FIELD OF THE INVENTION
The present invention relates to an automatic sampler system for sampling dry solid from
bulk flow. More particularly, the present invention is directed to an automatic sampling
system to collect sample from flow of material through a chute involving an electro-
mechanical system wherein a scoop mounted on a rail goes inside chute to collect sample
from free flowing solid material. The sampler collects the material for a pre selected period
and comes out with the material. To ensure representative sampling of a batch, the
material is collected throughout the cross section of the chute. The material is transferred
from the scoop to an intermediate hopper wherein a divider segregates the sampling
portion to collection bin and the rest material for recycling. The whole operation can be
carried out automatically through a PLC controller with provision for semiautomatic or
manual operation. The sampler system of the present invention is thus capable of wide
industrial application for representative sampling of various bulk solid material of different
particles size automatically at any desired stage of processing with minimum loss of
material and waste generation/disposal problem in a simple, safe and reliable manner at
desired periodicity without causing interruption in production.
BACKGROUND ART
It is well in the operation of different process industries, both input material , in process
stages as well as the final product require that quality and other parameters are regularly
monitored to maintain the quality of the end product. This is conducted by analysis of
representative samples collected at regular intervals either manually or by means of
mechanized/automatic system. Basic objective of all these procedure are to collect the
samples which will represent the whole lot of the material. The existing system and
methods include various practices for sampling of different types of materials and to meet
the requirement of qualitative assessment. These sampler systems adopted any of the
method of sampling wherein
(a) Mechanical plough type device is provided which moves in a particular frequency to
divert the material in a container. Material from the container is collected from time to
time for analysis.
(b) Collecting material from fall at the drive end of the conveyor.
(c) stopping the belt and collection of the total material from a cross section of the belt
interrupting the production.
In all the above cases sampling is not proper due to the fact that either the samples are
not collected in sufficient increments or collection in each increment is not proper.
Moreover, since the sample to be analyzed is very little as compared to the total sample
collected, there is unavoidable generation of wastes and their disposal poses additional
problem.
A number of related prior patents dealt with the problem of representative sampling of
particulate solid material in ascertaining parameters for process quality control.
US 4,215,579 states about a sampling apparatus for coal and the like comprising a
housing surrounding and enclosing a space wherein a discharge from the primary crusher
disposed to deliver crushed coal/material within the housing, a conveyor belt within the
housing, the conveyor being positioned below the primary crusher discharge to receive
crushed material there from and to convey the crushed material to the end of the belt for
free fall within the housing. A swing able arm along with a sample container in a holder is
made to traverse across and through a stream of material falling from the end of the
conveyor belt and thereby collecting sample in regular interval in relation to speed of the
conveyor belt.
The above prior art sampling system did not ensure proper representative sample
collection without wastage as sample material is collected from a part of the freely falling
crushed coal at the end of conveyor from within the housing.
WO 1998 010266 states about an apparatus for sampling of coal dust particles from a
transporting tube is characterized in that it partly comprises sampling parts according to
DS/ISO 9931 with unevenly long extraction pipes for the particle sampling, said tubes
being rotatable around the axis of the transporting tube, and partly has possible coal dust
particles in the chamber expelled by compressed air before and while the extraction pipes
of the sampling part, with said tubes being collected to a bunch, are taken to the stand-by
position in the chamber. Thereby an automatic sampling is achieved according to said
standard along with a high operating reliability.
us 5,413,004 states about a method and apparatus for sampling coal wherein a coal sampling
device is disclosed that provided for the efficient extraction of a core sample of coal from a
container, such as a coal truck or railroad hopper car, and crushing of the extracted coal sample into
particles useful for laboratory analysis. Uncrushed pieces of extracted coal are transported to a
separating device that favour collection of extracted coal pieces in a container and also allow
extracted coal pieces fall into a crushing device, where the coal pieces are crushed to pebble-sized
pieces. The crushed coal pieces are allowed to fall out of the bottom of the coal crushing device, and
a portion of the crushed pieces are collected by a sample collecting receptacle, which accumulates
portions of the crushed coal throughout the core extraction process so that a true representative
sample of the total extracted core is collected. Crushed coal sample is removed from the
receptacle by a vacuum or air pressure through a hose or pipe that directs the crushed
coal sample to a laboratory or collecting work station.
