Abstract:
What is presented is a permanent magnet drum separator for removal of a ferrous fraction from a material stream comprising a pickup magnet that is a rare earth permanent magnet that can be moved within the drum separator. The drum separator comprises a rotatable outer shell having tubular shape with a circular cross section. The drum separator includes a carry magnet that is positioned at a fixed location within the rotatable outer shell near the inside circumference of the rotatable outer shell. The pickup magnet is positioned on a hinge plate within the rotatable outer shell. The hinge plate has a first end attached to a hinge and a second end attached to a movable element. The hinge is positioned at a fixed location within the rotatable outer shell near the inside circumference of said rotatable outer shell. The movable element is able to move the pickup magnet about the hinge to vary the distance between the pickup magnet and the inside circumference of the rotatable outer shell.

Description:
BACKGROUND 
     There are several basic magnetic circuits that are used in magnetic drum separators that include permanent magnets, electromagnets, or a combination of the two types. Each type of magnetic circuit has its own drawbacks and advantages. Electromagnetic elements warm up during operation which reduces their effectiveness over time and further limit the distance over which they can operate. 
     There are also inefficiencies associated with the coil wrapped around a steel core in electromagnets that cannot be avoided which creates areas of lower strength magnetic fields near each end of the rotating drum assembly. In contrast, permanent magnets can be manufactured that take up the entire width of the drum shell giving a more even magnetic field across the entire width of the drum assembly. 
     When electromagnets heat up, they lose typically 30 percent of their ampere turns (ampere turns generate magnetic field). This corresponds to nearly 30 percent of the magnetic field they generate. Permanent magnets are less affected by heat increases than electromagnets. Permanent magnets also do not have the power requirements that electromagnets need to generate magnetic fields. 
     One of the biggest drawbacks with permanent magnets is there is no way to turn them off which makes maintenance, repair, and even routine cleaning difficult if any magnetic metal equipment is used. Therefore permanent magnets with lower strength than are ideal have been used in the past. What is proposed is a system in which stronger permanent magnets can be used in a drum separator such that the permanent magnet elements can be moved away from the surface of the rotating drum element to reduce the strength of the magnetic field as needed for maintenance, repair, and routine cleaning. In addition to making permanent magnet drum separators easier to maintain, making the rare earth permanent magnet pickup magnets moveable within the drum separator also allows the operator to “fine-tune” the strength of the magnetic field to vary the grade of the product stream in the ferrous and the non-ferrous fraction as required for the particular application. 
     SUMMARY 
     What is presented is a permanent magnet drum separator for removal of a ferrous fraction from a material stream comprising a pickup magnet that is a rare earth permanent magnet that can be moved within the drum separator. The drum separator comprises a rotatable outer shell having tubular shape with a circular cross section. The drum separator includes a carry magnet that is positioned at a fixed location within the rotatable outer shell near the inside circumference of the rotatable outer shell. The pickup magnet is positioned on a hinge plate within the rotatable outer shell. The hinge plate has a first end attached to a hinge and a second end attached to a movable element. The hinge is positioned at a fixed location within the rotatable outer shell near the inside circumference of said rotatable outer shell. The movable element enables the pickup magnet to move about the hinge to vary the distance between the pickup magnet and the inside circumference of the rotatable outer shell. 
     The pickup magnet can be built with rare earth magnets having energy products between 35 MGOe and 42 MGOe. More than one array of pickup magnets could be arranged in series on the hinge plate. The movable element may be hydraulically or electrically actuated cylinders. 
     Those skilled in the art will realize that this invention is capable of embodiments that are different from those shown and that details of the devices and methods can be changed in various manners without departing from the scope of this invention. Accordingly, the drawings and descriptions are to be regarded as including such equivalent embodiments as do not depart from the spirit and scope of this invention. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       For a more complete understanding and appreciation of this invention, and its many advantages, reference will be made to the following detailed description taken in conjunction with the accompanying drawings. 
         FIG. 1  depicts a close-up depicting a drum separator in operation; 
         FIG. 2  is a cut-out view of the outer shell of the drum separator of  FIG. 1  showing the cylinders in the fully extended position; 
         FIG. 3  shows the drum separator of  FIG. 1  with the cylinders in the fully retracted position; 
         FIG. 4  is a perspective view of the inner mechanisms of the drum separator of  FIG. 1  showing the cylinders in the fully extended position; 
         FIG. 5  is a perspective view of the inner mechanisms of the drum separator of  FIG. 1  showing the cylinders in the fully retracted position; 
         FIG. 6  is a different perspective view of the inner mechanisms of the drum separator of  FIG. 1  showing the cylinders in the fully extended position; 
         FIG. 7  is a perspective view of the inner mechanisms of the drum separator of  FIG. 1  showing the cylinders in the fully retracted position; and 
         FIG. 8  depicts an embodiment of drum separator in which two drum separators are used in series. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to the drawings, some of the reference numerals are used to designate the same or corresponding parts through several of the embodiments and figures shown and described. Corresponding parts are denoted in different embodiments with the addition of lowercase letters. Variations of corresponding parts in form or function that are depicted in the figures are described. It will be understood that variations in the embodiments can generally be interchanged without deviating from the invention. 
