Parts separator apparatus and method of shredding

A parts separator apparatus for use with a centrifugal separator includes a shredder apparatus located within an inlet section of the parts separator. The shredder apparatus shreds wet chip material prior to the wet chip material passing over a drop-out opening in the parts separator.

FIELD

The present invention is directed generally to a parts separator apparatus for use with a centrifugal separator and in a method of shredding, and, more particularly, to a parts separator apparatus having a shredder apparatus disposed within the parts separator.

BACKGROUND

In the course of machining operations, scrap materials, known as wet chips, are generated. The wet chips usually include relatively small wet chips, referred to as granular wet chips, stringy pieces of wet chips as well as bales of wet chip material. Additionally, undesired solids such as bolts, nuts, etc. sometimes are found in the bales or batches of wet chip material. Wet chip materials are conveyed from one or more machine stations to a centrifugal separator station where the wet chip material is centrifugally separated into dry chips and fluid.

Prior to entering a centrifugal separator apparatus, wet chips pass through a parts separator apparatus generally having an air lock assembly as well a material drop-out opening. The wet chip material enters the parts separator, travels past the air lock assembly located in an inlet chute or section, flows over the drop-out opening, and then, after passing through an outlet chute or section, enters into the centrifugal separator. Heavy unwanted solid objects, such as bolts and nuts, drop out of the system at the location of the parts separator drop-out opening. The air lock apparatus, which is generally a paddle wheel assembly, comprises a plurality of rotatable paddles, such as illustrated in Nemedi U.S. Pat. No. 5,106,487. The air lock assembly serves to assist in maintaining a desired negative air pressure within the parts separator during the operation of the centrifugal separator. The negative air pressure is generated upon actuation of the centrifugal separator to which the parts separator normally is connected. The negative air pressure in the parts separator normally allows for wet chip material to be pulled from the air lock assembly and across the parts separator drop-out opening following which the wet chip material enters the centrifugal separator apparatus.

In some instances, wet chip material entering a parts separator originates from a plurality of machine stations. In this situation, the size of the wet chips generated at one station sometimes varies substantially from wet chips generated at another work station. As a result, wet chip material of different sizes enters the parts separator. Unfortunately, it has been found that, in some instances, larger size wet chips from one machine station fail to pass over the parts separator drop-out opening. Instead, some larger size wet chips drop out of the parts separator drop-out opening, where they have to be collected and reintroduced into the wet chip separation system. It is thus desired to limit this problem.

Further, it has been found that, on occasion, some larger undesired solids, e.g., bolts or nuts travel at such a relatively high velocity within the parts separator apparatus that they cause damage to the air lock assembly or the parts separator frame. It is also desired to limit this problem.

Further, it is desired to limit the need for a conventional paddle-wheel-type air lock assembly that often is disposed within a parts separator apparatus.

SUMMARY

Briefly, a shredder apparatus having a shredder wheel assembly attached to a reversible motor, such as shown and disclosed in my pending patent application, Ser. No. 10/611,526, which is hereby incorporated by reference in its entirety in the present application, is disposed within the inlet section of a parts separator apparatus. The shredder apparatus is located within the inlet chute of the apparatus preferably contiguous to the parts separator drop-out opening. Wet chip material of varying sizes and/or bales enter the inlet chute of the parts separator apparatus where the wet chip material is shredded into wet chip material having a relatively uniform size. The shredded wet chip material then passes over the parts separator drop-out opening into the parts separator outlet chute from where it enters a centrifugal separator apparatus where the wet chips are centrifugally separated into dry chips and fluids.

In some instances, where relatively large undesired solid objects, e.g. bolts, nuts, etc., are found in the wet chip material entering the parts separator, the shredder apparatus is unable to shred these objects. The shredder apparatus will sense these undesired objects and stop. The shredder apparatus motor then will change direction whereupon shredder wheels will reverse direction and pick up the undesired object(s) and transport the object(s) within the system whereby the undesired object(s) can relatively easily exit the parts separator through the drop-out opening. Accordingly, the velocity of an undesired object within the parts separator can be reduced and the direction of the undesired object within the parts separator apparatus can advantageously changed.

Finally, in some instances, utilizing the above-referred shredder apparatus within the parts separator obviates the need for an air lock assembly in an inlet chute of the parts separator apparatus.

