Note: Descriptions are shown in the official language in which they were submitted.
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TITLE
METHOD AND SYSTEM FOR PACKAGING BITUMEN (ASPHALT) AND
PRODUCTS PRODUCED THEREFROM
TECHNICAL FIELD
[0001] The present disclosure relates to bitumen or asphalt. More
particularly, but not exclusively, the present disclosure relates to methods
and
systems including assemblies and apparatuses for packaging bitumen (asphalt)
as
well as to the packaged products produced from these methods and systems.
BACKGROUND
[0002] Bitumen (or asphalt) is a mixture of organic liquids that are highly
viscous, black, sticky, entirely soluble in carbon disulfide, and composed
primarily of
highly condensed polycyclic aromatic hydrocarbons. Naturally occurring or
crude
bitumen is a sticky, tar-like form of petroleum that is so thick and heavy
that it must
be heated or diluted before it will flow. At room temperature, it has a
consistency
much like cold molasses. Refined bitumen is the residual (bottom) fraction
obtained
by fractional distillation of crude oil. Bitumen (or asphalt) is primarily
used, when
mixed with mineral aggregates, to produce paving materials. Its other main
uses are
for bituminous waterproofing products, including production of roofing felt
and for
sealing flat roofs. Most natural bitumens contain sulfur and several heavy
metals
such as nickel, vanadium, lead, chromium, mercury and also arsenic, selenium,
and
other toxic elements. Bitumens can provide good preservation of plants and
animal
fossils.
[0003] Bitumen (or asphalt) is transported by way of tanks and large
containers onto sights for usage. It is a very costly, labour intensive and
long
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procedure to handle bitumen from its compartmentalization stage into shipment
units
within containers to its usage stage. There is the added burden of controlling
the
amount of bitumen. Much of this tar-like sticky substance is lost as it is
difficult to
control the amounts that will be used as the bitumen is kept in large
containers.
Moreover, handling bitumen during compartmentalization into shipping units is
also
challenging as the bitumen may cool down quickly and solidify make it
difficult to
pour and manipulate.
[0004] There thus remains a need for improvements in transporting
bitumen and controlling the amounts that are used all the while reducing loss
of the
product. There is also a need to provide a more convenient way of handling
bitumen
in order to prepare it for shipment in view of ultimate use.
OBJECTS
[0005] An object of the present disclosure is to provide a method for
packaging bitumen (asphalt) into bags. An object of the present disclosure is
to
provide a system for packaging bitumen (asphalt) into bags. An object of the
present
disclosure is to provide an assembly for packaging bitumen (asphalt) into
bags. An
object of the present disclosure is to provide apparatuses for packaging
bitumen
(asphalt) into bags.
[0006] An object of the present disclosure is to provide a product
comprising bag with bitumen product ready for use by melting the product.
[0007]An object of the present disclosure is to provide an assembly for
handling a
bag filled with bitumen prior to curing so as to stack the bitumen bag
packages. An
object of the present disclosure is to provide a method for handling a bag
filled with
bitumen prior to curing so as to stack the bitumen bag packages. An object of
the
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present disclosure is to provide apparatuses for handling a bag filled with
bitumen
prior to curing so as to stack the bitumen bag packages.
[0008] More particularly, but not exclusively, the present disclosure relates
to methods and systems including assemblies and apparatuses for packaging
bitumen (asphalt) as well as to the packaged products produced from these
methods
and systems.
SUMMARY
[00091 In accordance with an aspect of the disclosure, there is provided
an assembly for packaging bitumen comprising: a loading and bagging station
for
loading bitumen into a bag and sealing the bag once the bag has been filled
with
bitumen thereby providing a package; a support mounting station downstream the
bagging station for positioning the package on a movable support; a curing
station
downstream the support mounting station for curing the bitumen within the bag
on
the movable support; and a separating station downstream the curing station
for
separating the package after curing from the movable support.
[0010] In an embodiment, the assembly urther comprising a conveying
assembly for: conveying the package between the bagging station and the
support
mounting station; conveying movable support carrying the package between the
support mounting station said curing station; and conveying the movable
support
carrying the package between the curing station and the separating station.
[0011] In an embodiment, the support mounting station comprises a
movable support discharge station comprising a platform for holding a stack of
movable supports and having an opening positioned above a lower conveyor, a
higher conveyor positioned downstream the platform and above the lower
conveyor
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provides for carrying the package and selectively conveying the package, the
discharge station providing for selectively allowing a movable support to be
discharged via the opening onto the lower conveyor, the lower conveyor
providing for
conveying the package under the higher conveyor downstream thereof, the higher
conveyor providing for conveying the package onto the movable support. In an
embodiment, the higher conveyor comprises a font edge, the higher conveyor
providing for causing the package to fall off the front edge onto the movable
support
being conveyed thereunder and downstream thereof. In an embodiment, the
movable support discharge station further comprises movable supporting
elements
being positioned beneath the platform for holding the bottom movable support
of the
stack, the movable holding elements being retractable so as to allow the
bottom
movable support to fall through the opening onto the lower conveyor. In an
embodiment, the movable support discharge station further comprises lateral
grips
for gripping the stack so as not to fall though the opening when discharging
the
bottom movable support.
