Note: Descriptions are shown in the official language in which they were submitted.
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MATERIAL COM1'ACTION APPARATUS
Related Ap~Iications
This application is a Continuation-In-Part of Application No. 10/138,190,
filed May l,
2002, entitled "MATERIAL, COMPACTION APPARATUS", which in turns claims
priority to
Provisional Patent Application Nos. 60/287,820 and 601316,145, and this
Application also claims
benefit of U.S. Provisional Patent Application No. 60/443,702, filed January
29, 2003, entitled
"MATERJAL COMPACTION APPARATUS", with each of said applications being
incorporated herein by reference in their entirety.
Field of the Invention
This invention relates to material compaction and liquid separation. More
particularly,
this invention relates to the compaction of various materials, and the removal
of various liquids
from in and around those materials by pushing the materials and liquid through
a gateless,
adjustably taparable chamber.
Background of the Invention
In the manufacturing process, metals and other materials can be manipulated
through
various machining processes. During these processes, liquids are often applied
to serve as
lubricants and coolants. Depending on the material composition and the
specific manufacturing
needs, the liquid can be quite costly. The process inevitably results in waste
consisting of
material and liquid. Any material or liquid that can be saved and reused, or
properly disposed of,
can provide significant savings.
Costs associated with the disposal or recycling of the material waste are
increased if
liquid remains below or above the surface of the material following the
manufacturing process.
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Liquid used during a specific process may leave a material unusable until that
liquid has been
nearly completely separated from the material. Further, an efficient and
thorough separafiion of
the manufacturing material and the liquid can assure that material and liquid
reuse is maximized.
This in turn makes it more likely that reusable material or liquid is not
being disposed of with the
unusable or unwanted waste.
Further, various governmental laws and regulations require proper disposal and
removal
of many defined materials and liquids. If these laws and regulations are not
specifically
followed, costly fines and other penalties may be imposed. An e~cient
separation and
compaction process facilitates conformity with these requirements.
Conventional material compacting devices are so-called briqueting machines
that carry
out numerous steps to create a block of compacted material. The machines
compact relatively
comminuted shavings and scrap. The key to these machines is the repetitive
hydraulic or
mechanical steps that are performed on each block of material against a
resistive gate.
These briqueting machines focus the compaction process on this repetitive gate
system.
Material waste is fed into a compaction chamber. This compaction chamber
generally consists
of a ramming device and a gate, at opposing ends. The material waste is fed
into the chamber so
that it rests in between the ramming device and the gate. One or more
compaction stages are
performed on the material. Generally, an initial compaction stage advances the
ramming device
under low pressure, loosely compacting the material under pressure against the
gate. This
ramming device will be driven by either hydraulic or mechanical means. The
mechanical means
can function in the same manner as a mechanical device (i.e., punch press), or
other like devices,
for repeatedly advancing the ramming device forward, thus pressing the
material against the
gate.
Following initial compression, a second compaction stage generally occurs
where the
loosely compacted waste is subject to high pressure from the ramming device
against the gate.
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Desired compression levels and ramming steps and/or energy are directly
related, and as such, a
highly compacted mass of material requires significant ramming steps and/or
exerted energy on
the material. After compaction is complete the machine must engage in several
motions or steps
just to eject the material block and to set up for the next grouping of
material. The ramming
device must retract and the gate must be raised or relocated from its end
position in the
compaction chamber in order to allow for the ejection of the material. The
ramming device is
then operated at low pressure in a forward direction to discharge the
compacted material waste
from the compaction chamber. Upon discharge of the block, the ramming device
and the gate
must move back to their original positions in the compaction chamber. This
repetitive process
must be performed for each individual grouping of material loaded into the
compaction chamber.
There is an innate inefficiency embodied within the processes utilized by
these
conventional compaction machines. Wasted motion and energy is inevitable
within any of these
systems that rely on a gate system. A continuous cornpaction process is
impossible to achieve.
The wasted movement of the ramming device within a gate system means that such
a device will
unnecessarily increase manufacturing time and energy costs. Any attempt to
reduce the
processes or ramming steps with these conventional machines will inevitably
result in a
reduction in the level of compaction and liquid separation.
Even when conventionally acceptable ramming steps and exerted energy levels
are
utilized, material compaction and liquid separation are not optimal. While the
current machines
do measurably compact and remove liquid from the surfaces and interior of the
material waste,
there is room for sizeable improvement. Consequently, a more efficient and
effective machine is
needed to minimize costs and to maximize material compaction and liquid
separation.
