Automated Wand System

Abstract

A system comprising a plurality of wands, suction and pneumatic valves, pneumatic cylinders, a vacuum and tilt sensors, and a programmable logic controller configured to read input signals from the vacuum and tilt sensors and send output signals controlling the pneumatic valves and cylinders, which open and close the vacuum valves regulating suctioning of the wands to achieve uniform and maximum depletion of pelletized material from a bulk container.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

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STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

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THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

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REFERENCE TO A SEQUENCE LISTING

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BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to evacuating and receptacle emptying systems, and in particular, to systems that will efficiently evacuate particulate matter from an open container without intermittent manual intervention.

2. Description of Related Art

In the plastics processing industry raw material in the form of pellets (approximately the size of a rice grain) are usually packaged in a box whose dimensions are approximately 4 ft.×4 ft.×4 ft., also known as a Gaylord. Technicians typically use a wand hooked to a vacuum system to transfer the material from the Gaylord into a hopper from which it is gravity-fed into the processing equipment.

As the material is sucked out of the Gaylord, an inverted cone is formed in the material. The business end of the wand is at the tip of the cone. This results in the wand not being able to pick up any material. A worker has to repeatedly reposition the wand or “shovel” material to the wand in order to pick up material. The required frequency of repositioning or shoveling increases exponentially with decreasing material volume in the Gaylord. This situation results into several trips, by the technician, to and from the Gaylord. Typically there is also equipment downtime, restart waste, and technician time to contend with when the worker fails to make the necessary trips and the processing equipment shuts down due to lack of raw material. All are non-value-added activities that consume precious resources. Some companies employ the use of box tilters to try and improve efficiency, but box tilters are bulky and dangerous, and technician intervention is still necessary.

For example a typical box tilter is disclosed in U.S. Pat. No. 5,538,389, issued to Stone, consisting of a box tilter comprising a movable chassis and a container-supporting frame directly hinged to the chassis. The actuating force for lifting and tilting the container is provided by a hydraulic cylinder connected in retractable pulling relation between the chassis and a radial arm rigidly attached to the container-supporting frame and projecting backward from the hinge point. This radial-arm configuration reduces the distance of the container from the operator of the device and results in improved access to the items in the container.

In light of the foregoing, it would be further appreciated to develop a system that eliminates the inverted cone scenario, thus enabling material transfer to proceed unabated until the Gaylord is virtually empty. Such system would significantly reduce or eliminate the non-value-added activities that are described above.

BRIEF SUMMARY OF THE INVENTION

The present invention is directed toward systems and methods to achieve the objectives above. The present invention comprises a plurality of wands, vacuum valves, a vacuum sensor, and a programmable logic controller (PLC). The vacuum sensor provides input signals to the PLC. The PLC sends output signals, which signals open and close the vacuum valves regulating suctioning of the wands. The present invention employs tilt sensors and pneumatic valves. The PLC controls material suction via pneumatic cylinders that open and close vacuum ports, using input from the tilt and vacuum sensors thus keeping the material depletion uniformly distributed in a bulk container.

More particularly, the present invention is directed toward a system, comprising: a plurality of wands, vacuum valves, pneumatic cylinders, pneumatic valves, a vacuum sensor, tilt sensors, a PLC. The system is in electrical communication with a power source. The vacuum and tilt sensors provide input signals to the PLC. The PLC sends output signals activating the pneumatic valves controlling compressed air into the pneumatic cylinders, which cylinders open and close the vacuum valves regulating suctioning of the wands.

When the system is placed inside a bulk container and is connected to a vacuum loader hose, and when the vacuum loader hose is turned on, the vacuum sensor sends an input signal to the PLC. The PLC reads the input signals of vacuum and tilt sensors, the PLC sends output signals to the pneumatic valves controlling the cylinders to open and close the vacuum valves, which vacuum valves control suction through the wands, so that the system levels itself respecting a horizontal plane. When the system is level, the tilt sensors send input signals to the PLC, which PLC sends output signals to the pneumatic valves causing the cylinders to fully open all vacuum valves.

The wands are spaced apart to achieve uniform and maximum depletion of pelletized material in the bulk container when the system is level. When the system is unlevel the tilt sensors send input signals to the PLC, which PLC in turn sends output signals to the pneumatic valves, closing vacuum valves to wands extending below said horizontal plane and keeping fully open vacuum valves to wands extending only above level.

