Abstract:
The present invention relates to a system and method for disassembling scrapped vehicles in which multiple process-based facilities are provided in series on one path for performing each disassembling process from a loading process of a scrapped vehicle to a final vehicle body compression process. The scrapped vehicles are moved along the path while mounted on a truck that moves the vehicles via a transfer rail. The truck that has completed a transfer is lowered into the interior of a tunnel beneath the path and transferred back to the position where the first process was performed.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application claims priority to Korean Application No. 10-2004-0021004, filed on Mar. 27, 2004, the disclosure of which is incorporated fully herein by reference.  
       FIELD OF THE INVENTION  
       [0002]     The present invention relates to a system and a method for disassembling a scrapped vehicle, and in particular to a system and a method for disassembling a scrapped vehicle in which multiple process-based facilities are provided in series on one path for performing each disassembling process from a loading process of a scrapped vehicle to a final vehicle body compression process.  
       BACKGROUND OF THE INVENTION  
       [0003]     As personal vehicles become more and more indispensable as daily means of transportation, the number of vehicles has been on the increase, and the number of vehicles that have been scrapped is on the increase as well.  
         [0004]     Since scrapped vehicles are of little economical value because they are comprised of parts which are very old or beyond their expected lives, prearrangement appears essential to recycle reusable parts of the scrapped vehicles. However, most prearranging processes depend on labor-intensive work, and thus the cost involved in recycling and scrapping vehicles is usually very high. In addition, the life cycles of second hand parts are relatively short, so the second hand parts can be used in general for only a very limited period of time. Furthermore, frequent replacement of vehicles due to shortened launching periods of new products also restricts compatibility of the second hand parts.  
         [0005]     On average, 75% parts by weight of scrapped vehicles are recycled. Considering the complexity of the structure of the scrapped vehicles, the recycling rate is relatively high in comparison with other consumption goods. While ferrous or non-ferrous metals have been recycled, the remaining materials of about 25% have not been buried under the ground. The process of the scrapped vehicle is roughly classified into a collecting process of reusable parts and a shredding process of unrecyclable parts.  
         [0006]     The infrastructure for the process of scrapped vehicles is well developed in small countries such as Japan and European countries. For example, there are about 3,000 to 4,000 companies involved in processing the scrapped vehicles in Germany. In comparison, there are only about 10,000 of such companies in the U.S. In most foreign companies for processing the scrapped vehicles, the second hand parts are effectively recycled through the on-line system.  
         [0007]     According to recent environment-related regulations on recycling of scrapped vehicles in the European Union, the manufacturer of a vehicle is responsible for collecting all scrapped vehicles, including buses, with the capacity of below 9 passengers and trucks with capacity below 3.5 total weight bearing the cost at their end, which have been manufactured and sold since Jul. 1, 2002. With respect to vehicles sold before Jul. 1, 2002, the collecting responsibility will be upon the manufacturers as of Jan. 1, 2007.  
         [0008]     Ideally, in the collection and scrapping of all used vehicles, manufacturers should construct a scrapping system having same capacity of manufacturing. Therefore, problems arise if manufacturers use conventional scrapping systems and methods without suitable modifications. For example, a conventional disassembling system for a scrapped vehicle is illustrated in  FIG. 2 . The conventional disassembling system is provided with various facilities that are randomly arranged on the ground within a certain area. The facilities and processes are complicated and require a relatively large space. Because the disassembling facilities are randomly spread throughout a wide space, disassembling parts requires lengthy periods of time, which result in increased cost. Furthermore, safety problems abound in the current disassembling processes.  
       SUMMARY OF THE INVENTION  
       [0009]     It is an object of the present invention to provide a system and a method for disassembling a scrapped vehicle in which multiple process-based facilities are provided in series on one path for performing each disassembling process and a truck is provided for moving the scrapped vehicle along the line, whereby it is possible to compact a working site and facilities, to improve efficiency of the scrapping work with minimum labor.  
         [0010]     The present invention teaches a system and method for disassembling scrapped vehicles. The scrapped vehicles are seated on a truck and moved on a transfer rail along a facility line along which each disassembling process is sequentially performed. The truck that completes a transfer of the scrapped vehicles to a final process station continues on the transfer rail through an underground tunnel and returns back to the first process station.  
         [0011]     One embodiment of the present invention comprises multiple process-based facilities disposed in series on one path, a rail arranged along the line, a truck traveling on the rail while accommodating a scrapped vehicle thereon, and a truck returning system, in which the truck that completes a transfer of the scrapped vehicles to a final process station, enters a tunnel formed underground, and returns back to the first process station along a transfer rail in the tunnel.  
         [0012]     In another embodiment of the present invention, the process-based facilities are installed for sequentially performing the following steps of: checking disassembling objects; preparing the objects; eliminating explosive parts; collecting liquid; disassembling external parts; disassembling internal parts; dismounting engine, transmission, exhaust system, and chassis; and compressing a body of a vehicle.  
