Abstract:
A suspended automobile disassembly line that does not utilize any hydraulically operated equipment is provided. The disassembly line utilizes a plurality of electrically operated lift system to stabilize and suspend an automobile while at various stages of disassembly. Since the automobile is suspended throughout the disassembly line, human handling is reduced and efficiency of the disassembly process is improved. The lift system includes a plurality of grabber arms that provide a wide range of motion adapted to move and tilt a vehicle into various positions during disassembly.

Description:
RELATED APPLICATIONS 
       [0001]    This application is a divisional of U.S. patent application Ser. No. 11/058,404, filed on Feb. 14, 2005, which claims the benefit of U.S. Provisional Patent Application No. 60/544,613, filed on Feb. 13, 2004, both of which are incorporated by reference in their entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates generally to a method and apparatus for dismantling automobiles, and more particularly, to a suspended automobile disassembly line adapted to dismantle automobiles and recover recyclable part and materials. 
         [0004]    2. Description of the Related Art 
         [0005]    Scrapped automobiles are typically disassembled for recycling and salvage of various parts. After the reusable parts are removed from the automobile, the remaining parts are crushed and pressed as iron scrap. In a typical disassembly process, an auto dismantler removes battery, tires, oils and other fluids and hazardous materials from the car before sending the hulk of the car to a crusher such as glass, plastics, rubber, carpet which can end up in landfills as fluff or crushed residue. 
         [0006]    In a conventional scrap yard, the disassembly process typically takes place while the car remains in one area and often involves a very inefficient and disorganized process. Moreover, the dismantling activities are usually very labor intensive and messy. Additionally, vehicle fluid leakage from the dismantled cars often create a hazardous working condition and is one of the primary causes of accidents in scrap yards. In some cases when fluids are not completely removed from the car, leakage can also occur when the vehicle is tilted or lifted. 
         [0007]    Various automobile disassembly lines have been developed to stream line the disassembly process and address some of the above-described problems associated with the conventional dismantling operations. For example, U.S. Pat. No. 5,335,406 discloses a dismantling line which includes a device for rotating the automobile so as to facilitate removal of parts located on the bottom of the vehicle. However, this system requires the use of complicated, hydraulically operated equipment, which can create various maintenance and safety issues. Similarly, U.S. Pat. No. 6,594,877 provides a dismantling line that is focused on increasing the percentage of parts recycled but requires the use of complex hydraulic devices, which can increase the maintenance cost. U.S. Pat. No. 4,037,302 discloses a disassembly line that utilizes a conveyor belt for transporting vehicles while sequentially removing selected used parts. However, the conveyor belt is not designed to provide adequate access to the bottom of the vehicle. 
         [0008]    Hence, in view of the foregoing, it will be appreciated that there is a need for an improved automobile disassembly system and process. To this end, there is a particular need for an automobile disassembly line that improves process efficiency and safety, reduces human handling of the car and required equipment maintenance. 
       SUMMARY OF THE INVENTION 
       [0009]    In one aspect, the preferred embodiments of the present invention provide an automobile disassembly line. The disassembly generally includes a lift system configured to keep an automobile in a suspended position while the automobile is being disassembled. In one embodiment, the lift system is capable of stabilizing the automobile and tilting the automobile to its side so as to expose its lower side for parts to be removed therefrom. The lift system preferably comprises a plurality of grabber arm assemblies. The disassembly line further includes a track adapted to move the grabber arm assemblies down the disassembly line and a plurality of stations wherein each station is configured for removal of one or more parts of the automobile. In one embodiment, the grabber arms are configured to keep the automobile suspended throughout the entire disassembly line and can be operated by a gear assembly. In another embodiment, the entire disassembly line is electrically operated. In yet another embodiment, the weight of the disassembled parts and/or car removed at various stages of the disassembly is monitored and recorded. 