Thus while the above prior art aims to collect representative sample, it collects only portion of
crushed coal on each occasion resulting in wastage and disposal related problem.
US H001026 is directed to a sampler comprising a gravity hopper suspended above a
feeder. The feeder acts as a means of conveyance to provide a constant feed of the bulk
solid to a rotary distribution apparatus. The feeder itself can be either a stationary
member placed on an incline allowing free flow of the particles or a vibrating plate which
can shake the particles from one another. The individual samples then flow from the
feeder to a rotating distribution apparatus. A conveyor or chute is attached to a platform
which is connected to a motor that rotates the platform and conveyor/chute in a clockwise
or counterclockwise direction. This rotation allows the particles to be randomly and
sequentially distributed into the collection receptacles positioned underneath.
US 4548087 is directed to an invention comprising a device which has a rotating drum
with an adjustable slot through its periphery. A bag or other receptacle is mounted inside
the drum directly below the slot to receive the selected sample from a stream of
particulate matter which is flowing toward and around the outer periphery of the drum
from a conveyor. Means are provided to grant easy access to the receptacle for its removal
and replacement by another receptacle.
None of the above prior art thus provides for a totally automated system for sample
collection which would be representative of entire lot to be evaluated while at the same
time minimize wastage and disposal problem.
There has been therefore a need in the related art to developing an automatic sampler
system for sampling dry solid from bulk flow of material wherein representative sample
would be collected with minimum human intervention so that ultimate sample collection is
as per requirement and no wastage takes place and thereby no waste disposal problem
arises. The sampling system would need less cost, minimum maintenance, operate in a
simple, safe and reliable manner without interruption of production.
OBJECTS OF THE INVENTION
The basic object of the present invention is thus directed to providing an automatic
sampler system for sampling dry solid from bulk flow adapted to collect representative
sample avoiding wastage of material in a simple, safe, cost effective and reliable manner.
Another object of the present invention is directed to providing an automatic sampler
system for sampling dry solid from bulk flow which would involve an electro-mechanical
system for collection of sample from free flowing material through a chute.
A still further object of the present invention is directed to providing an automatic sampler
system for sampling dry solid from bulk flow wherein the to and fro movement (i.e. the
speed and number of times/hour) and duration of stay of the scoop inside the chute for
collection of material can be controlled/adjusted.
A still further object of the present invention is directed to providing an automatic sampler
system for sampling dry solid from bulk flow wherein entire sampling operation is carried
out at desired frequency by involving a PLC controller such that there is minimum
manpower requirement for operation/maintenance of the system.
A still further object of the present invention is directed to providing an automatic sampler
system for sampling dry solid from bulk flow wherein sample is collected according to
requirement and the rest is recycled to the conveyor system such that wastage is nil and
there arises no problem relating to waste disposal.
A still further object of the present invention is directed to providing an automatic sampler
system for sampling dry solid from bulk flow wherein same sampling principle can be used
for different particle size and type of dry solids.
A still further object of the present invention is directed to providing an automatic sampler
system for sampling dry solid from bulk flow wherein the system comprises electro
mechanical components and control electronics which is less maintenance prone reducing
down time. However, the system can also be operated using pneumatic/hydraulic drive.
A still further object of the present invention is directed to providing an automatic sampler
system for sampling dry solid from bulk flow wherein sampling bin is having a sensor
which will stop the system automatically if the sampling bin is full thus avoiding wastage
and economizing power consumption.
A still further object of the present invention is directed to providing an automatic sampler
system for sampling dry solid from bulk flow wherein provision of mechanical means is
there to bring back the scoop in case of its stuck up or mal function inside the chute.