Other objects and advantages of the present invention will be readily apparent upon a reading of the following brief descriptions of the drawing figures, detailed descriptions of preferred embodiments of the invention, the appended claims and drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The above mentioned and other objects and features of this invention and the manner of attaining them will become apparent, and the invention itself will be best understood by reference to the appended drawings. In the course of the following detailed description, reference will be made to the appended drawings in which:

FIG. 1: A schematic of a Prior Art Manual Wand Apparatus

FIG. 2A: A Side View of a preferred embodiment of the Automated Wand System

FIG. 2B: A Bottom View of a preferred embodiment of the Automated Wand System

FIG. 3: A Top View and sectional views of a preferred embodiment of the Automated Wand System

FIG. 4: A schematic of the NEMA Enclosure

FIG. 5: A Side View of a preferred embodiment of the Automated Wand System inside of a bulk container

FIG. 6A: A schematic of the Tilt Sensors' orientation superimposed on a preferred embodiment of the Vacuum Valve Housing

FIG. 6B: Sectionals of the Tilt Sensors

FIG. 7: Flow Chart of the PLC

FIG. 8: A bottom view of a preferred embodiment of the Vacuum Circumference of the Automated Wand System

FIG. 9: A Side View of a preferred embodiment of the Automated Wand System tilted inside a bulk container

DETAILED DESCRIPTION OF THE INVENTION

In the following description, like reference characters designate like or corresponding parts throughout the several views. Referring now to the drawings in detail, reference is made to FIGS. 2A and B, 3, 4, and 6A. The present invention is directed toward systems and methods for efficiently evacuating particulate matter from an open container without intermittent manual intervention. A preferred embodiment of the present invention comprises a plurality of wands (204 and 205), vacuum valves 75, pneumatic cylinders 71, pneumatic valves 56, a vacuum sensor 83, tilt sensors 99, and a Program Logic Controller (“PLC”) 81. As in FIG. 5, the system 100 is in electrical communication with a power source 86.

Referring to FIG. 6A the vacuum sensor 83 and tilt sensors 99 provide input signals to the PLC 81. Referring FIGS. 2A, 3 and 4, the PLC 81 sends output signals activating the pneumatic valves 56 controlling compressed air into the pneumatic cylinders 71, which open and close the vacuum valves 75 regulating suctioning of the wands (204 and 205). Referring to FIG. 5, when the system is placed inside a bulk container 53 and is connected to a vacuum loader hose 88, and when the vacuum loader hose 88 is turned on, the vacuum sensor 83 sends an input signal to the PLC 81; the PLC 81 reads the input signals of the vacuum sensor 83 and the tilt sensors 99, then the PLC 81 sends output signals to the pneumatic valves 56 controlling the pneumatic cylinders 71 to open and close the vacuum valves 75, which control suction through the wands (204 and 205), so that the system 100 levels itself inside the bulk container 53.

In a preferred embodiment, referring to FIG. 2A., each of the wands (204 and 205) has a first end (103 and 207) and second end 102; wherein the shape of the wands (204 and 205) as well as the gauge thickness of the wand material are sized to provide structural strength, so that the plurality of wands (204 and 205) are capable of supporting the weight of the entire system 100; wherein each wand 204 is substantially s shaped; and wherein the wand first ends (103 and 207) contain anti-plug loops 68, and the wand second ends 102 are connected to the vacuum valves 75. Referring to FIGS. 9 and 10, the cross sectional area of the wand first ends (103 and 207) are coplanar, thereby constituting the system plane 201. When the system plane 201 is parallel to the horizontal plane, the system 100 is level, thereby constituting the level system plane 202. In a preferred embodiment, each wand second end 102 is connected to a separate vacuum valve 75.

The system 100 in claim 6, wherein the system 100 is placed in a bulk container 53 with the wand first ends (103 and 207) placed substantially on top of the pelletized material 90; and wherein the wand first ends (103 and 207) are spaced apart to achieve uniform and maximum depletion of pelletized material 90 in the bulk container 53 when the system plane 201 is level. In a preferred embodiment, when the system plane 201 is unlevel, at least one wand first end 207 is below the system level plane 202 and at least another wand first end 207 is above the system level plane 202. When the system plane 201 is unlevel, the tilt sensors 99 send input signals to the PLC 81, which in turn sends output signals to the pneumatic valves 56, closing vacuum valves 75 to wands 204 whose first ends 207 extend below the level system plane 202 and keeping fully open vacuum valves 75 to wands 204 whose first ends 207 are above the level system plane 202.

