Patent Publication Number: US-9427745-B2

Title: Material processing apparatus with multi-mode feed conveyor assembly

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to Application No. 1302576.2, filed on 14 Feb. 2013 in the United Kingdom, the contents of which are hereby incorporated by reference in their entirety for all purposes. 
     FIELD OF THE INVENTION 
     The present invention relates to feed conveyors and feed conveyor assemblies for material processing apparatus, particularly aggregate processing apparatus. The invention relates particularly but not exclusively to feed and pre-screening assemblies for material crushing apparatus. 
     BACKGROUND TO THE INVENTION 
     International PCT patent application WO 2008/129287 discloses a crushing machine with a feed conveyor that is movable to accommodate normal and bypass feeding modes as well as a transport mode. One disadvantage with this machine is an inefficient use of space having the effect of increasing the overall size of the machine. 
     It would be desirable to provide an improved material processing apparatus. 
     SUMMARY OF THE INVENTION 
     A material processing apparatus comprising: a base; a first material processing unit mounted on the base; a feed conveyor movable between a first state in which the feed conveyor is positioned to feed material to said first processing unit, and a second state in which the feed conveyor is retracted from said first processing unit relative to said first state; and a second material processing unit mounted on the base and movable between a deployed state and a stowed state, wherein when said feed conveyor is in said second state and said second material processing unit is in said deployed state, said feed conveyor is positioned to feed material to said second material processing unit, and wherein when said feed conveyor is in said first state and said second material processing unit is in said stowed state, said second material processing unit is located beneath said feed conveyor. 
     In typical embodiments, when said second material processing apparatus is in said deployed state it is positioned to feed material to said first material processing apparatus. 
     The apparatus may include a feed conveyor assembly comprising said feed conveyor and a support structure for the feed conveyor, said feed conveyor assembly being movable between said first and second states and wherein said feed conveyor is movable with respect to said support structure between an advanced state and a retracted state. The feed conveyor is for example movable between said advanced and retracted states along an axis aligned with the feed direction of said feed conveyor. 
     Typically, when said feed conveyor assembly is in said first state, the feed conveyor is positioned to feed material to said first processing unit when in said advanced state. Also typically, when said feed conveyor assembly is in said second state, the feed conveyor is positioned to feed material to said second processing unit when in said advanced state. 
     In preferred embodiments, said first material processing unit comprises a crusher and said second material processing unit comprises a screening apparatus. 
     Other preferred features are recited in the dependent claims. 
     From another aspect the invention provides a material processing apparatus comprising: a base; a first material processing unit, for example a crusher; a feed conveyor; and a second material processing unit, for example a screening unit, the feed conveyor and the second material processing unit both being movable with respect to the first material processing unit and with respect to each other so that material can be fed into the first material processing unit directly from the feed conveyor, or indirectly from the feed conveyor via the second material processing unit. The second material processing unit can be stored beneath the feed conveyor when not in use. 