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Summary of the Invention
The material compaction system and methods of the present invention
substantially
address and solve the innate problems of conventional compaction machines and
methods. The
compaction system in accordance with the present invention provides highly
efficient and
effective compaction that substantially minimizes costs associated with wasted
manufacturing
steps, while at the same time substantially maximizes material compaction and
liquid separation.
The material compactor in accordance with the present invention generally
includes an
initial feed apparatus and a final compaction apparatus. The final compaction
apparatus
generally includes an adjustably taperable compaction chamber. The area of the
inner cavity of
the compaction chamber can be tapered to become measurably smaller or larger
at the
discharge/expelling end or port. Consequently, compacting movement of the
material through
the compaction chamber significantly subjects the material to compacting
restriction, or
funnelized pressure in those cases where there is a reducing taper, which in
turn compacts the
material and performs liquid separation with each operationally continuous
movement of the
1 S material through the compaction apparatus. Even if there is no taper, ox
if there is a measurable
increase in the chamber area at the discharge port, restriction occurs on the
material within the
limited confines of the chamber.
In one embodiment, area adjustment at the discharge port of the compaction
apparatus is
achieved through the use of a generally rectangular compaction chamber. The
chamber is
generally constructed of adjustable confrontable compression plates. These
plates permit
angular/tapered adjustments to the chamber to advantageously control
restriction, or funnelizing
pressure, through to the discharge port. The chamber is continuously open at
the discharge port
and compacted material may be continuously discharged out of this port
following rigorous and
repeated compaction.
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An initial compaction stage can be provided with the use of the feed
apparatus, such as a
bin and at least one auger. The force-exerting movement of the material into
and through the
feed apparatus by way of the auger can provide for this initial compaction.
'The at least one
auger may be a so-called "pig tail" auger, supported at its driven end and
merely being rofatably
disposed in an auger tube or feed channel at its discharge end. Further
embodiments can direct
the material through the first compaction stage utilizing chain feeds,
conveyor systems, manual
feeds, multiple auger systems, and other known devices and technidues. In
addition, it is
envisioned that the initial compaction can be conducted at a machine or
manufacturing process
distinct and/or separate from the machinery of the present invention and
directed into the
compaction apparatus. A material shredder may be operably connected to the
feed apparatus
such that at least some of the material within the apparatus is further
shredded to facilitate
movement of large, stringy, and/or clumped material groupings through to the
compaetion
apparatus. Further, a second auger device can be implemented adjacent or
proximate the first
auger. The second auger can substantially rotatably operate in a reverse
orientation to the first
auger such that excess material can be fed back into the bin to maintain a
circular feed operation.
Generally, the compaction apparatus includes a single ramming device to
promote
efficiency in motion and energy. A compaction ram or device is operably
aligned for repeated
movement through the compaction chamber of the compaction apparatus.
Specifically, the ram
drives the material through the inner cavity of the compaction chamber, thus
repeatedly
subjecting the material to the adjustable and confined area of the inner
cavity through to the open
discharge port.
The present invention provides for a nearly continuous feeding action of the
compactable
material through the machine and, particularly, through the compaction
apparatus and out the
discharging port of the corresponding compaction chamber. The process of
feeding the material
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through the final compaction apparatus is only momentarily halted while a new
grouping of
material is fed into the chamber, during retreating of the ram from the
compaction chamber.
Brief Descn_ption of the Drawings
Fig. 1 is a side view of a material compaction apparatus in accordance with an
embodiment of the present invention.
Fig. 2a is a top view of a compaction chamber in accordance with an embodiment
of the
presentinvention.
Fig. 2b is a top view of a shearing die holder of the compaction apparatus of
an
embodiment of the present invention.
Fig. 2c is a side view of a shearing die holder of the compaction apparatus of
an
embodiment of the present invention.
Fig. 3 is a side view of a compaction chamber in accordance with an embodiment
of the
presentinvention.
Fig. 4 is a front view of a compaction chamber in accordance with an
embodiment of the
presentinvention.
Fig. 5 is a top view of a first compaction chamber compression plate in
accordance with
an embodiment of the present invention.
Fig. 6 is a side view of the first compaction chamber compression plate of
Fig. 5.
Fig. 7 is a back view of the first compaction chamber compression plate of
Fig. 5
Fig. 8 is a front view of the first compaction chamber compression plate of
Fig. 5.
Fig. 9 is a top view of a second compaction chamber compression plate in
accordance
with an embodiment of the present invention.
Fig. 10 is a side view of the second compaction chamber compression plate of
Fig. 9.
Fig. 11 is a back view of the second compaction chamber compression plate of
Fig. 9.
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Fig. 12 is a front view of the second compaction chamber compression plate of
Fig. 9.