[0012] In an embodiment, the movable support comprises a tray.
[0013] In an embodiment, the assembly further comprising a separation
station downstream the curing station for separating the package from the
movable
support. In an embodiment, the separating station comprises: a conveyor for
conveying the movable support carrying the package in a downstream direction;
a
first sub conveyor downstream from and contiguous to the conveyor for engaging
the package only and conveying the package in the downstream direction; and a
second sub conveyor for receiving the movable support once the package is
engaged by the first sub conveyor for conveying the movable support separately
from the package. In an embodiment, the second sub conveyor is a ramp. In an
embodiment, the separating station further comprises a split floor structure
defining
an upper floor portion providing for the package to be conveyed thereon and a
lower
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floor portion providing for receiving the movable support thereon and being
contiguous with the second sub conveyor. In an embodiment, the separating
station
comprises a conveyor for conveying the movable support carrying the package in
a
downstream direction and a clamp for clamping and lifting the package from the
tray.
5 In an embodiment, the separating station further comprises a movable
platform
continuous with the conveyor providing for moving upwardly relative the
conveyor
thereby providing a space for the movable support to be conveyed therein. In
an
embodiment, the separating station comprises a conveyor for conveying the
movable
support carrying the package in a downstream direction and movable platform
continuous with the conveyor providing for moving upwardly relative the
conveyor
thereby blocking the package from moving downstream and providing a space for
the movable support to be conveyed therein.
[0014] In an embodiment, the loading and bagging station comprises a
reservoir with bitumen having a discharge outlet, a first arm with a suction
for
suctionally engaging the bag at one side thereof and positioning the bag to
the
discharge outlet, a second arm with a suction for suctionally engaging the bag
at
another opposite side thereof, the arms providing for being moved away from
each
other thereby opening the top edge of the bag so as to receive bitumen therein
from
the discharge outlet. In an embodiment, the loading and bagging station
further
comprises clamp members for holding the bag at opposite longitudinal ends of
the
top edge thereof and spreading members for being positioned within the open
top
edge to maintain the top edge in an open position.
[0015] In an embodiment, the assembly further comprising a pair of
oppositely disposed carriages mounted on respective rails and comprising top
arm
members for engaging the bag therebetween when the bitumen has been
discharged within the bag so as to move the bag along the rails to a sealing
station.
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[0016] In an embodiment, the assembly further comprising a rack
positioning and loading station for loading the packages on the movable
supports on
a rack having a plurality of shelves, the rack positioning and loading station
comprising: a ramp conveyor for conveying the packages on the movable supports
to a top conveyor; an elevator for carrying the rack thereon providing for
lifting the
rack so that each shelf is positioned adjacent the top conveyor; and a pusher
for
pushing the packages on the top conveyor unto the adjacent shelf.
[0017] In an embodiment, the assembly further comprising a rack
unloading station for uloading the packages on the movable supports from the
rack,
the rack unloading station comprising: an out-feed conveyor providing for
receiving
the packages on the trays from the rack; an elevator for carrying the rack
thereon
providing for lifting the rack so that each shelf is positioned adjacent the
out-feed
conveyor; and a pusher for pushing the packages from each shelf adjacent the
out-
feed conveyor onto the out-feed conveyor.
[0018] In an embodiment, the assembly further comprising a pallet
loading station for loading the separated packages onto a pallet thereby
building a
bundle, the pallet loading station comprising: a top platform comprising an
opening
and a floor adjacent the opening; an elevator platform for carrying the pallet
and
lifting the pallet or the top most packages of the bundle mounted thereon to
the
opening so as to be adjacent to the floor; a pusher for pushing the packages
on the
floor onto the pallet or the top most packages of the bundle mounted thereon
when
the pallet or the top most package is adjacent the floor; and a top pusher for
exerting
a top pressure on the bundle. In an embodiment, the platform is rotatable so
as to
provide for wrapping the bundle in a wrapping material from a dispenser during
rotation thereof.
[0019] In accordance with an aspect of the present disclosure, there is
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provided a bitumen package as provided by the assembly herein.
[0020] In accordance with an aspect of the present disclosure, there is
provided a method for packaging bitumen comprising: positioning a bag at the
discharge outlet of bitumen reservoir; suctionally opening the bag; pouring
the
bitumen within a bag; sealing the bag thereby providing a package; positioning
the
package on a tray; positioning a plurality of trays with packeges thereon on a
rack
with shelves for curing; curing the bitumen; separating the packages from the
trays;
and stacking the packages on a pallet.
