Patent Publication Number: US-2020276781-A1

Title: Compacting system and method

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application Ser. No. 62/811,671, filed on Feb. 28, 2019, which is hereby incorporated by reference herein in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to systems, methods and apparatuses for compacting and handling waste material and the like and, more particularly, to improved means for receiving, compacting and facilitating the conveyance and disposal of waste material. 
     BACKGROUND OF THE INVENTION 
     Waste compactors are used to compact waste and refuse materials to reduce the size and volume of the materials. It is desirable to compact waste and refuse materials for a number of reasons. For example, it is desirable to compact waste and refuse materials to into an economically manageable size to reduce the space that is taken up by the materials in waste containers, dumps, landfills, etc. It is also desirable to compact waste and refuse materials to reduce the frequency of which a waste container must be emptied, in order to reduce the costs associated with the emptying of the waste container. 
     Waste compactors are available in various sizes, from relatively small units which are utilized in the home, to large scale industrial systems. Regardless of size, however, the typical compactor utilizes an actuatable ram for compressing the waste into a reduced volume. Generally, a hydraulically operated cylinder and piston assembly is connected to the ram for reciprocally displacing the ram between a waste-receiving and a waste-compressed position. In larger units, the compressed waste holding container is separable from the ram unit in order to permit changing of the containers as they are filled. 
     Frequently, the user of the compactor utilizes a waste hauler for the purpose of changing the filled container. Naturally, the cost of changing the containers will be related to the number of containers which are changed. Consequently, it is economically advantageous for the user of the compactor to utilize the services of the hauler only at such times as when the compactor is full. Conventional compactors, including the containers, fail to provide any indication of when the container is approaching fullness. Therefore, the user must estimate the amount of waste which is contained therein if he is to minimize his hauling costs. 
     In addition to the above, conventional compactors often suffer from waste fallback or spring-back, whereby when trash is loaded into the hopper or loading area, compacted, and the ram is retracted, some portion of the waste will fall back or spill into the loading area. Such phenomenon, and the presence of waste in the loading area after compacting, reduces the amount of new waste that can be loaded into the loading area, and may give the false indication that the waste holding container is full. Accordingly, waste fallback may trigger premature emptying of the container. 
     In view of the above, there is a need for a compacting system and method that inhibits compacted waste from falling or retracting into the loading/hopper area, and provides an accurate indication of when the waste holding container is full. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide a compacting system capable of indicating when refuse and waste material has been compacted within a waste holding container to its practical capacity. 
     It is an object of the present invention to provide a compacting system that prevents waste from falling back into a loading area of the system. 
     It is an object of the present invention to provide a compacting system that automatically deploys a gate or like means to prevent waste from falling back into the loading area in response to feedback from sensors. 
     These and other objects are achieved by the present invention. 
     A compacting system includes a container, a ram extendable into the container to compact waste, and a gate that is selectively deployable to close off the opening in the container to prevent the fallback of waste into the loading area. The system also includes at least one sensor for providing information as to an actual level of waste within the container. 
     In an embodiment, a compacting system includes a container having an open end, the container having at least one sensor for detecting a level of waste within the container, and a compactor apparatus aligned with the open end of the container, the compactor apparatus having a loading area for the loading of waste, and a ram, the ram being movable between a retracted position in which the ram is positioned rearward of the loading area, and a compacting position in which the ram extends through the open end of the container and into the container to move the waste from the loading area into the container. 
     In another embodiment, a method for compacting waste includes the steps of providing a container having an open end and at least one pressure sensor configured to detect a level of waste within the container, providing a compacting apparatus having a loading area for receiving waste, and compacting ram movable between a retracted position and a deployed position, actuating the compacting ram to move waste from the loading area into the container, and receiving feedback from the at least one pressure sensor regarding the level of waste within the container after the compacting ram moves the waste into the container. 
     In yet another embodiment, a compacting system includes a container having an open end, the container having at least one pressure sensor configured to detect a level of waste within the container, a compactor apparatus aligned with the open end of the container, the compactor apparatus having a hopper, a loading area in communication with the hopper and being configured to receive a quantity of waste loaded into the hopper, and a compacting ram, the ram being movable between a retracted position in which the compacting ram is positioned rearward of the loading area, and a compacting position in which the compacting ram extends through the open end of the container and into the container to move the quantity of waste from the loading area into the container, and a controller configured to receive information from the at least one sensor regarding a level of waste within the container. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention will be better understood from reading the following description of non-limiting embodiments, with reference to the attached drawings, wherein below: 
         FIG. 1  is a side elevational view of a compacting system according to an embodiment of the present invention. 