Referring to FIG. 9, in preferred embodiment, a wand first end (103 and 207) comprises an area of suction 203, which is the maximum lateral range of suction of the wand first end (103 and 207) when the system 100 is level. Referring to FIG. 2B, the plurality of wands (204 and 205) consist of 9 wands (204 and 205), comprising 1 inner wand 205, and 8 outer wands 204, all wands (204 and 205) equally spaced apart, such that when the system 100 is placed level inside in the middle of a 4′×4′×4′ bulk container 53 full of pelletized material 90, the area of suction 203 of the wand first ends (103 and 207) extend equidistant between adjacent wand first ends (103 and 207), and the area of suction 203 of the outer wands 204 extend to the container walls 91.

Referring FIG. 10, in a preferred embodiment, the first end 103 of the inner wand 205 is equidistant to the first end 207 of the outer wands 204, such that when the system 100 is unlevel, at least one outer wand first end 204 extends below the system level plane 202 about the inner wand first end 103 and at least another outer wand first end 207 is above the system level plane 202 about the inner wand first end 103. When the system 100 is unlevel, the angle between the system plane 201 and level system plane 202 about the inner wand first end 103 constitutes the angle of tilt 199 of the system 100. When an outer wand first end 207 is below the system level plane 202, the angle of tilt 199 of that outer wand first end 207 is negative, and when an outer wand first end 207 is above the system level plane, the angle of tilt 199 of said wand 204 is positive.

Referring to FIG. 3, in a preferred embodiment, the system 100 comprises a vacuum valve housing 69, containing the vacuum valves 75, a plenum 104, a vacuum loader hose connection 77, a bottom surface 105 and top surface 106, a box-shaped compartment forming the plenum 104 with a plurality of spaced apart ports 73 in the bottom surface 105, and a plurality of apertures 107 in the top surface 106. As in FIGS. 2A and 3, the second ends 102 of the wands (204 and 205) attach to the ports 73, such that when a vacuum loader hose 88 is connected to the vacuum loader hose connection 77 and turned on with the vacuum valves 75 open, the pelletized material 90 is suctioned through the wands (204 and 205) into the plenum 104, and into the vacuum loader hose 88.

Still referring to FIG. 3, in a preferred embodiment, each vacuum valve 75 has a valve stopper 74; wherein the pneumatic valves 56 are controlled by solenoids (not shown). Each pneumatic cylinder 71 includes a cylinder rod 72. Each pneumatic cylinder 71 is connected to a separate pneumatic valve 56. Each cylinder rod 72 is inserted in a separate aperture 107 in the top surface 106 of the vacuum valve housing 69 and is connected to at least one vacuum valve 75. Each vacuum valve's valve stopper 74 is aligned with a separate vacuum port 73, such that filling each of the cylinders 71 with compressed air forces the connected cylinder rod 72 to push the connected valve stopper 74 inside and closing the vacuum port 73 aligned therewith, preventing suctioning through the wand (204 and 205) connected thereto. In another preferred embodiment, each cylinder rod 72 is connected to two vacuum valves 75.

In a preferred embodiment, the vacuum sensor 83 detects when the vacuum loader hose 88 is turned on by measuring the vacuum pressure in the vacuum valve housing 69, and the tilt sensors 99 detect when the system 100 is level by measuring the angle of tilt 199 of the system 100; and each tilt sensor 99 is capable of detecting the tilt angle 199 of at least one wand first end 207. In a preferred embodiment, the tilt sensors 99 send on or off, input signals to the PLC 81. Still referring to FIG. 10, in a preferred embodiment, tilt sensor 99 sends an off input signal to the PLC 81 if the tilt sensor 99 detects a negative angle of tilt 199 of a wand first end 207; and a tilt sensor 99 sends an on input signal to the PLC 81 if the tilt sensor 99 detects a positive angle of tilt 199 of a wand first end 207. In a preferred embodiment, the PLC 81 will send an output signal to a pneumatic valve 56 energizing the solenoid to fill the connected pneumatic cylinder 71 with compressed air and in turn closing the connected vacuum valve 75, thereby preventing suctioning in the connected wand 204 whose angle of tilt 199 is negative. The PLC 81 will send an output signal to a pneumatic valve 56 de-energizing the solenoid to withdraw compressed air from the connected pneumatic cylinder 71 and in turn opening the connected vacuum valve 75, thereby allowing suctioning in the connected wand 204 whose angle of tilt 199 is positive.