[0021] In accordance with an aspect of the disclosure, there is provided
an a method for packaging bitumen comprising: pouring the bitumen within a
bag;
sealing the bag; positioning the bag on a tray; curing the bitumen within the
bag on
the tray; separating the bag with the bitumen from the tray. In an embodiment,
the
method further comprises stacking a plurality of bags with bitumen after
separation
from their respective trays. In accordance with an aspect of the disclosure,
there is
provided a product comprising bitumen within a sealed bag.
[0022] In accordance with an aspect of the present disclosure, there is
provided a bitumen package as provided by the methods herein.
[0023] Other objects, advantages and features of the present disclosure
will become more apparent upon reading of the following non-restrictive
description
of non-limiting illustrative embodiments thereof, given by way of example only
with
reference to the accompanying drawings.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0024] In the appended drawings, where like reference numerals denote
like elements throughout and in where:
[0025] Figure 1 is a schematic perspective view of a bitumen reservoir
assembly in fluid communication via in-feed and return conduits with a bitumen
container reservoir for discharging the bitumen within a housing structure in
accordance with a non-limiting illustrative embodiment of the present
disclosure;
[0026] Figure 2 is a schematic perspective view of a bitumen loading and
bagging station for packaging bitumen in accordance with a non-limiting
illustrative
embodiment of the present disclosure;
[0027] Figure 3 is a schematic front view of the bitumen loading and
bagging station of Figure 2 when positioning a bag at a bitumen discharge
outlet for
bitumen loading in accordance with a non-limiting illustrative embodiment of
the
present disclosure;
[0028] Figure 4 is a schematic front view the bitumen loading and bagging
station of Figure 2 when opening the bag for loading bitumen therein in
accordance
with a non-limiting illustrative embodiment of the present disclosure;
[0029] Figure 5 is a schematic front view the bitumen loading and bagging
station of Figure 2 when engaging the bag so as to close its top end after
loading
bitumen therein in accordance with a non-limiting illustrative embodiment of
the
present disclosure;
[0030] Figure 6 is a schematic front view the bitumen loading and bagging
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station of Figure 2 when sealing the engaged bag with bitumen thereby
providing a
package in accordance with a non-limiting illustrative embodiment of the
present
disclosure;
[0031] Figure 7 is perspective view of a support mounting station for
mounting the package to a movable support in accordance with a non-limiting
illustrative embodiment of the present disclosure;
[0032] Figure 8 is a schematic front elevational view of the movable
support discharging station of the support mounting station of Figure 7 in
accordance
with a non-limiting illustrative embodiment of the present disclosure;
[0033] Figure 9 is a perspective view of a rack positioning and loading
station in accordance with a non-limiting illustrative embodiment of the
present
disclosure;
[0034] Figure 10 is a perspective top view of a ramp conveyor of the
leading to the rack positioning and loading station of Figure 9 in accordance
with a
non-limiting illustrative embodiment of the present disclosure;
[0035] Figure 11 is a perspective side view of the top area of the rack
positioning and loading station of Figure 9 when pushing packages on movable
supports onto the rack in accordance with a non-limiting illustrative
embodiment of
the present disclosure;
[0036] Figure 12 is a perspective view of a rack loaded with packages on
movable supports being conveyed from the rack positioning and loading station
in
accordance with a non-limiting illustrative embodiment of the present
disclosure;
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[0037] Figure 13 is a partial perspective view of a rack unloading station
for unloading the movable supports carrying the packages in accordance with a
non-
limiting illustrative embodiment of the present disclosure;
[0038] Figure 14 is a perspective view of a separating station for
5 separating the package from the movable support in accordance with a non-
limiting
illustrative embodiment of the present disclosure;
[0039] Figure 14A is a side elevational schematic view of the separating
station of Figure 14;
[0040] Figure 14B is a side elevational schematic view of a separating
10 station for separating the package from the movable support in accordance
with
another non-limiting illustrative embodiment of the present disclosure;
[0041] Figure 14C is a side elevational schematic view of a separating
station for separating the package from the movable support in accordance with
a
further non-limiting illustrative embodiment of the present disclosure;
[0042] Figure 14A is a side elevational schematic view of a separating
station for separating the package from the movable support in accordance with
yet
another non-limiting illustrative embodiment of the present disclosure;
[0043] Figure 15 is perspective top view of a conveyor downstream the
separating station in accordance with another non-limiting illustrative
embodiment of
the present disclosure;
[0044] Figure 16 is top perspective view of a pallet loading station in
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accordance with a non-limiting illustrative embodiment of the present
disclosure; and
[0045] Figure 17 is a front perspective view of bundle wrapping station in
accordance with a non-limiting illustrative embodiment of the present
disclosure.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0046] Generally stated and in accordance with an embodiment of the
present disclosure, there is provided a method and a system including
assemblies
and apparatuses for packaging bitumen as well as the products produced
therefrom.