         FIG. 2  is a top plan view of the compacting system of  FIG. 1 . 
         FIG. 3  is a simplified perspective view of the compacting system of  FIG. 1 . 
         FIG. 4  is a detailed perspective view of a portion of the compacting system of  FIG. 1 . 
         FIG. 5  is a detailed perspective view of a gate of the compacting system of  FIG. 1 . 
         FIG. 6  is a schematic illustration of the compacting system of  FIG. 1 , illustrating the gate and ram in a retracted position. 
         FIG. 7  is a schematic illustration of the compacting system of  FIG. 1 , illustrating the gate in a lowered/closed position. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to  FIG. 1 , there is shown a compactor container  10  supported on a rail, casters or wheels  12  and positioned for loading by-a stationary refuse compactor  14  having a charging hopper  16 . The container  10  may be of conventional construction and generally is designed for use with a vehicle for transporting compacted material to a dumping area. The container may include a tailgate (not shown) which is swung open when the contained refuse is to be discharged. Such tailgate includes an opening which is aligned with the compactor  14 . The container  10  and the compactor  14  are secured together by means of chains, turnbuckles or latches, such as the turnbuckle  18 . Together, the container  10  and the compactor  14  form a compacting system  100 . 
     Those skilled in this art will understand that refuse and/or waste is deposited into the charging chamber or loading area  32  of the compactor through the hopper  16 , which charging chamber includes a hydraulically driven ram  20 . When the charging chamber  32  is substantially filled, the operator actuates a control switch, causing the ram  20  to extend to transfer the refuse from the charging area below the hopper  16  and into the container  10  and then returns to its normal position. After a number of operating cycles, the bulk material in the container will begin to compact under the force of the ram  20 . The loading of the charging chamber  32  of the compactor  14  and the compaction of the material in the container  10  is continued until the refuse in the container  10  has been fully compacted, after which the container  10  is disengaged from the compactor  14  and carted away. 
     To ensure that a full compacted load is carted away, one or more pressure sensors  22 ,  24 ,  26  may be positioned inside the container  10 . For example, as illustrated in  FIG. 1 , the sensors  22 ,  24 ,  26  may be positioned adjacent to, and secured to, the roof of the container. While  FIG. 1  illustrates three pressure sensors positioned at various longitudinal or axial locations within the container  10 , more or fewer than three pressure sensors may be utilized without departing from the broader aspects of the invention. Moreover, while  FIG. 1  illustrates the use of pressure sensors, it is contemplated that other types of sensors, such as optical sensors, may also be utilized. The pressure sensors  22 ,  24 ,  26  are communicatively coupled to a controller  50  of the compactor  14 , and provide feedback to the controller indicating a level of fullness of the container  10 . In an embodiment, the coupling may be a wired or wireless connection. For example, in operation, when the pressure sensor  26  is triggered by the compacting of waste within the container  10 , this will indicate that waste takes up the majority of the volume within the container  10 , indicating to a user that it is time to schedule a pickup. Conversely, if the pressure sensor  22  or pressure sensor  24  does not sense pressure from the compacting of waste, then this indicates that there is more room in the container  10  for waste. 
     While the embodiment described above discloses pressure sensors within the container  10 , it is contemplated that the pressure sensor may alternatively be integrated with the ram  20 . In such an embodiment, an increase in pressure seen by the ram  20  and/or the sensor integrated therewith, indicates an increase in the volume of waste within the container  10 . In this respect, the pressure seen by the ram  20  can be utilized to determine how much waste is in the container  10 , and ultimately whether more waste can be added or if it is time for emptying. 
     In addition to the above, and with reference to  FIG. 2 , in an embodiment, the system  100  may include a gate  30  that is selectively movable to close off the opening in the end of the container  10  to prevent waste from falling back into the loading area  32  beneath the hopper  16  once the ram  20  is retracted.  FIG. 3  is a simplified schematic illustration showing the relative location of the container  10 , ram  20 , loading area  32  and gate  30 . In an embodiment, the gate  30  may include a plurality of fingers or bars  34  that are configured to be received in corresponding grooves  36  in a face of the ram  20 , as more clearly shown in  FIG. 4 . 
     As illustrated in  FIG. 5 , the gate  30  is moveable upwardly and downwardly between an open position, whereby the ram  20  may enter the container  10  to compact waste, and a closed position, whereby the opening in the container  10  is closed off by the gate  30 , preventing waste from falling back into the loading chamber/area  32 . In an embodiment, the gate  30  may be motor driven through one or more connecting chains or linkages  33 , although other driving means may be utilized without departing from the broader aspects of the invention. The gate  30  is selectively movable under control of the controller  50 , and in response to feedback received from the pressure sensors and/or a position of the ram  20 , as discussed hereinafter (and is thus likewise communicatively coupled therewith). 
