Patent Grant
9573333
The present invention relates to a double-acting apparatus and method for manufacturing metal scrap compression materials, and more particularly, to a double-acting apparatus and method for manufacturing metal scrap compression materials, in which a variety of shapes of collected metal scrap are compressed into pieces having a standardized shape such that they can be directly loaded into a blast furnace, thereby enhancing productivity.
The inventor of the present invention proposed an apparatus and method for manufacturing metal scrap compression materials as disclosed in Korean Patent No. 10-1134916 issued Apr. 17, 2012, entitled “Metal Scrap Compression Material and Manufacturing Apparatus and Manufacturing Method thereof” to Lee Tae Ho (hereinafter, referred to as “the cited reference”), in which the compression materials can be efficiently melted and the inner layer thereof can be observed.
The cited reference relates to metal scrap compression materials having at least one through-hole and an apparatus and method for manufacturing such metal scrap compression materials. The scrap compression materials are manufactured using a metal scrap compression apparatus, as shown in
Since metal scrap compression materials which are manufactured by the cited reference as above have at least one through-hole, when these metal scrap compression materials are loaded into a melting furnace, molten metal not only contacts the circumference of the metal scrap compression materials but also permeates into the central portions of the metal scrap compression materials through the through-holes. Consequently, the metal scrap compression materials can be melted at a fast rate like small pieces of metal scrap compression materials, thereby greatly reducing the amount of energy that is consumed in the manufacture of metal products.
In addition, according to the manufacturing apparatus of the cited reference, when forming the through-hole in the metal scrap compression material, the metal scrap around the core 201 is first compressed in the first low-density compression process of compressing the metal scrap, and the compression of the metal scrap is completed in the second high-density compression process of compressing the metal scrap. It is therefore possible to minimize friction and stress that are applied to the core 201 from the metal scrap during the compression process.
In particular, in the cited reference, the length of the core 201 that is exposed inside the compression chamber in order to form the through-hole in the metal scrap compression material is set to the length of the actual through-hole of the metal scrap compression material. In the first and second compression processes, bending stress due to a variation in the density of the metal scrap is minimized. Furthermore, since the core itself is short, deformation is minimized, thereby significantly improving endurance. Accordingly, the apparatus can operate reliably and its longevity is increased.
Furthermore, in the cited reference, the first and second compression processes are carried out after the metal scrap has been loaded in the state in which the core is erected in the compression chamber. It is therefore possible to prevent the metal scrap from being caught between the core 201 and the cover 601 and between the core 201 and the bottom of the compression chamber 140, which would otherwise obstruct the operation, irrespective of the shape or type of the metal scrap. Accordingly, the apparatus can smoothly and reliably operate.
As mentioned above, the cited reference is configured such that the metal scrap is compressed twice in the first and second compression processes while surrounding the core 201, and the length of the core that corresponds to the length of the actual through-hole is exposed, unlike in a traditional metal scrap compressing apparatus. Therefore, the apparatus of the cited reference exhibits advanced properties, such as high strength and toughness, little bending or deformation, irrespective of high-pressure friction being applied to the metal scrap, increased longevity and a minimized possibility of breakdown. According to the cited reference, however, a minimum amount of time (e.g. 160 seconds) is required for the entire process of manufacturing one compression material from the metal scrap. The manufacturing process includes loading the metal scrap for first and second compression processes, starting the first compression using the first compression plate 150 by actuating the first compression cylinder 110, starting the second compression using the second compression plates 160 after the first compression is complete, and discharging the compression material after the second compression is complete. However, in this manufacturing process, it is difficult to further decrease the overall process time, thereby productivity cannot be increased, which is problematic.
Although a method for fabricating, constructing and using two or more apparatuses for manufacturing metal scrap compression materials can be considered, this requires an enormous manufacturing cost and the area required to accommodate the facilities is doubled. In addition, a labor cost is inevitably doubled in order to operate the two individual apparatuses. Therefore, the introduction of a more efficient apparatus for manufacturing metal scrap compression materials is required.
Accordingly, the present invention has been made keeping in mind the above problems occurring in the related art, and is intended to provide a double-acting apparatus and method for manufacturing metal scrap compression materials, in which one apparatus for manufacturing metal scrap compression materials can exhibit a high level of productivity that is similar to a level of productivity that would be obtained by operating two apparatuses for manufacturing metal scrap compression materials.
In an aspect for realizing the foregoing object, the present invention provides a double-acting apparatus and method for manufacturing metal scrap compression materials, in which two compression chambers are disposed at both sides of a first compression cylinder such that metal scrap is loaded into the compression chambers. In particular, when one of first press plates moves forward inside a first compression space of one of the compression chambers, the other one of the first press plates moves backward and returns to an idle position.