Referring to FIGS. 4 and 6A, in a preferred embodiment, the system plane 201 comprises axis one 96 and axis two 94. Axis one 96 extends through the first end 103 of the inner wand 205 and through the first ends 207 of two outer wands 204 on opposite sides of the inner wand 205. Axis two 94 is perpendicular to axis one 96 and extends through the first end 103 of the inner wand 205 and through the first ends 207 of two outer wands 204 on opposite sides of the inner wand 205. Referring to FIG. 4, in a preferred embodiment, the system 100 includes a NEMA enclosure 63, comprising a bottom surface 206 parallel to the system plane 201, and containing the pneumatic valves 56, vacuum sensor 83, tilt sensors 99, the PLC 81, and other electrical components. The NEMA enclosure 63 is bracketed to the vacuum valve housing 69 and in electrical communication with a power source 86. Referring to FIGS. 4 and 6A, in a preferred embodiment, four tilt sensors 99 are placed on the bottom surface 206 of the NEMA enclosure 63, paired and spaced apart along axis one 96 and axis two 94, such that if a tilt sensor 99 detects a negative tilt angle 199, its pair will detect an equal and opposite tilt angle 199.

Referring to FIG. 3, in a preferred embodiment, to maintain a pressure differential in the plenum 104, to maximize the flow of material through the plenum 104 into the vacuum loader hose 88, the negative pressure at the vacuum loader hose connection 77 is approximately the same as the pressure at the open ports 73. In a preferred embodiment, to achieve the pressure differential in the plenum 104, the negative pressure in the vacuum loader house is −7.5 in Hg (−3.7 psi), having a Flow of 100 ft³/min.

The invention works just as well when only one port 73 is open at any one time. In this case, if a tilt sensor 99 detects a positive tilt angle 199, the PLC 81 sends a sequencing output signal to open and close the vacuum valves 75 one at a time in a clockwise sequence of the outer wands 204, starting with the vacuum valve 75 connected to the outer wand 204 whose first end 207 is aligned with the same axis as said tilt sensor 99 (such as axis three 93 or axis four 95, as in FIG. 6A), and opening and closing the inner wand 205 last.

In a preferred embodiment, when the system 100 is level, the tilt sensors 99 send input signals to the PLC 81, which PLC 81 sends output signals to the pneumatic valves 56 causing the cylinders 71 to fully open all vacuum valves 75. In this case, the plenum 104 comprises a relief valve 200, and a plenum saturation level (not shown), which occurs when the negative pressure at the open ports 73 approximates the negative pressure at the vacuum loader hose connection 77. The vacuum sensor 83 detects when the plenum 104 is saturated and sends an input signal to the PLC 81, which PLC 81 sends output signals closing all ports 73 until the vacuum loader hose 88 has suctioned virtually all of the pelletized material 90 out of the plenum 104, and which PLC 81 sends an output signal opening the relief valve 200 introducing compensating air into the plenum 104.

Referring now to FIGS. 2A and 5, a preferred embodiment comprises, when the system 100 is level, the system 100 having a height between 21-24 inches and a weight between 25-35 pounds. A suitable material of the wands 67 is 6061 Aluminum Tubing, with an outside diameter of 2 inches, a wall thickness of 0.065 inches, and a length between 24-27 inches. A preferred radius of the area of suction of the wand first ends 101 is 8-10 inches. A preferred distance between the outer wand first ends 101 and wall of Gaylord is 6 inches. A preferred embodiment of the Vacuum Valve Housing material is 6063 90° Aluminum angle rod, having fabrication cut and welded to form a 10″×10″×3″ frame. A preferred construction of the Vacuum Valve Housing 69 top surface 106 is 10″×10″×⅛″ 6061 Aluminum Plate and bottom surfaces 105 is 10″×10″×¼″ 6061 Aluminum Plate, and side surface is 10″×3″× 3/16″ Clear Polycarbonate.

FIG. 6B illustrates a suitable embodiment of a pair (X1 and X3) of tilt sensors 99, placed on the bottom surface 206 of the NEMA enclosure (as in FIG. 4), the pair (X1 and X3) of tilt sensors 99 comprising electrical contacts 97 and a metal ball 98. The electrical contacts 97 are placed on opposites sides of the respective ball 98 in each pair (X1 and X3), such that when axis 94 is tilted in one direction the ball 98 will touch the electrical contact 97 in X1 but not in X3, as illustrated in Section A-A in FIG. 6B.

