanying drawings, wherein:

FIG. 1 is a depiction of two silos 10 with sensor cables that are both connected to a single computing device;

FIG. 1 A is a magnified view of an area of Fig. 1 which includes the computing device;

FIG. 2 is a cutaway view of a single silo 10;

FIG. 2A is a magnified view of the sensor cable depicted in Fig. 2;

FIG. 3A is an isometric view of an exemplary embodiment of a PCB sensor 130 fixedly mounted on a section of cable 122;

FIG. 3B is a cross-sectional view of a section of the sensor cable 120;

FIG. 4 is a block diagram of the instant system;

FIG. 5 is a flow diagram of the automated controlling and monitoring process.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The principles and operation of device and system for monitoring as well as controlling food-stuff storage in a silo and dispensation therefrom, according to the present invention, may be better understood with reference to the drawings and the accompanying description. Similar components have the same reference numbers throughout the figures.

The storage of raw materials and /or food for livestock and /or in general can be conducted in many ways. In the case of the holding and storage of high quality foods, in a dry, closed and controlled storage area, it is very important to have access to clear, precise and immediate indications regarding the status of the raw material and /or food located in the storage tank.

Fivestock located in farming / commercial / industrial structures must receive fresh food of high quality and with easy access so as to ensure their optimal development on a physical and mental level under proper health and sanitation conditions. Therefore, it is of utmost importance that the entire storage system, both storing and dispensing the food, will be professional and of high quality, with the ability to command and control the process immediately (i.e. in real time or almost real time) online.

A breakdown in the system and control of the stored food that is dispensed to the animals in a manner that is unhealthy and / or untimely and /or otherwise flawed will lead to a dramatic and /or critical effect on the entire growing process, and more specifically, the quality of the animals themselves.

The product, system and method presented herein are designed to enable livestock farmers to manage and control food storage (especially in a storage silo or feeder bin), by optimizing the livestock feeding process to make it more efficient.

There is described hereafter a system, product and method. For the sake of conciseness, the generic term ‘bin’ will mainly be used hereafter, but it is made clear that the term is intended to refer to all types of embodiments, including but not limited to: a silo, a feeder bin, a storage tank.

Figure 1 illustrates two silos 10 with sensor cables that are both connected to a single computing device. Figure 1A is a magnified view of an area of Fig. 1 which includes the computing device. The computing device may be a central computing device or a secondary device that is in communication with a remote central computing device (see below for a detailed discussion).

Figure 2 illustrates a cutaway view of a single silo 10. A sensor cable 120 is visible within the silo, extending down the center of the bin. Figure 2A is a magnified view of the sensor cable depicted in Fig. 2. The sensor cable 120 is suspended down the center (or approximate center) of the silo, e.g. extending out the opening of the silo and attached to the roof of the silo. The feed (or other material) moves down the silo by gravity in the downward direction, indicated by an arrow 12. The movement and weight of the feed holds the sensor cable in place.

The sensor cable 120 is depicted with a plurality of sensors. The sensors may all be one type of sensor. Alternatively, the sensors may be different types of sensors. Accordingly, each of the plurality of sensors of the sensor cable is of a type of sensor selected from the group of: temperature sensors, humidity sensors, proximity sensors, PH sensors, motion sensors, audio sensors, and weight sensors. Figure 3A illustrates an isometric view of an exemplary embodiment of a PCB sensor 130 fixedly mounted on a section of cable 122. Figure 3B is a cross-sectional view of a section of the sensor cable 120. The sensors are disposed on a plurality of printed circuit boards spaced apart along a length of cable 122. It is made clear that the depicted embodiment and configuration is merely exemplary and simply one preferred manner of implementing the sensor cable. Cable 122 has an integrated power and communications line 126 disposed within the cable. The sensor 130 includes a printed circuit board (PCB) 132 with one or more sensor modules 134 disposed thereon. Accordingly, one PCB may house more than one type of sensor, such that at least one of the PCBs houses more than one of the sensors.

The PCB is mounted on the cable with two self-tap screws 136. The screws are conductive and at least one screw forms an electrically conductive connection between the PCB (including the sensor module(s) 134) and the power and communications line 126. The power and communications line communicates energy to the sensor from an external energy source. In the opposite direction, the sensor data gathered by the sensor modules is transferred via the power and communications line 126 out of the silo and to the local computing device 110, 114.

Figure 4 illustrates a block diagram of the instant system 100 which is a holistic management system for managing animal feed and including storage, dispensing and consumption tracking. The product/ system provides professional and online identification, alert, tracking, command and control of the feeding process for livestock in pens / coops.

The instant system 100 includes a number of components. Some of the components are installed beside a storage tank or silo 10, whereas one of the main components is installed inside the silo. If there are a number of tanks on the farming site, all will be connected simultaneously to the central control system.

A central electronic control system referred to hereafter as a processing unit 110 is the ‘brain’ of the system and also provides the interface for users. The control system can manage a single unit 10 (e.g. one storage silo or feeder bin) or a number of combined units (e.g. a plurality of silos located in a single geographic location). The processing unit is installed outside the silo / tank / bin. The processing unit may be a single computer collocated with the silo(s) or may be made up of multiple, interconnected computing devices that are both local and remote. Accordingly, in some embodiments, a local (i.e. located on or near a silo 10) computing device 110 or 114 can receive data from various components and sensors via a communications cable 116 or a via wireless communications. According to embodiments which only include local devices, all the processing is done on the local device 110. According to embodiments which include local and remote devices, the local device 114 (depicted in the diagram with a broken line indicating that it is an optional component) then sends this data to a remote central system 110, e.g. located inside an office. As mentioned, the local connections may be wired or wireless. The same applies for remote connections, however, a wireless connection is preferred. Each computing device (local or central) can be a Human Interface Device, i.e. having a display and user interface (UI) 112.