     Drum separators are used to remove the ferrous fraction from a material stream in recycling, municipal solid waste, wood waste, slag, incinerator bottom ash, foundry sand, and in mineral processing applications. As shown in  FIG. 1 , the drum separator  10  according to one embodiment of this invention consists of an outer shell  12  that is rotated by a drive mechanism (not shown) in the direction indicated in the figure around a number of magnetic elements that are housed within the outer shell  12 . As shown in  FIG. 2 , the magnetic elements include at least one pickup magnet  14  and at least one carry magnet  16 . 
     As can be best understood by comparing  FIGS. 1 and 2 , the material stream  18  to be sorted comprises a mixture of ferrous  20  and non-ferrous  22  materials. The material stream  18  is passed under the drum separator  10  using any appropriate first transfer system  24  such as conveyors, chutes, vibrators, etc. while the outer shell  12  is rotated. The ferrous  20  fraction is magnetically attracted to the pickup magnet  14  relatively under the drum separator  10  and becomes magnetically attached to the surface of the outer shell  12 . The non-ferrous  22  fraction of the material stream  18  that is not attracted to the outer shell  12  falls off the first transfer system  24  into a chute  26  or other means for disposal or further processing. 
     The outer shell  12  has a series of cleats  28  that assist the movement of the ferrous  20  material along the rotation axis of the drum separator  10 . As the outer shell  12  rotates, the ferrous  20  material passes from the magnetic field generated by the pickup magnet  14  to the magnetic fields of the carry magnet  16 . A bucking or interpole magnet (not shown) can be interposed between the pickup magnet  14  and the carry magnet  16  to reduce, if not eliminate, instances in which material falls away from the outer shell  12  during the transfer from the pickup magnet  14  to the carry magnet  16 . The rotating outer shell  12  carries the ferrous  20  fraction around past the carry magnets  16  to discharge onto any appropriate second transfer system  30  such as conveyors, chutes, vibrators, etc. as demanded by the specific application for disposal or further processing. 
     The pickup magnet  14  and the carry magnet  16  are permanent magnets and may be single magnets or stacks of magnets arranged to form a desired configuration. The pickup magnets  14  are rare earth magnets and the carry magnet  16  may be ceramic or ferrite magnets. Ceramic and ferrite magnets have energy products of about 3.5 MGOe (mega gauss oersteds). The rare earth magnets used for the pickup magnets  14  have are at least 35 MGOe to about 42 MGOe. The pickup magnets  14  and carry magnets  16  are sized and arrayed to stretch across the width of the outer shell  12 . The embodiments shown in the figures show drum separators  10  in which there are two arrays of pickup magnets  14  and three arrays of carry magnets  16 , but it will be understood that the number of arrays of pickup magnets  14  and carry magnets  16  can vary depending on the application. One array of pickup magnets  14  would be able to provide separation. More than two arrays of pickup magnets  14  could also be used if constructed to fit within the allowable space within the outer shell  12 . The number of arrays of carry magnets  16  can similarly be varied depending on the application. 
     In the prior art, the pickup magnets  14  tended to be electromagnets. Electromagnets are created by wrapping a conductive coil around a rectangular steel core and passing an electrical charge through the coil which generates a corresponding magnetic field. The strength of the magnetic field varies with the amount of current passed through the coil. Electromagnets suffer from a number of drawbacks. Firstly, passing an electric current through the coil generates heat in the coil. The heat builds up over time and increases the electrical resistance in the coil which reduces the ampere turns of the coil (the amount of current that can pass through the coil) and decreases the strength of the magnetic field. Over the course of a day&#39;s use, the drop off in ampere turns in the coil could be in the range 60-70% of what it was when the electromagnet is first turned on cold. The drop in field strength roughly parallels the drop in ampere turns. Force index is a value that can be both measured and used to predict the resulting separation. Force index is the magnetic field strength, gauss, (B), times the gradient, (dB/dx), at that point in units of B 2 /inch. A linear change in ampere turns in the coil results in a non-linear change in force. At a 70 percent value of original field strength the value of the force index is about 49 percent of the original force index. 
     Secondly, because electromagnetic coils must occupy a certain amount of space, the rectangular core of electromagnets cannot be as wide as the outer shell  12 . Various techniques are used to widen the magnetic effect of a narrow core in electromagnetic drum separators, but the issue persists in that ferrous objects are missed at the outer edges of the drum. 