Fig. 13 is a top partial cross-section view of an embodiment of the compaction
apparatus
and chamber of the present invention having pivoting choke plates.
Fig. 14 is a flow chart diagram of a compaction chamber overload control
system in
S accordance with an embodiment of the present invention.
Detailed DescriQtion of the Drawings
Referring to Figs 1-14, embodiments of a material compactor 10 in accordance
with the
present invention are shown. This material compactor 10 generally comprises an
initial feed
apparatus 12 and a compaction apparatus 16. In relevant figures, certain
dashed lines are
included to demonstrate the potential movement (i.e., the start and finishing
positions} for
corresponding movable components (i.e., rams, plates, and the like), and to
show hidden
structures. Various embodiments of the present invention include, in part at
least, structure,
functions, and devices descn'bed and disclosed previously by the present
Applicant in U.S.
Patent Application No. 10/138,190, and as a result said application is
incorporated herein by
I S reference in its entirety.
Referring primarily to Fig. 1, the feed apparatus 12 generally comprises a bin
l7, at least
one auger 18, and a feed channel or auger tube 20. The feed channel 20 is in
communication
with the bin 17 and generally receives at least a portion of the auger 18. The
feed channel 20 can
include an entry portion 24, an exit portion 26, and a feed apparatus coupling
28. The feed
channel 20 provides a channel for communication of material 11 through the bin
17 into the
compaction apparatus 16. In particular, the entry portion 24 receives the
material driven through
the bin 17 by the auger 18. The exit portion 26 can be smaller in diameter
than the entry portion
24 such that tapering will provide an additional degree of initial compaction
as the material is
forceably passed through the feed channel 20 into the compaction apparatus 12.
The feed
coupling 28 provides an attachment point for joining the feed apparatus 12 to.
the compaction
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apparatus 16. The auger 18 can be rotationally driven from at least one end by
a motor and
transmission, in forward and reverse. Various auger and like feeding devices
known to one
skilled in the art are envisioned for implementation with the compactor of the
present invention.
The auger 18 extends from the bin 17 into the feed channel 20. The inner
diameter of the
feed channel 20 is some size larger than the outer diameter of the rotating
auger 18 so that
rotation of the auger 18 is available for the portion of the auger 18 received
within the channel
20. Further, the feed coupling 28 can be implemented and connected in a
modular fashion with
other couplings to permit variable connectability to promote flexibility in
positional
configurations for the feed apparatus 12 relative to the final compaction
apparatus 16. With each
embodiment of the present invention 10, a chain system can be implemented
wherein a chain
(i.e., a barn chain) with connected paddles, and/or other devices, to carry
and transport the
material throughout the work environment or plant. For instance, the chain
system can be
implemented to carry the material into the bin 17 for further feeding through
the feed apparatus
12 by the auger 18. The chain system can connect multiple material compactors
10, or it can
connect or link other manufacturing, processing; or fabricating machines to
the material
compactor 10 to provide a line of communication of chip material from the
applicable machine
to the compactor 10 for compaction and liquid separation.
Alternative embodiments of the feed apparatus 12 can further include a second
auger
device (not shown) implemented adjacent or proximate the first auger device
18. The second
auger can substantially rotatably operate in a reverse orientation to the
first auger 18 such that
excess material can be fed back into the bin 17 to maintain a circular feed
operation. As such,
material fed through and accumulated within the feed channel 20, and which is
not immediately
fed into the compaction apparatus 16, can be re-circulated back into the bin
17. A material feed
loop is therefore created to permit generally continuous material through the
feed apparatus 12
prior to traversal into the compaction apparatus 16. A material shredder
device (not shown)
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known to those skilled in the art may be operably connected to the feed
apparatus 12 such that at
least some of the material within the apparatus 12 or bin 17 is further
shredded to facilitate
movement of large, stringy, and/or clumped material groupings through to the
compaction
apparatus 16.
One embodiment of the compactor 10 and the final compaction apparatus 16 is
shown in
Figs. 1-12. The compaction apparatus 16 generally comprises a ramming device
30, a
compaction chamber 32, a final feed channel 34, and a compaction apparatus
coupling 36, The
ramming device 30 is oriented for axial movement along an inner chamber cavity
54 of the
compaction chamber 32, horizontal or vertical. This ramming device 30
comprises a driving
means 40 for advancing a ramming portion 42 into the compaction chamber 32 and
the inner
chamber cavity 54. Those skilled iii the art will understand the driving means
40 to include
hydraulic, pneumatic, mechanically driven technology, and the like. For one
mechanical
embodiment of the present invention, the driving means 40 can comprise
mechanically driven
technology such as a punch press. Depending on the desired speed,
manufacturing and energy
costs, and efficiency goals, various rated/tonnage machines and shaped
machines (L, H, etc.) can
be utilized.