The upper portions of the compression chambers are opened or closed by cover cylinders. A compression material is manufactured using second press plates which slide by power from second compression cylinders at both sides of second compression spaces of the two compression chambers, and is discharged to the outside.
The direction in which compression is carried out by the first press plates disposed in the two compression chambers is orthogonal to the direction in which compression is carried out by the second press plates in the two compression chambers. One core is disposed in each of the two compression chambers. The core is erected at each center of the second compression chambers such that it is orthogonal to each of the direction in which the first press plate is compressed and the direction in which the second press plates is compressed.
One core cylinder is disposed in each of the two compression chambers in order to lift up the core, and is disposed on the bottom such that the core can be retracted to a level that is at or below the bottom plate of the compression chamber or the upper end of the core can be protruded to a height at which it adjoins the undersurface of a cover.
According to the present invention as described above, it is possible to sequentially compress metal scrap which is loaded into two compression chambers using only one first compression cylinder which occupies a large area due to its large volume. It is therefore possible to carry out the process of compressing the metal scrap in one compression chamber while carrying out the process of discharging a compression material, the compression of which has been completed, from the other compression chamber and loading new metal scrap into the other compression chamber.
Accordingly, there are the following effects: Even though the overall fixed time is somewhat increased, the time required for the manufacture of each material is significantly decreased since compression materials are continuously manufactured. Also, it is more possible to decrease a labor cost than in the case in which the two apparatuses are fabricated and constructed. Since only the construction of one first compression cylinder is required, it is possible to reduce power consumption of, for example, a hydraulic motor.
A double-acting apparatus for manufacturing metal scrap compression materials includes: a core which is vertically erected in the central portion of a compression chamber, and a first press plate which is to be actuated by a first compression cylinder, and a second press plate which is to be actuated by a second compression cylinder, the second press plate being disposed so as to orthogonally intersect the first press plate. First compression cylinders and first press plates are additionally disposed at both left and right end sides of the compression chamber about the first cylinder, and each length of the first compression cylinders which are disposed at both left and right end sides of the compression chamber is half of the length of the first compression cylinder which is disposed at the center.
In order to illustrate the detailed operation of the double-acting apparatus for manufacturing metal scrap compression materials according to the present invention, the overall configuration of the manufacturing apparatus is shown in a perspective view of
The upper portions of the compression chambers 140 are opened or closed by cover cylinders 600. A compression material 100 is compressed by second press plates 160 which slide by power from second compression cylinders 120 at both sides of second compression spaces 400 of the two compression chambers 140, and is discharged through a discharge hole 501.
The direction in which compression is carried out by the first press plates 150 disposed in the two compression chambers 140 is orthogonal to the direction in which compression is carried out by the second press plates 160 in the two compression chambers 140. One core 201 is disposed in each of the two compression chambers 140. The core 201 is erected at each center of the second compression chambers 400 such that it is orthogonal to each of the direction in which the first press plate 150 is compressed and the direction in which the second press plates 160 is compressed.
One core cylinder 200 is disposed in each of the two compression chambers 140 in order to lift up the core 201, and is disposed on the undersurface of a discharge plate 502 such that the core 201 can be retracted to a level that is at or below the height of the discharge plate 502 or be protruded to a height at which it adjoins the undersurface of a cover 601.
The present invention having the above-described configuration differs from the cited reference in which one first press plate 150 is fixed to the first compression cylinder 110 so as to slide. Rather, each of the first compression cylinders 110 of the present invention is manufactured such that the pistons thereof protrude in opposite directions. In particular, both ends of each piston protrude into the two compression chambers 140, and each end of the piston is fixed to the corresponding first press plate 150.
Therefore, the two first press plates 150 carry out the conflicting operations in the compression chambers 140 in response to actuation of the first compression cylinders 110. Consequently, when a compression process is being carried out in the state in which the cover 601 is closed after scrap has been loaded into one compression chamber 140, the first and second press plates 150 and 160 return and the core 201 moves down in the other compression chambers 140. After the cover 601 is opened and the compression material 100 is discharged, new metal scrap can be loaded. Accordingly, one worker can manage and operate the double-acting apparatus for manufacturing metal scrap compression materials.
A detailed description will be given below of the process that is concurrently carried out in the two compression chambers 140 according to the present invention.