DETAILED DESCRIPTION

Referring to the drawings,FIG. 1illustrates a parts separator apparatus10having an outboard end12and an inboard end14located downstream from end12. End12often is flanged (not shown) and is adapted to be connected to a flange of a conventional mechanical conveyor as, for example, an auger type conveyor. The mechanical conveyor conveys both wet chips to be separated as well as heavy undesired heavy pieces, e.g., bolts, nuts, tools, to parts separator10.

Parts separator10includes a frame assembly comprising a chute member16comprising a first, inlet section18that extends in a first direction from outboard end12and has an inlet opening; a second, outlet section20that extends in the first direction and has an outlet opening; and, a heavy material drop-out opening22that is located in the bottom wall24at the exit end of first chute section18and is positioned contiguous to the first and second sections18,20. A drop-out chute26is positioned below heavy material drop-out opening22.

End14of parts separator10includes flange28, which is illustrated as being connected to the top of a centrifugal separator30, such as is offered for sale by Intersource Recovery Systems, Inc., Kalamazoo, Mich. and is shown in Intersource's catalog entitled “Chip Processing,” copyrighted in 1997 or such as is shown in any one of U.S. Pat. Nos. 4,936,822, 5,252,208, 5,264,124, 5,275,727, 5,944,992, and 6,129,851, all of which are hereby incorporated in their entirety herein. Typically, upon actuation of the centrifugal separator apparatus30, a vacuum or negative air pressure is created within parts separator apparatus10, such that wet chips and other materials entering parts separator10are pulled through the parts separator apparatus into centrifugal separator apparatus30, where the wet chips are centrifugally separated into dry chips and fluid.

Baffle plates32,34are disposed within parts separator apparatus10to assist in directing materials through parts separator apparatus10. Baffle plate36can be mounted for adjustment on the bottom wall24of chute section18. Similarly, baffle plate38can be mounted for adjustment on bottom wall27of drop-out chute26, while baffle plate40can be mounted for adjustment on baffle plate32. Baffle plates36,38,40can be adjustably positioned to either increase or decrease the open area surrounding material drop-out opening22at the exit end of first chute section18, as well as the size of the entrance opening leading into second chute section20.

Heretofore a rotary air seal assembly, such as illustrated in Nemedi U.S. Pat. No. 5,106,487, normally was disposed within the first chute section18of chute member16. The rotary air seal, which comprises a plurality of rotatable paddles, served to act as a seal to some extent and, at the same time, to contact wet chip material to be separated in the first chute section18and to assist the material as it traveled along in the parts separator apparatus10. In the particular embodiment shown herein, the rotary air seal assembly has been replaced by shredder apparatus100disposed within the first section18of chute member16.

Turning toFIGS. 1 and 2, shredder apparatus100comprises housing assembly102that includes base or bottom wall104, front wall106(seeFIG. 4), back or rear wall108and side wall110. Front wall106has a relatively large opening in it. Open top wall114is fixed at top wall ends and top wall sides to the appropriate housing front106, back108and side wall110.

Motor mount wall124extends outward from base wall104. Wall124is substantially parallel to side wall110. A second wall125is spaced from and substantially parallel to wall124. Top wall126, which can be made of either a rigid or flexible material, is removably attached to spaced side walls124,125.

A drive assembly140includes motor142having a shaft144(seeFIG. 1) with a bushing keyed to the shaft144. Screws148,150extend through threaded openings both in motor flange152and wall124. Screws148,150thread into tapped holes in a motor mounting plate which abuts wall124. It has been found that a 460 Volt, three phase, 60 Hz electric motor may be employed. It is appreciated that other size motors could be utilized by one of ordinary skill in the art.

Positioned below motor142is fixed shaft164(see alsoFIG. 1) which is greater in length than the distance between outer sidewall110and side wall125. Elongated shaft164is tapered for a portion at each shaft end166,168. The taper extends inwardly for a discrete distance from each shaft end, and includes a first, outer tier of smaller diameter and a second, inner tier of larger diameter.

As shown inFIG. 3, cylindrical rotor194having an outer surface196and inner surface198is positioned over fixed shaft164. Rotor194is recessed at each rotor end200,202. Two bearings204(which may define a bearing assembly) are sandwiched between shaft164and rotor194, with one bearing disposed on the second tier of shaft164contiguous to shaft end166and one bearing disposed on the second tier of shaft164contiguous to shaft end168. Moreover, first and second seal members206(which may define a seal assembly) are also disposed between shaft164and rotor194, with one seal member being disposed on the first tier of the shaft164at shaft end166and a second seal member being disposed on the first tier of the shaft164at shaft end168. The first and second seal members206may be made of any conventional sealing material such as polyvinyl chloride (PVC) or Buna N, so long as the material aids in providing a seal at the location of the rotor ends.

