1. Field of the Invention
Material sorting discs and material sorting screen.
2. Description of the Related Art
Discs, rolls, screens, and/or other types of material sorting systems may be used as part of a multi-stage materials separating system. For example, material sorting systems may be used in the materials handling industry for screening large flows of materials to remove certain items of desired dimensions, or in classifying desired materials from residual materials. The material sorting system may separate the materials fed into it by size. The size classification may be adjusted to meet virtually any specific application.
The material being separated and/or classified may consist of various constituents, such as soil, aggregate, asphalt, concrete, wood, biomass, ferrous and nonferrous metal, plastic, ceramic, paper, cardboard, or other products or materials recognized as material throughout consumer, commercial and industrial markets.
A major problem with disc and/or roll screens is jamming Material that jams between the disc/roll and the adjacent shaft may, in some cases, physically cause the screen to stop working properly, or produce momentary stoppages. Such stoppages may not cause the drive mechanism of the material sorting system to turn off but they may cause substantial mechanical shock. This mechanical shock may eventually result in the premature failure of the material sorting system's assemblies and drive mechanism.
A disc for a material separation screen is herein disclosed, as comprising a first side, a to second side located on an opposite side of the disc as the first side, and a contact surface adjoining both the first side and the second side. A width of the contact surface may vary along a perimeter of the disc.
A disc screen is herein disclosed, as comprising a shaft, a first disc mounted on the shaft, and a second disc mounted on the shaft. An interfacial opening (IFO) may extend between the first disc and the second disc. A width of the IFO, as measured between the first disc and the second disc, may vary according to a rotational position of the IFO about the shaft.
A length of the IFO may be made to vary according to a rotational position of the IFO about the shaft. The length of the IFO may be measured between one or more shafts, spacers, and/or discs. In some embodiments, both the width and length of the IFO may be made to vary at the same time. A distance as between two discs located on parallel spaced apart shafts may be made to vary as a function of angular rotation of one or both of the two discs and/or two shafts.
The foregoing and other objects, features and advantages of the invention will become more readily apparent from the following detailed description and accompanying drawings.
Material separation systems, including disc screens, may have a screening bed with a series of rotating spaced parallel shafts. Each shaft may have a longitudinal series of concentric screen discs separated by spacers which interdigitate with the screen discs of the adjacent shafts. The relationship of the discs and/or spacers on one shaft to the discs and/or spacers on each adjacent shaft form an opening generally known in the industry as an interfacial opening or “IFO”. The IFO may be configured such that only material of acceptable size is allowed to pass downwardly through the disc screen. The acceptable sized material which drops through the IFO is commonly referred to in the industry as “Unders”.
The discs on the disc screen may all be driven to rotate in a common direction from an infeed end of the screening bed to an outfeed or discharge end of the screening bed. Thus, materials which are larger than the IFO, referred to in the industry as “Overs”, may be advanced on the screening bed to the outfeed end, where they may be sorted and/or processed further.
Material to be screened may be delivered to an infeed end 22 of screen bed 14 as indicated by directional arrow A. The constituents of sufficiently small and/or acceptable size (i.e., Unders) drop through the IFOs associated with discs 18 and are received in a hopper 24. Materials and/or constituents which are too large to pass through the IFOs (i.e., Overs) may be advanced and discharged, as indicated by directional arrow B, from end 26 of screening bed 14.
A plurality of discs, including a second disc 32, may be mounted in a spaced-apart parallel orientation on a second shaft 16B. As first shaft 16A and/or second shaft 16B rotate, the first disc 31 may be separated from the second disc 32 by a disc space Dsp. Each of the discs 18 on first shaft 16A may be separated from adjacent discs, located on second shaft 16B, by a disc space. In some embodiments, the distance associated with disc space Dsp remains constant as first disc 31 and/or second disc 32 are rotated about their respective shafts 16A, 16B.
The discs 18 may be mounted on first shaft 16A in a substantially coplanar row in substantially parallel relation and radiating outwardly at right angles to the longitudinal axes of first shaft 16A. The discs 18 can be held in place by the spacers 30. The discs 18 and/or spacers 30 may comprise central apertures to receive first shaft 16A therethrough. The spacers 30 may be of substantially uniform size and placed between the discs 18.