Hot bitumen is discharged from a silo into a container. Polymeric bags are
provided
for being filled by this container. The bags are sealed thereby providing
separate
bitumen packages and placed on movable supports such as trays which are
conveyed to a rack with shelves so as to be set aside for curing. Once the
curing
operation is completed, the trays and the packages are removed from the rack
and
the packages are subsequently separated from their tray to be stacked in a
bundle
on a pallet for shipment thereof. The bundle is conveniently wrapped. Also
provided
is a package comprising a polymeric bag filled with bitumen that is ready for
use by
melting the package so as to access the bitumen.
[0047] With reference, to the appended Figures, non-restrictive illustrative
embodiments will be herein described so as to further exemplify the disclosure
only
and by no means limit the scope thereof.
[0048] With respect to Figure 1, the present system S includes a reservoir
assembly R including three reservoirs. Two reservoirs 10 and 12 are insulated
and
contain therein heated bitumen; the third reservoir 14 is not insulated and
provides
for cooling down the bitumen received therein. A discharge pump 16 provides
for
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receiving bitumen within the reservoir assembly R. As is known in the art,
each top
side T of each reservoir 10, 12 and 14 includes sampling valves and
thermometers
for temperature control, hot oil tanks 15 for heating the bitumen therein,
interrupter
switches for shutting down in feed when a content indicator signals that the
reservoirs are over capacity. Temperature indicators are also mounted to the
reservoirs as is known in the art. Each reservoir 10, 12, and 14 is in fluid
communication with a respective discharge conduit 18, 20 and 22.
[0049] A discharge conduit line 24 runs from the reservoir assembly R to
the housing structure 25 and a return conduit line 26 runs from the housing
structure
25 back to the reservoir assembly R. In this way there is flow of the bitumen
from the
reservoir assembly R to the housing structure 25 and back again, if the
bitumen is
not used as described herein. The narrower conduits 28 provide for heating the
conduit lines 24 and 26. It is convenient for the bitumen to flow within this
circuit
daily. The bitumen is kept at a very stable temperature.
[0050] A monitor 30 with indicators provides for indicating the temperature
of the hot oil as well as the bitumen and for control thereof. A conduit
circuit
network 32 provides for heating the bitumen discharge conduits 18, 20 and 22
during
both the flow of bitumen from the reservoir assembly R to the housing
structure 25
and its return.
[0051] The discharge conduit line 24 acts as an in-feed conduit line within
the housing structure 25 as it runs therein and towards an actuator 34 which
controls
the in-feed of bitumen from the in-feed line 24 into the discharge tube 36 and
from
there into the dispensing reservoir 38 which is a large rectangular container.
The
dispensing reservoir 38 is insulated and kept at high temperature so as not to
allow
the received bitumen to cool down. The actuator 34 provides for returning the
unused bitumen back to the reservoir assembly via the return conduit line 26.
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[0052] An actuator 40 is interposed between the discharge tube 36 and
the dispensing reservoir 38 for stopping bitumen fluid in case of an
emergency. A
temperature indicator 42 is connected to the actuator 34 for confirming the
temperature of the bitumen before it is discharged into reservoir 38 via tube
36. A
temperature indicator 44 is also positioned at the in-feed opening of the
reservoir 38
in order to monitor the temperature of the dispensed bitumen as well as the
temperature of the bitumen within the reservoir 38. Of course, the reservoir
38 also
includes a plunger to indicate the level of bitumen therein, thereby avoiding
over
feeding the reservoir 38 beyond capacity. A heating element provides for
maintaining the bitumen therein at the desirable constant temperature.
[0053] Once sufficient bitumen has been discharged within the reservoir
38, the actuator 44 is shut down and discharge is arrested. The remaining
bitumen
within the tube 36 and in-feed conduit 24 is returned to the reservoir
assembly R via
the action of actuator 34 by way of conduit 26.
[0054] It should be noted that the temperature of the bitumen is monitored
and controlled by a controller in order to be maintained at suitable levels
throughout
its flow.
[0055] With reference to Figures 2-6, the bitumen loading and bagging
station 48 as well as the related process of packaging bitumen will now be
described.
[0056] The bitumen loading station 48 includes a discharge outlet 50 for
discharging the bitumen within the reservoir 38. A controller provides for
controlling
pumps that modulate the amount of bitumen that is discharged at each loading
operation.
