Patent Publication Number: US-9833787-B2

Title: Folding hopper

Description:
RELATED APPLICATION DATA 
     This application is a §371 National Stage Application of PCT International Application No. PCT/EP2015/059185 filed Apr. 28, 2015 claiming priority of EP Application No. 14169869.6, filed May 26, 2014. 
     FIELD OF INVENTION 
     The present invention relates to a folding hopper for bulk material processing apparatus and in particular, although not exclusively, to a folding hopper in which side and end walls are capable of being moved between a lowered and a raised position and to interlock via mechanical interlocking flanges. 
     BACKGROUND ART 
     Bulk material processing plants or machines can be static or transportable between operational sites. In some instances, the processing machines are transportable to be assembled or configured for use in situ or may be self-propelled to be easily manoeuvred on site and to facilitate loading and unloading at a platform of a transport vehicle. 
     Example processing plants include screeners, crushers and combined crushing and screening apparatus. These machines typically include a loading hopper which receives a supply of bulk material that is then fed to a screen box or a crusher for subsequent discharge via one or a number of intermediate or discharge conveyors. The supply from the hopper to the primary or secondary processing units (screen or crusher) typically relies on gravity discharge such that the screen or crusher is generally positioned lower than the input hopper that typically determines the maximum height of the processing plant and is the uppermost component. Accordingly, it is known to configure the hopper with walls that are capable of falling or collapsing downwardly to appreciably reduce the overall machine height and allow convenient transport along public highways without risk of impact with overhead obstructions such as bridges and the like. Example foldable hopper arrangements are described in US 2004/0035963; US 2006/0016104; US 2008/0041984; EP 2664492; GB 2496522 and US 2014/0124337. 
     However, conventional adjustably mounted hoppers are disadvantageous for a number of reasons. In particular, service personnel are often required to physically climb the plant to manually manipulate locking components at the hopper walls. As will be appreciated, in use, the walls must be secured reliably to withstand the significant loading forces that are imparted to the walls as the hopper is supplied with bulk material. Additionally, it is not uncommon for power operated actuators to become worn over time or to fail and this represents a significant safety risk to personnel where the hopper wall locking mechanism relies or is dependent upon the integrity of electronic or fluid based actuators. Accordingly, what is required is a hopper arrangement that addresses these problems. 
     SUMMARY OF THE INVENTION 
     It is an objective of the present invention to provide a folding hopper arrangement that provides an automated or semi-automated movement of the hopper walls between a lowered transport position and a raised operative position. It is a further specific objective to provide a hopper assembly having hopper walls that mechanically interlock to provide a secure interconnected unitary structure without the risk of the walls falling unintentionally downward due to wear or failure of electronic or fluid based components or in response to significant loading forces imparted to the hopper walls. 
     It is a yet further objective to provide an actuating mechanism for a folding hopper that is does not increase the overall width of the bulk material processing apparatus and that may be accommodated conveniently within an inner region of apparatus against or between other components of the processing apparatus. 
     The objectives are achieved, in part, via a folding hopper arrangement in which the side or end walls of the hopper are configured to be moved between a lowered and a raised position and mechanically interlocked (in the raised position) via remote control without the need for personnel to manually engage locking components. 
     Advantageously, the present arrangement via the type of mechanical interlocking connections and the power operated actuating mechanisms (configured to move the walls between the lowered and raised positions) is capable of engaging and disengaging lockable flanges at the end (or the start) of the wall movement procedure such that the mechanical lock is actuated via the same mechanical actuators that control and provide the movement of the hopper walls. 
     Additionally, the locking connections are arranged such that the strength of the locking connection is proportional to the weight of the hopper walls. That is, the present interengaging connections are provided by locking flanges that are attached rigidly to the end and sidewalls and comprise hooked shaped portions configured to overlap one another. Accordingly, the end and sidewalls are held and locked into engagement and prevented from pivoting downwardly under gravity (without the need for support from the power operated movement mechanisms) by the hooked portions that are maintained in the engaged state by the weight of the hopper walls. 
     The locking and unlocking of the hopper walls is achieved via the power operated actuating mechanism of the side or end wall being configured to displace the wall in a first pivotal movement and a second substantially linear translational movement in the upward and downward direction. In particular, to provide locking engagement, one of the hopper walls may be first pivoted from the lowered position to the raised position where it may then be lowered vertically by the power operated mechanism to allow the side and end wall mounted hooks to interengage. The reverse linear and pivoting movement of the hopper wall may then be conveniently actuated to provide the unlocking of the walls to enable their subsequent downward folding. 