     Further advantageous aspects of the invention will become apparent to those ordinarily skilled in the art upon review of the following description of a preferred embodiment and with reference to the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       An embodiment of the invention is now described by way of example and with reference to the accompanying drawings in which like numerals are used to denote like parts and in which: 
         FIG. 1  is a side view of a material processing apparatus embodying the invention, the apparatus including a feed assembly shown in a transport mode; 
         FIG. 2  is a side view of the apparatus of  FIG. 1  with the feed assembly shown in a direct feed mode; 
         FIG. 3  is a side view of the apparatus of  FIG. 1  with the feed assembly shown in transition between modes; 
         FIG. 4  is a side view of the apparatus of  FIG. 1  with the feed assembly shown in a pre-screening mode; 
         FIG. 5  is a perspective view of part of the apparatus of  FIG. 1 , showing the feed assembly in the transport mode; 
         FIG. 6  is a perspective view of part of the apparatus of  FIG. 1 , showing the feed assembly in the direct feed mode; 
         FIG. 7  is a perspective view of part of the apparatus of  FIG. 1 , showing the feed assembly in transition between modes; 
         FIG. 8  is a perspective view of part of the apparatus of  FIG. 1 , showing the feed assembly in the pre-screening mode; 
         FIG. 9  is a side view of an alternative material processing apparatus embodying the invention, the apparatus including a feed assembly shown in a pre-screening mode; 
         FIG. 10  is a side view of the apparatus of  FIG. 9 , showing the feed assembly in the direct feed mode; and 
         FIG. 11  is a side view of the apparatus of  FIG. 9 , showing the feed assembly in the transport mode. 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
     Referring now to the drawings, there is shown, generally indicated as  10 , a material processing apparatus, The illustrated material processing apparatus  10  is configured primarily for performing material crushing and may be referred to as a material crushing apparatus, In alternative embodiments, the apparatus may be configured to perform any one or more of a plurality of processes, such as feeding, screening, separating, crushing, waste recycling or demolition and/or washing, on one or more types of aggregate or other material, for example rocks, stones, gravel, sand and/or soil, or any other material that is quarried, mined or excavated. To this end, the apparatus may include one or more material processing units adapted to perform one or more of the foregoing processes. 
     In typical embodiments, the apparatus  10  is mobile and comprises one or more wheels and/or tracks  11  mounted on a chassis  13 . The apparatus  10  may be self-propelled and to this end may comprise a drive system (not shown), e.g. comprising an engine or electrical power plant, for driving the wheels/tracks  11 . In any event, the apparatus  10  may include a power plant  9 , which may comprise at least some components of the drive system and/or other apparatus for powering the apparatus, e.g. electrical, hydraulic and/or pneumatic apparatus for powering rams or other devices, and may also include a control unit (not shown). The control unit is configured for controlling the apparatus, including causing the apparatus  10  to adopt the modes described hereinafter, and may include manually operable controls and/or be adapted to allow remote control by an operator. 
     The apparatus  10  comprises a first material processing unit in the form of a crusher  30  which may take any suitable conventional form, for example a cone crusher. The crusher  30  has an inlet  32 , typically comprising a feed box, at its top and an outlet  34  at its bottom, A feed conveyor  40  is provided for, in a direct feed mode, feeding material into the inlet  32 . A main conveyor  36  is aligned with the outlet  34  of crusher  30  to receive crushed material therefrom. The main conveyor  36  is typically configured to discharge material from the apparatus  10 , and in the illustrated example has a discharging end  37  projecting from an end of the apparatus (the front of the apparatus in this example). In alternative embodiments, more than one conveyor may be provided for receiving material from the crusher  30  and discharging it from the apparatus  10 . 
     In the illustrated embodiment, the crusher  30 , power plant  9 , feed conveyor  40  and main conveyor  36  are mounted on the chassis  13 , but may be mounted on an alternative base structure in embodiments where the apparatus  10  is not mobile. 
     The feed conveyor  40  comprises a frame  42  adapted to support conveying means, typically comprising a powered conveyor belt (not shown). The conveyor  40  has a discharge end  44  and a feed end  46 , and may also comprise a hopper structure  48  arranged to receive material and guide it onto the conveyor  40 . The illustrated hopper structure  48  comprises a respective flare  49  on each side of the frame  42 , but may take other forms. 
     The feed conveyor  40  is slidably mounted on a conveyor support structure  50  and is capable of sliding back and forth with respect to the structure  50  along an axis that runs from end to end  44 ,  46 , of the conveyor  40 , i.e. its longitudinal axis in typical embodiments. The axis typically also coincides with the direction in which the conveyor  40  conveys material from end to end  44 ,  46 . Any suitable slidable coupling may be provided between the conveyor  40  and the support structure  50 . For example, in the illustrated embodiment, a respective rail  52  is provided on each side of the support structure  50  running along the sliding axis, the conveyor frame  42  carrying a respective one or more rollers (not visible) running in a respective one of the rails  52 . It will be apparent that any other convenient sliding mechanism(s) may alternatively be used. 