         [0013]     In yet another embodiment of the present invention, the truck returning system comprises a tunnel for moving the truck therein. The tunnel includes two vertical paths extending downward from both ends of the rail and a horizontal path connecting the vertical paths to each other, a transfer rail that is installed along the interior of the pit for transferring the truck, and an elevator for lifting or lowering the truck in the vertical paths of the tunnel.  
         [0014]     In a further embodiment of the present invention, the elevator comprises an extending rail being connecting to the ends of the rail on the ground of the working site and to the ends of the transfer rail in the tunnel.  
         [0015]     In yet a further embodiment of the present invention, the truck returning system further comprises a truck transferring device including a chain connecting the truck and a winding device. The winding device being positioned at one end of the tunnel where a first process station is located and the winding device pulls the truck to a location below the first process station by winding the chain.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0016]     The aforementioned aspects and other features of the present invention will be explained in the following description, taken in conjunction with the accompanying drawings, wherein:  
         [0017]      FIG. 1  is a view illustrating a conventional disassembling procedure of a scrapped vehicle;  
         [0018]      FIG. 2  is a plane view illustrating a conventional disassembling system of a scrapped vehicle;  
         [0019]      FIG. 3  is a perspective view illustrating a disassembling system of a scrapped vehicle according to the present invention; and  
         [0020]      FIGS. 4A and 4B  are views illustrating a driving state of a disassembling system of a scrapped vehicle according to the present invention. 
     
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS  
       [0021]     The preferred embodiments of the present invention will be described with reference to the accompanying drawings.  
         [0022]      FIG. 3  is a perspective view illustrating a system for disassembling scrapped vehicles according to the present invention, and  FIGS. 4A and 4B  are views illustrating a driving state of a system for disassembling scrapped vehicles according to the present invention.  
         [0023]     Referring to  FIG. 3 , the system according to the present invention is implemented in the following example sequence: checking disassembling objects  10 , preparing the vehicle  20 , eliminating explosive parts  30 , collecting liquids  40 , disassembling external parts  50 , disassembling internal parts  60 , dismounting engine, transmission, exhaust system, and chassis  70 , and compressing the body of a vehicle  80 . This sequence of processes is performed along one path.  
         [0024]     Referring now to  FIG. 4   a , when checking disassembling objects  10 , the scrapped vehicle  1  is mounted on a truck  110  using a forklift  1 , and the disassembling object parts are checked and recorded before the disassembling procedures are performed (disassembling work order sheet is made). In the preparing step  20 , the scrapped vehicle  1 , including tires, hood, and battery, is disassembled.  
         [0025]     When eliminating explosive parts  30 , explosive parts are first removed in order to prevent any damage on workers or disassembling devices before recyclable parts are disassembled. Various airbags (airbags in the side of driver&#39;s seat and passenger&#39;s seats, side airbags, curtain airbags) or seat free tensioners are connected to an explosive part, and are thus processed at this station. A screen automatic door system adapted to aid entry into the vehicle  1 , a soundproof device for preventing sound during explosion, and a duct device for sucking explosion gases are provided.  
         [0026]     In the liquid collection step  40 , the vehicle  1  is mounted on a lift  41  together with the truck  110 , and over 95-98% of fuel, engine oil, anti-freezing solution, brake oil, power steering oil, transmission oil, refrigerant, and washer liquid are collected. In the disassembling of external and disassembling of internal parts  50  and  60 , the reuse or recyclable parts are collected from the vehicle  1 . Over 200 to 250 parts, such as trim parts, cover parts, and seat parts, are collected. The vehicle  1  is mounted on the table lift  51  together with the truck  110 , and the external parts, such as glass, are dissembled, and the vehicle  1  is moved to the disassembling step  60  together with the truck  110 , and then the seat, trim parts, gauge parts and peripheral parts are disassembled.  
         [0027]     In the engine, transmission, exhaust system, chassis parts disassembling step  70 , the engine and partial chassis parts are disassembled using a vehicle body rotation device  71 . When the above parts are collected, the steel material parts, consumable parts still remaining in the vehicle body (plastic materials less than 50 g, rubber parts) and the full-length parts that could not be reused and could not be recyclable are left. In the compressing a body of a vehicle step  80 , the vehicle body is lifted up from the truck  110  together with the remaining parts and is moved and placed in the compression press  81  and is compressed.  
         [0028]     The above disassembling processes are sequentially performed while truck  110  and scrapped vehicles  1  are being moved along transfer rail  111 . In the present invention, the process-based facilities  10  through  81  adapted to perform each disassembling procedure from the loads of the scrapped vehicles to the final vehicle body compression procedures are arranged in series, and transfer rail  111  is installed on the ground so that truck  110  is moved along each facility.  
         [0029]     In one embodiment, there is provided a truck returning system in which truck  110 , after completing the transfer of the scrapped vehicle up to the final compressing a body of vehicle  80  is returned to the checking disassembling objects  10  through tunnel  120  below the path along which truck  110  moved the scrapped vehicles (hereinafter “scrap process path”). Truck return transfer rail  123  is installed in the interior of the tunnel  120 .  