The compaction chamber 32 of one embodiment is shown in Figs. 3-12, wherein
the
compaction chamber 32 includes a confronting, or opposing, first compression
or compaction
plate 44 and a second compression or compaction plate 46, at least one
hydraulic cylinder 48, a
connecting compression housing 50 and a shearing die 52. The inner chamber
cavity 54 can
include an entry portion 56 and a discharge port 58 distal one another.
The first compression plate 44 generally includes a first plate channel 60, a
first plate
entry portion 62, a first plate discharge portion 64, a first plate stepped
portion 66, at least one
die portion 68, at /east one first plate fastening aperture 70, at /east one
first plate housing
aperture 72, an adjustment slotlgroove 74, and at least one plate fastener 76.
The first plate
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fastening apertures 70 are capable of selectively receiving the plate
fasteners 76 to provide
selective securement of the first compression plate 44 with the second
compression plate 46.
The plate fasteners 76 can include known pins, screws, bolts, and the like for
aligning, attaching,
and/or securing the plates 44, 46 and other components together or in place.
S The second compression plate 46 generally includes a second plate channel
80, a second
plate entry portion 82, a second plate discharge portion 84, a second plate
stepped portion 86, at
least one die portion 88, at least one second plate fastening aperture 90, and
at least one second
plate housing aperture 92. The second plate fastening apertures 90 are capable
of selectively
receiving the plate fasteners 76 as indicated herein to secure the
confrontable plates 44, 46
together. The housing apertures 72, 92 facilitate securement of the connecting
compression
housing 50 to at least one of the plate 44, 46 for selective tapered
adjustment of the chamber 32
and inner cavity 54 proximate the housing 50. The second plate channel 60 is
confrontable with
the first plate channel 60 to form the channel of the inner cavity 54.
In one embodiment, the at least one device 48, such as a hydraulic cylinder
48, is adapted
for operable connection proximate at least one of the plates 44, 46, and
preferably the second
plate 46 as demonstrated in Figs. 3 and 4. The hydraulic cylinder 48 is
operably connected to the
compression housing 50 and the discharge portion 84 of the second compression
plate 46. The at
least one hydraulic cylinder 48 can include-two cylinders capable of applying
pressure down on
at Ieast one of the compression plates 44, 46, to reduce or taper the area of
the inner cavity 54 at
the discharge port 58. This tapering or pinching action brings the discharge
portion 84 of the
second compression plate 46 closer to the respective discharge portion 64 of
the first
compression plate 44. This tapering can create a funnelizing pressure on the
material 11
contents forceably moving through the inner cavity S4. Other plate 44, 46
configurations are
also envisioned such that tapered control of the inner cavity S4 at the
corresponding discharge
port 58 similarly is accomplished. This housing 50 can provide forceable
support to facilitate the
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actuation of the at least one cylinder 48 down onto the second plate 46 to
taper the discharge port
58 portion of the compaction chamber 32. Other known devices and techniques
for performing
this pressing/compression function are also envisioned to replace the
cylinders 48. For instance,
adjustable fastening systems, such as bolts, screws, and/or pins can be
communicated through
the confronting plates 44, 46 to adjust the relative proximity thereof, and
the resulting taper at
the discharge port 58. A myriad of other adjustment devices and systems known
to one skilled
in the art for compressing and adjusting the plates 44, 46 can be employed
without deviating
from the spirit and scope of the present invention.
Referring primarily to Figs. 3, 6, and 10, the second plate 46 is
longitudinally stepped
IO along the bottom suzface at the stepped portion 86 to define two levels of
side material thickness.
The division between the two levels of thickness can proximate the center of
the longitudinal
length of the plate 46, or it can be offset toward the portions 82, 84. The
first plate 44 is
generally similarly stepped. The top surface of the first plate 44 is
confrontable and/or matable
with the bottom surface of the second plate 46 in a stepped manner, measurably
mirroring or
mating the second plate 46 as demonstrated in Fig. 3. However, rather than
providing for an
exact abutment of the plates 44, 46, an axial perimeter gap 59 is generally
provided along a
portion of the confronted plates 44, 46. This separation of the plates 44, 46
along the gap 59
enables increased control over the compressability and taperable adjustment of
the plates 44, 46
relative'to one another upon actuation of the device 48. The at least one
adjustment slot/groove
74 further facilitates adjustment of the plates 44, 46 and the corresponding
area of the inner
cavity 54 of the chamber 32 by providing for "give" or a relative bending
region during
compression or pressure upon the plate 46 by the operably connected
compressing device 48,
i.e., the hydraulic cylinder.