First, the basic process according to the present invention is shown in
In the meantime, the compression chamber 140 in the right part of the figure is covered with the cover 601. However, the cover 601 is not shown in order to illustrate the inside of the compression chamber 140, which is marked with solid lines. At present, the first press plate 150 of the first compression cylinder 110 has advanced to the end toward the core 201, thereby completing first compression. The second press plates 160 of the second compression cylinders 120 at both sides of the first press plate 150 are waiting to be operated.
In this state, the cover 601 in the left part of the figure is erected and opened by the cover cylinder 600, so that any compression material that has been completely compressed is discharged in a continuous process. However, there is no compression material that has been completely compressed because this is the initial state. Illustrations of the cover cylinders 600 or the like are omitted for the sake of convenience.
In this state, as shown in
After the second compression has been carried out, during a suspension time, the operations of lifting up the core 201, loading new scrap, and closing the cover 601 are carried out in response to actuation of the core cylinder 200.
Afterwards, first compression is carried out in the compression chamber 140 in the left part of the figure, and the first and second press plates 150 and 160 are retracted in response to actuation of the first and second compression cylinders 110 and 120, the state of which is shown in
When this state is maintained, in the compression chamber in the left part of the figure, the compression using the first press plate 150 is completed. In the compression chamber in the right part of the figure, the first and second press plates completely return to the idle positions, and the core 201 is moved down in response to actuation of the core cylinder
In sequence, as shown in
In the subsequent operation, as shown in
In sequence, the present invention determines whether or not an operation stop button for stopping a typical power supply which is not shown is pressed. When the operation stop button is pressed, the supply of power is stopped, and all operations are stopped.
When the operation stop button is not pressed, the compression chamber 140 in the left part of the figure instantly proceeds to a suspension time. In the compression chamber in the right part of the figure, the operations of lifting up the core 201 using the core cylinder 200, loading scrap, and closing the cover 601 using the cover cylinder are carried out. Afterwards, first compression is carried out using the first press plate 150. In the left part of the figure, the first and second press plates 150 and 160 return to the idle positions, and the core 201 is moved down, as shown in
In addition, an embodiment of the present invention is also shown, wherein the embodiment includes the discharge holes 501 through which the compression material 100 is discharged to the bottom of the two compression chambers 140 in order to take out the compression material 100 after the compression thereof has been completed, the discharge plates 502 which close or open the discharge holes 501, and hydraulic cylinders 504 which slide the discharge plates 502. The hydraulic cylinders 504 serve to slide the discharge plates 502 to which the core cylinders 200 are fixed. According to this embodiment, the cores 201 are moved down in response to actuation of the core cylinders 200, and the discharge plates 502 and the core cylinders 200 are moved in response to actuation of the hydraulic cylinders 504. The metal scrap compression materials 100 can drop through the discharge holes 501 and be discharged to the outside as being moved on a conveyor that is positioned below. In sequence, the hydraulic cylinders 504 are actuated again in order to return the discharge plates 502 and the core cylinders 200 to the original positions.
In addition to this embodiment, it may be difficult to construct and operate facilities precisely because of poor or undesirable site conditions. In such a case, it is possible to pick up and deliver the compression material using an excavator after a time point when the core 201 is moved down and released from the compression material, as will be described in Embodiments 1 and 2.
In addition, according to the present invention, in the compression chamber 140 in the left part of the figure, when the cover 601 is closed in response to actuation of the cover cylinder 600, the piston is fitted into a locking hole in the compression chamber 140, so that the cover 601 is firmly fixed while covering the compression chamber 140.
Since the present invention as described above is intended to sequentially compress the metal scrap loaded in two compression chambers 140 using one first compression cylinder 110, a suspension time is set in order to synchronize the processes in the two compression chamber 140. Accordingly, the continuous processes are smoothly carried out even though one first compression cylinder 110 is shared in the two compression chambers 140.
In this method according to the present invention, a number of essential processes that must be carried out in order to compress the metal scrap require different amounts of time. Accordingly, when concurrently carrying out the individual processes, certain times required for corresponding processes must be increased. This inevitably leads to a time delay in which, although one process has been completed at one side, it is required to wait for the completion of the corresponding process at the other side before starting the next process at the one side. For this, a suspension time must be set, which causes a considerable amount of overall time delay. However, it can be understood from the following embodiments that productivity per unit time is significantly improved since two compression materials 100 are manufactured.
This will be described in detail as follows with reference to appended
In order to help understanding of an embodiment of the present invention, the process of manufacturing scrap compression materials 100 which are compressed to an intended density by compressing the metal scrap according to the cited reference is described as follows.