     According to a first aspect of the present invention there is provided a folding hopper for bulk material processing apparatus comprising: at least one sidewall pivotally mounted to a support frame via at least one first pivot mount; a first power operated mechanism having a first power operated actuator to provide pivoting of the sidewall between a lowered first position and a second raised position; at least one end wall pivotally mounted to the support frame via at least one second pivot mount and extending perpendicular or transverse to the sidewall; a second power operated mechanism having a second power operated actuator to provide pivoting of the end wall between a lowered first position and a second raised position; characterised by: first and second mechanical interlock connections provided respectively at the side and end wall such that when interlocked the side and end walls are prevented from being pivoted from the raised second position to the lowered first position; wherein the first or second power operated mechanism comprises a third power operated actuator configured to provide a translational movement of the side or end wall in an upward and downward direction such that a locking and unlocking of the first and second interlock connections comprises the pivoting and the translational movement of the side or end wall. 
     Preferably, the first and second interlock connections comprise flanges having hooked portions that are configured to overlap one another when interlocked. Preferably, the flanges are positioned at or towards respective end edges of the side and end walls to engage one another as the end edges are mated in touching or near touching contact when the walls are in the raised first position. The hooked portions are advantageous to ensure a secure and reliable interconnection of the hopper walls and to provide sufficient physical overlap of the rigid flanges. The flanges are shaped and dimensioned to have sufficient integrity and strength to support the weight of the hopper walls exclusively and importantly without a reliance on additional electronic or fluid based actuators. The end regions of the hooked portions on each wall are effective to prevent the adjacent wall from unintentionally falling downward by representing an abutment to hold and retain the adjacent wall in the raised position. 
     Optionally, the first power operated mechanism comprises a first arm pivotally mounted to a second arm such that the first and second arms are configured to fold relative to one another and the support frame when the sidewall is moved to the lowered first position and to align to form a straightened support brace when the sidewall is in the raised second position. Such an arrangement is beneficial to provide further support to the sidewalls and in turn the end wall so as to stabilise the walls against impact loading forces. 
     Optionally, the second arm is pivotally mounted to the frame and the first arm is attached to the sidewall such that the first and second arms are configured to fold inwardly towards a position underneath the hopper when the sidewall is moved to the lowered first position. Advantageously, the folding mechanism does not present a safety hazard to operating personnel as it folds inwardly and also enables the apparatus to be operated in confined regions or in close proximity to other processing devices or structures that would otherwise not be possible with an outward folding mechanism. 
     Preferably, the first power actuator is attached at a region of the first arm and a region of the second arm. Such an arrangement is advantageous to provide a direct coupling between the actuator and the movable arms to enable the actuator to be isolated when the arms are straightened. Preferably, the first power actuator is mounted at the first arm and the second arm such that when the arms are aligned to form the straightened support brace the first powered actuator is isolated from compressive forces transmitted through the support brace from the sidewall. 
     Optionally, the second power actuator is mounted to extend between the frame and the end wall and the third power actuator is mounted to extend between the frame and the second pivot mount to provide a translational movement of the second pivot mount in the upward and downward direction. The third power actuator is preferably mounted directly in contact with the end wall so as to maintain to a minimum the load transmitted through the actuator in raising and lowering the end wall during operation. 
     Optionally, the second pivot mount comprises: a mount bracket provided at the support frame, the bracket having a first elongate slot; and a first pivot pin about which the end wall can pivot, the first pivot pin slidably mounted within the elongate slot. A pivot pin and slot arrangement is advantageous to provide a reliable and lightweight mechanism for displacing the hopper wall and in particular to minimise the number of working components and the overall complexity of the mechanism. 
     Preferably, the third power actuator is mounted to act on the first pivot pin to cause the first pivot pin to slide in the upward and downward direction within the first slot; and the second power actuator is mounted between the end wall and the bracket to cause the end wall to rotate about the first pivot pin. Movably mounting the third power actuator is advantageous to minimise stress at the actuator by maintaining the desired loading angles and limiting the range of extension of the actuator to achieve longevity of the operating components. 
     Preferably, the third power actuator is mounted at the bracket via a second pivot pin slidably mounted within a second elongate slot provided in the bracket, the third power actuator configured to move in the upward and downward direction with the translational movement of the end wall. The pin and slot arrangement is advantageous to provide a reliable mechanism for displacing the actuator without the need for additional components that would otherwise increase the complexity and weight of the movement mechanism. 
     Preferably, the second power operated mechanism comprises: a pair of brackets, a pair of first pivot pins and a pair of first and second elongate slots; and a pair of second power operated actuators and a pair of third power operated actuators provided respectively at each bracket. Such an arrangement is beneficial to provide a robust and stable movement mechanism whilst maintaining to a minimum the weight of the components associated with displacing the hopper wall. 
