Abstract:
A rock and stone tumbling apparatus is provided for mobile transport to desired sites for continuous, uninterrupted operation to repeatingly receive, load and tumble large amounts of raw stone materials in order to give them a worn, aged, weathered and decorative appearance, and then wash, size and discharge the tumbled stone product in sorted condition according to finished stone size, for the extremely efficient and cost effective large scale tumbling processing of rock and stone materials for use in landscaping, building and other industries.

Description:
[0001]    This application claims benefit under 35 U.S.C. 119(e) of U.S. Provisional application Serial No. 60/393,711, filed 3 Jul. 2002. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    This invention relates to rock and stone tumbling apparatus for the tumbling processing of large amounts of stone, and more particularly to a rock tumbler apparatus that is arranged to receive, load and tumble large amounts of raw stone materials in order to give them a worn, aged, weathered and decorative appearance, and then wash, size and discharge the tumbled stone product in sorted condition according to finish stone size for use of the finished stone product as decorative building and landscaping stone.  
           [0003]    As is known, decorative stone is widely used for building facades, floors and other elements of building constructions and very widely used in the landscape industry in forms ranging from larger stones for rookeries and retaining walls down to small stone sizes used for ground cover for planting areas and walkways. Natural decorative stones can be quite expensive as is well known, and therefore the industry is endeavoring to utilize alternative decorative stone materials that are being manufactured to resemble and imitate naturally weathered decorative stones and the like. However, these too can be expensive, and do not necessarily well replicate naturally weathered and worn stone.  
           [0004]    Apparatus for the large scale commercial tumbling processing of rock, stone and other materials has been provided heretofore as is illustrated in U.S. Pat. Nos. 5,586,925 (DiNorcia, S R. etal.); 2,912,803(Sinjian); and 1,946,440 (Herrmann) which each disclose tumbling apparatus representative of the structures heretofore known in the art. In each case, large cylindrical drums are provided with closed opposite longitudinal end walls which mount opposite, axially aligned pivot bearing supports configured to mount the tumbling drum rotatably therebetween on a supporting framework. Access panels are provided on the peripheral wall of the respective tumbling drums for access to the interior cavity of the drum for loading raw material into the drum and unloading finished, tumbled material from the drum.  
           [0005]    As will be apparent to those skilled in the art, the loading and unloading of the tumbling drums of the first and last patent identified above requires that the drum be stopped for the accessing of the interior of the drum by personnel to physically remove the tumbled contents of the drum after each operation. The second identified patent provides a side wall access panel configured such that after tumbling, the drum may be stopped, the access panel manually opened, and the drum rotated to and stopped at a point at which the entire contents of the drum will simply fall out of the drum to the space therebelow, although this is merely an interpretation of the drawings and is not taught or suggested in the teachings of the patent.  
         SUMMARY OF THE INVENTION  
         [0006]    In its basic concept, this invention provides a rotating tumbling drum, open at one of its longitudinal ends for loading of raw stone material into the interior confines of the drum for tumbling operation and for discharging tumbled, finished stone out of the drum after tumbling operation, the finished stone product being discharged from the drum into sorted condition separated according to preselected finished stone sizes, all during continuous rotation of the tumbling drum.  
           [0007]    It is by virtue of the foregoing basic concept that the principal objective of this invention is achieved; namely, the provision of a stone tumbling apparatus of the class described which overcomes the limitations and disadvantages of tumbling apparatus of the prior art.  
           [0008]    Another object of this invention is the provision of a stone tumbling apparatus of the class described which also rinses the finished stone product during sizing and discharge from the tumbling drum.  
           [0009]    Another object of this invention is the provision of a stone tumbling apparatus of the class described in which discharge of the stone from the tumbling drum is accomplished by tilting the rotating drum during rotation to move the stone being tumbled therein toward and out of the drum opening by continued rotation of the drum.  
           [0010]    Another object of this invention is the provision of a stone tumbling apparatus of the class described which includes an associated drum loading apparatus to deliver a load of stone to be tumbled into the interior of the drum during rotation thereof.  