First, according to the cited reference, the locking cylinder 602 is actuated so that the piston thereof protrudes from the locking hole, the cover 601 is opened and erected in response to actuation of the cover cylinder 600, and then the core 201 is lifted up into the compression chamber 140 for about 10 seconds. In sequence, metal scrap is loaded into the compression chamber 140. This takes about 20 seconds in a case where the scrap has been prepared in advance. In sequence, the cover 601 is moved down in response to actuation of the cover cylinder 600, and the locking cylinder 602 is actuated so that the piston thereof is fitted into the locking hole formed in the compression chamber 140, thereby firmly closing the cover 601, which takes 13 seconds.
In sequence, the first compression is carried out using the first press plate 150 by actuating the first compression cylinder 110. A time of 34 seconds is required until the first press plate 150 moves to the end. In addition, 22 seconds are required to carry out the second compression using the second press plates 160 of the second compression cylinder 120. After the first compression and the second compression as above are completed, the first and second press plates 160 return to the idle positions in response to actuation of the first and second compression cylinders 110 and 120, which take 24 and 15 seconds.
In addition, 5 seconds are required to move down the core 201 in response to actuation of the core cylinder 200, and 13 seconds are required to erect and open the cover 601 in response to actuation of the cover cylinder 600 after the locking cylinder 602 is actuated so that the piston thereof protrudes from the locking hole. In sequence, the process of discharging the scrap compression material 100 out of the compression chamber 140 is repeated. 19 seconds are required to discharge the compression material using heavy equipment.
In the process of manufacturing scrap compression materials of the related art, the sequential processes must be continuously carried out. Since the processing steps require the absolute times, it is impossible to improve productivity by decreasing the time.
In the related art, as illustrated in
The present invention has been devised considering that it is difficult to reduce the whole process time when the fixed processes are sequentially carried out, and is configured such that the process of the cited reference is carried out in both the compression chambers 140 which are disposed at both sides of the first compression cylinder 110. Since the first press plates 150 disposed at both sides are disposed at opposite positions, different processes are carried out in the compression chambers 140. Accordingly, the process is carried out as shown in the lower part of the table of
Specifically, according to this embodiment of the present invention, as shown in
After such operations are completed, the second press plates 160 in the compression chamber 140 in the right part of the figure start second compression, which operation proceeds for 22 seconds.
In addition, the cover 601 in the compression chamber 140 in the left part of the figure completes the opening operation for 13 seconds. 19 seconds are required to discharge the compression material.
In the compression chamber 140 in the right part of the figure, second compression using the second compression cylinder 120 is carried out for 22 seconds.
In sequence, in the compression chamber 140 in the left part of the figure, about 10 seconds are required to lift up the core 201, 20 seconds are required for the process of loading the metal scrap into the compression chamber 140, and 13 seconds are required to actuate the cover cylinder 600 so that the cover 601 is moved down and then actuate the locking cylinder 602 so that the piston thereof is fitted into the locking hole in the compression chamber 140 so that the cover 601 is firmly closed. During this time, the right compression chamber 140 has a suspension time.
In sequence, the first press plate 150 which is disposed in the compression chamber 140 in the left part of the figure carries out the first compression process for 34 seconds, during which time the first and second press plates 150 and 160 in the right compression chamber 140 return to the idle positions within 24 seconds. In sequence, while the second compression on the metal compression material 100 is being carried out using the second press plates 160 in the left compression chamber 140, the cover is opened for 13 seconds and the compression material is discharged for 19 seconds in the right compression chamber 140. Afterwards, as described above, while the left compression chamber 140 is waiting, the above-described operations of lifting up the core 201, loading scrap, and closing the cover 601 are repeated. Accordingly, the compression can be continuously carried out by operating one compression cylinder 110 in the two compression chambers 140.
According to this embodiment, as indicated in
In addition, according to embodiment 1 of the present invention, only one first compression cylinder 110 which consumes a large amount of power is used. This can lead to the effect of saving electric power compared to the case in which two individual facilities for manufacturing scrap compression materials are fabricated, constructed and used. It is also possible to significantly reduce the manufacturing cost and significantly reduce the area of construction. Furthermore, since only one worker is required to operate the facilities, the present invention can contribute to a reduction in labor cost.
Furthermore, according to the present invention, as shown in
That is, according to this embodiment, both of two masses of metal scrap loaded around the cores 201 inside the compression chambers 140 are compressed using the first compression cylinders 110. Therefore, the length of the first compression cylinders 110 and the length of the pistons thereof can be decreased to be about half of those shown in
In the right part of
Since the first press plates 150 disposed at both sides of the first compression cylinders 110 are disposed at opposite positions, processes are carried out as indicated in the lower part of the comparison table of
Specifically, according to this embodiment of the present invention, as shown in
After such operations are completed, the second press plates 160 in the compression chamber 140 in the right part of the figure start second compression, which proceeds for 22 seconds.