A still further object of the present invention is directed to providing an automatic sampler
system for sampling dry solid from bulk flow wherein provision is there to link it with the
incoming material so that the system will operate only when there is material in the belt.
A still further object of the present invention is directed to providing an automatic sampler
system for sampling dry solid from bulk flow wherein the divider in the intermediate
hopper can be adjusted depending upon the frequency and duration of collection of
material by the scoop, so that only the required amount is collected in the sampling pipe
and rest is recycled in the conveyor belt through other pipe for processing.
SUMMARY OF THE INVENTION
The basic aspect of the present invention is thus directed to a sampler system adapted for
sampling dry solid minimizing wastage comprising
a chute means allowing the flow of the solid material for sampling ;
a scoop mounted on rail adapted for to and fro motion to enter inside the chute to collect
sample from falling solid material;
an intermediate hopper disposed outside said chute for collection of the discharged
material upon at least a partial opening of said scoop exiting from said chute with sample
material;
said intermediate hopper having an adjustable divider inside adapted to divert and
discharge the material falling into said intermediate hopper in two parts (i) forwarding
part of the material to a sampling bin at the bottom for collection from time to time for
analysis/tests and (ii) discharging the rest to a conveyor belt for recycling rest of the
material.
Another aspect of the present invention is directed to said sampler system which is an on-
line automatic sampler comprising an electro-mechanical drive system providing desired to
and fro motion of said scoop to collect sample from falling solid material;
a PLC controller for co-coordinating and controlling the functions of different components
of the system to carry out sampling operation automatically.
A further aspect of the present invention is directed to said sampler system wherein to
ensure proper sampling representative, said scoop is adapted to collect material from
throughout the cross section of the chute.
A still further aspect of the present invention is directed to said sampler system,
comprising means adapted such that number of times the scoop collects the sample per
hour and duration of stay inside the chute for collecting the sample are adjustable.
According to an advantageous aspect of the present invention directed to said sampler
system, said divider in the intermediate hopper is adjusted depending upon the frequency
and duration of collection of material by the scoop, such that only the required amount is
collected in the sampling pipe and rest is recycled in the conveyor belt through the other
pipe for processing.
A still further aspect of the present invention is directed to said sampler system, wherein
sampling bin comprises a sensor adapted to stop the system automatically when the
sampling bin is full to avoid any choking in the pipeline or wastage of material.
Advantageously in said sampler system, a signal bulb/indicator indicates the status of the
sampling bin.
According to a further advantageous aspect of said sampler system of the present
invention, provision is there to operate the system in semi-automatic/manual mode also
for any special sampling.
According to yet another aspect of the present invention is directed to said sampler
system, wherein mechanical means is provided to bring back the scoop in case it is stuck
up or malfunction inside the chute.
A still further aspect of the present invention directed to said sampler system wherein two
numbers of emergency switches are provided in the field as well as in the PLC panel itself
for maintenance purpose during any urgent situation.
Also in said sampler system, there is provision to link it with the incoming material so that
the system operates only when there is material in the belt.
According to yet another aspect of the present invention directed to a method for sampling
dry solid from bulk flow using the above described system, comprising the steps of
collecting a representative sample of material from throughout the cross section of
chute in a scoop going inside the chute on rails;
discharging the collected sample material in an intermediate hopper from said scoop
coming out of the chute, by opening the bottom plate of scoop;
dividing the total material collected in the hopper in two parts by means of an
adjustable divider and discharging it in two discharge pipes - one part to the sampling
point at the bottom while other part to the conveyor belt for recycling rest of the
material;
collecting the required sampled material in a sampling bin for analysis/test from time
to time;
stopping the system automatically when the sampling bin is full;
recycling the rest of the material by a conveyor to minimize wastage.