           [0011]    Another object of this invention is the provision of a stone tumbling apparatus of the class described in which a water supply apparatus is arranged to deliver water into the tumbling drum during loading of the drum.  
           [0012]    Still another object of this invention is the provision of a stone tumbling apparatus of the class described which may be mounted on a wheeled transport trailer so as to provide a substantially self-contained mobile tumbling apparatus arranged for transport to different sites for operation, thereby avoiding the heretofore necessary requirement and expense of shipping raw stone material to a dedicated processing site.  
           [0013]    A further object of this invention is the provision of a stone tumbling apparatus of the class described which provides the industry with an acceptable, cost efficient decorative stone product that utilizes common, readily available materials including recycled materials normally not usable as decorative stone material including recycled or broken pieces of concrete slabs and blocks, bricks and common stones that can be made decorative and “weathered” with rounded edges by tumbling.  
           [0014]    A further object of this invention is the provision of a stone tumbling apparatus of the class described which virtually eliminates physical handling of the stone and the apparatus throughout continued operations, thereby reducing labor expenses and enhancing personnel safety.  
           [0015]    A still further object of this invention is the provision of a stone tumbling apparatus of the class described which is of simplified construction for economical manufacture, reliable operation, and simplified maintenance.  
           [0016]    The foregoing and other objects and advantages of the present invention will appear from the following detailed description, taken in connection with the accompanying drawings of the preferred embodiment. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0017]    [0017]FIG. 1 is a fragmentary side elevation of a stone tumbling apparatus mounted on a mobile, wheeled trailer frame and embodying features of this invention, the apparatus shown in a stone discharge condition.  
         [0018]    [0018]FIG. 2 is a fragmentary side elevation of the apparatus of FIG. 1 but showing the apparatus in a stone loading and tumbling condition of operation.  
         [0019]    [0019]FIG. 3 is a fragmentary sectional view of the open end portion of the tumbling drum to show internal detail and illustrate the stone sizing structure and operation of the sizing ring members on the tumbling drum. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0020]    At the outset it is to be understood that, although the preferred embodiment of this invention is illustrated and disclosed herein as a mobile tumbler apparatus mounted on the bed of a truck-drawn, flatbed-type trailer, the apparatus may alternatively be mounted in fixed, stationary condition at a dedicated stone processing facility if desired. In such a case the base support structure illustrated herein as a road transport trailer  10  would instead be provided as a stationary base support structure for fixedly securing the apparatus on an underlying ground or floor surface.  
         [0021]    In the preferred embodiment illustrated however, a road transport trailer, shown here as a flatbed trailer  10  has, as typical, a longitudinally-extending framework  12  mounting transport wheels  14  adjacent its rear end and front end-supporting jack stands (not shown) adjacent its forward, truck-engaging hitch end (not shown), as is known in the industry. The framework  12  is configured to mount a generally rectangular drum-supporting tilt frame apparatus  16  which provides means for rotatably supporting a tumbler drum for longitudinal tilting movement on the trailer framework  12 , as seen in viewing FIGS. 1 and 2 of the drawings. In this regard, the generally rectangular tilt frame apparatus  16  in this embodiment is mounted at one of its longitudinal ends to the frame of the trailer by pivot brackets  18  and at its opposite longitudinal end by powered tilt means such as hydraulic cylinders  20  which interconnect the trailer frame  12  and the tilt frame end for tilting movement of the frame about pivot mounting brackets  18 , as is apparent in viewing FIGS. 1 and 2 of the drawings.  
         [0022]    Bearing support means is provided to support a tumbling drum for rotation on the trailer frame. In this regard, the tilt frame apparatus  16  shown herein mounts a plurality of support rollers  22  along its opposite longitudinal sides, the support rollers arranged to support, in cradle-like manner, a large, generally cylindrical, hollow tumbler drum  24 , open at its rear longitudinal end and supported for rotation on the rollers  22  as is apparent Powered drive means is provided for rotating the drum  24  on the support rollers  22 . Although many various different arrangements may be provided for powered rotation of the tumbler drum  24 , a variable speed hydraulic or electric drive  26  is mounted  28  on the tilt frame assembly  16  to engage the drum and rotate it at desired revolutions per minute on the supporting rollers  22 . A hydraulic pump (not shown) and electric generator  30  are also provided on the trailer  10  along with a water pump and any necessary and desired controls, etc. as may be needed for operation of the various equipment of the trailer-mounted apparatus of this invention as will become clear from the following.  