         [0010]    In another aspect, the preferred embodiments of the present invention provide a method of disassembling automobiles. The method comprises positioning an automobile to be assembled in a suspended position, moving the automobile to a first station, removing selected parts from the automobile at the first station, weighing the automobile after the selected parts are removed, recording the weight of the automobile, and moving the automobile to a second station. In one embodiment, the method further comprises tilting the automobile at the second station such that the parts can be removed from the underside of the automobile. In certain embodiments, the fuel and fluids in the car are drained before the car is tilted. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  is a schematic illustration of an automobile disassembly system of one preferred embodiment of the present invention; 
           [0012]      FIG. 1A  shows an automobile at the entrance of the disassembly line having its tires and doors removed; 
           [0013]      FIGS. 2A and 2B  are detailed schematic illustrations of the first set of grabber arms of the automobile disassembly system of  FIG. 1 ; 
           [0014]      FIG. 3  is a detailed schematic illustration of the second set of grabber arms of the automobile disassembly system of  FIG. 1 ; 
           [0015]      FIG. 4  provides schematic illustrations of some of the ranges of motion of the grabber arms of the automobile disassembly system of  FIG. 1 ; 
           [0016]      FIG. 5  is a schematic illustration of a cross sectional view of the track system of the automobile disassembly system of  FIG. 1  used in conjunction with the second set of grabber arms; 
           [0017]      FIGS. 5A-D  are schematic illustrations of a grabber arm assembly of one embodiment interconnected to a track system; 
           [0018]      FIG. 6  is a schematic illustration of a cross sectional view of the track system of the automobile disassembly system of  FIG. 1  used in conjunction with the first set of the grabber arms; 
           [0019]      FIGS. 6A-B  are schematic illustrations of a grabber arm assembly of another embodiment interconnected to a track system; 
           [0020]      FIGS. 7A-B  are schematic illustrations of portions of an automobile disassembly process of one embodiment of the present invention; and 
           [0021]      FIGS. 8A-B  are schematic illustrations of the disassembly line of one preferred embodiment and the manner in which the automobiles can be maintained in a tilted position for disassembly. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0022]    The aforementioned needs are satisfied by certain preferred embodiments of the present invention, which provide an automobile disassembly process and system that is efficient, low maintenance, safe to operate, and designed to increase recycle rate of automobiles. 
         [0023]      FIG. 1  is a schematic illustration of a preferred system and process  100  for dismantling a vehicle and collecting recyclable parts therefrom. As shown in  FIG. 1 , the system  100  generally includes an elongated, overhead track system  108  and a plurality of grabber arms  106 ,  116  coupled thereto. As will be described in greater detail below, the grabber arms  106 ,  116  and track system  108  are configured such that an arm can travel from a starting point of the track system to an end point and then rotate back to the starting point without obstructing the movement of other arms. The disassembly line  100  also includes a plurality of stations, each having functions and features to be described in greater detail below. In some embodiments, a grating system extends across the floor space below the track system  108  so that fluids can flow past the grates and into drainage systems underneath in case of leakage. This reduces pools of fluid from forming on the floor and creating an unsafe condition. 
         [0024]    As shown in  FIG. 1 , the vehicle to be disassembled is first moved to a prep station  102  positioned near the entrance to the disassembly line  100 . The vehicle can be moved to the prep station  102  via a transporting device such as a trolley  104  with load cell as shown in  FIG. 1 . Preferably, the doors, tires, wheels, and seats of the vehicle are removed from the vehicle while it is on the trolley  104   a  as shown in  FIG. 1A . In one embodiment, the removed parts can be separated into groups and stacked at designated locations adjacent the prep station  102  for pick-up and transporting to storage, etc. Once the vehicle is in position at the prep station  102 , the vehicle is lifted off the ground and suspended via a set of grabber arms  106 ,  116  movably mounted on the overhead track  108 , which will be described in greater detail below. Preferably, one has the choice of selecting the first  106  or second set of grabber arms  116 , depending on the condition and dimensions of the vehicle. For example, the first set of grabber arms  106  is generally shorter than the second set  116  and is thus designed to pick up vehicles by the roof instead of by the lower edges of the chassis. The shorter arms  106  are particularly suitable for vehicles having crushed doors or side panels, or vehicles that would be difficult to pick up by the lower edges of the chassis because of a wrecked frame. The longer arms  116  are more suitable for vehicles without damaged sides and that can be picked up by the lower edges of the chassis. As will be described in greater detail below, the set of grabber arms can be adjusted to suspend the vehicle at a height that would allow a person to work on or remove parts from the vehicle without bending. 
         [0025]    The vehicle is moved by the grabber arms along the overhead track  108  to a fluid removal station  110 , at which point various fluids such as fuel, oil, coolant are extracted from the vehicle and drained into different collection containers  112 . In one embodiment, the floor of the fluid removal station and the entire disassembly line is grated such that fluids can drain to a drainage system positioned below, which reduces spills and dangers of slip and fall in case of fluid leakage. Furthermore, waste oil dripped into the drainage system can be collected and used to provide heat or generate power for the disassembly line. 