The present invention and its objects and advantages are described in greater details with
reference to the following non limiting accompanying drawing.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Figure 1: is the schematic illustration of the automatic sampler system for representative
sampling of dry solid from bulk flow free of wastage according to the present invention
showing the various components of the system.
DETAILED DESCRIPTION OF THE INVENTION WITH REFERENCE TO THE
DRAWINGS
The present invention relates to an automatic sampler system for sampling dry solid from
bulk flow. More particularly, the present invention is directed to an automatic electro-
mechanical sampling system to collect sample from free flowing material through a chute.
Reference is first invited to the accompanying Figure 1 that schematically illustrate the
electro-mechanical system for sampling of dry solid from bulk flow according to the
present invention. The system comprises a scoop (SC) mounted on a rail which goes inside
chute (CH) to collect sample from falling solid material. It stays there for a pre selected
period to collect the material and then comes out with the material. The movement of the
scoop(SC) is conducted by an electro-mechanical drive comprising a motor and gear(MG)
assembly providing the to and from motion to the scoop. As the scoop comes out of the
chute(CH) after collection of material, the bottom plate of the scoop gets opened and
discharges material in an intermediate hopper(IH). This hopper is having an adjustable
divider(AD) inside to discharge the material in two discharge pipes(DP). One pipe sends
the material in the sampling point at the bottom while other pipe discharges to the
conveyor belt for recycling the material. The material thus stored in the sampling bin(SB)
(sampling point) is collected time to time by concerned person for analysis/tests. The
frequency of collection of sample i.e. number of times the scoop will collect the sample per
hour and duration of stay inside the chute for collecting the sample is adjustable. The
whole operation is done automatically through a PLC controller (not shown). Provision is
there to operate the system in semi-automatic/manual mode also for any special
sampling.
To ensure that the sample is representative, the material is collected throughout the cross
section of the chute. For minimizing the wastage, the divider(AD) in the intermediate
hopper(IH) can be adjusted depending upon the frequency and the amount of material
collected by the scoop(SC), so that only the required amount is collected in the sampling
pipe(SP) and rest is recycled in the conveyor belt through the other pipe for processing.
The sampling bin(SB) is having a sensor which stops the system automatically if the
sampling bin is full. A signal bulb/indicator indicates the status of the sampling bin. The to
and fro motion of the scoop is done through electro - mechanical drive. Two numbers of
emergency switches are provided in the field as well as in the PLC panel itself for
maintenance purpose during urgent situation. Provision of mechanical means is also there
to bring back the scoop in case it is stuck up or malfunctions inside the chute. Provision is
there to link the sampler with the incoming material so that the system will operate only
when there is material in the belt.
It is thus possible by way of the present invention to developing an electro-mechanical
automatic sampler system for dry solid materials from bulk flow adapted to minimize
wastage while ensuring timely collection of representative sample from batches of
material. The system is less costly device requiring less manpower involvement. The PLC
based control to enable auto-stop function when the sampling bin is full and linking the

operation with incoming material saves idling as well as wastage. Provisions for optional
semi-automatic or manual mode enable special sampling. The sampler system of the
present invention is thus having wide prospect for sampling a variety of incoming or in-
process materials in a large number of process industry to control quality/standard related
issues in fast and reliable manner minimizing wastage and eliminating waste disposal
problems.

We Claim:
1. A sampler system adapted for sampling dry solid minimizing wastage comprising:
a chute means allowing the flow of the solid material for sampling ;
a scoop mounted on rail adapted for to and fro motion to enter inside the chute to
collect sample from falling solid material;
an intermediate hopper disposed outside said chute for collection of the discharged
material upon at least a partial opening of said scoop exiting from said chute with
sample material;
said intermediate hopper having an adjustable divider inside adapted to divert and
discharge the material falling into said intermediate hopper in two parts (i) forwarding
part of the material to a sampling bin at the bottom for collection from time to time for
analysis/tests and (ii) discharging the rest to a conveyor belt for recycling rest of the
material.