Faceplate208is bolted at210to sidewall125, while faceplate212is bolted at214to a sidewall110. Shaft end166extends through an opening in faceplate208, and shaft end168extends through an opening in faceplate212. Lock member216is disposed on shaft164at shaft end166and seats against faceplate208. Lock member218is disposed on shaft164at shaft end168and seats against faceplate212. Each lock member216,218is illustrated as being welded to a respective faceplate208,212. If desired, other shaft locking arrangements, for example, a two piece clamp trough, could be employed. Similarly, the shaft ends could be threaded and lock nuts could be utilized in place of the locking arrangement shown in the drawings.

Returning toFIG. 1, a first sprocket222is keyed to motor shaft144. A second sprocket226is bolted at228to sprocket mounting plate230(seeFIG. 2), the latter being welded at232to rotor194at outer rotor surface196. A drive chain234connects sprockets222,226whereupon activation of motor142and the sprocket chain assembly, rotor194rotates on its bearings204. Shaft164is fixed in place and does not rotate. Drive assembly140includes motor142and the sprocket chain assembly, the latter being enclosed by walls124,125, and126.

Referring next toFIGS. 3 and 4, a plurality of spaced shredder wheels250, each wheel including spaced shredder arms252extending outwardly from the wheel (seeFIG. 4), are keyed at different locations to rotor194. As seen inFIG. 4, each shredder arm252has sides256,258formed or grooved inwardly at260to define a concave surface. The shredder wheels250define a shredder assembly.

A plurality of spaced shredder comb members262is mounted or seated on rotor194, and is positioned so that a comb member262is adjacent a shredder wheel250. As seen in the embodiment ofFIG. 4, each comb member262includes base portion264, a first arm266and a second, spaced arm268extending outwardly from base portion264. An opening is formed in base portion264, while a key slot272is formed at the outboard end of comb arm266. Comb arm268preferably is serrated at274along substantially the length of one side276of comb arm268. The shredder comb members262also define a shredder assembly.

Each comb member262is adapted to be inserted on rotor194, and seats on the rotor at the location of a comb member opening; however, the comb members262are free from rotation (i.e., do not rotate) with rotor194. Each comb member262is keyed at the location of slot272to key bracket278, the later being fixed to rear wall108. Accordingly, shredder wheels250rotate relative to fixed adjacent comb members262and together, the shredder wheels250and comb members262cooperate to shred or otherwise cut wet chip material passing through shredder apparatus100.

Spacers, in the form of washer-like members280, are disposed on rotor194and positioned between adjacent shredder wheels250and comb members262. The spacers280serve to space the shredder wheels250and comb members262apart so that, should any vertical misalignment of a shredder wheel250occur, the spacer280will preclude contact with another shredder wheel250or comb member262.

Compression spring assembly282formed of compression spring284and spring plate286is positioned against the outboard surface of comb member262located near one end of rotor194. Compression spring assembly288formed of compression spring290and spring plate292is positioned against the outboard surface of comb member262near the opposite rotor end.

As illustrated inFIG. 4, during the operation of the embodiment of shredder apparatus100, wet chip materials to be shredded, comprising materials such as granular wet chips, stringy wet chips, unwanted solids (such as bolts, nuts, etc.), and lubricating, cooling, flume or other fluid, are delivered to an opening in the front wall106of shredder apparatus100. The wet chip material moves into the shredder apparatus100traveling in the direction shown by the arrow “A”.

Upon actuation of drive assembly140, rotor194rotates and travels in a direction, represented by an arrow “B”, that is the same direction as the direction of the wet chip material travel. As the wet chip material passes into shredder apparatus100, shredder arms252engage the wet chip materials and direct at least the stringy wet chips toward a shredding station disposed at comb arm268. Comb arms268and shredder arms252cooperate to shred the wet chips. As rotor194continues to rotate, shredded wet chips drop onto bottom wall104and pass toward and over drop-out opening22. The shredded wet chips, now reduced to a desired size, then can be processed out of shredder apparatus100.