         [0026]    After the fluids are removed, the vehicle is tilted to its side for removal of the undercarriage parts such as mufflers, fuel tanks, etc. The vehicle is then moved along the overhead track  108  to a pre-drive train removal station  114 , at which point pre-drive train removal procedures are performed, which preferably include unplugging wires in preparation of drive train removal. After the pre-drive train removal step is complete, the vehicle is subsequently moved to a drive train removal station  118 , at which point the drive train of the vehicle is removed. In one embodiment, the removed drive train is placed on a conveyor system  120  extending from adjacent the vehicle to the sides of the disassembly line. The conveyor system reduces the likelihood of injury resulting from one trying to lift or carry the parts. Preferably, the conveyor system  120  is adapted to transport the heavy and cumbersome drive trains from the vehicle to locations where they can be picked up and transported by a fork truck. 
         [0027]    As  FIG. 1  further shows, the suspended vehicle is subsequently moved along the overhead conveyor  108  to a precutting station  122 , at which point carpets, plastics, rubber, and other flammables are removed from the vehicle. Again, the removed parts can be separated into different groups based on their condition and usage. After the precutting station, the vehicle is then moved to a cutting station  124 , at which point the vehicle is cut into sections in a known manner. In one embodiment, the vehicle is cut in a manner such that the front and rear fenders are separated from the rest of the body. Preferably, fenders that are not damaged are separated from those that will be salvaged as scrap metal. In certain embodiments, the vehicle is cut by automated saws that can be operated at a distance, such as from the side of the disassembly line. Preferably, a person can stand at a distance from the vehicle and maneuver robotic arms to cut the car, which is a safer procedure. In one embodiment, a special cutting saw is used, in which the saw is preferably counter balanced with an extended arm and a water sprinkler or mister attached. 
         [0028]    After cutting, the suspended vehicle is moved to a pre-bailer prep station  126  at which point the remaining rubber, glass and plastics are removed from the vehicle so as to substantially minimize residue of these substances during the crushing process. In one embodiment, a rubber crumb machine is positioned at the precutting station to process the removed rubber. Following the pre-bailer prep station  126 , the vehicle is moved to a crushing station  130  at which point the remaining chassis of the vehicle is substantially clean and free of all rubber and glass parts, and other residue parts before it is pressed together in a crusher for compact handling. As  FIG. 1  further shows, air and vacuum hoses  134  are positioned throughout the disassembly line  100  so that they can be conveniently accessed. It will be appreciated that the height of the suspended vehicle can be adjusted and fine tuned at each station by adjusting the grabber arms in a manner to be described in greater detail below. 
         [0029]    In certain embodiments, the system  100  further includes a water recycling system  132  in which water used in the steam washer is recycled for repeated use. In certain other embodiments, the type and quantity of removed parts from each vehicle can be entered into computer terminals positioned adjacent the disassembly line. The computers are preferably equipped with software programs capable of comparing the actual removed quantity with the expected weight of recyclable material provided by each car manufacturer. In one embodiment, the software can report, store and save scrapped vehicle data per weight per material. 
         [0030]      FIG. 2A  is a detailed schematic illustration of the first set of grabber arms  106 , which in certain preferred embodiments is the shorter set adapted to lift vehicles with crushed doors or other damages that would require the grabbers to engage with the upper roof area as opposed to the lower chassis. As shown in  FIG. 2A , the grabber arms  106  comprise two elongated arms  200   a,    200   b  extending from a common base  202 . Each arm  200   a,    200   b  has an upper portion  204   a,    204   b  and a lower portion  206   a,    206   b  connected together by a joint  208   a,    208   b.  The lower portion  206   a,    206   b  of the arm  200   a,    200   b  can be pivoted around the joint  208   a,    208   b  relative to its respective upper portions  204   a,    204   b  while the upper portion  204   a,    204   b  of each arm is pivotable relative to the base  202 . These concurrent pivot actions allow the grabber arms to pick up and lift a vehicle off the ground in a similar manner as human arms pick up items. As described above, the first set of grabber arms  106  are generally shorter than the second set and is configured to lift the vehicle by grabbing the edge of the vehicle roof. As will be described in greater detail below, the base  202  of the grabber arms  106  is movably mounted to the overhead track via connecting beams  210  extending between the base  202  and the overhead track  108 . 
         [0031]      FIG. 2B  shows the manner in which the lower portion  206   a,    206   b  of each grabber arm pivots relative to the upper portion  204   a,    204   b  while the upper portions pivot relative to the base as the grabber arms pick up a vehicle  208  by its roof. To fine tune the height of the vehicle, fine adjustments can be made to the grabber arms so that the angle between the lower and upper portions changes slightly. In one embodiment, the smallest increment of the degree of change of the angle between the lower and upper portions of each arm is about 0.1 degrees. 