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[0057] A plurality bags 52 are provided on a support table 54. The bags
52 are made of a pair of interposed sheets and include unsealed edge to be
opened
for filing. The bags 52 that are engaged by a first movable robotic arm 56
having
suction elements 57 for suctioning a portion of the bags 52 on one side 53
(see
Figure 3) thereof thereby lifting the bags 52 towards the discharge outlet 50.
[0058] Once the bag 52 is positioned at the discharge outlet 50, an
opposite second arm 58 having suction elements 60 engages the bag 52 on the
other side 55 thereof and suctions a portion thereof as shown in Figure 3. Top
clamp members 62 engage opposite longitudinal ends of the top unsealed edge of
the bag 52 to keep it in place. The arms 56 and 58 are moved away from each
other
such that the opposite sheets (at each side 53 and 55) of the bag 52 are
pulled away
from each other, by the action of suction elements 57 and 60 spreading the bag
52
and opening the bag 52 as shown in Figure 4. Spreader elements 64 are pivoted
away from each other engaging the inside of the open top portion of the bag 52
to
maintain the top end of the bag open. The suctions 57 and 60 are disengaged
from
the bag 52.
[0059] With the bag 52 being clamped in position, the discharge outlet 50
proceeds to discharge and load bitumen therein.
[0060] Once the bag 52 is loaded with bitumen, a carriage assembly 65
including carriage members 66 positioned at each side of the bag 52 and
movably
mounted on respective rails 68 engage the bag 52. Each carriage member 66
includes a movable top platform 70 movably mounted on the top end thereof and
including an outwardly protruding longitudinal clamp member 72. Carriage
members
66 move along their respective rails 68 to interface with the bag 52 which is
positioned at the discharge outlet 50. The platforms 70 move towards the bag
52
providing for the clamp members 72 to clamp the bag 52. The clamps 62 release
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the bag 52 and the spreader elements 64 pivot inwardly to disengage the top
open
edge of the bag 52 as shown in Figure 6.
[0061] The carriage members 66 move along their rails 68 towards and
through a Y-shaped guide 74 which keeps the top of the bag 52 above the
portion
5 clamped by clamp members 72 from outwardly spreading. At the exit of the a Y-
shaped guide 74 the carriage members 66 move the bag 52 towards a sealing
assembly 76 comprising a pair of oppositely disposed and movable sealing arms
78
which include emitters 80 for ultrasound sealing of the bag 52 as shown in
Figure 6.
Of course other types of sealing processes, such as heat sealing, can also be
10 contemplated.
[0062] Once the bag 52 is sealed the clamp members 72 disengage the
bag 52 as they are moved away from the bag 52 by their respective platforms 70
allowing the bag 52 with the to drop onto a conveyor 82 as better shown in
Figure 7.
[0063] Therefore the sealed bag 52 and bitumen therein provides a
15 bitumen bag, product or package 84.
[0064] As shown in Figure 7, the package is conveyed downstream to
support mounting station 83 from conveyor 82. More specifically, conveyor 82
moves the package 84 to a lower conveyor 86 including a tagging station 88
with a
laser tag 90 for tagging the package 84. The package 84 is then moved
downstream
onto a conveyor platform 92 which is laterally moved above an adjacent
conveyor 94
(hence, conveyor 92 is a higher conveyor and conveyor 94 is a lower conveyor)
for
mounting the package 84 onto a movable support such as a tray 96 discharged
from
a movable support or tray discharging station 98.
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[0065] With reference to both Figures 7 and 8, the tray discharging station
98 includes a plurality of stacked trays 96 on a support surface 100
positioned above
the conveyor 94 and having an opening 102 for allowing the trays 96 to fall
onto the
conveyor 94. The stack of trays 98 is held in place by a pair of oppositely
disposed
lateral grips 104 including reciprocating lateral grips 103 elements movably
extendible from pistons 105. As shown in Figure 8, support elements 108,
having
reciprocating L-shaped support fingers 107 movably extendible from pistons 109
which provide for holding the bottom most tray 96 from falling through the
opening
102. When the support elements 108 retract, the bottom most tray 96 falls onto
the
conveyor 94. The grips 104 are positioned above the bottom most tray 96 so as
not
to grip it and prevent it from falling. Once the bottom most tray 96 has
fallen onto the
conveyor 94, the support elements 108 return to their initial position. The
grips 104
retract so as to allow the stack to fall via the opening 102 for a distance of
one tray
96, namely the next bottom most tray. The stack is prevented from falling onto
the
conveyor 94 by the support elements 108. The grips 104 again engage the stack
with the exception of the next bottom most tray 96 which is positioned within
the
opening 102. Each bottom tray 96 is discharged in a similar fashion until
expiry of
the stack. Sensors detect the position of the trays within the tray
discharging station
98.