Depending on the character and size of the material to be sorted and/or classified, the discs 18 may range from a few inches to more than a foot in diameter. Again, depending on the size, character and quantity of the material, the number of discs per shaft range from several discs to several dozen discs.
A perimeter of the first disc 31 and/or the second disc 32 may be defined by three sides having substantially the same degree of curvature. For example, the perimeter of the first disc 31 may be defined by drawing an equilateral triangle which has vertices A1, B1, and C1, and thereafter drawing three arcs.
A first side may be defined by drawing a first arc between vertices B1 and C1 using vertex A1 as the center point of the first arc. A second side may be defined by drawing a second arc between vertices C1 and A1 using vertex B1 as the center point for the second arc. And a third side may be defined by drawing a third arc between vertices A1 and B1 using vertex C1 as the center point of the third arc. The disc space Dsp between first disc 31 and second disc 32 may be determined as the distance between vertex C1 of the first disc 31 and vertex A2 of the second disc 32.
In some embodiments, first disc 31 and/or second disc 32 may be mounted as disc assemblies or disc sets arranged concentrically and in an axially extending relation on the one or more hubs 28 complementary to and adapted for slidable concentric engagement with the perimeter of first shaft 16A and/or second shaft 16B. First disc 31 and/or second disc 32 may comprise central apertures to receive the hubs 28 therethrough. First disc 31 and/or second disc 32 may be attached in spaced relation to other discs axially along the hubs 28 in any suitable manner, as for example by welding or applying mounting bolts and/or brackets.
First disc 31 and/or second disc 32 may have a perimeter shaped so that disc space Dsp remains substantially constant during rotation of one or both discs 31, 32. The disc space Dsp may change location, or shift laterally towards either first shaft 16A or second shaft 16B, during the rotation of first disc 31 and/or second disc 32. As first disc 31 and/or second disc 32 rotate, they may move the material in an up and down fashion which creates a sifting effect and facilitates classification and/or sorting of the material.
1) determining the desired center distance L between adjacent shafts
2) determining the desired clearance or gap Dsp between adjacent coplanar discs; and
3) drawing a square having corners A, B, C, and D and side length S.
The side length S may be calculated as follows:
S=(L−Dsp)*COS 45/COS 22.5.
Where S is the length of side S of disc 18a, L is the distance between shafts and/or centers of rotation of two adjacent discs, and Dsp is the distance between the two adjacent discs.
Arcs may then be drawn between corners A and B, B and C, C and D, and D and A. to The radii R of the arcs may be calculated as the difference between distance L and the disc space Dsp, or where
R=L−D
SP.
Disc 18a may be used for classifying materials which are more fragile or delicate. As the number of sides of the discs are increased, from 3 to 4 or 5 (or more) for example, the amplitude of rotation decreases. While discs having fewer sides may enhance the sifting action of the screen, the associated higher amplitudes of the sifting action may be more likely to damage delicate or fragile materials.
A disc screen, or combination of disc screens, may be used to sort small, intermediate, and large sized materials, as discussed above. In the case of sorting small sized materials, in particular, the material may tend to adhere to itself (e.g., clump) and/or adhere to the discs, particularly in humid operating conditions, or where the material itself contains a sufficiently high level of liquid saturation or wet components. The adhesion may result in less efficient separation of the materials, with clumps of materials being improperly sorted as larger sized Overs and, in some cases, may obstruct and/or “jam” the discs.
First disc 51 and second disc 52 are illustrated as having three sides, although discs having more sides may be used. First disc 51 may have three vertices, or corners, which connect the three sides. For example, first disc 51 may have a first vertex A1, a second vertex B1, and a third vertex C1. Similarly, second disc 52 may have a first vertex A2, a second vertex B2, and a third vertex C2.
As compared to
One or more discs on first shaft 61 may be separated from one or more discs on second shaft 62 by disc space Dsp. For example, first disc 64 may be separated from an adjacent disc, such as third disc 66, by disc space Dsp. Second disc 68 may also be separated from fourth disc 69 by disc space Dsp.