     The feed conveyor  40  is slidable between an advanced state, in which it adopts a relatively advanced position with respect to the crusher  30  (or other material processing unit with which the conveyor  40  may be co-operable in alternative embodiments), and a retracted state, in which it adopts a relatively retracted position with respect to the crusher  30  (or other material processing unit with which the conveyor  40  may be co-operable in alternative embodiments). 
     One or more powered actuators, conveniently one or more rams  54  or other linear actuators, are provided for effecting sliding movement of the feed conveyor  40 . In the illustrated embodiment, a ram  54  is coupled between the conveyor  40  and the support structure  50  and is configured to cause the conveyor  40  to slide back and forth as the ram  54  extends and retracts. In the drawings, the piston rod  56  is coupled to the conveyor  40  and the housing  58  is coupled to the support structure  50 , although an opposite arrangement may be effected. In either case, the actuator is conveniently aligned with the sliding axis. A corresponding actuator (not shown) may be provided on the opposite side of the conveyor  40 . 
     The feed conveyor  40  and the conveyor support structure  50  may together be referred to as a feed conveyor assembly  40 ,  50 . The feed conveyor assembly  40 ,  50  is movable with respect to the chassis  13  between a first state (shown in  FIGS. 1, 2, 5 and 6 ) a second state (shown in  FIGS. 3, 4, 7 and 8 ). In the illustrated embodiment, the feed conveyor assembly  40 ,  50  is coupled to the chassis  13  by a pivotable linkage mechanism  60  configured to allow the assembly  40 ,  50  to move between the first state the second state. In the first state, the assembly  40 ,  50  assumes a relatively lowered position with respect to the chassis  13 , and a relatively advanced position with respect to the crusher  30  (or other material processing unit with which the assembly  40 ,  50  may be co-operable in alternative embodiments). In the second state, the assembly  40 ,  50  assumes a relatively raised position with respect to the chassis  13 , and a relatively retracted position with respect to the crusher  30  (or other material processing unit with which the assembly  40 ,  50  may be co-operable in alternative embodiments). 
     The linkage mechanism  60  comprises at least one link pivotably coupled between the assembly  40 ,  50  and the chassis  13 . The illustrated embodiment shows the linkage mechanism  60  connected to the support structure  50 , although it may alternatively be connected to the conveyor  40 . In the illustrated embodiment, there are first and second links  62 ,  64  spaced apart longitudinally of the conveyor  40 , the first link  62  being closer to the discharge end  44  of the conveyor  40  and the second link  64  being closer to the feed end  46 . The links  62 ,  64  may be configured any convenient manner to incline the conveyor  40  in the first and second states such that the discharge end  44  is above the feed end  46 . In the illustrated embodiment, each link  62 ,  64  comprises a respective pair of spaced-apart link members, the respective link members of each pair preferably being connected together by one or more crosspiece to form a respective frame. Typically, one or more stops are provided to limit the movement of the linkage mechanism  60  in one or both directions and so to define the position of the assembly  40 ,  50  in one or both of the first and second states. For example, and as can best be seen from  FIGS. 7 and 8 , a stop member  66  is provided in the path of the link  62  to define the position of the assembly  40 ,  50  in the second state. To facilitate this, the link  62  conveniently includes an elbow portion, or other stop-engaging portion, for engaging with the stop  66 . Referring in particular to  FIGS. 3 and 4 , one or more stop members  67  may be provided on the or each link  64  and configured for engagement with the assembly  40 ,  50  in the deployed state. 
     Alternatively or in addition, the position of the assembly  40 ,  50  in the first and/or second states may be determined by the relative extension/retraction of one or more actuators and/or by engagement of the assembly  40 ,  50  with the chassis  13  or one or more components mounted on the chassis  13 . 