[0066] As shown in Figure 7, once the tray 96 is discharged onto
conveyor 94, the tray 96 is moved forwardly beneath the platform conveyor 92,
as
the leading edge of the tray 96 exceeds the front edge of the platform
conveyor 92,
the conveyor 92 is actuated to move the package 84 forwardly so as to
progressively
fall onto the moving tray 96, thereby mounting the package 84 on the tray 96.
[0067] In this example, each tray 96 includes a relatively flat platform 95
surrounded by a upwardly protruding short lip edge 97 in order to maintain the
package therein during the conveying operation which will be described herein.
In
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this example, small protrusions 99 at each corner 93 thereof which act as
supports
so that the trays 96 when they are stacked do not get stuck one within the
other. The
trays 96 allow the packages 84 to be manipulated without tearing the bag 52.
[0068] Moreover, the bitumen product within the sealed bag 52 is non-
cured and therefore the uncured package 84 would be difficult to move along a
conveyor system as it would deform and get stuck at various positions along
the
conveying circuit. Pusher elements, rollers and various conveyor belts would
further
deform the uncured package 84 causing the finished products to have greatly
varying configurations which would not be convenient for packaging. The tray
96
thus allow the bitumen within the bag 52 to settle and provide a generally
uniform
package 84 as the product is not directly engaged by any of the conveying
elements
prior to curing and after it has been positioned on the tray 96. Therefore, it
is
convenient that once the bag 52 is loaded with bitumen, the conveying process
until
it is positioned on a tray is short. The structures described above meet these
requirements as the bag 52 with bitumen is dropped directly on a conveyor 82
which
is slightly longer than the length the of the package 4 providing for the
package 84 to
begin being dropped onto the lower conveyor 86 for tagging once it is fully
dropped
onto the conveyor 82. Conveyor 86 is also slightly longer than the package 84
thereby providing for progressively moving the package 84 on the platform 92
as the
package 84 almost concurrently with tagging. The package 84 then rests on the
platform 92 and is progressively dropped onto the tray 96 as the tray 96 is
moved
forward. In this way, movement of the uncured package 84 is minimized prior to
it
being positioned on the tray 96.
[0069] As shown in Figure 9, the tray 96 carrying the package 84 on the
tray 96 is conveyed onto a ramp conveyor 110 towards a rack positioning and
package loading station 112 including a tower structure 114. More
specifically, both
tray 96 with the package 84 positioned thereon are conveyed upwardly along the
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ramp conveyor 110 towards the top 115 of the tower structure 115.
[0070] The rack positioning and package loading station 112 includes
longitudinal conveyor 116 (such as a conveyor belt or rollers) for carrying a
rack
structure 118 thereon and conveying this rack 118 towards an elevator 120
which
lifts up the rack 118 by way of a movable platform 122 that is lifted by an
actuator
assembly 124 (such as a hydraulic cylinder) towards the top 115 of a tower
structure
114, in position to receive trays 96. The elevator 120 includes a pair of
alignment
members 126 for keeping the rack 118 in position during conveying.
[0071] As shown in Figure 10, the ramp 110 brings the tray 96 carrying
the package 84 to a first conveyor 128 made of a plurality of rollers which
causes the
tray 96 to engage a centrally positioned vertical roller rod 130 which rotates
the tray
96 carrying the package 84 causing it to change directions from a
longitudinally
conveyed position to a transversal position for example and be moved to a
platform
132 shown in Figure 11. The vertical roller rod 130 is retractable so as to
selectively
provide for trays 96 carrying packages 84 to not be rotated as shown in Figure
10
and thus be conveyed onto platform 132 in the same position that they are in
when
being moved along ramp 110.
[0072] Turning now to Figure 11, a pusher 134 is positioned at platform
132 and connected to a piston actuator assembly 135 for imparting a reciprocal
forward and rearward movement thereto as is guided along lateral guide-rack
137.
The pusher 134 provides for pushing the trays 96 carrying the packages 84
towards
the rack 118 by way of roller conveyor 136 interposed between the rack 118 and
the
platform 132. The rack 118 includes a plurality of rack shelves 138, the
elevator
platform 122 provides for positioning a given rack shelf 136 at the same level
as the
conveyor 136 thereby allowing conveyor 136 and pusher 134 to feed load a given
shelf 136 with trays 96 carrying bitumen packages 84 on trays 72. In the
current
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example, three trays 96 carrying bitumen packages 84 are simultaneously as a
row
pushed onto a shelf 138.
[0073] Sensors provide for detecting when a preferred number of bitumen
packages 84 on trays 96 have been positioned for being conveyed onto the rack
118. Each time a tray 96 with a bitumen bag 84 is positioned on the platform
132,
the sensors provide for detecting its position, transmitting this information
to a
controller which in turn controls the various conveyors and pushers of the
present
circuit or system S. Such sensors also provide detecting the speed at which
the
trays 96 with bitumen packages 84 or as separate elements are conveyed
throughout the system S. The sensors can also be used to detect the number of
bitumen packages 84 on trays 96 positioned on each shelf 138 or on each rack
118,
thereby providing greater bitumen packaging control.