     Thirdly, transfer of ferrous objects from electromagnetic pickup magnets  14  and the permanent magnet carry magnets  16  can be difficult. The magnetic geometry is such that an area of low force is seen at the transfer point between the electromagnetic pickup magnets  14  and the permanent magnet carry magnets  16 . Objects are frequently dropped. While these may be picked up again by the electromagnet, this contributes to a higher average loading on the outer shell  12  as the dropped materials are picked up again. This adds to the wear on outer shell  12  shortening its life and increasing maintenance costs. 
     To address these concerns, pickup magnets  14  comprising rare earth magnets have been developed. Because rare earth magnets are permanent magnets, they always generate a more or less constant magnetic field that does not vary significantly over the course of a work day. Rare earth permanent magnets can be sized to make the most use of the width of the outer shell  12 . Drum separators  10  in which both the pickup magnets  14  and the carry magnets  16  are permanent magnets have a smoother transfer of ferrous materials between the rare earth pickup magnet  14  and the lower strength ceramic or ferrite carry magnets  16 . 
     Rare earth permanent magnets were not used for pickup magnets  14  because the size of the magnets required and the strength of rare earth magnets makes them expensive and very strong. The strength of rare earth magnets make rare earth pick up magnets  14  quite dangerous to construct around and handle. Furthermore, as rare earth magnets cannot be turned off, there was no practical way to easily remove material attached to the drum separator  10  in case the rotating outer shell  12  was jammed. Required maintenance can also be difficult if metal equipment is required to make repairs. In order to reduce the magnetic field strength of the rare earth magnets near the surface of the outer shell  12 , the pickup magnets  14  are mounted to a hinge plate  32 . One end of the hinge plate  32  is connected to hydraulically or electrically actuated cylinders  34 , as shown in  FIGS. 2-7 . The other end of the hinge plate  32  is mounted to a hinge  36 . The hinge plate  32  is rotatable about the hinge  36 . 
     When the drum separator  10  is in operation, the cylinders  34  are fully extended to position the pickup magnets  14  close to outer shell  12 . This position maximizes the strength of the magnetic field at the outer surface of the outer shell  12 . When the cylinders  34  are fully retracted, as shown in  FIGS. 3 ,  5 , and  6 , the hinge plate  32  is pulled towards the center of the drum separator  10  which pulls the pickup magnets  14  away from the outer shell  12 . This reduces the strength of the magnetic field at the outer surface of the outer shell  12 . Generally with the pickup magnets  14  in the retracted position the strength of the magnetic field in the area influenced by the pickup magnet  14  would be reduced to be around that of ceramic or ferrite magnets. While this still a fairly strong magnetic field, it is an order of magnitude less than when the pickup magnets  14  are positioned closer to the inner circumference of the outer shell  12 . The position of the cylinders  34  could be set to vary the strength of magnetic field at the outer surface of the outer shell  12  if particular applications require magnetic fields of greater or lesser strength. 
     Mounting the pickup magnets  14  to a movable hinge plate  32  not only allows for easier maintenance activities on the drum separator  10 , but also provides the operator with the option of fine tuning the separation of the material stream  18 . When the pickup magnets  14  are fully extended, the magnetic field extending from the outer shell  12  is at its strongest and the drum separator  10  will capture more of the ferrous fraction  20  from the material stream  18 . In addition, stronger magnetic fields are more likely to pick up that fraction of the material stream  18  that is a conglomeration of ferrous and non-ferrous materials that may be missed with lower strength magnetic fields. If the drum separator  10  is in operation with the pickup magnets  14  fully retracted, the magnetic field extending from the outer shell  12  would be at its weakest and therefore more of the ferrous fraction  20  would likely pass with the non-ferrous fraction  22 . By adjusting the position of the pickup magnets  14 , the operator can “fine tune” the strength of the magnetic field to vary the grade of the product stream in the ferrous and the non-ferrous fraction as required for the particular application. 
       FIGS. 4-7  show various views of the internal workings of the drum separator at different angles in which the pickup magnets  14  are variously in the fully extended and the fully retracted positions. Other movable elements could be used to position the hinge plate  32  in the drum separator  10  instead of the cylinders  34  shown in the figures. Pulleys, chains, etc. would work just as well. 
       FIG. 8  shows an embodiment of drum separator  10   a  in which two drum separators  10   a  are placed in series. In this instance, the transfer systems used to move the material stream to and from each drum separator  10   a  are a series of vibrating chutes  24   a ,  30   a ,  36   a . The non-ferrous material from the material stream that is not attracted to the drum separators  10   a  drop into a chute  26   a  for disposal or further processing. In this embodiment, the first drum separator  10   a  does an initial screening of the material stream for ferrous materials which may inadvertently catch non-ferrous material. The second drum separator  10   a  is used to clean up the material stream further for a better sorted product. 
     This invention has been described with reference to several preferred embodiments. Many modifications and alterations will occur to others upon reading and understanding the preceding specification. It is intended that the invention be construed as including all such alterations and modifications in so far as they come within the scope of the appended claims or the equivalents of these claims.