     One or more powered actuators, conveniently one or more rams  68  or other linear actuators, are provided for effecting movement of the assembly  40 ,  50  between the first and second states, In the illustrated embodiment, rams  68  are coupled between the chassis  13  and the second link  64 , but in other embodiments, one or more actuators may alternatively or additionally be coupled between the chassis  13  and the linkage mechanism  60  or the assembly  40 ,  50 . In the illustrated embodiment, the rams  68  have one end pivotably coupled to the chassis  13  and the other end pivotably coupled directly to the link  64 . Alternatively, one or more intermediate link members (not shown) may be provided between the rams  68  (or other actuators) and the link  64  and be pivotably coupled to each. For example, the or each intermediate link member may be substantially V shaped, having its apex pivotably coupled to one or more of the rams  68  and its free ends pivotably coupled to the link  64 . This arrangement advantageously increases the distance between the point at which the link  64  is coupled to the chassis  13  and the end of the rams  68  (in comparison to cases where the ends of the rams  68  are connected directly to the link  64 ) and so reduces the amount of work the rams  68  are required to do. 
     When the assembly  40 ,  50  is in the first state, and when the feed conveyor  40  is in its advanced state, the discharge end  44  of the feed conveyor  40  is positioned over or otherwise aligned with the inlet  32  of the crusher  30  (or other material processing unit with which the conveyor  40  may be co-operable in alternative embodiments) such that material discharged from the end  44  falls into the inlet  32 . This configuration corresponds to a direct feed mode of the apparatus  10  and is illustrated in  FIGS. 2 and 6 . 
     As can best be seen from  FIGS. 1 and 5 , when the assembly  40 ,  50  is in the first state, and when the feed conveyor  40  is in its retracted state, the conveyor  40  and in particular its discharge end  44  is relatively low (e.g. in comparison with the direct feed mode of  FIG. 2 ). This facilitates transporting of the apparatus  10 , e.g. on a trailer (not shown), since it reduces the overall height of the apparatus  10 . The configuration of  FIGS. 1 and 5  may therefore be referred to as a transport mode. 
     In preferred embodiments, the apparatus  10  includes a second material processing unit typically comprising a screening unit  70 . The screening unit  70  comprises a screen  72 , which typically comprises one or more mesh or apertured screening layers, carried by a frame  74 . The screen  72  is configured to allow only material that is smaller than a particular size (which may vary depending on the application) to pass through the screen  72 . The screen  72  is preferably removable so that screens with suitably sized apertures may be selected for a given application. 
     The screening unit  70  has an outlet  73 , typically below the screen  72 , by which material that passes through the screen  72  is output from the unit  70 . Usually, the screening unit  70  includes drive means  76  coupled to the screen  70  to impart motion, typically vibratory and/or oscillatory motion, to the screen  72  to assist the screening action. 
     The screening unit  70  has a feed end  78  and a discharge end  80 . When deployed ( FIGS. 4 and 8 ), the preferred configuration of the unit  70  is such that the screen  72  is inclined with the discharge end  80  being below the feed end  78 . This arrangement, advantageously in combination with the motion imparted by the drive means  76 , helps to cause material that has not passed through the screen  72  to pass along the screen  72  and be discharged via the discharge end  80 . In alternative embodiments, the screen may adopt other dispositions when deployed and may, for example, be parallely or substantially parallely disposed with respect to the chassis when deployed (i.e. horizontal or substantially horizontal as view in  FIGS. 1 to 4 ). 
     When the screening unit  70  is deployed, the outlet  73  is aligned with a conveyor and/or a chute  75  aligned with a conveyor, for example the same conveyor with which the outlet of the crusher  30  is aligned, or other destination as applicable. In the illustrated embodiment, chute  75  is arranged to direct material from the outlet  73  of the screening unit  72  onto the main conveyor  36 . 
