Presses – Automatic or material triggered control
Reexamination Certificate
1999-11-22
2002-07-16
Gerrity, Stephen F. (Department: 3721)
Presses
Automatic or material triggered control
C100S045000, C100S048000, C100S049000, C100S22900A
Reexamination Certificate
active
06418841
ABSTRACT:
FIELD OF THE INVENTION
This invention is generally related to solid waste handling. More particularly, this invention is related to a system and method that improves the efficiency of transporting waste material such as scrap metal.
BACKGROUND OF THE INVENTION
One of the byproducts of a metal shaping process is the generation of scrap metal. These scrap metal pieces are the remnants of the workpiece that are cut or punched away from the workpiece as it is shaped to formed the desired end product. Some metal processing facilities, such as those that produce automobile/truck parts or parts for other high volume products, produce large amounts of this scrap metal. This scrap metal is collected and shipped to a recycling facility where it is used as feed stock to form new metal.
Often, this scrap metal is shipped from the location at which it is generated to the recycling facility in large open-topped truck trailers. In this process, the scrap is simply discharged into these trailers from an overhead chute at the location at which it is generated. A disadvantage of this method of hauling the scrap is that one these trailers, though it may be approximately 38 feet in length, it can only hold approximately 20,000 pounds of scrap metal before it is completely full. Consequently, at a location where high volumes of scrap are generated, it is often necessary to frequently remove a trailer that is full of scrap and provide an empty replacement. The cartage costs associated with having to frequently remove these trailers accumulates. There have been attempts to increase the amount of scrap metal removed in each haul by compressing the metal. Specifically, there have been efforts to use conventional compactor systems to increase the amount of scrap metal that is can be loaded in a single trailer. This type of system includes a compactor and a complementary closed container; the container is closely mated to the compactor. The scrap metal is placed in the compactor. A ram integral with the compactor forces the metal into the container. As the container becomes full, the ram compresses the scrap metal in the container. Consequently, the containers integral with this type of system are able to be filled with more scrap metal than can be held in a comparably sized open-topped trailer.
However, there are limits to the amount to which scrap metal can be compressed using conventional compression systems and their complementary containers. One limitation is due to the fact that, as the metal fills the container, it surrounds the opening through which it is filled. When the ram is retracted out of the container, some of the waste becomes caught in the interstitial space between the top of the ram and the a adjacent opening-defining lip of the container. This scrap can wedge between the container and ram. If this occurs, the scrap blocks further retraction of the ram and the subsequent further filling of the container. In order to free the ram, manpower must be employed to remove the trapped metal.
Another problem with a scrap metal compression system is that it is necessary to ensure that the system does not overfill the container in which the scrap metal is compressed. If this occurs, the structural members forming the container may bend or break, rendering the container useless. In theory, it should be possible to simple measure container fullness by simply weighing the container as it is filled with scrap metal. However, these containers, when empty, weight a minimum of 22,000 pounds. As a container is filled with scrap metal, its gross weight can exceed 100,000 pounds. To date, the most convenient means of measuring this type of container as it is loaded is to place the container on a large pit scale. This type of scale includes a platform that is seated in a pit. in a pit that extends below the ground level. The platform has a ground-level surface on which the container is located. This type of scale works reasonably well. However, it is expensive to install.
There have been some attempts to provide above ground scales for measuring the weight of a filled scrap metal container. However, the platforms integral with these scales upon which these containers are seated cannot be positioned too far above the ground level. Consequently it has proven impractical to use the conventional above-ground scales to monitor the weight/fill state of a scrap metal container. Thus, given the expense associated with installing a pit scale and the impracticalities associated with using an above-ground scale, it has proven difficult to provide an economical means for measuring the weight of a container used to hold compressed scrap metal.
Also, there are some instances when gross container weight does not serve as an accurate measure of container fullness. This is because, depending on the product being produced, the weight-per-unit volume of the scrap metal may vary. For example, steel, per unit volume, is heaver than aluminum. At many metal forming facilities, different types of scrap metal may be forwarded to the same container. Given the differences in weight of these different materials, the gross container weight may not serve as an accurate measure of container fullness.
Moreover, once the scrap metal is placed in the container, it eventually needs to be unloaded. In a conventional open topped trailer, the unloading is relatively simple. The trailer is simply inclined so that gravity flows the scrap out of the container. However, it has not proven as easy to unload scrap metal from a closed container in which the metal is compressed. The compressed scrap metal appears to adhere to the internal surfaces of the container. When the container is inclined, gravity alone does not provide sufficient force for causing the scrap to unload from the container.
Consequently, at facilities where the scrap metal is compressed, the metal is often compressed into what is referred to as an “injection” container. An injection container is a closed container with a front wall that is capable of being moved toward the rear of the container. This movement is accomplished by applying a hydraulic force to move the wall. When the container is being filled, the wall is placed in its most forward position. At the unloading facility, a hydraulic pump integral with the container is actuated so as to force the wall rearward. The movement of the wall results in a like rearward movement of the compressed scrap metal out of the container. While injection containers work reasonably well, they are clearly more expensive to provide than conventional containers with fixed front walls. Moreover, providing the supplemental hardware and hydraulic equipment needed to facilitate the front wall of an injection container increases its empty weight by 12,000 pounds or more over a comparable-sized fixed-wall container. This increase in container weight reduces the net weight of the scrap the container is able to transport.
Thus, given the above limitations of current compacting systems, these system are generally not used to load more than 30,000 pounds of compressed scrap metal in a single container. Consequently, while use of these systems reduces the haulage costs associated with removing this material, these costs can still be appreciable.
SUMMARY OF THE INVENTION
This invention relates generally to a new and improved system and method for compacting and transporting material such as scrap metal. The system and method of this invention includes a compactor with members designed to eliminate the likelihood that the waste can become trapped and prevent the compactor's ram from retracting. The method by which the scrap metal is compressed further reduces the likelihood that the metal will wedge against the ram so as to block its retraction. The system and method of this invention also include a scale especially designed to weight the multi-ton containers in which heavy waste such as scrap metal is compacted. The scale of this invention is further designed to simply be placed on the ground surface of the location at which use of the scale is de
Little Jonathan A.
Schomisch Donald R.
Flynn ,Thiel, Boutell & Tanis, P.C.
Gerrity Stephen F.
Huynh Louis
PMDS, LLC
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