         [0030]     In the truck returning system, the truck returning line includes vertical paths  121  and  122  extending downward from the scrap process path from both ends of the transfer rail  111 , a tunnel  120  that connects the two vertical paths  121  and  122  at a certain depth below the scrap process path, truck return transfer rail  123  that is capable of moving truck  110  in the interior of tunnel  120 , and lifting and lowering devices  130   a  and  130   b  that lift and lower truck  110  in the interior of vertical paths  121  and  122 .  
         [0031]     When the vehicle body is moved to compression press  81 , an empty truck is left. At this location, vertical path  122  is formed at the end of transfer rail  111  in which empty truck  110  is positioned. In addition, vertical path  121  is formed at the location that the checking disassembling objects  10  starts, namely, at the opposite end of transfer rail  111 . Tunnel  120  connecting vertical paths  121  and  122  is formed at a certain depth below the scrap process path, and truck return transfer rail  123  is installed in the interior of tunnel  120  through which truck  110  is moved.  
         [0032]     In one embodiment, transfer rail  111  and truck return transfer rail  123  form a continuous loop along the surface of the ground, through vertical path  122 , then through tunnel  120 , and finally through vertical path  121 .  
         [0033]     In another embodiment, transfer rail  111  and truck return transfer rail  123  are disconnected from each other. Lifting and lowering devices  130   a  and  130   b  are installed in vertical paths  121  and  122  for lifting and lowering truck  110  between the scrap process path and tunnel  120 . Lifting and lowering devices  130   a  and  130   b  include bases  131   a  and  131   b  on which truck  110  is positioned, hydraulic cylinders  132   a  and  132   b  for lifting and lowering supports  131   a  and  131   b , and supports  133   a  and  133   b  for supporting the bases  131   a  and  131   b . Rails  134   a  and  134   b  are installed on the upper surfaces of the bases  131   a  and  131   b  for easily mounting truck  110  by connecting both ends of transfer rail  111  of the upper side and truck return transfer rail  123  in tunnel  120 .  
         [0034]     In an embodiment of the present invention, in the truck returning system, there is further provided truck transferring device  140  for automatically transferring through tunnel  120  empty truck  110  from a location beneath where the compressing a body of a vehicle  80  is performed, to a location beneath where the disassembling object part check process step  10  is performed.  
         [0035]     In another embodiment, the truck returning system includes chain  141 , one end of which is connected to truck  110 , and the other end of which is connected to winding device  142  that is installed at one end of tunnel  120 . Winding device  142  winds chain  141  and transfers truck  110 . Here, winding device  142  includes motor  143  that provides a rotational force, and winding shaft  144  that is installed at a rotary shaft of the motor  143  and winds chain  141  opposite to the truck using the rotational force of the motor.  
         [0036]     After the compressing a body of a vehicle step  80  is performed, empty truck  110  is moved to rail  134   b  of the upper surface of base  131   b  of lowering device  130   b  and is automatically lowered together with base  131   b  by the operation of hydraulic cylinder  132   b , and is moved to truck return transfer rail  123  of tunnel  120 . At this time, chain  141  is connected to empty truck  110  and winding device  142  operates on chain  141  so that truck  110  is transferred to a location beneath where the checking disassembling objects step  10  is performed. When empty truck  110  arrives at rail  134   a  of the upper surface of base  131   a  of opposite lifting device  130   a , chain  141  is disconnected from truck  110 , and truck  110  is lifted to the surface. Truck  110  is then moved to the area in which the checking of disassembling objects  10  is performed.  
         [0037]     As described above, in the present invention, the process-based facilities adapted to perform each disassembling process from the first load of the scrapped vehicles to the final vehicle body compression process are installed along one path in series, so that each disassembling process of the scrapped vehicles is sequentially performed while the scrapped vehicles are being moved along the facility lines while mounted on the truck. Therefore, the facilities and processes are not as complicated as the conventional system for disassembling scrapped vehicles. In the present invention, the disassembling processes are performed by sequentially moving the scrapped vehicles along each line using the truck without using the forklift except for the steps in which the scrapped vehicles are mounted on the truck before the disassembling object part check process is performed, and the remaining vehicle body is placed into the compression press. The use of a movable truck enhances efficiency, and a large scale operation could be achieved with relatively small crew of workers.  
         [0038]     Additionally, the truck that completed the transfer of the scrapped vehicle up to the final process is descended into the tunnel formed in the lower side and is moved to the first process along the transfer rail in the tunnel and is ascended to the upper side, thereby successfully returning the truck to the starting point of the process. In the present invention, it is possible to easily adjust the scrapped vehicle process capacity based on the numbers of trucks and workers.  
         [0039]     The foregoing description, for purposes of explanation, used specific examples to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that the invention is not limited to these examples. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. Thus, the foregoing disclosure is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings.  
         [0040]     It is intended that the scope of the invention be defined by the following claims and their equivalents.