FIG. 7 illustrates a suitable algorithm for the PLC 81 in the embodiment described above where only one vacuum valve 75 is open at any one time. Referring to FIG. 4, the solenoids 56 are housed in a solenoid bank 78 comprising solenoids Y1, Y2, Y3, Y4, and Y5. The solenoids Y1, Y2, Y3, Y4, and Y5 are matched with the cylinders 70 in FIG. 6A, wherein solenoid Y1 is connected to cylinder CY1, solenoid Y2 is connected to cylinder CY2, solenoid Y3 is connected to cylinder CY3, solenoid Y4 is connected to cylinder CY4, and solenoid Y5 is connected to cylinder CY5.

Referring to the flow chart in FIG. 7, when metal ball 98 touches the electrical contact 97 in tilt sensor X1 the PLC 81 sends an on output sequencing instruction energizing the solenoid valves 56 in the solenoid bank 78 (FIG. 4) one at a time in the sequence Y1, Y2, Y3, Y4, Y5, resulting in opening and closing the vacuum valves 75 one at a time, in turn only allowing suctioning through the wands (204 and 205) one at a time, starting with the outer wand 204 connected to the vacuum valve 75 connected to cylinder CY1, which is connected to solenoid valve Y1, which is connected to tilt sensor X1. In this manner, the flow chart in FIG. 7 illustrates that the PLC 81 sequencing instructions control suctioning in the wands starting with the wand 75 connected to the tilt sensor 99 whose metal ball 98 first touches its contact 97. The sequence ends with allowing suctioning in the inner wand 204 last.

All of the above descriptions are merely illustrative of the many applications of the system 100 of present invention. Although only a few embodiments of the present invention have been described herein, it should be understood that the present invention might be embodied in many other specific forms without departing from the spirit or scope of the invention. Therefore, the present examples and embodiments are to be considered as illustrative and not restrictive, and the invention is not to be limited to the details given herein, but may be modified within the scope of the appended claims.

Claims

1. A system, comprising: a plurality of wands, vacuum valves, a vacuum sensor, and a PLC; the system is in electrical communication with a power source;

the vacuum sensor provides input signals to the PLC; the PLC sends output signals, which signals open and close the vacuum valves regulating suctioning of the wands.

2. A system, comprising: a plurality of wands, vacuum valves, pneumatic cylinders, pneumatic valves, a vacuum sensor, tilt sensors, and a PLC; the system is in electrical communication with a power source;

the vacuum and tilt sensors provide input signals to the PLC; the PLC sends output signals activating the pneumatic valves controlling compressed air into the pneumatic cylinders, which open and close the vacuum valves regulating suctioning of the wands.

3. The system in claim 2, wherein when the system is placed inside a bulk container and is connected to a vacuum loader hose, and when the vacuum loader hose is turned on, the vacuum sensor sends an input signal to the PLC; the PLC reads the input signals of the vacuum sensor and the tilt sensors, then the PLC sends output signals to the pneumatic valves controlling the pneumatic cylinders to open and close the vacuum valves, which control suction through the wands, so that the system levels itself inside the bulk container.

4. The system in claim 3, wherein each of the wands have first and second ends; wherein the shape of the wands as well as the gauge thickness of the wand material are sized to provide structural strength, so that the plurality of wands are capable of supporting the weight of the entire system; wherein each wand is substantially s shaped; and wherein the wand first ends contain anti-plug loops, and the wand second ends are connected to the vacuum valves.

5. The system in claim 4, wherein the cross sectional area of the wand first ends are coplanar, thereby constituting the system plane; when the system plane is parallel to the horizontal plane the system is level, thereby constituting the level system plane.

6. The system in claim 5, wherein each wand second end is connected to a separate vacuum valve.

7. The system in claim 6, wherein the system is placed in a bulk container with the wand first ends placed substantially on top of the pelletized material; and wherein the wand first ends are spaced apart to achieve uniform and maximum depletion of pelletized material in the bulk container when the system plane is level.

8. The system in claim 7, wherein when the system plane is unlevel, at least one wand first end is below the system level plane and at least another wand first end is above the system level plane.

9. The system in claim 8, wherein when the system plane is unlevel, the tilt sensors send input signals to the PLC, which in turn sends output signals to the pneumatic valves, closing vacuum valves to wands whose first ends extend below the level system plane and keeping fully open vacuum valves to wands whose first ends are above the level system plane.