First disc 61 is shown as including a curved profile, or varied disc width, from a first width T0, to a second width T1. The second width T1 may be greater than the first width T0. As first disc 64 rotates about first shaft 61, the width of the first disc 64 when measured from a position that is adjacent third disc 66 may continuously vary between first width T0 and second width T1. The proximate width of one or more of second disc 68, third disc 66, and/or fourth disc 69 may similarly vary when the discs are rotated past a fixed point and/or position.
Disc 67 may be illustrative of one or more of the discs 64, 66, 68, and/or 69 of
A width of contact surface S0 may vary along a perimeter of disc 67. The width of contact surface S0 may continuously vary along the perimeter of the disc 67. Contact surface S0 may intersect first side S1 along an edge of disc 67. The edge may comprise a convex shape relative to a position located normal to the contact surface S0. In some embodiments, at least a portion of the width of contact surface S0 may vary according to a parabolic function. For example, contact surface S0 may vary from the narrowest width at width T0, to the greatest width at width T1, and then back to width T0. The variation in width of the disc 67 may be more or less than that shown in this and various other figures for purposes of illustration.
Additionally, or alternatively, the edge at which contact surface S0 intersects first side S1 may comprise a concave shape relative to a position located normal to the contact surface S0. At least a portion of the width of contact surface S0 may vary according to a hyperbolic function. For example, contact surface S0 may vary from the greatest width at width T1, to the narrowest width at width T0, and then back to width T1. The two edges of contact surface S0 may vary form alternating parabolic and hyperbolic outlines along the perimeter of disc 67. Contact surface S0 may vary continuously between width T0 and width T1 along the perimeter to of disc 67.
At least one edge of contact surface S0 may vary between a convex shape and a concave shape, and in some embodiments, the at least one edge may continuously vary between the convex shape and the concave shape. The edge at which contact surface S0 intersects first side S1 and/or second side S2 may be sinusoidal in shape.
A first side S4 may comprise a first section S5 of disc 67C which may vary from the narrowest width at width T0, to the greatest width at width T1. Additionally, first side S4 may comprise a second section S7 which may vary from the greatest width T1, and to the narrowest width T0. The width of disc 67C may vary linearly between width T0 and width T1, and/or from width T1 to width T0. In some embodiments, each of the three sides S4, S6, and S8 may vary linearly between width T0 and width T1 and/or between width T1 and width T0.
Width W0 of the IIFO may extend between the side of first disc 64 and the side of second disc 68. Additionally, width W0 of the IFO may extend between the side of third disc 66 and the side of fourth disc 69. Length W1 of the IFO may be formed between adjacent shafts, such as first shaft 61 and second shaft 62. In some embodiments, length W1 of the IFO may extend between spacers or secondary discs mounted on first shaft 61 and/or second shaft 62. The spacers and/or secondary discs may be mounted intermediate first disc 64 and second disc 68 and/or between third disc 66 and fourth disc 69, respectively.
A disc space Dsp may exist between discs mounted on shafts 61 and 62. First shaft 61 and second shaft 62 may rotate in the same direction. In some examples, first shaft 61 and second shaft 62 may rotate at the same rotational speed.
As width T1 is greater than width T0, the width W0 of the IFO as illustrated in
The disc space Dsp between first disc 64 and third disc 66 may equal the disc space Dsp between second disc 68 and fourth disc 69. In some embodiments, disc space Dsp remains uniform, constant, and/or does not change as the discs and shafts rotate.
The widths of first disc 64 and second disc 68 are shown as having an approximate width T0 at the portion of the discs adjacent the IFO. The widths of third disc 66 and fourth disc 69 are shown as having an approximate width T2 at the portion of the discs adjacent the IFO. Width T2 may be understood as being a width which is greater than width T0 and less than width T1. In some examples, width T2 is intermediate width T0 and width T1.
Again with reference to
Second shaft 62 (and the associated discs 66, 69) may be rotationally offset from first shaft 61 (and its associated discs 64, 48) by a fixed amount of rotation. In some embodiments, first shaft 61 may rotate at a different speed than second shaft 62. Third disc 66 and fourth disc 69 may become rotationally offset from first disc 64 and second disc 68 due to the difference in rotational speed. The amount of rotational offset may vary with time.