[0074] Each time a shelf 138 receives a capacity number of bitumen trays
96 carrying packages 84, the rack 118 moves up one level to place the next
lower
shelf 138 at the level of the conveyor feeding conveyor 136, thereby filling
each shelf
138 with trays 96 carrying bitumen packages 84. Alternatively, the rack 118 is
fully
raised upwardly by platform 122 and then moved down one level as each next
upper
shelf 138 is fully loaded until it reaches the bottom.
[0075] Turning now to Figure 12, once a rack 118 has been loaded with a
predetermined number of trays 96 carrying bitumen packages 84 it is descended
downwardly via the elevator platform 122 which includes a conveyor surface
that is
continuous to an adjacent out-feed conveyor 140 for removing the rack 118
loaded
with bitumen packages 84 and trays 96 from the rack positioning and bag
loading
station 112.
[0076] A fork lift (not shown) removes the rack 118 from the conveyor
CA 02777205 2012-05-16
124, to place the hot bitumen packages 84 on the trays in an appropriate
location for
curing. Once curing is complete the fork lift recuperated the rack 118 with
the
bitumen packages 84 on trays 96 to bring load to a subsequent processing line
for
separating the bitumen packages 84 from the rack 118 and the trays 96.
5 [0077] Figures 13 shows a rack unloading station 140 comprising a tower
structure 152 similar to the tower structure 114 with an elevator platform
that lifts the
rack 118 towards the top end 153 of the tower structure 152 providing for each
shelf
to be positioned adjacent an out-feed conveyor 154 comprising a plurality of
independently actuated rollers 156. A pusher member 158 opposite the shelf 138
10 pushes each row of trays 96 carrying packages 84 from a given shelf 138
onto the
conveyor 154. Once a given shelf 138 is unloaded the rack 118 is descended so
that the next upped shelf 138 is similarly unloaded until the full rack 118 is
emptied.
Again, the foregoing is controlled and monitored by sensors along the pathway
of the
packages 84 linked to a controller which is linked to each actuator of the
present
15 system S.
[0078] The conveyor 154 leads each tray 96 carrying a package to a
downstream separating station for separating the cured package 84 from the
tray 96.
[0079] Figure 14, 14A, 14B, 14C and 14D show various separating
stations that will be described herein.
20 [0080] Figures 14 and 14A shows a separation station 160 comprising a
separation conveyor 162 contiguous with the conveyor 154 for receiving the
coupled
package 84 and tray 96; guide walls 164 keep the package tray combination in
position as it moves towards the separation conveyor 162. The separation
conveyor
162 includes a first sub conveyor 168 comprising a pair of side conveying
chains 170
which engage the package 84 but not the tray 96 thus moving the package 84 and
CA 02777205 2012-05-16
21
therewith dragging the tray 96 in the downstream direction. The separation
conveyor
162 also includes a chute or ramp 172. The ramp 172 and an upper level floor
portion 174 define a split floor structure 176 at the mouth of the chute or
ramp 172.
Therefore, as the chains 170 convey the package 84, the dragged tray 96
thereunder falls onto the ramp 172 and slides towards a bottom tray
recuperating
area (not show) while the package 84 continues on upper level floor portion
174 to
be conveyed onto a downstream conveyor belt 178.
[0081] In another embodiment, the chains 170 are mounted to lateral and
movable shafts 180 that provide for lifting the chains 170 therewith and
thereby the
engaged package 84 so as to mount it to the upper level floor portion 174.
[0082] Figure 14B shows a separating station 182 comprising a clamping
assembly 184 including a pair of clamping members 186 (only one shown here)
having an arm 188 mounted to top horizontal guide track 190 and an actuator
192 at
one end and having a clamping element 192 at its free end. The clamping
members
186 clamp the package 84 therebetween as it is being conveyed on the tray 96
by
the conveyor 154. The arms 188 are retractable and hence, lift the package 84
from
the tray 96, the tray continued to move towards the and onto the downstream
ramp
172. The lifted package 84 is conveyed by the clamp members 186 as they move
forward along the guide track 190 above the conveyor 178. At this point, the
arms
188 are extended until the package 84 is placed on the conveyor 178 and the
clamp
members 186 release the package 84 allowing it to be conveyed by conveyor 178.
[0083] Figure 14C shows a separating station 192 comprising a platform
194 in the form of a conveyor including a belt 196 on a pair of rollers 198
and being
so positioned at higher position relative to the tray as to block passage of
the tray 96
while it is being conveyed yet allowing the package 84 to be frictionally
engaged by
the speed of the belt 196 in such a way as to be conveyed thereon to be moved
CA 02777205 2012-05-16
22
towards the downstream conveyor 178. A small passage 200 is provided between
the conveyor 194 and the conveyor 158, thereby allowing the tray 96 to move
therein
and slide along the ramp 72 due to the pressure exerted thereon by the package
84
as it is being conveyed onto the conveyor 194.