A continuous communication path is created by the connecting of the feed
apparatus 12
to the final compaction apparatus 16. Referring to Figs. Za-2c, the feed
channel 20 is coupled to
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the final compaction apparatus 16 by securing the feed apparatus coupling 28
to the compaction
apparatus coupling 36. As such, fluid communication continues from the feed
channel 20 to the
axially aligned final feed channel 34 and into the inner cavity 54 of the
chamber 32. The final
feed channel 34 can generally comprise a shearing die 52 comprised of a first
die portion 108, a
second die portion 110 couplable to the first die portion 108, a material
entry aperture 112
defined therein, and a ram passage 114 defined therein. The shearing die 52 is
couplable to the
compaction chamber 32 at the corresponding die portions 68, 88. The aperture
112 and passage
114 are generally in transverse communication. Further, a plurality of
mounting apertures 116
and corresponding fasteners comprise the system for coupling the die 52 to the
compaction
chamber 32, as shown in Fig. 2a. The final feed channel 34, and the material
entry aperture 112,
is generally transversely aligned with the axis of the inner cavity 54.
Conversely, the ramming
portion 42 of the ramming device 30 is disposed and aligned for axial movement
along, and in
and out of, the inner cavity 54 to provide the ramming force to forcibly move
and compact the
material 11 through the compaction chamber 32, from the entry portion 56 to
the discharge port
58. The final feed channel 34 can further include internal plating systems to
provide a level of
"give" within the confines of the channel 34, andlor the entry aperture 112,
when material 11 is
moved into, and compacted within, the channel 34 before compaction through the
traversely
aligned compaction chamber 34. Namely, adjustable plates, spring-loaded
plates, defined voids,
and like techniques known to one skilled in the art enables adjustment,
including dynamic
adjustment, of the internal area of the final feed channel 34 upon filling
with pre-compacted
material l l .
Embodiments of the present invention can further include a discharge trough
100 and
corresponding shrouding device coupled to, or proximately aligned with, the
discharge port 58
such that a channel or material guide path is created for compacted material
11 exiting the
system 10. These paths can be adjusted to feed the compacted material to
storage bins, barrels,
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other machines, or systems and apparatus within the environment of operation
to further
transport and re-locate the materials 11. The shroud can protect the compacted
material from
fluids and other items while exiting the compacting system 10 proximate the
discharge port 58.
Fig. 13 shows an alternative embodiment of the compaction chamber 32. This
alternative
embodiment includes a chamber 32 generally defined by opposing plates 120,
defining the inner
cavity S4, wherein confronting pivoting choke plates 128, 129 provide the
tapering adjustment of
the inner cavity 54 to compactably funnelize material 11 through the chamber
32 during
operation. Such an embodiment of the compaction chamber 32 can substantially
include the
compaction chamber, or components and structure thereof, shown and described
in U.S. Patent
Application No. 10/138,190, which has been incorporated herein by reference.
The compaction
chamber 32 generally includes a first side plate 124, a second side plate 126,
a first choke plate
128, and a second choke plate 129. The positional configuration of these
plates forms the
generally rectangular inner cavity 54 or channel of the compaction chamber 32.
Generally, the
inner cavity 54 is defined horizontally by the inner boundaries of the spaced
choke plates 128,
129 and vertically by the inner boundaries of the spaced opposing plates 120.
A plurality of oversized apertures 130 intersect the respective opposing
plates 120 and
choke plates 128, 129 such that substantial axial alignment of the respective
apertures 130
provides a bore for receiving a corresponding one of a plurality of first
fasteners 131. All
fasteners described herein (for each connection and embodiment) can be a known
bolt, pin,
screw (i.e., socket head cap screws), and a myriad of other known fastening
devices and means.
The first fasteners 131 can secure the generally horizontal plates 120 with
the choke plates 128,
129. However, the oversized apertures 130 are some size larger in diameter
than the outside
diameter of the received portion of the fasteners 131 through the choke plates
I28, 129 to permit
for rotatational adjustment of the choke plates 128, 129 around a pivot
point/pin 140. In
addition, to facilitate rotation of the choke plates 128, 129, the choke
plates can be made some
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measurable size thinner at the region proximate the choke chamber 32 such that
pivoting at the
pivot pin 140 is not restricted by frictional engagement of the choke plates
128, 129 against the
opposing plates 120. Further, to provide a small gap between the plates 120
and the choke plates
128, 129, bushings can be inserted within the oversized apertures 130. This
can provide a gap
between the opposing plates 120. In addition, the bushings can provide for a
start and stop
position for the choke plates I28, 129 rotating in toward the inner cavity 54.