In addition, the cover 601 in the compression chamber 140 in the left part of the figure takes 13 seconds to complete the opening operation, and 19 seconds are required to discharge the compression material.
In sequence, in the compression chamber 140 in the left part of the figure, about 10 seconds are required to lift up the core 201, 20 seconds are required for the process of loading the metal scrap into the compression chamber 140, and 13 seconds are required to actuate the cover cylinder 600 so that the cover 601 is moved down and then actuate the locking cylinder 602 so that the piston thereof is fitted into the locking hole in the compression chamber 140 so that the cover 601 is firmly closed. During this time, the right compression chamber 140 has a suspension time.
In sequence, the first press plates 150 which are disposed in the compression chamber 140 in the left part of the figure carry out the first compression for 20 seconds, during which time the first and second press plates 150 and 160 in the right compression chamber 140 return to the idle positions within 15 seconds. In sequence, while the second compression on the metal compression material 100 is being carried out using the second press plates 160 in the left compression chamber 140, the cover is opened for 13 seconds and the compression material is discharged for 19 seconds in the right compression chamber 140. Afterwards, as described above, while the left compression chamber 140 is waiting, the above-described operations of lifting up the core 201, loading scrap, and closing the cover 601 are repeated. Accordingly, the compression processes can be continuously carried out by operating one compression cylinder 110 in the two compression chambers 140.
According to Embodiment 2 as described above, the time required for actuating the first press plates 150 using the first compression cylinders 110 so that the first press plates 150 perform compression and return to the original positions is about half of the time required for Embodiment 1. Therefore, as indicated in
This embodiment of the present invention is based on the structure of Embodiment 2, except that, as shown in
According to this embodiment, it is of course possible to dispose the locking cylinders 602 and the locking holes 603 at both sides instead of disposing them at the center in
According to this embodiment, when carrying out the operation of moving the cover 601 using the cover cylinder 601 so that the cover 601 is vertically erected or covers the compression chamber 140, the cover 601 of the cover cylinder 600 is not erected or laid in the lengthwise direction, but the piston of the locking cylinder 602 slides along only the short width of the compression chamber 140 that is equal to or shorter than the half of the length. Accordingly, the sliding length of the piston of the cover cylinder 600 is decreased to be half or less. This is shown in
In other words, as shown in
According to this embodiment of the present invention as above, the operation time of the cover cylinder 600 for opening/closing the cover 601 is significantly decreased to be half or less, and the piston slides only the decreased distance. Therefore, the traditional times of 10 seconds and 13 seconds required for opening/closing the cover 601 can be decreased to 5 seconds, which does not exceed the half of the traditional times. In this case, as shown in
This result shows that the two compression materials 100 can be manufactured while the process time is decreased by 1.25%. Accordingly, the time required for each material is decreased from 160 seconds to 79 seconds. This result indicates that 2.026 compression materials can be manufactured in 160 seconds, which is the time required for the manufacture of one compression material in the related art.
In addition, Embodiment 3 is based on Embodiment 2, except that the cover is fixed to the hinge shaft disposed at one edge of the compression chamber, the cover cylinder is disposed at the side of the cover, and the locking cylinder and the locking hole are disposed in the direction identical to that of the cover cylinder.
However, it is of course possible to embody a configuration which is based on the structure of Embodiment 1, in which the compression chambers are disposed at both sides of the first compression cylinder, and the core cylinders, the first press plates and the second press plates using the second compression cylinders are disposed in the compression chambers, except that the cover is fixed to the hinge shaft disposed at one edge of the compression chamber, that the cover cylinder is disposed at the side of the cover, and that the locking cylinder and the locking hole are disposed in the direction identical to that of the cover cylinder.
The present invention is not limited to the certain embodiments that have been described above, but various variations and changes are possible without departing from the concept and idea of the present invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10-2012-0087861 | Aug 2012 | KR | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/KR2013/003320 | 4/18/2013 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2014/025118 | 2/13/2014 | WO | A |
| Number | Name | Date | Kind |
|---|---|---|---|
| 3129656 | Judd | Apr 1964 | A |
| 3141401 | Lindemann | Jul 1964 | A |
| 3577912 | Busi | May 1971 | A |
| 3791289 | Lamorte | Feb 1974 | A |
| 9321232 | Lee | Apr 2016 | B2 |
| Number | Date | Country |
|---|---|---|
| 1134916 | Apr 2013 | KR |
| Number | Date | Country | |
|---|---|---|---|
| 20140158003 A1 | Jun 2014 | US |