         [0032]      FIG. 3  provides a detailed schematic illustration of the second set of grabber arms  116 . As shown in  FIG. 3 , the grabber arms  116  comprise a plurality of arms  300   a,    300   b  each extending from a respective base  302   a,    302   b.  The bases  302   a,    302   b  are movably mounted in parallel tracks as shown in  FIG. 3 . Similar to the first set of arms, each arm  300   a,    300   b  has a lower portion that is pivotable relative to the upper portion about a joint  308   a,    308   b  and each upper portion is pivotable relative to its respective base. The second set of arms are generally longer than the first set and is adapted to lift cars by the lower edge of the chassis as shown in  FIG. 3 . As will be described in greater detail below, the base of each arm is removably mounted to a respective track with the tracks extending parallel to each other. Moreover, the longer arms provide a larger range of movement and can accommodate cars of various dimensions. 
         [0033]      FIG. 4  provides schematic illustrations of the range of motion the grabber arms of one preferred embodiment are capable of performing. Preferably, the grabber arms are electrically operated such that all lifting motions of the vehicle are gear driven and powered by electricity and no hydraulic systems are required, which can substantially reduce leaks and other maintenance problems associated with hydraulic systems. In one embodiment, safety motion sensors are located on each set of arms to stop operation of the arm if linear motion is sensed within a predetermined distance, which further improves safety. In one embodiment, the sensor can use a laser beam to detect motion. As such, the suspended vehicle would be unlikely to move into the next station when there is an interruption in the laser beam such as by a person or another vehicle. 
         [0034]    As shown in  FIG. 4 , the upper and lower portions of each arm may be tilted at the base and/or joints. As such, the arms are capable of making panning motions, which can place the vehicle in various positions to facilitate the disassembly process. In one embodiment, cameras are mounted on the arms to assist viewing and adjustment of the arms at a remote location. Preferably, the arms can be adjusted at a remote location via a joystick controller, PC or the like. In another embodiment, control and adjustment of the arms can be automatically accomplished by integrating the camera with software and controllers that can adjustment the positions of the arms based on pre-programmed parameters and data collected from the camera. 
         [0035]    In another embodiment, the arms are connected to weight scales adapted to measure the weight of the vehicle being suspended by the arms. Preferably, the weight of the vehicle is constantly monitored and reported to a data base. As such, one would be capable of obtaining accurate weight data of the vehicle from point of entry to the end of the disassembly line. Moreover, disassembling product weight data can be readily obtained at each stage of the disassembly process and the system can be set up to correlate the weight of a vehicle at each station and with the type of material that is being removed at each station. 
         [0036]      FIG. 5  is a partial schematic illustration of a cross sectional view of the track system working in conjunction with the second set of the grabber arms  116 . As shown in  FIG. 5 , the track system  108  generally comprises four substantially parallel tracks  500   a - d,  with each track adapted to receive the base of a grabber arm. The two inner tracks  500   b,    500   c  are configured for the grabber arms holding the vehicle to move from the entry point of the disassembly line to the end. The two outer tracks  500   a,    500   d  are configured for the grabber arms to move back to the entrance of the line once the vehicle has been moved to the end of the disassembly line and dismounted from the arms. This track system allows the grabber arms to continuously circulate through the system as additional cars are moved down the disassembly line. 
         [0037]      FIGS. 5A-5D  are partial schematic illustrations of one embodiment of a grabber arm assembly  700  working in conjunction with a track system  704 . The grabber arm assembly  700  illustrated is for the second set of grabber arms described above, which are generally longer and adapted to engage with a vehicle at the lower end of the chassis. As shown in  FIG. 5A , the assembly  700  generally includes a pair of parallel elongated arms  702  extending downwardly from the track  704 . A pair of grabbers  706  are positioned at a lower end of each arm  702 . The assembly  700  further includes gear assemblies  708   a - c  positioned at joint locations on each arm  702  and can be activated to move the arms  702  and grabbers  706  in a known manner. In one embodiment as shown in  FIG. 5A , each gear is interconnected to both arms  702  so that the motion of the two arms in lifting a vehicle is synchronized and/or can be moved simultaneously. In other embodiments, the system  700  further includes gear boxes containing circuits  710  used to cause the gears  708   a - c  to rotate in different directions and speeds in manners known in the art so as to allow the arm various ranges of motion. 