To enhance liquid
separation, a plurality of grooves, at various preselected angles, can be
provided for in the
surfaces of the choke plates 128, 129 such that liquid can be channeled into
and/or away from
the inner cavity 54 of the chamber 32.
The side plates 124, 126 are abuttably secured against the respective
proximate plates
120 and choke plates 128, 129 by a plurality of second fasteners 134. The
second fasteners 134
intersect the side plates 124, 126 through the side apertures 137 and continue
some distance into
the respective proximate plates 120 to provide adjustable abuttable
securement. A plurality of
choke plate fasteners 136 pass through the side plates 124, I26 proximate the
mid-point of the
generally vertical cross-section of the side plates 124, 126. W one
configuration, the choke plate
fasteners 136 completely pass through the side plates 124, 126 and abut the
outside surface of the
choke plates 128, 129 without actually penetrating the choke plates 128, 129.
As such,
adjustments of the choke plate fasteners I36 provides for a corresponding
adjustment of the
abutted choke plate 128, 129. This adjustment to the positioning or angle of
the choke plates
I28, I29 is made possible as a result of the oversized apertures 130 through
the choke plates 128,
129. Rotational motion at the pivot points 140 of the respective choke plates
128, 129 is not
impeded by the presence of the fasteners 131. It will be understood that other
methods of
adjusting the angles of the choke plates 128, 129 can be implemented without
deviating from the
spirit and scope of the present invention. For instance, the choke plate
fasteners 136 could
partially pass through and secure within the choke plates 128, 129 such that
adjustment of the
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fasteners 136 in and out causes a corresponding direct angular adjustment of
the choke plates
128, 129 about the pivot point 140.
Additionally, at least one adjustment or compression device 138, for instance
hydraulic
device 48, can be implemented at the chamber 32 to facilitate adjustment of
the angular
orientation of the choke plates 128, 129. With such an embodiment, the at
least one hydraulic
device 138 can be connected to at Least one of the choke plate fasteners 136,
or directly to the
choke plates 128, 129 thxough the side plates 124, 126, wherein angular
adjustment (pushing or
pulling the choke plates at the expelling end) of the choke plates 128, 129
around the pivot point
140 is thereby controlled by a corresponding hydraulic movement or actuation
from the device
,138. Similar devices can also be implemented to facilitate angular adjustment
of the choke
plates 128, 129. 'The compaction chamber 32 and its inner cavity 54 defined by
the various
plates of the choke chamber 32 have a longitudinal axis generally transverse
to the axis of the
channel 34.
With angular adjustment around the pivot points 140 of the choke plates 128,
129, the
width or distance (i.e., horizontal} across the portion of the cavity 54 at
the discharge port 58 can
be measurably different than the corresponding width or distance at the
portions of the cavity 54
proximate the pivot points 140. Preferably, as will be discussed herein, the
distance and area of
the cavity 54 is adjusted to measurably increase or decrease the taper from
the pivot points 140
to the discharge port 58. Similarly, the cavity 54 can be tapered for the area
between the entry
portion 56 and the pivot points 140. As stated, a reduction in the area is not
required to provide
for resfiricting compaction of the material 11 within the cavity 54 since the
forceable
advancement of the material 11 thzough the limited confines of the cavity 54
will provide a level
of restrictive compacting by itself.
In operation, each of the embodiments of the present invention, Figs. 1-14,
utilize the
taper-adjustable chamber 32 to perform effective material compaction and/or
liquid separation.
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Unlike conventional compactors, there is no use of a gate system. In fact, the
inner cavity 54 is
open at the discharge port 58, there being no gate as is required in the prior
art devices.
Compaction and liquid separation is made possible by repeatedly forcing
material 11 through the
adjustably taperable final compaction chamber 32 with repeated hammering blows
from the
ramming device 30. Further, and unlike embodiments of the compactor of U.S.
Patent
Application No. 10/138,190, the ramming device 30 of the present invention can
provide the
only substantial compaction ramming. A preliminary compaction chamber and
corresponding
driving means/device is not required, thus reducing motion, energy, and costs.
