Warp resistant access door assembly for a high temperature combustion chamber

Abstract

A warp resistant fuel feed door assembly for use in injecting supplemental fuel into a high temperature combustion chamber such as a rotating cement kiln without substantial loss of heat or combustion gases. The apparatus, which is positioned on the exterior side of a fuel passage transecting the wall of a rotating kiln, opens to receive fuel and then seals during the balance of the rotation of the kiln. Warping, bearing fracture, shaft distortion and jamming due to exposure to extreme heat and cooling are minimized by the sectional construction of the doors. The door includes a plate positioned over the mouth of the passage, a plurality of support arms attached to the plate and a hinge shaft attached to the arms. Stresses on the door structure from inconsistent expansion of the plate are reduced due to symmetrically spaced oblong and oversized bolt attachment bores in the support arms. Synchronous opening of the feed doors is achieved by levered rotation of the hinge shafts by an electric motor. Selective introduction of supplemental fuel into a rotating kiln can be controlled by electrical actuation of the feed doors.

Description

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not Applicable

REFERENCE TO A COMPUTER PROGRAM APPENDIX

[0003] Not Applicable

NOTICE OF MATERIAL SUBJECT TO COPYRIGHT PROTECTION

[0004] A portion of the material in this patent document is subject to copyright protection under the copyright laws of the United States and of other countries. A portion of the material in this patent document is also subject to protection under the maskwork registration laws of the United States and of other countries. The owner of the copyright and maskwork rights has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the United States Patent and Trademark Office file or records, but otherwise reserves all copyright and maskwork rights whatsoever. The copyright and maskwork owner does not hereby waive any of its rights to have this patent document maintained in secrecy, including without limitation its rights pursuant to 37 C.F.R. §1.14.

BACKGROUND OF THE INVENTION

[0005] 1. Field of the Invention

[0006] This invention pertains generally to high temperature kiln access door assemblies, and more particularly to a warp resistant supplemental fuel feed door assembly for a rotating kiln.

[0007] 2. Description of the Background Art

[0008] Rotating cylindrical kilns are frequently used in the production of cement. Because such kilns operate at extremely high temperatures, it is possible to burn various forms of liquid and solid combustible waste materials as a source of supplemental heat. Waste materials tend to completely combust at the high operating temperatures found in such kilns, which are on the order of 3400 degrees Fahrenheit and above, while producing little or no undesirable gaseous or solid emissions. Therefore, these waste materials can serve as a form of supplemental fuel, thereby reducing the demand for and cost of the primary fuel.

[0009] Worn rubber vehicle tires are particularly suited as a supplemental fuel for a rotary cement kiln. The extremely high temperatures within a cement kiln will cause the rubber tires to burn without any significant liquid, solid or gaseous waste byproducts which might otherwise be detrimental to the environment. Since worn out tires currently present a disposal problem, burning the tires in rotary kilns helps alleviate the growing problem of disposal without impairing the environment.

[0010] Various secondary fuel feed mechanisms have been developed to introduce fuel through a kiln wall into the interior of a rotating cylindrical kiln. Typically, these feed systems have an entrance chute which transects the kiln wall with an outer portion protruding through the outer wall of the kiln and an inner portion protruding into the interior of the kiln. The outer portion of the chute normally includes a feed door which opens to allow passage of the secondary fuel into the kiln. Some feed systems positively inject the supplemental fuel into the kiln using a ram or advancing screw mechanism. Other feed systems known tend to use gravity to inject the supplemental fuel into the kiln. A kiln feed door is utilized in both systems to prevent the escape of heat and combustion gases when the supplemental fuel is fed into the interior of the kiln.

[0011] The repetitive opening and closing of the kiln feed door results in the exposure of the door to higher temperatures when closed and lower temperatures when open. Such heating and cooling of the door results in expansion and contraction of the door surfaces and warping of the door over time. Warped doors do not properly seal against the entrance chute and allow heat and combustion gases to escape when the door is closed. Replacement of the warped kiln feed door can be costly requiring the kiln to be shut down during the time a new door is installed.

[0012] In addition, most door actuating mechanisms are mechanically controlled by the use of cams or rollers and operate within a fixed operating cycle. Such mechanical mechanisms must open the door on each revolution of the kiln and can not skip a cycle. Thus, the rate of secondary fuel introduced into the kiln can not be modified efficiently.