         [0038]      FIG. 5B  illustrates an upper side view of the grabber arm assembly  700  and the manner in which it is operatively interconnected to the track system  704 . As shown in  FIG. 5B , the track system  704  generally includes an I-beam having a rotating screw assembly  722  extending along its length therein. Preferably, the rotating screw assembly  722  is activated by a motor and is in constant rotation. As  FIG. 5B  also shows, a supporting rod  712  having a wheel  714  on each end is connected to the upper ends of the grabber arms  702 . The wheels  714  in turn are movably positioned inside grooves  718  formed in the track system  704 . The grabber arm assembly  700  further includes a hinged arm hanger  720  which is connected to the grabber arms  702  and can be pivoted to contact the screw jack  722  extending along the track  700 . As will be described in greater detail below, the rotating screw jack  722  can move the hinged arm hanger  700  forward along the track  700 . The hinged arm hanger  720  being connected to the grabber arm assembly  700  will in turn move the grabber arm assembly down the track. 
         [0039]    When the grabber arm assembly  700  has reached a selected station, the hinged arm hanger  720  is programmed to retract away from the rotating screw jack  722  as shown in  FIG. 5C  so that the grabber arm assembly will stop its linear motion and remain stationary at the particular station. Preferably, once the hinged arm hanger  720  is retracted from the rotating screw jack  722 , gears are electrically activated to control the lifting movement of the grabber arms  702 . As shown in  FIG. 5C , a plurality of elongated gears  724 ,  726  are positioned below the track  704  and can be activated by a motor. Once activated, the gears  724 ,  726  can in turn activate the gears in the grabber arm assembly  700  in manners known in the art to enable the arms various ranges of motion to perform various lifting functions. Preferably, the gears operating the grabber arm assembly  700  can be activated only when the hinged arm hanger  720  is not in contact with the rotating screw jack  722 . 
         [0040]      FIG. 6  is a partial schematic illustration of a cross sectional view of the track system working in conjunction with the first set of the grabber arms  106 . As shown in  FIG. 6 , the base  202  of the grabber arm  106  is mounted on the connecting bar  210  which extends between the two inner tracks  500   b,    500   c.  The end portions  600   a,    600   b  of the connecting bar  210  are received in a respective track  500   b,    500   c  such that the bar  210  can move through the tracks, thereby moving the grabber arms  106  as well. When the grabber arm assembly has reached the end of the disassembly line, a spinning mechanical arm is preferably used to push the grabber arm around and back through an adjacent track. 
         [0041]      FIGS. 6A-6B  are partial schematic illustrations of another embodiment of a grabber arm assembly  800 , which is for the first set of grabber arms and shows the manner in which the first set of grabber arms  106  work in conjunction with the track system  500   b,    500   c.  As shown in  FIG. 6A , parallel channels  806  are formed on an upper surface of the track system  500   b,    500   c.  The grabber arm assembly  800  is supported by the tracks  500   b,    500   c  via a rod  802  that is attached to the grabber arm assembly  800  and connected to a plurality of wheels  804  that are received in the channels  806 . Movement of the first set of grabber arms are controlled by gears and rotating screw jack similar to that described above for the second set of grabber arms. Additionally, the weight of the grabber arm assembly  800  is preferably supported by the track system  500   b,    500   c  via the wheels. 
         [0042]      FIGS. 7A-7B  show the manner in which the second set of grabber arms (longer) can be maneuvered by gears to lift a vehicle off of a trolley at the beginning of the disassembly line.  FIGS. 8A and 8B  illustrate the manner in which the grabber arms can be used to keep the vehicle suspended throughout the entire disassembly line in certain preferred embodiments. As shown in  FIG. 8B , the grabber arms can also be maneuvered to tilt a vehicle to the side so that parts on the bottom of the vehicle can be worked on without having to remove the vehicle from the grabber arm assembly. 
         [0043]    Advantageously, the disassembly system and process of the preferred embodiments provide a safe, clean and efficient way to disassemble an automobile and collect recyclable parts. In particular, the system utilizes a novel lifting system that provides a wide range of motion. Moreover, once the vehicle is suspended by the grabber arms, it is moved through the disassembly line without requiring much human handling. The vehicles are suspended at all times and the height of the vehicle can be automatically adjusted to a desired level for particular dismantling operations. Moreover, the weight of the crushed car is reduced with more components effectively removed, which in turn reduces the transportation cost of the crushed chassis and amount of fluff or residue to land fill. Furthermore, it is a centralized indoor environment that is laid out to be motion efficient. In certain implementations, this system is generally suitable for all robotic removal of parts. 
         [0044]    Although the foregoing description of the preferred embodiment of the present invention has shown, described and pointed out the fundamental novel features of the invention, it will be understood that various omissions, substitutions, and changes in the form of the detail of the apparatus as illustrated as well as the uses thereof, may be made by those skilled in the art, without departing from the spirit of the invention. Consequently, the scope of the invention should not be limited to the foregoing discussions.