Material 11 is initially channeled into the feed channel 20 of the feed
apparatus 12 by the
auger l 8. The material 11 can be channeled by the auger 18 or other known
means directly from
and through the bin 17 and into the feed channel 20. As material 11 is
directed into the entry
portion 24, through the feed channel 20, and through to the material exit
portion 26, the once
loosely grouped chips from the bin 17 are subjected to initial compaction from
the forceable
movement of the chips through the limited space of the channel 20. As stated,
this compaction
can be further facilitated by a tapering of the channel 20 toward the exit
portion 26. As the
material 11 fills up the feed channel 20 and is forceably advanced to the exit
portion 26, the
material 11 is forced into the final feed channel 34. As material 11 is forced
up against
preceding material 1.1 in the channel 20, the material is moved through the
feed channel 34 into
communication with the transversely coupled compaction chamber 32 and its
positioned entry
portion 56. At this point, the material 11 is in a position to be rammed or
compressed by the
ramming portion 42 of the ramming device 30, as the ramming portion 42 travels
through the
final feed channel 34 and the axially aligned ram passage 114, and toward the
entry portion 56 of
the chamber 32.
Upon approaching the entry portion 56 of the inner cavity 54, the material 11
being fed
into tine entry aperture 112 is in position for repeated forceable compaction
and movement
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through the inner cavity 54 and out the discharge port 58. With the
advancement of the ram 42
of the ramming device 30, a guillotine-type motionlaction occurs, wherein the
motion of the ram
42 through the transversely aligned feed channel 34 and into the compaction
chamber 32 pushes
the material along and through the inner cavity 54 of the compaction chamber
32. Specifically,
the ram 42 enters the ram passage 114 of the shearing die 52, passes into the
material entry
portion I 12 and shears off a section of the material 11 within the channel 34
as it pushes the
material I 1 into the inner cavity 54. With each forceable movement of the
group of material 1 I
through the inner cavity 54 and out the discharge port 58, it is being
subjected to pressure within
the cavity 54, and further compaction against leading material 11 or material
groups.
The compaction chamber embodiments of Figs. 1-12 include the inner cavity 54
formed
of the spaced compression plates 44, 46. Pressure from the at least one device
48 mounted and
operably connected to at least one of the plates, i.e., the second plate 46,
permits adjustable
tapering of the inner cavity 54 pzoximate the discharge port 58. Namely,
pressure down on the
plate 46 narrows or decreases (relative to plate 44) the area of the subject
portion of the inner
cavity 54 (generally considered to be the height of the cavity 54). As such,
selective tapered
adjustment of the inner cavity 54 toward the discharge port 58 provides for an
inner cavity 54
narrower at the dischaxge port 58 than at the distal entry portion 56. The
adjustability enabling
the taper is made possible by the adjustment groove 74 and/or the axial gap 59
formed from the
spatial alignment of the plates 44, 46. These structural features promote the
bend or give
required to taper the discharge port 58 region of the imier cavity 54 up and
dov~m. The taper will
generally begin at the groove 74 and the proximate beginning portion of the
axial gap 59 and
decrease the internal cavity 54 area to the end portion of the axial gap 59 at
the discharge port
58. The greater the taper at the discharge port 58, the tighter the compaction
and liquid
separation as a fimnelized pressure is exerted on the passing material 11
during operation.
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Liquid is permitted to separate at least through the gap 59 during this
forceful
compressiou'compaction.
Refen-ing to Fig. 14, the compression or hydraulic device 48 can be operably
connected
to a pressure control overload system 150. 'The pxessure control system 150
generally comprises
a system of digital and/or analog controls; and/or programmable logic devices
known to those
r
skilled in the art for monitoring and contxolling pressure systems, such as
hydraulic. mechanical
and other ramming or compression devices. The pressure regulator controls can
be operably
coru~ected to the at least one device =~8 to mozutoF and control overloads,
such as thosE occurzing
durizzg operation of the hydraulic cylinder 48. Communication between the at
least one cylizzder
I~3 48 and the controller system 150 perzmits adjustment of the load on the
cylinders 48 based on a
pizdetes~nined lead settings/readings (i.e., maximum pezmitted tonnage,
current, and the likej
monitored though the operation of the dovicc; :30. Those pressure regulators
or portions of the ..,
control s;-stem 1 ~0 can be in operable communication with the ramming device
or ores: 30 such , ,
that optinnal. opera.iional tonnagL of the devise :30 can be maintained,
andlor pressure at the :.
hydraulic: cylinder 40 can .he solectively adjusted. Ss such readings at the
press 30 (i.e., a
currEntiamperage~ can be monitored to determine t~he,parameters of the
ranuning operation. ,.
Mors;over, the control system 150 can be operably connected to the feed
apparatus 12,
and the oiler :tine motor of the awger 18 specifically, to adjust the speed of
material 11 fed into
the compaciinn apparatus i.6. F'or instance, if overload is detected at the
predetezrnined,limit at
this ramming device or press 30 (i.e., ex_ess amperage detected at the press
30) a reduction in the
press 30 operation carp be initiated, adjustment can be made to the
compression force applies; by
the cylinder 48, andJor a slow down in the feed rate of mater?.al 11 through
the feed apparatus l
can be adjusted by Gdjasting,the auger 18, speed.