[0013] Accordingly, there is a need for a kiln feed door that is resistant to warpage when repetitively exposed to hot and cold temperatures, and which can be opened and closed such that the rate of secondary fuel can be varied. The present invention satisfies those needs, as well as others, and generally overcomes deficiencies found in convention kiln feed door assemblies.

BRIEF SUMMARY OF THE INVENTION

[0014] The present invention is a kiln feed door assembly that restricts the loss of heat and combustion gases when feeding tires and other combustible materials into a rotating kiln as a source of supplemental fuel. By way of example, and not of limitation, the apparatus comprises a kiln feed door assembly that preferably includes two feed doors pivotally mounted to a baseplate on the exterior entrance of a chute which transects the wall of the rotary kiln. Each door includes a pivot shaft which preferably pivots within two high temperature pillow block bearings. Preferably four door plate mounting arms are attached to the pivot shaft and extend radially from the center of the pivot shaft. Planar rectangular door plates are mounted to the mounting arms with bolts secured through bores or apertures in the mounting arms.

[0015] In the preferred embodiment, there are at least two apertures in each mounting arm. The apertures are matched in pairs in each mounting arm. Some apertures are oblong in shape with the lengthwise portion of the aperture aligned with the direction of the width of the mounting arm. Other oblong apertures are aligned such that the lengthwise portion of the aperture is in the direction of the length of the mounting arm and perpendicular to the length of the pivot shaft. Still other apertures are circular. Each aperture may be sized to receive a bushing.

[0016] The bushings and linear alignment of the oblong apertures allow the door plates to expand and contract inconsistently without causing stress or otherwise warping the door. An efficient seal against the loss of heat and combustion products is maintained when the door plates keep their planer shape.

[0017] The two kiln doors pivot outwardly from the base plate and center of the kiln. One door assembly has a lip on the outer surface of the door. The lip is positioned to cover and seal the small space between the doors when the doors are in the closed position.

[0018] Each kiln feed door of the door assembly is preferably counterbalanced on the pivot shaft, preferably with two counterweights, one disposed near each of the block bearings. The door and counterweights are equally balanced with respect to the pivot shaft allowing for the opening and closing of the doors with little effort.

[0019] In one preferred embodiment, the kiln doors synchronously open and close using an electric motor, gearbox, actuating arms, rods and transfer arms. An actuating arm is radially mounted to one end of the pivot shaft of one door and a transfer arm is radially mounted to the other end of the shaft. The actuating arm is connected by an actuating rod to a rotating armature from the gearbox. This portion of the mechanism translates the rotational motion of the armature to oscillating motion of the actuating arm and partial rotation of the pivot shaft. Rotation of the pivot shaft results in movement of the transfer arm. An elongate transfer rod is pivotally connected to the transfer arm on one end and to an arm mounted to the pivot shaft of the opposing door on the other. Therefore, both kiln feed doors open simultaneously when the electric motor is activated.

[0020] In one embodiment, the actuating rod that is coupled with the door actuating arm on one end and the rotating linkage of the gearbox on the other includes a dampening member which tempers the impact of the closure of the doors against the rim of the opening to the kiln thereby reducing stress on the doors and linkage.

[0021] In another embodiment, the activity of the motor is regulated during various times of the cycle of the rotation of the gearbox armature with sensors thereby regulating the rate of movement of the door-actuating rod. When the motor is momentarily turned off just before the doors are fully closed or opened, the stress on the seals, doors and linkage of impact against the kiln opening under power is eliminated.

[0022] In operation, tires or other combustible materials are presented to a feed ramp or injection platform. As the kiln rotates, the feed door assembly eventually comes into proper alignment with the feed ramp. The kiln feed doors are mechanically or preferably electrically opened to allow the kiln to receive the combustible materials from the ramp. The doors are closed after the combustible material enters into the kiln to eliminate the loss of heat and combustion products from the kiln during rotation.

[0023] An object of the invention is to provide secondary fuel access doors for a rotating kiln that can expand linearly or laterally without warping.