In the event that a heavy, unwanted solid enters shredder apparatus100, the solid travels in chute section18to the shredder station disposed at the comb arm268. Inasmuch as shredder apparatus100cannot shred the unwanted solid, an increase in the motor amperage occurs, whereupon motor142stops and changes direction of rotation. With the change in the direction of rotation of the motor142(and in particular motor shaft144), rotor194will change its direction of rotation, and shredder wheels250, fixed to the rotor194, will then rotate in the direction indicated by arrow “C”. As the shredder wheels250rotate in the direction of arrow “C”, the unwanted solid will be carried on one or more surfaces260on the shredder arm252, and transported in the direction of arrow “C.” The unwanted solid may be transported in somewhat of a circular direction until the unwanted solid, for example, drops onto the top of first comb arm266and passes therealong into the drop-out opening22. After rotor194travels in the direction of arrow “C” for a period of time, for example, until at least the unwanted solid passes into the drop-out opening, motor142again changes direction and rotor194travels in the direction of arrow “B”, whereupon shredding of the wet chip material resumes. As a result of this reversible motor operation, the speed of the undesired solid has been reduced and the direction of the solid has been changed, both of which serve to obviate parts separator damage which heretofore sometimes has occurred due to unwanted solids.

In normal operation, centrifugal separator30is first activated whereby the centrifugal separator will achieve its desired speed of operation, causing a negative pressure to be created in parts separator apparatus10during the start-up step. Then shredder apparatus100will be activated and shredding of wet chip material will commence. As the wet chip material is shredded, the negative air pressure will assist in pulling the shredded wet chip material over drop-out opening22. Any unwanted solids that may have escaped the shredding operation will drop out of the system through opening22. The unwanted solids can be collected in an unwanted solid bin or the like. The shredded wet chip material passes on to the centrifugal separator30, where it is centrifugally separated into dry chips and fluid.

In addition to the shredder apparatus serving as a device to shred wet chip material within the parts separator, it has been found that shredder apparatus100may obviate the need for a conventional air seal assembly often utilized in the inlet chute of a parts separator. Further, the velocity of an unwanted solid is changed within the first chute section18as the unwanted solid changes direction as it is directed toward the parts separator drop-out opening when the rotor194reverses its direction upon sensing the unwanted solid.

FIG. 5illustrates a controller system300associated with the embodiment of the shredder apparatus100. The controller system300includes a controller302. When controller302is turned to an “on” position, centrifugal separator apparatus30is actuated and achieves its normal speed of operation. Then the controller302closes forward switch304and actuates motor142, which causes motor shaft144to rotate in the direction of arrow “B”.

Upon contact of an unwanted solid with comb arm268, increased amperage occurs in motor142and is sensed by sensor306. The controller302receives signals from the sensor306representative of the increased amperage, and, in response, turns off motor142and opens forward switch304to a disconnect position. Following a dwell period of, for example, approximately one second, the controller302closes reverse switch308and actuates motor142, causing motor shaft144to rotate in the direction of arrow “C”.

Following a time period during which an unwanted solid is transported to the top of comb arm266, the controller302turns off motor142and opens reverse switch308. Following a dwell period of, for example, approximately one second, the controller closes forward switch304and actuates motor142, whereupon motor shaft144again rotates in the direction of arrow “B” and shredding occurs at the location of shredder arm268.

It is appreciated that while one system300for actuating motor142to permit shaft rotation in the direction of arrows “B” and “C” has been shown, other systems for rotating motor shaft144in the desired directions would be apparent to one of ordinary skill in the art. For example, rather than using the controller302to control the motor142to make motor shaft144rotate in a particular direction for a particular amount of time, the controller may control the motor142to make the motor shaft144rotate in a particular direction for a particular number of revolutions or over a particular angular distance.

Similarly, it is appreciated that a timing switch can be employed to initially actuate the centrifugal separator30and, after the desired time period during which separator30achieves its desired operational speed, shredder apparatus100then can be actuated.

While the bales of stringy wet chips are shredded principally at the shredder stations at the second comb arms268in the illustrated embodiment, shredding can also occur at the location of the first comb arms266during the course of the unwanted solid removal.

While comb arm268has been shown to have a serrated shredding or cutting surface274along side276, it may be that, in some applications, serrations are not required. Accordingly, a person of ordinary skill in the art could select other shapes for the sides276, for example, a smooth surface.

While one or more embodiments have been illustrated and described in detail herein, it will be understood that modifications and variations thereof may be effected without departing from the spirit of the invention and the appended claims.