Tiio ccnsxol and monitoring s~.hernatic of Fig. 14 demonstrates an embodiment
of the
pressure canhol o,rcrload system.150 For hydraulic overload protection
monitoring ("HOLP")
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First, The press 30 is started and a cycle of compressing activity of the ram
42 through the
compaction chamber 32 begins. At this point, the feed auger 18 can be
initiated and the speed of
the auger 18 can be tied into the operation of the ramming device 30. If the
device 30 exceeds a
programmed or predetermined parameter, or parameter range, such as a
predetermined current
value, the controller 150 can initiate the slow dawn in the auger 18 speed
and/or reduce the
pressure provided by the hydraulic cylinder 48 upon the chamber 32 (i.e., the
second plate 46 or
the choke plate 128, 129). Similarly, if the control system 150 determines
that the device 30 is
below the predetermined parameters, the pressure from the cylinder 48 can be
increased, the
auger 18 speed can be increased, and/or the ramming device 30 can be romped
up. As stated
herein the monitoring parameter from the ramming device 30 can be
currenbamperage readings.
Other known parameter monitoring variables can be employed to monitor the
device 30 and the
cylinder 48. Further, various other sensing systems, and means of providing
pressure regulation
and monitoring known to one of ordinary skill in the art can be implemented
without deviating
from the spirit and scope of the present invention. '
The compaction chamber 32 embodiment of Fig. 13 promotes pressure or
restriction on
the material from the pivot points 140 to the discharge port 58 of the chamber
32. Adjustments
can be made to the size or area of the inner cavity 54 proximate the discharge
port ~58 by angular
adjustments to either of the pivotable choke plates 128, 129. In a "no-choke"
configuration there
is substantially no taper or reduction, or even an increase, in the area of
the inner cavity 54
between the pivot points 140 and the discharge port 58. In a "choke"
configuration there is a
taper, and the taper is variable. A myriad of angles, and angle restrictions,
are envisioned for the
taper between the pivot pin 140 and the discharge port 58, depending on the
particular
compaction and liquid separation needs of the user. Material hardness, the
power limitations of
the ramming device 30, power consumption concerns, and similar goals and
limitations must be
considered in making such a determination. This angular adjustment is made by
retreating or
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advancing at least one of the plurality of choke plates 128, 129 at the end
proximate the
discharge port 58, either manually, hydraulically, or with like means, by
adjusting at least one of
the fasteners I36. This results in the pivoting of the respective choke plate
128, 129 about the
pivot pin 140. Compaction of the material 11 during forceable advancement
through to the
discharge port 58 can be achieved in a choke or no-choke configuration. Again,
the pressure
overload control system 150 can be implemented as well.
Each of these embodiments obviate the need for the prior art gate systems
(described
herein) such that the ram 42 of the present invention acts against compressed
chips being
restrained and further compressed by the preferably decreasing angle and area
of the inner cavity
54 of the chamber 32 toward the discharge port 58. As stated, restrictive
compaction pressure
can even be obtained without substantially tapering the inner cavity 54 to the
discharge port 58.
This is possible since the grouped or preliminarily compacted material 11 can
be some size
larger in size than that~of the area of the inner cavity 54 regardless of any
tapering. Simply
repeatedly pushing the material through the cavity 54 provides significant
compaction and
restrictive chokW g until the material 11 is forced out the open discharge
port 58.
With each embodiment, the material 11 can receive compaction hits for a period
of
minutes before being ejected from the final compaction apparatus 16 at the
discharge port 58.
With each compaction hit, a new guillotined slice/cube of material 11 is
thrust into the final
compaction chamber 32 and an existing slice is moved through the inner cavity
54 toward
ejection from the discharge port 58 such that slices are being repetitively
compacted against
preceding or leading slices with each hit of the ram 42.
It is also envisioned that the embodiments of the final compaction chamber 32
need not
necessarily be distinct. Simply put, the features can be combined such that a
chamber 32 is
capable of both up and down (compression of plates 44, 46) and lateral
(compression pivoting of
plates 128, 129) tapering of the area of inner cavity 54. The structural
components of the
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embodiments of Figs. 1-12 can be selectively combined with the structural
components of the
embodiment of Fig. 13 to create such a mufti-dimensional tapering material
compaction
apparatus.
The present invention may be embodied in other specific forms without
departing from
S the spirit or essential attributes thereof, and it is therefore desired that
the present embodiment be
considered in all respects as illustrative and not restrictive, reference
being made to the appended
claims rather than to the foregoing description to indicate the scope of the
invention.