10. The system in claim 9, wherein a wand first end comprises an area of suction, which is the maximum lateral range of suction of the wand first end when the system is level.

11. The system in claim 10, wherein the plurality of wands consist of 9 wands, comprising 1 inner wand, and 8 outer wands, all wands equally spaced apart, such that when the system is placed level inside in the middle of a 4′×4′×4′ bulk container full of pelletized material, the area of suction of the wand first ends extend equidistant between adjacent wand first ends, and the area of suction of the outer wands extend to the container walls.

12. The system in claim 11, wherein the first end of the inner wand is equidistant to the first end of the outer wands, such that when the system is unlevel, at least one outer wand first end extends below the system level plane about the inner wand first end and at least another outer wand first end is above the system level plane about the inner wand first end.

13. The system in claim 12, wherein when the system is unlevel, the angle between the system plane and level system plane about the inner wand first end constitutes the angle of tilt of the system; and wherein when a wand first end is below the system level plane, the angle of tilt of that wand first end is negative, and when a wand first end is above the system level plane, the angle of tilt of said wand is positive.

14. The system in claim 13, wherein the system comprises a vacuum valve housing, containing the vacuum valves, a plenum, a vacuum loader hose connection, bottom and top surfaces, a box-shaped compartment forming the plenum with a plurality of spaced apart ports in the bottom surface, and a plurality of apertures in the top surface; the second ends of the wands attach to the ports, such that when a vacuum loader hose is connected to the vacuum loader hose connection and turned on with the vacuum valves open, the pelletized material is suctioned through the wands into the plenum, and into the vacuum loader hose.

15. The system in claim 14, wherein each vacuum valve has a valve stopper; wherein the pneumatic valves are controlled by solenoids; and wherein each pneumatic cylinder includes a cylinder rod, each pneumatic cylinder is connected to a separate pneumatic valve, each cylinder rod is inserted in a separate aperture in the top surface of the vacuum valve housing and is connected to at least one vacuum valve, each vacuum valve's valve stopper is aligned with a separate vacuum port, such that filling each of the cylinders with compressed air forces the connected cylinder rod to push the connected valve stopper inside and closing the vacuum port aligned therewith, preventing suctioning through the wand connected thereto.

16. The system in claim 15, wherein each cylinder rod is connected to two vacuum valves.

17. The system in claim 16, wherein the vacuum sensor detects when the vacuum loader hose is turned on by measuring the vacuum pressure in the vacuum valve housing.

18. The system in claim 17, wherein the tilt sensors detect when the system is level by measuring the angle of tilt of the system; and wherein each tilt sensor is capable of detecting the tilt angle of at least one wand first end.

19. The system in claim 18, wherein the tilt sensors send on or off, input signals to the PLC;

wherein a tilt sensor sends an off input signal to the PLC if the tilt sensor detects a negative angle of tilt of a wand first end; wherein a tilt sensor sends an on input signal to the PLC if the tilt sensor detects a positive angle of tilt of a wand first end; wherein the PLC will send an output signal to a pneumatic valve energizing the solenoid to fill the connected pneumatic cylinder with compressed air and in turn closing the connected vacuum valve, thereby preventing suctioning in the connected wand whose angle of tilt is negative; and wherein the PLC will send an output signal to a pneumatic valve de-energizing the solenoid to withdraw compressed air from the connected pneumatic cylinder and in turn opening the connected vacuum valve, thereby allowing suctioning in the connected wand whose angle of tilt is positive.

20. The system in claim 19, wherein the system plane comprises axis one and axis two; axis one extends through the first end of the inner wand and through the first ends of two outer wands on opposite sides of the inner wand; axis two is perpendicular to axis one and extends through the first end of the inner wand and through the first ends of two outer wands on opposite sides of the inner wand.

21. The system in claim 20, wherein the system includes a NEMA enclosure, comprising a bottom surface parallel to the system plane, and containing the pneumatic valves, vacuum sensor, tilt sensors, the PLC, and other electrical components; the NEMA enclosure being bracketed to the vacuum valve housing and in electrical communication with a power source.

22. The system in claim 21, wherein four tilt sensors are placed on the bottom surface of the NEMA enclosure, paired and spaced apart along axis one and two, such that if a tilt sensor detects a negative tilt angle, its pair will detect an equal and opposite tilt angle.

23. The system in claim 22, wherein to maintain a pressure differential in the plenum, maximizing the flow of material through the plenum into the vacuum loader hose, the negative pressure at the vacuum loader hose connection is approximately the same as the pressure at the open ports.