[0084] Figure 14D shows a separating station 202 comprising a liftable
conveyor 204 that blocks the movement of the package 84 when lifted upwards
and
provides a passage 206 for allowing the tray 96 to be conveyed onto the ramp
172
by conveyor 158. Thereafter, the conveyor 204 is descended and actuated to
allow
the package 84 to be conveyed onto the downstream conveyor 178.
[0085] In an embodiment, the ramp 172 comprises a conveyor belt or
conveyor rollers.
[0086] It should be noted that the liftable conveyor 204 can be used in
conjunction with the clamping members 184 so as to support the lifted package
84
and to allow the tray to fall into the ramp by creating an opening thereunder.
[0087] It should be noted that the various elements of the separating
stations described above can be combined in a variety of ways.
[0088] Sensors linked to a controller provide for sensing the position of
the package 84 and tray 96 in order to take the appropriate action during the
separation step.
[0089] Once the bitumen package 84 is removed from the tray is moved
downstream towards a pallet loading station 210 shown in Figure 16.
CA 02777205 2012-05-16
23
[0090] As shown in Figure 15, a conveyor 208 contiguous with conveyor
178 provides for moving the cured package 84 within the system S, if the
position of
the package 84 needs to be rotates this can be accomplished by various roller
rods
130 strategically positioned along the system S trajectory.
[0091] Turning back to Figure 16, the pallet loading station 210 includes a
platform 212 having an opening 214 for providing packages to be mounted onto a
pallet 216 (see Figure 17) via the opening 214. The pallet 216 is mounted on
an
elevator platform 218 which lifts the pallet up to opening 214. The packages
are
conveyed onto a guide floor 220 via the conveyor 208. The pallet loading
station
210 comprises a pusher 222 having a pushing element 224 for engaging and
pushing packages 84 towards opening 214. The pushing element 224 depends from
an upper beam 226 having downwardly extending guide fingers 228 for slidably
engaging a guide track 230. Pinion gears 232 mounted to the beam 226 via
supports (not shown), provide for moving the pusher 222 forward towards the
opening 214 along the guide-rack 234. In this way, pusher element 224 pushes
packages 84 into the opening 214 and onto the pallet 216. As the pallet 216
received rows of packages 84 thereon the elevator platform 218 subsequently
descends in order to create a space for the next row of packages 84 thereby
building
a bundle 240 on the pallet 216 as the platform 218 descends (see Figure 17). A
top
pusher 242, movably actuated by piston rods 242, pushes the packages 84 of the
bundle 240 downwards onto the pallet 216 to stabilize the bundle 240 and
maintain
the packages 84 under tension between the force of the pusher 242 and the
pallet
216. Once a sufficient number of packages 84 is mounted on the pallet, the
bundle
240 is sent downstream to be wrapped for shipment.
[0092] As shown in Figure 17, a wrapping station 250 comprises a
wrapping dispenser comprising a roller 252 carrying a wrapping material 254,
the
elevator platform 218 is mounted to a pivoting assembly thereunder (not shown)
CA 02777205 2012-05-16
24
providing for the platform 218 along with the bundle 240 thereby wrapping the
bundle
240 in the material 254. Once the bundle 240 is wrapped, the platform 218
provides
via its conveyor rollers 256 to convey the pallet with the wrapped bundle on
an out-
feed conveyor 258 for shipment.
[0093] Again, sensors determined the number and position of bitumen
bags or packages 84 during the above operations so as to send this information
to a
controller which can thereby actuate the various movable components described
above.
[0094] When using the packages 84, the user may simply melt the bag 84
along with the contents in there. The polymeric material of the external bag
52 melts
and disperses with the bitumen when heated and in this way users have a
greater
control of the amount of bitumen that is used as well as facilitating the
handling of
bitumen for transport and use and the while reducing loss of the product
during
handling and use.
[0095] It should be noted that the various components and features of
the embodiments described above can be combined in a variety of ways so as to
provide other non-illustrated embodiments within the scope of the disclosure.
As
such, it is to be understood that the disclosure is not limited in its
application to the
details of construction and parts illustrated in the accompanying drawings and
described hereinabove. The disclosure is capable of other embodiments and of
being practiced in various ways. It is also to be understood that the
phraseology or
terminology used herein is for the purpose of description and not limitation.
Hence, although the present disclosure has been described hereinabove by way
of
embodiments thereof, it can be modified, without departing from the spirit,
scope
and nature of the subject disclosure as defined herein and in the appended
claims.