     The screening unit  70  movable with respect to the chassis  13  between a deployed state (shown in  FIGS. 4 and 8 ) a stowed state (shown in  FIGS. 1, 3, 5, 6 and 7 ). In the illustrated embodiment, the screening unit  70  is coupled to the chassis  13  by a pivotable linkage mechanism  82  configured to allow the unit  70  to move between the deployed and stowed states. In the deployed state, the unit  70  assumes a relatively raised position with respect to the chassis  13 , and a relatively advanced position with respect to the crusher  30  (or other material processing unit with which the assembly  40 ,  50  may be co-operable in alternative embodiments). In particular, in the deployed state, the unit  70  is adjacent the crusher  30  with its discharge end  80  aligned with, and typically above, the inlet  32  of the crusher  30  such that material discharged from end  80  falls into the inlet  32 . In the stowed state, the unit  70  assumes a relatively lowered position with respect to the chassis  13 , and a relatively retracted position with respect to the crusher  30  (or other material processing unit with which the assembly  40 ,  50  may be co-operable in alternative embodiments). 
     The linkage mechanism  82  comprises at least one link pivotably coupled between the screening unit  70  and the chassis  13 . In the illustrated embodiment, there are first and second links  84 ,  86  spaced apart longitudinally (i.e. in the end-to-end direction) of the screen, the first link  84  being closer to the discharge end  80  of the unit  70  and the second link  86  being closer to the feed end  78 . The links  84 ,  86  may be configured any convenient manner to cause the screen  72  to be inclined in the deployed state such that the discharge end  80  is below the feed end  78 , although in alternative embodiments the screen need not be inclined with respect to the chassis when deployed, it may instead be disposed parallely or substantially parallely with the chassis when deployed. The linkage mechanism may be configured in any convenient manner to hold the screen in the desired disposition when deployed. In the illustrated embodiment, each link  84 ,  86  comprises a respective pair of spaced-apart link members, One or more stops (not shown) may be provided to limit the movement of the linkage mechanism  82  in one or both directions and so to define the position of the unit  70  in the stowed and/or deployed states, Alternatively or in addition, the position of the unit  70  in the stowed and/or deployed states may be determined by the relative extension/retraction of one or more actuators and/or by engagement of the unit  70  with the chassis  13  or one or more components mounted on the chassis  13 . 
     One or more powered actuators, conveniently one or more rams  88  or other linear actuators, are provided for effecting movement of the screening unit  70  between the deployed and stowed states, In the illustrated embodiment, rams  88  are coupled between the chassis  13  and the first link  84 , but in other embodiments, one or more actuators may alternatively or additionally be coupled between the chassis  13  and the linkage mechanism  82  or the screening unit  70 . 
     As can be seen from  FIGS. 1, 2, 5 and 6 , when the screening unit  70  is in its stowed state, it fits beneath the feed conveyor assembly  40 ,  50  when in its first state. In particular the screening unit  70  is beneath the support structure  50  and does not impede movement of the feed conveyor  40  between its advanced and retracted states, Hence, in the transport and direct feed modes the screening unit  70  is stowed beneath the feed conveyor assembly  40 ,  50 . Advantageously, the arrangement is such that the screening unit  70  does not project beyond the feed conveyor assembly  40 ,  50  in a longitudinal direction (left or right as viewed in  FIGS. 1 and 2 ) and, as such does not contribute to the length of the apparatus  10  when stowed. 
     In order to deploy the screening unit  70  from its stowed state, the feed conveyor assembly  40 ,  50  is first caused to adopt its second state such that it is raised with respect to the chassis  13  to allow the screening unit  70  to be raised from its stowed state. This is illustrated in  FIG. 3  which shows a transitionary configuration between the transport or direct feed modes and a pre-screening mode, which is now described. 
     When the screening unit  70  is deployed, it is located between the feed conveyor assembly  40 ,  50  and the crusher  30  (or other material processing unit with which the assembly  40 ,  50  may be co-operable in alternative embodiments). When the feed conveyor  40  is in its advanced state, its discharge end  44  is aligned with the feed end  78  of the screening unit  70  and positioned such that material can be fed from the conveyor  40  onto the screen  72  ( FIGS. 4 and 8 ). This configuration corresponds to the pre-screening mode. In the pre-screening mode, material discharged from the feed conveyor  40  is screened by the screening unit  70  before it can reach the crusher  30 . In the illustrated embodiment, material that passes through the screen  72  is directed to the main conveyor  36  (although in alternative embodiments it may be directed to some other destination, e.g. a side conveyor) via the chute  75  and so bypasses the crusher  30 . Material that does not pass through the screen  72  is discharged from end  80  of the screening unit  70  and fed into the crusher  30 . Hence, the screening unit  70  can reduce the quantity of material that is fed to the crusher  30  thereby improving the efficiency of the apparatus  10 . 