First shaft 61 and/or second shaft 62 may comprise one or more spacers and/or discs located intermediate discs 64 and 68, and discs 66 and 69 respectively. The one or more spacers and/or discs may similarly be rotationally offset in order to vary length W1 of the IFO as one or both of first shaft 61 and second shaft 62 rotate.
The size of the IFO can be adjusted by employing spacers of various lengths and widths corresponding to the desired sized opening without replacing the shafts or having to manufacture new discs. The distance between adjacent discs can be changed by employing spacers of different lengths. Similarly, the distance between adjacent shafts (e.g., the length of the IFO) can be changed by employing spacers of different radial widths. The location of the shafts can be adjusted to also vary the size of the IFOs.
First disc 64 may comprise a first side 64A adjacent the IFO, and a second side 64B located on an opposite side of first disc 64 as the first side 64A. A distance between first side 64A and second side 64B may vary between width T0 and width T1 according to a rotational position of first disc 64 about its axis of rotation and/or about a shaft. Similarly, second disc 74 may comprise a first side 74A adjacent the IFO, and a second side 74B located on an opposite side of second disc 74 as the first side 74A. A distance between first side 74A and second side 74B may vary between width T0 and width T1 according to a rotational position of second disc 74 about its axis of rotation and/or about a shaft.
The width of the IFO may vary as a function of the widths of the first disc 64 and/or second disc 74. For example, a width W2 of the IFO at width T0 of second disc 74 is shown as being greater than width W3 of the IFO at width T1 of second disc 74. First disc 64 may comprise a contact surface having a width corresponding to the distance between first side 64A and second side 64B. The width of the contact surface may vary according to the rotational position of first disc 64 about the shaft. The width of the IFO may vary as a function of both the width of the first disc 64 and the width of the second disc 74.
A portion of first side 64A and/or second side 64B of first disc 64 may comprise a convex surface. In some embodiments, a portion of the width of the contact surface adjoining to first side 64A and second side 64B of first disc 64 may vary according to a parabolic function. Additionally, a portion of first side 64A and/or second side 64B of first disc 64 may comprise a concave surface. In some embodiments, a width of the contact surface adjoining first side 64A and second side 64B may vary according to a hyperbolic function.
The first disc 76 may comprise a first side 76A and a second side 76B. Similarly, the second disc 78 may comprise a first side 78A and a second side 78B. An IFO may extend between first side 76A of first disc 76 and first side 78A of second disc 78. First disc 76 is illustrated as having a width 73 with a uniform thickness around its perimeter. In some embodiments, second disc 78 may also have a width of uniform thickness.
One or more of sides 76A, 76B, 78A, and/or 78B may vary between a convex shape and a concave shape, and in some embodiments, may continuously vary between the convex shape and the concave shape. The one or more of sides 76A, 76B, 78A, and/or 78B may be sinusoidal in shape.
The IFO may vary in width according to a rotation of one or both of first disc 76 and second disc 78, according to a change in proximate distance between first side 76A of first disc 76 and first side 78A of second disc 78. For example, a first width W4 measured at a first position of rotation is illustrated as being greater than a second width W5 measured at a second position of rotation.
The first disc 75 may comprise a first side 75A and a second side 75B. Similarly, the second disc 77 may comprise a first side 78A and a second side 77B. An IFO may extend between first side 75A of first disc 75 and first side 77A of second disc 77. First disc 75 is illustrated as having a width 73 of approximately uniform thickness around its perimeter. In some embodiments, second disc 77 may also have a width of uniform thickness.
One or more of sides 75A, 75B, 77A, and/or 77B may comprise a plurality of angled and/or beveled shapes, forming a series of linear connected segments that form the perimeter of first disc 75 and/or second disc 77, respectively.
The IFO may vary in width according to a rotation of one or both of first disc 75 and second disc 77, according to a change in proximate distance between first side 75A of first disc 75 and first side 77A of second disc 77. For example, a first width W6 measured at a first position of rotation is illustrated as being greater than a second width W7 measured at a second position of rotation
Secondary disc 82 may be located adjacent primary disc 81 and share a common axis of rotation. Secondary disc 82 may also have three arched sides S2 that form an outside perimeter substantially the same shape as primary disc 81, but with a smaller footprint. For example, the outside perimeter of secondary disc 82 may be smaller than the outside perimeter of primary disc 81. One side S2 of secondary disc may be formed between vertex 82A and vertex 82B of secondary disc 82. Secondary disc 82 may comprise three vertices, including first vertex 82A, second vertex 82B, and third vertex 82C.