     Preferably, the apparatus further comprises at least one cover shield pivotally mounted to hang from a region of the end wall to cover the second and third power operated actuators when the end wall in the raised second position. The shield is beneficial to provide a safety guard for operational personnel and to at least partially cover the internal components of the actuating mechanism from dust and debris during use. Preferably, the apparatus comprises a plurality of guards or shields to protect and cover all actuating mechanisms associated with the hopper walls. 
     Preferably, the apparatus comprises two sidewalls wherein each wall comprises a plurality of the flanges at a respective end edge, each flange of the sidewalls arranged such that each hook portion extends upwardly; and wherein the end wall comprises a plurality of flanges at each end edge wherein each flange of the end wall is arranged such that each hook portion extends downwardly; wherein when the flanges are interlocked the respective upward and downward extending hook portions overlap to interlock the sidewalls with the end wall. 
     According to a second aspect of the present invention there is provided mobile bulk material processing apparatus comprising: a mainframe; a processing unit supported at the mainframe; tracks or wheels to allow the apparatus to move over the ground; and a folding hopper as claimed herein to contain material to be fed to the processing unit. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       A specific implementation of the present invention will now be described, by way of example only, and with reference to the accompanying drawings in which: 
         FIG. 1  is an external side elevation view of a mobile crushing apparatus having a mainframe, a crusher, a feed hopper and tracks to enable the apparatus to be self-propelled over the ground according to a specific implementation of the present invention; 
         FIG. 2  is a rear perspective view of the mainframe and input hopper of the apparatus of  FIG. 1  according to the specific implementation; 
         FIG. 3  is a further rear perspective view of the hopper and mainframe of  FIG. 2  with selected components removed for illustrative purposes; 
         FIG. 4  is a side perspective view of the hopper and mainframe of  FIG. 3  with selected components removed for illustrative purposes; 
         FIG. 5  is a rear perspective view of the hopper and mainframe of  FIG. 4  with selected components removed for illustrative purposes; 
         FIG. 6  is further rear perspective view of the hopper and mainframe of  FIG. 5  with an end wall in a raised position to disengage hopper wall interlock connections having selected components removed for illustrative purposes; 
         FIG. 7  is a rear perspective view of the hopper and mainframe of  FIG. 6  with the end wall pivoted to a lowered intermediate position; 
         FIG. 8  is a further rear perspective view of the hopper and mainframe of  FIG. 7  with the end wall pivoted to a lowest position with selected components removed for illustrative purposes; 
         FIG. 9  is a rear perspective view of the hopper and mainframe of  FIG. 8  with a sidewall and end wall pivoted downwardly to their lowest positions with selected components removed for illustrative purposes; 
         FIG. 10  is an upper perspective view of the hopper and mainframe of  FIG. 9  with a sidewall and end wall pivoted to their lowest positions. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENT OF THE INVENTION 
     Referring to  FIG. 1 , a bulk material processing machine  100  comprises a mainframe  104  that supports an undercarriage to mount a pair of endless tracks  105  to enable machine  100  to be self-propelled over the ground. Machine  100  further comprises a primary motor  106 , an input feed hopper indicated generally by reference  101 , a material crusher  102  and a discharge conveyor  103 . Hopper  101  comprises folding hopper walls  107  movable between a raised uppermost position (illustrated in  FIG. 1 ) and a pivoted or collapsed lower position (illustrated in  FIGS. 9 and 10 ). 
     Referring to  FIGS. 2 and 3 , hopper  101  comprises a pair of sidewalls  200  aligned generally with a longitudinal axis of mainframe  104  and an end wall  201  provided at a rear end of machine  100  and extending generally perpendicular to sidewalls  200 . With walls  200 ,  201  orientated in the uppermost raised position of  FIG. 2 , end wall  201  extends between a rear edge  310  of each sidewall  200  so as to enclose the inner region of hopper  101  to contain the fed bulk material. In particular, end wall  201  comprises a pair of end edges  311  configured to mate in touching or close touching contact with the sidewall end edges  310 . 
     Machine  100  comprises a pair of first power operated mechanisms indicated generally by reference  203  configured to actuate raising and lowering of each sidewall  200  between the positions of  FIG. 1  and  FIG. 9 . Each mechanism  203  comprises a first elongate arm  206  pivotally mounted to a relatively short second arm  207 . Referring to  FIG. 4 , first arm  206  comprises first uppermost end  405  pivotally attached to a mount region  314  provided at an outermost part of sidewall  200  via a pivot pin  400 . The second lowermost end  406  of first arm  206  is pivotally mounted at an uppermost end  408  of second arm  207  via a pivot pin  313 . Second arm  207  is pivotally mounted to frame  104  via a base mount  312 . In particular, a lower end  407  of arm  207  is received within base mount  312  and pivotally mounted via pivot pin  402 . 