2. A sampler system as claimed in claim 1 which is an on-line automatic sampler
comprising:
an electro-mechanical drive system providing desired to and fro motion of said scoop
to collect sample from falling solid material;
an intermediate hopper disposed outside said chute for collection of the discharged
material upon opening the bottom plate of said scoop exiting from said chute with
sample material;
said intermediate hopper having said adjustable divider inside adapted to divert and
discharge the material falling into said intermediate hopper in two parts (i) forwarding
part of the material to a sampling bin at the bottom for collection from time to time for
analysis/tests and (ii) discharging the rest to a conveyor belt for recycling rest of the
material;and

a PLC controller for co-coordinating and controlling the functions of different
components of the system to carry out sampling operation automatically.
3. A sampler system as claimed in anyone of claims 1 or 2 wherein to ensure proper
sampling representative, said scoop is adapted to collect material from throughout the
cross section of the chute.
4. A sampler system as claimed in any one of claims 1 to 3, comprising means adapted
such that number of times the scoop collects the sample per hour and duration of stay
inside the chute for collecting the sample are adjustable.
5. A sampler system as claimed in any one of claims 1 to 4, wherein said divider in the
intermediate hopper is adjusted depending upon the frequency (i.e. number of
times/hour) and duration (i.e. amount) of collection of material by the scoop, such that
only the required amount is collected in the sampling pipe and rest is recycled in the
conveyor belt through the other pipe for processing.
6. A sampler system as claimed in any one of claims 1 to 5, wherein sampling bin
comprises a sensor adapted to stop the system automatically when the sampling bin is
full.
7. A sampler system as claimed in any one of claims 1 to 6 wherein a signal bulb/indicator
indicates the status of the sampling bin.
8. A sampler system as claimed in any one of claims 1 to 7, wherein there is provision to
operate the system in semi-automatic/manual mode also for any special sampling.
9. A sampler system as claimed in any one of claims 1 to 8, wherein mechanical means is
provided to bring back the scoop in case it is stuck up or malfunction inside the chute.
10. A sampler system as claimed in any one of claims 1 to 9, wherein two numbers of
emergency switches are provided in the field as well as in the PLC panel itself for
maintenance purpose.

11. A sampler system as claimed in any one of claims 1 to 10, wherein there is provision
to link it with the incoming material so that the system operates only when there is
material in the belt.
12. A method for sampling dry solid from bulk flow using the system as claimed in claims
1 to 11, comprising the steps of
collecting a representative sample of material from throughout the cross section of
chute in a scoop going inside the chute on rails;
discharging the collected sample material in an intermediate hopper from said scoop
coming out of the chute, by opening the bottom plate of scoop;
dividing the total material collected in the hopper in two parts by means of an
adjustable divider and discharging it in two discharge pipes- one part to the sampling
point at the bottom while other part to the conveyor belt for recycling rest of the
material;
collecting the required sampled material in a sampling bin for analysis/test from time
to time;
stopping the system automatically when the sampling bin is full;
recycling the rest of the material by a conveyor to minimize wastage.
13. A sampler system and a method of sampling using such system as hereindescribed
with reference to the accompanying drawing.

There is disclosed an automatic sampler system for sampling dry solid from bulk flow
through a chute involving an electro-mechanical system wherein a scoop rails goes inside
chute to collect sample from free flowing solid material. The sampler collects the material
for a pre selected period and comes out with the material. To ensure representative
sampling of a batch, the material is collected throughout the cross section of the chute.
The sample is transferred from scoop to an intermediate hopper wherein an adjustable
divider segregates the sampling portion to a collection bin and the rest material to
conveyor for recycling. The whole operation is controlled automatically through a PLC
controller with provision for semiautomatic or manual operation. The sampler system is
thus capable of wide industrial application for representative sampling of solid material of
different particles size from bulk flow automatically with minimum loss/waste generation,
in a simple, safe and reliable manner without causing interruption in production.