24. The system in claim 23, wherein to achieve the pressure differential in the plenum, the negative pressure in the vacuum loader house is −7.5 in Hg (−3.7 psi), having a Flow of 100 ft3/min.

25. The system in claim 24, wherein only one port is open at any one time.

26. The system in claim 25, wherein if a tilt sensor detects a positive tilt angle, the PLC sends a sequencing output signal to open and close the vacuum valves one at a time in a clockwise sequence of the outer wands, starting with the vacuum valve connected to the outer wand whose first end is aligned with the same axis as said tilt sensor, and opening and closing the inner wand last.

27. The system in claim 24, wherein when the system is level, the tilt sensors send input signals to the PLC, which PLC sends output signals to the pneumatic valves causing the cylinders to fully open all vacuum valves.

28. The system in claim 27, wherein the plenum comprises a relief valve, and a plenum saturation level, which occurs when the negative pressure at the open ports approximates the negative pressure at the vacuum loader hose connection; and wherein the vacuum sensor detects when the plenum is saturated and sends an input signal to the PLC, which PLC sends output signals closing all ports until the vacuum loader hose has suctioned virtually all of the pelletized material out of the plenum, and which PLC sends an output signal opening the relief valve introducing compensating air into the plenum.

29. A system, comprising: 9 wands, comprising 1 inner wand, and 8 outer wands, each of the wands have first and second ends; wherein the shape of the wands as well as the gauge thickness of the wand material are sized to provide structural strength, so that the plurality of wands are capable of supporting the weight of the entire system; wherein each wand is substantially s shaped; and wherein the wand first ends contain anti-plug loops;

the cross sectional area of the wand first ends are coplanar, thereby constituting the system plane; when the system plane is parallel to the horizontal plane the system is level, thereby constituting the level system plane;

a wand first end comprises an area of suction, which is the maximum lateral range of suction of the wand first end when the system is level;

all wands are equally spaced apart, such that when the system is placed level inside in the middle of a 4′×4′×4′ bulk container full of pelletized material, the area of suction of the wand first ends extend equidistant between adjacent wand first ends, and the area of suction of the outer wands extend to the container walls; the first end of the inner wand is equidistant to the first end of the outer wands;

when the system is unlevel, the angle between the system plane and level system plane about the inner wand first end constitutes the angle of tilt of the system; when a wand first end is below the system level plane, the angle of tilt of that wand first end is negative, and when a wand first end is above the system level plane, the angle of tilt of said wand is positive;

a vacuum valve housing, comprising vacuum valves, a plenum, a vacuum loader hose connection, bottom and top surfaces, a plenum with a plurality of spaced apart ports in the bottom surface, and a plurality of apertures in the top surface; the second ends of the wands attach to the ports and to the vacuum valves, such that when a vacuum loader hose is connected to the vacuum loader hose connection and turned on with the vacuum valves open, the pelletized material is suctioned through the wands into the plenum, and into the vacuum loader hose;

tilt sensors, which detect when the system is level; pneumatic valves, pneumatic cylinders, a vacuum valve, and a PLC; a tilt sensor sends an off input signal to the PLC if the tilt sensor detects a negative angle of tilt of a wand first end; a tilt sensor sends an on input signal to the PLC if the tilt sensor detects a positive angle of tilt of a wand first end; the PLC will send an output signal to a pneumatic valve energizing the solenoid to cause the connected pneumatic cylinder to close the connected vacuum valve, thereby preventing suctioning in the connected wand whose angle of tilt is negative; and the PLC will send an output signal to a pneumatic valve de-energizing the solenoid to cause the connected pneumatic cylinder to open the connected vacuum valve, thereby allowing suctioning in the connected wand whose angle of tilt is positive;

to maintain a pressure differential in the plenum, maximizing the flow of material through the plenum into the vacuum loader hose, the negative pressure at the vacuum loader hose connection is approximately the same as the pressure at the open ports;

the plenum comprises a plenum saturation level, which occurs when the negative pressure at the open ports no longer approximate the negative pressure at the vacuum loader hose connection; and wherein the vacuum sensor detects when the plenum is saturated and sends an input signal to the PLC, which PLC sends output signals closing all ports until the vacuum loader hose has suctioned virtually all of the pelletized material out of the plenum.