     A power operated linear actuator (in the form of a hydraulic cylinder)  409  is mounted at respective ends to first and second arms  206 ,  207 . In particular, a lowermost end  412  of cylinder  409  is pivotally mounted to pivot pin  403  at second arm  207 . Cylinder  409  comprises a retractable rod  410  that is mounted at its uppermost end  411  to first arm  206  via pivot pin  404 . Accordingly, via actuation of cylinder  409 , first and second arms  206 ,  207  are configured to fold or collapse inwardly via pivot pin  313  such that in their folded or hinged configuration, arms  206 ,  207  extend generally inwardly to region  315  positioned substantially below a lower region  401  of hopper  101 . In particular, the inward folded arms  206 ,  207  are illustrated further in  FIG. 10  such that the first arm lower end  406  and the second arm upper end  408  are positioned immediately below hopper region  401  when the arms are collapsed. Advantageously, the first and second arms  206 ,  207  do not fold or hinge outwardly that would otherwise increase the overall width of machine  100 . Moreover, each of the sidewall actuating mechanisms  203  are configured so as to not interfere with one another when hinged to the position of  FIG. 10 . 
     Pivoting of each sidewall  200  is achieved via a pair of pivot mounts provided at a rearward end and towards a forward end of each sidewall  200 . Each pivot mount comprises a base mount  210  provided at mainframe  104  and a sidewall mount  307  extending generally downward from an outside region of each sidewall  200 . Mount  307  is configured to pivot relative to mount  210  via an intermediate pivot pin  208 . Each power operated mechanism  203  and in particular arms  206  and  207  are shielded by a substantially planar plate  202  pivotally mounted to the outside of each sidewall  200 . Plate  202  hangs downwardly to conceal arms  206 ,  207  and cylinder  409  to both protect the mechanism from dust and debris and to increase the operational safety of the apparatus  100  with regard to operating personnel. 
     Machine  100  further comprises a pair of second power operated mechanisms indicated generally by reference  204 . Each second mechanism  204  is mounted to extend between a rear part of mainframe  104  and end wall  201  to be capable of actuating raising and lowering of end wall  201  between the raised position of  FIG. 1  and the lowered position of  FIG. 8 . Each mechanism  204  comprises an upstanding mount bracket  205  rigidly mounted at frame  104  and formed by a pair of spaced apart plate like bodies. Bracket  205  comprises an upper region  300  positioned closest to the upper region of end wall  201  and a lower region  303  mounted at frame  104 . A first substantially vertically extending elongate slot  301  is provided at bracket upper region  300  and a second substantially vertically extending elongate slot  302  is provided at bracket lower region  303 . Both slots  301 ,  302  are aligned substantially parallel and are spaced apart in a vertical direction by the main length of bracket  205 . The end wall  201  comprises a pair of generally downwardly projecting wall mounts  306  each having a lowermost end  317  that is at least partially received within each bracket upper region  300 . A pivot pin  209  is slidably mounted within slot  301  and extends through wall mount end  317  to pivotally couple end wall  201  to each bracket  205  and, in turn, frame  104 . Accordingly, end wall  201  is capable of pivoting in the upward and downward direction via pivot pin  209 . An elongate guard  304  hangs from each wall mount  306  via a pivot pin  305  and is shaped and dimensioned to conceal the internal components of each power operated mechanism  204 . That is, the internal components of each mechanism  204  are encased within each bracket  205  and guard  304 . 
     Referring to  FIGS. 3, 5 and 6 , each mechanism  204  comprises a pair of power operated linear actuators (in the form hydraulic cylinders)  501 ,  502  positioned side by side within the internal space defined by each bracket  205 . Cylinder  502  is aligned to be inclined relative to the horizontal such that an uppermost end  507  of an elongate rod  505  (retractably mounted at cylinder  502 ) is positioned rearwardly of a lowermost end of cylinder  502 . In particular, cylinder  502  (via its lowermost end) is moveably mounted at bracket  205  via a pivot pin  316  that is slidably mounted within lower elongate slot  302 . Uppermost rod end  507  is in turn mounted at a pivot pin  504  that is attached to wall mount  306 . Neighbouring cylinder  501  also comprises a retractably mounted elongate rod  506  having an uppermost end  503 . Upper end  503  is mounted at pivot pin  209  whilst a lowermost end of cylinder  501  is mounted at a lower pivot pin  500  attached to bracket lower region  303 . 