     In an embodiment, the system  100  may include a display (not shown) for indicating a level of waste within the container  10 , a detected by the sensors. In an embodiment, the controller  50  may be configured to generate an alert, e.g., a visual indication or audible alert as to the level of waste within the container  10 , including, for example, an alert when the container  10  is at capacity or near capacity. 
     Turning now to  FIGS. 6 and 7 , schematic illustrations of the operation of the system are shown. With reference to  FIG. 6 , the ram  20  is in the retracted position and the gate  30  is up (also referred to as being in a retracted position). Waste, trash, refuse  80  or the like can then be loaded into the loading area  32  through the hopper  16 . The ram  20  is then actuated to compact the waste  100  into the container  10 . In doing so, the pressure sensor(s)  22 ,  24 ,  26  sense the force of the waste  100 , providing feedback to the controller  50 . (In  FIGS. 6 and 7 , the pressure sensor  22  is located on the back wall of the container  10 , and is activated by a linearly movable wall  38  within the container  10  that presses against the sensor  22  under force from the ram  20 . 
     In an embodiment, once a certain pressure level is reached (or if certain sensors detect the presence of trash), the controller  50  may automatically lower the gate  30  as the ram  20  is retracted to prevent spring-back or fallback of waste  100  into the loading area  32 .  FIG. 7  illustrates movement of the gate  30  to the lowered/closed position and the ram  20  retracted from the container  10 . As the gate  30  is lowered, the bars or fingers  34  in the gate  30  are received in the corresponding grooves  36  of the ram  20 , as discussed above. In an embodiment, each of the grooves  36  may have an associated flap cover that prevents waste from entering into the grooves  36  and obstructing the fingers  34 . Importantly, the flap covers are only movable in one direction (pivoting outwardly from the face of the ram  20 . The flap covers, therefore, are not moveable inwardly, preventing trash or waste from entering the grooves  36 . 
     In particular, in operation, the ram  20  is withdrawn to a position such that the grooves  36  are directly beneath the gate  30  (and the fingers  34  thereof). The gate  30  is then lowered so that the fingers  34  of the gate  30  are received in the grooves  36  on the front face of the ram  20 . At this point, the ram  20  is retracted, whereby during such movement the flap covers are opened (by simple retraction of the ram and under contact with the fingers  34  as the am pulls back). The ram  20  can then be fully retracted past the loading area  32 . 
     Importantly, the gate  30 , in its lowered position, prevents waste  100  from inside the container  10  from spilling out into the loading area  32 . This maintains a clear loading area  32  for more waste  100  to be loaded, and obviates the possibility that a user will be deceived into thinking that the container  10  is full by observing waste in the loading area  32 . Once additional waste is loaded into the loading area, the gate may be retracted and the ram  20  activated to compact the waste into the container  10 . 
     Importantly, in an embodiment, the gate  30  is automatically deployed and retracted by the controller  50  in dependence upon feedback received from the sensor(s) and/or the position of the ram  20 . In particular, in an embodiment, the gate  30  may be lowered or closed when a certain pressure threshold (as detected by the sensor) is reached, or simply when waste is sensed by one or more of the sensors (e.g., sensor  26 ). The ram  20  may then be retracted out of the container  10  and past the loading area  32 . Similarly, when the ram  20  is activated to compact waste, the gate  30  may be correspondingly raised to make room for the ram  20  to enter. In other embodiments, the gate  30  may be manually activated. 
     Importantly, therefore, the present invention provides a compacting system  100  that prevents compacted waste from falling back into the loading area  32 , which could deceive a user into thinking that the container  10  is full, as well as obstructing the loading of additional waste into the loading area  32 . Furthermore, the system  100  of the present invention includes one or more sensors  22 ,  24 ,  26  that provide feedback as to the level of waste within the container  10 , which can be used to trigger automatic lowering of the gate  30 , as well as provide information as to the actual level of waste in the container  10  to prevent premature emptying/carry-away/disposal. 
     While the above description provides examples of the embodiments, it will be appreciated that some features and/or functions of the described embodiments are susceptible to modification without departing from the spirit and principles of operation of the described embodiments. Accordingly, what has been described above has been intended to be illustrative of the invention and non-limiting and it will be understood by persons skilled in the art that other variants and modifications may be made without departing from the scope of the invention as defined in the claims appended hereto. The scope of the claims should not be limited by the preferred embodiments and examples, but should be given the broadest interpretation consistent with the description as a whole.