Composite disc assembly 80 may be made from a unitary piece of rubber, polymer, nylon, plastic, steel, metal, other materials of varying hardness and/or softness, or any combination thereof. A softer material, such as rubber, may provide more friction force, whereas a harder material, such as steel, may have improved durability. In some embodiments, primary disc 81 may be formed from a separate piece and/or pieces of material as secondary disc 82. Primary disc 81 may comprise a first material and/or first combination of materials, and secondary disc 82 may comprise a second material and/or second combination of materials. The second material may be harder than the first material. In other embodiments, the first material may be harder than the second material.
Composite disc assembly 80 may comprise a spacer 83. The spacer 83 together with primary disc 81 and secondary disc 82 may be mounted on a shaft 16. Spacer 83 may comprise a plurality of sides, such as side S3. In some embodiments, spacer 83 may comprise six sides formed between a plurality of vertices, such as vertices 83A, 83B, 83C, 83D, 83E, and 83F, although more or fewer numbers of sides and/or vertices are contemplated herein.
In some embodiments, spacer 83 may comprise a third disc, having a plurality of arched sides. Spacer 83 may be associated with a smaller perimeter than secondary disc 82. Spacer 83 may be formed from the same material as primary disc 81 and/or secondary disc to 82. Additionally, spacer 83 may be formed from a single unitary piece of material as primary disc 81 and/or secondary disc 82, or from a separate piece and/or pieces of material.
An IFO may extend laterally between secondary disc 82 of first disc assembly 80 and a primary disc 87 of the second disc assembly 85. Additionally, the IFO may extend laterally between a primary disc 91 of third disc assembly 90 and a secondary disc 97 of the fourth disc assembly 95. The IFO may extend longitudinally between spacer 83 of first disc assembly 80 and a spacer 93 of fourth disc assembly 95.
Primary disc 81 of first disc assembly 80 may be mounted in lateral alignment with a secondary disc 92 of third disc assembly 90. Additionally, secondary disc 82 may be mounted in lateral alignment with primary disc 91 of third disc assembly 90.
In some embodiments, primary discs 81, 87 may maintain a substantially constant spacing (e.g., disc space) with secondary discs 92, 97, respectively, during rotation. The primary discs 81, 87 may be alternating aligned with the secondary discs 82, 89 laterally across each shaft. Similarly, primary discs 81, 87 may be longitudinally aligned with secondary discs 92, 97 on the adjacent shaft.
Composite disc assemblies 80, 85, 90, 95 may comprise one or more discs and/or spacers having a triangular profile with three arched sides. However, the discs can have any number of arched sides, such as the example shown by the four sided disc in
The different sizes and alignment of the discs on the adjacent shafts may create a stair-step shaped spacing laterally between the discs on the two shafts. Different spacing between the primary discs and secondary discs, as well as the size and shapes of the primary and secondary discs can be varied according to the types of materials being separated.
Spacer 93 may be rotationally offset from spacer 83. Rotationally offsetting one or more of the spacers 83, 93 may cause the longitudinal length W1 of the IFO to vary during rotation. Accordingly, both the lateral and longitudinal dimensions of the IFO may be made to vary through a rotation of one or more of the disc assemblies 80, 85, 90, 95. The lateral width W0 and the longitudinal length W1 may vary at the same time, or concurrently with each other.
In some embodiments, primary disc 91 may be rotationally offset from secondary disc 82. Similarly, primary disc 87 may be rotationally offset from secondary disc 97. Rotationally offsetting one or more discs may cause the disc spacing between adjacent discs to vary during rotation.
It will be understood that variations and modifications may be effected without departing from the spirit and scope of the novel concepts of this invention.
This application is a continuation of U.S. application Ser. No. 13/683,982 filed Nov. 21, 2012, which is herein incorporated by reference in its entirety.
Number | Date | Country | |
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Parent | 13683982 | Nov 2012 | US |
Child | 14628789 | US |