In some embodiments, the local device 114 is attached to the top of the silo and in direct, wireless communication with the central processing unit 110. In such cases, it may not be necessary for the local device to have a HID. Additional components (e.g. wireless communications modules, power connectors, internal computer memory, computer storage, processors etc.), as well as variations and modifications that would be obvious to one skilled in the art are considered to be included within the scope of the invention.

Each silo or storage tank 10 has a sensor cable 120 disposed inside the tank / silo / bin. The sensor cable includes a cable 122 and one or more sensors 130 which are integrated therein or attached thereon. Any configuration of sensors 130 on, in or about (i.e. encircling) the cable 122 are considered within the scope of the invention.

The vertical cable sensor 120 is installed in the center of the silo, extending down its length. A weight 124 is disposed on the distal, bottom end of the cable and functions to pull the cable downwards and, together with the weight of the stored material (e.g. animal feed or grain etc.), ensures stable and taut suspension. The sensors continuously gather data and information about the material / food that is in the tank 10. Additional and/or alternative sensors include, but are not limited to: thermal sensors, humidity sensors, proximity sensors, motion sensors, PH sensors, acoustic sensors, and weight sensors.

In some embodiments, the weight 124 at the bottom of the cable also houses a sensor or a sensor array. For example, the sensor inside the weight may be an imaging sensor. Additionally, or alternatively, the sensor can be a thermal sensor. Additional and/or alternative sensors include, but are not limited to, humidity sensors, motion sensors, PH sensors, acoustic sensors, and weight sensors.

A feeder engine 140 controls the movement of animal feed from the bin or silo 10 to the receptacles (feeding troughs) for the animals. In some embodiments, the engine controls the release of feed and the conveyance of feed to the animal enclosures. Exemplarily, the conveyance mechanism includes a conveyer belt and each of the feeding troughs includes a collection element that retrieves a portion of the feed from the conveyer belt and deposits into the feeding trough.

A feeder sensor arrangement 150 monitors consumption of the feed by the animals. The feeder sensor arrangement may be made up of one or more feeder sensors that inform the processing unit of the status of the animal feed. Feeder sensors may include imaging sensors, proximity sensors, humidity sensors, PH sensors, thermal sensors, etc.

For example, a given feeding area may be monitored by an imaging sensor, such as a high definition camera. The camera captures images (still images at regular intervals and/or continuous video) of the feeding as well as how much feed is left. Feeding is usually an ongoing process with more activity when new food is introduced and then only occasional grazing. The still and/or video images are communicated to a central processing unit. The image data (raw or initially processed) is transmitted to the central unit and/or storage continuously or according to a predefined schedule and/or based on a trigger (e.g. unusual activity, such as more movement than is usual). The data is processed by image processing software and/or human users.

The processing may include, inter alia, identifying animals and accumulated animal feed in the troughs or feeding areas. The processed images are then analyzed by software and/or human users. The analysis helps understand feeding behavior (e.g. in a calibration stage, providing a baseline for acceptable or normal feeding patterns) and monitor individual or group deviation from the normal behavior. The analysis may indicate that some livestock are ill (e.g. an animal is noticeably eating less than regular) or that there is something wrong with the food, as most of the animals are not eating. If a single group is not eating newly provided food, this may indicate that there is a problem with the trough / receptacle and/or that there is an external problem (e.g. there is a snake is in the receptacle, scaring off the animals). In embodiments, the system additionally or alternatively continuously tracks the accumulative state and/or quality of the material/food both inside the bin and at the feeding points. The system synchronizes information received from the sensors and analyzes of the parameters with regard to the temperature, weather, humidity, PH and/or any other data and factors that may have a positive or negative effect on the status of the material / food and/or its transfer to the livestock.

In preferred embodiments, the processing unit, sensor cable, feeder engine and feeder sensor arrangement are connected via a communications cable/connection or cables/connections 116. Some, or all, of the components can alternatively or additionally be connected wirelessly, via a wireless connection. The main control system 110 receives information from the sensors and, in coordination with designated software and/or online instructions, knows how to perform tasks such as dispensing food or halting the supply and/or transferring updated information online to the farmer and/or veterinarian and/or food supplier and / or any other relevant party in the system.

Figure 5 depicts a flow diagram of the automated controlling and monitoring process 500. The process includes various steps which may or may not be sequential. Some of the steps are repetitive such that various steps happen simultaneously.

In step 502, a user enters the initial bin and/or feed information, via the user interface 112 to the system processor unit 110. For e.g. bin information may include bin dimensions, and feed information may include feed type and density etc. All other initial or baseline information is also entered in this step.

In step 504, the system processor unit continually (e.g. at predefined, regular intervals) queries the sensor cable 120. For example, the system may ask: “which sensors are covered by the feed?” in order to ascertain how full the bin is. The type of information requested from the sensors depends on what type or types of sensors are on the sensor cable.

In step 506, the sensors transmit feedback (sensor data) to the processor unit. Carrying on the example above, the sensors report back which sensors are covered by feed.

In step 508, the system display 112 is continually updated with processed sensor information. In the example, the display shows a continually updated representation of the amount of feed in the bin. In step 510, sensors V-in (e.g. proximity sensors) measure the feeder engine 140 working time. In step 512 digital feedback is transmitted to the processor. The processor calculating the amount of feed that went through the feeder engine.

In step 514, the processor unit continually compares the feed amount measured by the sensor cable 120 to the feed amount measured by the feeder sensors 150.

While the invention has been described with respect to a limited number of embodiments, it will be appreciated that many variations, modifications and other applications of the invention may be made. Therefore, the claimed invention as recited in the claims that follow is not limited to the embodiments described herein.