     In preferred embodiments, the feed conveyor  40  adopts its advanced state prior to deployment of the screening unit  70 , this facilitates a preferred configuration of the apparatus  10  whereby the discharge end  44  of the feed conveyor  40  overlaps (in the longitudinal direction) with the feed end  78  of the screening unit  70  in the pre-screening mode, and wherein the proximity of the discharge end  44  and feed end  78  in this mode is such that, the feed end  78  lies in the path of the discharge end  44  as the conveyor  40  travels from the retracted state to the advanced state, For the same reason, the screening unit  70  is stowed, or at least moved out of the deployed state, prior to retracting the feed conveyor  40 . 
     Respective movements of the feed conveyor assembly  40 ,  50 , the conveyor  40  itself, and the screening unit  70  are conveniently controlled by an operator using one or more controls, e.g. provided on the control unit, or provided on a remote control unit, Advantageously, respective sequences of movements of the feed conveyor assembly  40 ,  50 , the conveyor  40  itself, and the screening unit  70  may be automated to allow the operator to initiate mode-to-mode reconfigurations of the apparatus  10 . 
     It will be apparent that, in preferred embodiments, the apparatus  10  is re-configurable to operate in any one of multiple operating modes (direct feed and pre-screening modes in this example). When not in use, the screening unit  70  is stowed such that it fits beneath the feed conveyor assembly and does not contribute to the length, or preferably the height, of the apparatus  10 . The feed conveyor  40  is movable to a relatively lowered position in order to reduce the height of the apparatus  10  to facilitate transport. 
     In alternative embodiments, the support structure  50  may be omitted and, as can be appreciated from  FIGS. 2, 3 and 4 , the feed conveyor  40  may still be configurable to adopt the direct feed or pre-screening modes even when not slidable. 
     Referring now in particular to  FIGS. 9 to 11  of the drawings, there is shown an alternative material processing apparatus  110  embodying the invention, The apparatus  110  is similar to the apparatus  10  (unless hereinafter indicated otherwise), like numerals being used to denote like parts and the same or similar description applying as would be apparent to a skilled person. 
     The feed conveyor assembly  140 ,  150  is mounted on the apparatus  110  by means of a linkage mechanism and an assembly support structure  190 . In this example, the linkage mechanism comprises a link  164 , which conveniently corresponds to the second link  64  of the apparatus  10  but no link corresponding to the first link  62 . The support provided to the assembly  140 ,  150  by the support structure  190  replaces the support provided by link  62  in  FIGS. 1 to 8 , The support structure  190 , which conveniently comprises a frame, includes a track  192 . The track  192  is may be straight and/or curved as required and may extend along any suitable part, e.g. bar or beam, of the support structure  190 . The track  192  is configured, e.g. shaped and dimensioned, to receive one or more running device  194 , for example a wheel or roller, that is provided on the assembly  140 ,  150 . The runner  194  moves back and forth in the track  192  as the assembly  140 ,  150  moves between respective states, e.g. the pre-screening state and the direct feed state, In the illustrated embodiment, as the link  164  is moved by rams  168  to effect movement of the assembly  140 ,  150 , the runner  194  runs correspondingly back and forth along the track. This can be seen by comparison of  FIGS. 9 and 10  which show, respectively, the feed assembly  140 ,  150  in its pre-screening and direct feed modes.  FIG. 11  shows the assembly  140 ,  150  in the transport mode. The screening unit  170  may move from mode to mode in the manner described above in relation to  FIGS. 1 to 8 , as can be seen from  FIGS. 9 to 11 . 
     The invention is not limited to the embodiments described herein which may be modified or varied without departing from the scope of the invention.