30. A system, comprising: a plurality of wands, vacuum valves, pneumatic cylinders, pneumatic valves, a vacuum sensor, tilt sensors, and a PLC; the system is in electrical communication with a power source;

each of the wands have first and second ends; wherein the shape of the wands as well as the gauge thickness of the wand material are sized to provide structural strength, so that the plurality of wands are capable of supporting the weight of the entire system; wherein each wand is substantially s shaped; and wherein the wand first ends contain anti-plug loops, and the wand second ends are connected to the vacuum valves;

the cross sectional area of the wand first ends are coplanar, thereby constituting the system plane; when the system plane is parallel to the horizontal plane the system is level, thereby constituting the level system plane;

a wand first end comprises an area of suction, which is the maximum lateral range of suction of the wand first end when the system is level;

the plurality of wands consist of 9 wands, comprising 1 inner wand, and 8 outer wands, all wands equally spaced apart, such that when the system is placed level inside in the middle of a 4′×4′×4′ bulk container full of pelletized material, the area of suction of the wand first ends extend equidistant between adjacent wand first ends, and the area of suction of the outer wands extend to the container walls;

the first end of the inner wand is equidistant to the first end of the outer wands;

when the system is unlevel, the angle between the system plane and level system plane about the inner wand first end constitutes the angle of tilt of the system; when a wand first end is below the system level plane, the angle of tilt of that wand first end is negative, and when a wand first end is above the system level plane, the angle of tilt of said wand is positive;

a vacuum valve housing, containing the vacuum valves, a plenum, a vacuum loader hose connection, bottom and top surfaces, a plenum with a plurality of spaced apart ports in the bottom surface, and a plurality of apertures in the top surface; the second ends of the wands attach to the ports, such that when a vacuum loader hose is connected to the vacuum loader hose connection and turned on with the vacuum valves open, the pelletized material is suctioned through the wands into the plenum, and into the vacuum loader hose;

each vacuum valve has a valve stopper; the pneumatic valves are controlled by solenoids; and each pneumatic cylinder includes a cylinder rod, each cylinder rod is inserted in a separate aperture in the top surface of the vacuum valve housing and is connected to at least one vacuum valve, each valve's valve stopper is aligned with a separate vacuum port, such that filling each of the cylinders with compressed air forces the connected cylinder rod to push the connected vacuum stopper inside and closing the vacuum port aligned therewith, preventing suctioning through the wand connected thereto; each cylinder rod is connected to two vacuum valves;

the tilt sensors detect when the system is level by measuring the angle of tilt of the system; and wherein each tilt sensor is capable of detecting the tilt angle of at least one wand first end;

a tilt sensor sends an off input signal to the PLC if the tilt sensor detects a negative angle of tilt of a wand first end; a tilt sensor sends an on input signal to the PLC if the tilt sensor detects a positive angle of tilt of a wand first end; the PLC will send an output signal to a pneumatic valve energizing the solenoid to fill the connected pneumatic cylinder with compressed air and in turn closing the connected vacuum valve, thereby preventing suctioning in the connected wand whose angle of tilt is negative; and wherein the PLC will send an output signal to a pneumatic valve de-energizing the solenoid to withdraw compressed air from the connected pneumatic cylinder and in turn opening the connected vacuum valve, thereby allowing suctioning in the connected wand whose angle of tilt is positive;

the system plane comprises axis one and axis two; axis one extends through the first end of the inner wand and through the first ends of two outer wands on opposite sides of the inner wand; axis two is perpendicular to axis one and extends through the first end of the inner wand and through the first ends of two outer wands on opposite sides of the inner wand;

a NEMA enclosure, comprising a bottom surface parallel to the system plane, and containing the pneumatic valves, vacuum sensor, tilt sensors, the PLC, and other electrical components; the NEMA enclosure being bracketed to the vacuum valve housing and in electrical communication with a power source;

four tilt sensors are placed on the bottom surface of the NEMA enclosure, paired and spaced apart along axis one and two, such that if a tilt sensor detects a negative tilt angle, its pair will detect an equal and opposite tilt angle;

to achieve the pressure differential in the plenum, the negative pressure in the vacuum house loader is −7.5 in Hg (−3.7 psi), having a Flow of 100 ft3/min; only one port is open at any one time;

if a tilt sensor detects a positive tilt angle, the PLC sends a sequencing input signal to open and close the vacuum valves one at a time in a clockwise sequence of the outer wands, starting with the vacuum valve connected to the outer wand whose first end is aligned with the same axis as said tilt sensor, and opening and closing the inner wand last.