     Accordingly, via each mechanism  204 , end wall  201  is configured to move in a substantially linear upward and downward translational direction and to pivot or fold in the upward and downward direction. In particular, the linear vertical raising and lowering of end wall  201  is provided by actuating cylinder  501 . As rod  506  is extended from cylinder  501 , pivot pins  209  and  316  are configured to slide in a vertical direction within the respective slots  301 ,  302 . Pivoting of end wall  201  is provided by actuation of cylinder  502  such that the change in length of retractable rod  505  causes wall mount  306  to pivot about pin  209 . That is, cylinder  502  is also displaced vertically via the actuation of cylinder  501  to maintain the actuation alignment angle of cylinder  502  relative to wall mounts  306 . 
     So as to secure hopper walls  107  in the raised position of  FIG. 1 , each wall  107  comprises a plurality of interlocking flanges indicated generally by reference  211 . In particular, to provide a reliable and conveniently engagable and releasable lock, each flange  211  is formed exclusively as a mechanical component being rigidly mounted to each respective wall  200 ,  201 . As such, flanges  211  are fixed rigidly to each respective wall  200 ,  201  and the walls  200 ,  201  may be interlocked together exclusively by the frictional contact and mechanical interlock provided by flanges  211 . 
     In particular, each sidewall  200  comprises a pair of flanges  211  having hooked portions  309  projecting rearward from the rear end edge  310  at a location at or just above wall mount  307 . Each hook portion  309  is orientated such that the hook projects generally upward. Similarly, end wall  201  comprises a pair flanges  211  provided at each lengthwise end edge  311 . Each end wall flange  211  comprises a corresponding hooked portion  308  projecting in the widthwise direction from end edge  311 . Each hooked portion  308  is orientated to be downward facing so as to mate in overlapping contact against the respective hooked portions  309  of wall flanges  211  when the walls  107  are in the uppermost raised position of  FIG. 1 . 
     The hooked portions  308 ,  309  within each pair are positioned above and below one another so as to be spaced apart in the vertical direction. With walls  200 ,  201  in the upright position, end wall  201  may be considered to be hooked onto and supported by each sidewall  200  via overlapping engagement of the respective hooked portions  308 ,  309 . Additionally, sidewalls  200  in the raised position of  FIG. 1  are further supported by arms  206 ,  207  that are capable of aligning to extend parallel to one another to form a straightened support brace or strut as illustrated in  FIG. 3 . That is, arms  206 ,  207  are configured to pivot to a straightened ‘locked-out’ position. Such a configuration is advantageous to isolate each cylinder  409  from compressive forces imparted by the weight of sidewall  200  and impact forces as hopper  101  is loaded with bulk material. Arms  206 ,  207  also support the interlocking of hooked portions  308 ,  309  so as to provide a robust and reliable hopper wall interlocking assembly. 
     Engagement and disengagement of hooked portions  308 ,  309  is achieved via a combined actuation of cylinders  409 ,  501  and  502 . Referring to  FIGS. 3 to 10 , with the walls  107  in the upright position of  FIG. 1 , end wall  201  is initially displaced upwardly in the vertical direction by actuation of cylinder  501 . Pivot pins  209 ,  316  are therefore caused to slide within corresponding slots  301 ,  302  as illustrated in  FIGS. 5 and 6 . This initial linear translational movement as shown in  FIG. 6  disengages hooked portions  308  from hooked portions  309 . End wall  201  is then capable of pivoting downwardly about pivot pins  209  via actuation of cylinder  502  to achieve the partially pivoted orientation of  FIG. 7 . Wall  201  continues to pivot to the fully lowered position of  FIG. 8  with pins  209 ,  316  still positioned at the uppermost end of respective slots  301 ,  302 . Accordingly, cylinder  502  is maintained in the upward displaced position via cylinder  501 . Cylinder  409  is then actuated to fold inwardly first and second arms  206 ,  207  into region  315  as illustrated in  FIGS. 9 and 10 . Accordingly, each sidewall  200  is folded downwardly about pivot pins  208  to the fully declined position of  FIGS. 9 and 10 . The configuration of arms  206 ,  207  to fold inwardly is advantageous to maintain to a minimum the overall width of machine  100  and to provide a convenient region  401  below the hopper main body to accommodate other components such as a fines conveyor (not shown). 
     Raising and interlocking walls  107  is then achieved by the reverse order of steps involving both the pivotal movement of the side walls  200  then end wall  201  followed by the linear vertical lowering of end wall  201  to complete the interlocking of hooked portions  308 ,  309 .