         [0023]    Preferably, means is provided for sorting the tumbled material being discharged from the drum by separating the material according to its size. In the embodiment shown herein, the drum mounts on its rear, open longitudinal end, at least one stone sizing ring member  32  arranged to extend rearwardly from the drum in opening-encircling condition as shown. The ring member  32  is provided with a plurality of stone sizing openings  32 ′ therethrough, the diameter of the openings being selected to permit stones of a certain diameter and smaller to fall therethrough for reasons which will be explained later. In the embodiment illustrated, a second, inner sizing ring member  34  is mounted to the drum inwardly of and projecting further rearwardly from the first ring member  32 , the ring member  34  being provided with a plurality of stone sizing openings  34 ′ having a larger diameter than openings  32 ′ through which stones having an equal or smaller diameter can pass through. Clearly, stones capable of passing through the openings  32 ′ will easily have first fallen through the larger openings  34 ′.  
         [0024]    In the preferred form shown herein, the ring member  34  is mounted to the drum by a radially projecting flange member  36  which provides a wall surface that forms a step or ledge which prevents passage of a portion of the remaining sand and fines F out of the drum during discharge of a load of tumbled stone material as will be explained. These fines are preferably retained in the drum for use as abrasive material in the next and subsequent tumbling operations of the drum, and they also serve to protect and cushion the drum itself against scraping and impact damage by the larger tumbling stone material during the tumbling process.  
         [0025]    Positioned on the frame  12  beneath the outfeed of the drum and the ring members  34 ,  32  are, in this embodiment, three discharge chute members  38 ,  40 ,  42  arranged to catch stone material falling through the openings  32 ′,  34 ′ in the ring members  32 ,  34  and out the central opening  44  of the ring member  34 . As indicated in FIGS. 1 and 2, during discharging of tumbled stone from the drum after tumbling, these discharge chute members, which may be electrically or hydraulically driven conveyors if desired, are arranged to deliver stones falling thereonto laterally outwardly to convenient discharge points alongside the trailer as finished stone product sorted by size as will be understood in viewing FIG. 3 of the drawings and as will be described later.  
         [0026]    As shown, a high pressure spray wash line  46  is provided for connection (not shown) to a trailer-mounted water pump or other outside source of water under pressure, the spray wash line configured with a terminal end portion  48  arranged to extend into the rear central opening  44  of the ring assembly. As best seen in FIG. 3 of the drawings, the water line portion  48  is positioned preferably adjacent the uppermost portion of the ring member  34  so as to leave as much of the interior confines of the ring members free of obstruction as possible. Spray nozzles  50  are positioned along the terminal end portion  48  so that substantially all of the interior working length of the sizing rings  32 ,  34  may receive a water spray therefrom. This terminal end portion  48  may extend further into the hollow interior confines of the drum itself if desired to provide a source of water to the interior of the drum for use in the tumbling operation.  
         [0027]    Mounted on the frame  12  rearward of the central opening  44  of the drum is a feed hopper  52  arranged for electrically or hydraulically driven longitudinal carriage movement on the frame  12  between a first retracted position seen in FIG. 1 and a second, extended position as seen in FIG. 2. The feed hopper is configured to receive and hold a load of raw stone material, as for example delivered by a front end loader or other suitable type of equipment. The interior of the hopper is configured to deliver stone material contained in the hopper to an electrically or hydraulically driven conveyor apparatus having a forwardly projecting discharge end  54  arranged to extend into the drum opening  44  when the hopper is moved into said second, extended position. In this position the conveyor apparatus may be operated to move the contents of the hopper into the hollow confines of the drum.  
         [0028]    With the foregoing basic structure of the stone tumbling apparatus of this invention thus now described, the operation of the preferred embodiment of the invention illustrated herein is as follows:  
         [0029]    With the tumbler apparatus set up at a work site, connected to a supply of water and placed in the condition of FIG. 1 and having completed the discharge of a load of tumbled stone from a previous tumbling operation, the hydraulic cylinder  20  is operated to pivot the drum tilt frame  16  downward, placing the drum into the lowered, downwardly tilted condition of FIG. 2. The feed hopper carriage is then operated to move the loaded feed hopper  52  forward into its extended condition in which the outfeed end of the hopper conveyor  54  extends into the confines of the drum as also seen in FIG. 2. The drum drive means  26  is operated to rotate the drum, and the conveyor  54  is operated to convey the raw stone material from the hopper through the opening  44  and into the confines of the rotating drum. As the drum is being filled with the raw stone material, water is simultaneously being introduced into the drum, and the rotation of the downwardly tilting drum facilitates the movement of the raw stone material toward the opposite, lower end of the drum. Once the drum has been filled with raw stone material from the hopper, the speed of the rotation of the drum is selected to give the desired tumbling effect of the stone, and the tumbler is left to run continuously until the desired finish on the stone is achieved, typically one-half hour to one hour in duration. Different types of stone material will require different amounts of tumble time and rotation speed in order to achieve the desired effect.  
         [0030]    When a desired tumbling operation has been completed, the feeder hopper assembly is moved into its first, retracted condition of FIG. 1 and may be re-loaded with raw stone material from a front end loader or other suitable equipment in preparation for the next tumbling operation. The hydraulic cylinder  20  is operated to raise the tilt frame  16 , placing the drum in the raised, discharge condition of FIGS. 1 and 3, whereupon continued rotation of the drum causes the stone material contained therein to move out of the drum through the central opening  44  formed by the ring member  34  as seen best in FIG. 3 of the drawings. As will be understood, during the tumbling operation, as the stone tumbles, small pieces chip off of the stones and create fines which serve well as a grinding or smoothing compound during the tumbling operation. During the discharge operation, because of the ledge  36  configuration at the open end of the drum, much of these fines remain trapped in the interior of the drum for use in subsequent tumbling operations.  
         [0031]    As the tumbled stone product exits the drum through the center opening  44  of the ring member  34 , small stones, fines and water immediately pass through the larger sizing openings  34 ′ onto the inner surface of ring member  32  and, thence through the smaller openings  32 ′ if the material is small enough to pass therethrough. In this manner, small stones  56 , sand-like fines and water are able to pass directly to discharge chute  42  as waste and smallest size tumbled stone material. Stone material having passed through openings  34 ′ but are too large to pass through openings  32 ′ are moved rearwardly and out of the space between the ring members  32 ,  34  and fall, together with stones  58  of a size able to fall through openings  34 ′ downward onto a second discharge chute  40  as a mid-size stone product.  
         [0032]    Finally, stones  60  that are larger than the sizing openings  34 ′ are simply carried along the inner surface of the ring member  34  whereupon they ultimately fall out of the central opening  44  and onto a third discharge chute  38  or conveyor as a third, larger size finished stone product. Accordingly, all of the finished stone material is delivered to preselected discharge points alongside the trailer apparatus in sorted condition according to finished stone size. As the stone material passes from the drum member through the ring members  32 ,  34 , a high pressure spray wash provided by nozzles  50  cleans the stone product of fines and other materials as they pass through the ring assembly and prior to their being delivered to their various sort piles. Accordingly, with raw stone material being dumped into the hopper in bulk by a front end loader or the like, the apparatus of this invention not only provides tumbled, finish stones as an end product, but provides stones that have been washed, sized and delivered out of the apparatus to discharge locations sorted by stone size without any manual handling of the stone material.  
         [0033]    From the foregoing it will be apparent to those skilled in the art that various changes other than those already discussed may be made to the size, shape, type, number and arrangement of parts described hereinbefore without departing from the spirit of this invention and the scope of the appended claims.