[0024] Another object of the invention is to provide kiln feed doors that will efficiently prevent the escape of heat and combustion products from the interior of the kiln yet allow the efficient entry of tires or other combustible material into the kiln.

[0025] Another object of the invention is to provide a kiln feed door that can be repetitively exposed to heat extremes and cooling and maintain its shape.

[0026] Yet another object of the invention is to provide a door actuating mechanism that efficiently and reliably allows momentary access to the interior of the kiln without releasing large amounts of heat or combustion gases.

[0027] Still another object of the present invention is to provide a kiln supplemental fuel feed door assembly that can be programmed to open and close at desired times and is capable of skipping cycles.

[0028] Further objects and advantages of the invention will be brought out in the following portions of the specification, wherein the detailed description is for the purpose of fully disclosing preferred embodiments of the invention without placing limitations thereon.

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The invention will be more fully understood by reference to the following drawings which are for illustrative purposes only:

[0030] FIG. 1 is a perspective view of a feed door assembly according to the present invention showing the warp resistant doors in the open position.

[0031] FIG. 2 is a side view of the feed door assembly of the invention with the doors shown in the open position, and showing the feed door assembly in relation to the fuel guide of a rotating kiln and a feed chute.

[0032] FIG. 3 is a top view of the warp resistant doors of the present invention showing the positioning of the bores in the arms and pivot shafts, and showing one of the doors partially cut away for clarity.

[0033] FIG. 4 is a front view of the feed door assembly of FIG. 1 with the warp resistant doors shown in the closed position.

[0034] FIG. 5 is a rear view of the feed door assembly of FIG. 1 with the warp resistant doors shown in the closed position.

[0035] FIG. 6 is a perspective view of a rotating kiln with the attached feed door assembly of FIG. 1 shown the warp resistant doors in the open position to receive secondary fuel from the feed chute.

[0036] FIG. 7 is a side view of an alternative embodiment of the motor and gear mechanism of the feed door assembly of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

[0037] Referring more specifically to the drawings, for illustrative purposes the present invention is embodied in the apparatus generally shown in FIG. 1 through FIG. 7, where like reference numbers denote like parts. It will be appreciated that the apparatus may vary as to configuration and as to details of the parts without departing from the basic inventive concepts disclosed herein.

[0038] Referring first to FIG. 1 and FIG. 2, the invention comprises a kiln access door assembly 10 that is used to allow the injection of combustible material into a rotating kiln of the type that is commonly used in the production of cement. The invention includes a pair of outwardly opening warp resistant feed doors 12a, 12b which provide access to a feed opening 14 in the side wall of a kiln 16. It will be appreciated, however, that the present invention can be used with any combustion chamber such as a stationary kiln, furnace or boiler that exposes an access door to high temperatures. As can be seen, feed opening 14 is at the exterior end of a fuel feed inlet tube 18 which transects the sidewall of the kiln.

[0039] In the configuration shown in FIG. 1 and FIG. 2, the feed door assembly 10 of the invention is supported by a baseplate 20 mounted on the exterior end of feed tube 18. Feed opening 14 is an opening in baseplate 20 that allows the passage of combustible material to the interior of the kiln through feed tube 18.

[0040] Doors 12a and 12b include door plates comprising planar members 22a and 22b, respectively, which face the interior of the kiln when the doors are in the closed position. Preferably, the periphery of feed opening 14 has a lip 24 that engages the face of planar members 22a and 22b sealing the opening when doors 12a and 12b are closed.

[0041] A fuel guide 26 is mounted on the baseplate 20 such that the plane of surface 28 of the guide is perpendicular to the baseplate. Preferably door 12a opens to a position that is perpendicular to the baseplate and then stops. Fuel guide 26 is positioned such that guide surface 28 is substantially contiguous with the inner surface of planar member 22a when the door is open. In this manner, tires and other combustible materials can be deposited on the surface 28 of fuel guide 26 and slide by the forces of gravity along the guide and the surface of door member 22a, and through the interior of feed tube 18 into the interior of the kiln as the kiln rotates.

[0042] Door 12b preferably opens to a position approximately one-hundred and ten degrees from horizontal and then stops. This positioning effectively directs stray fuel into the feed opening 14 as it slides down the guide and into feed opening 14.

[0043] In FIG. 2, a tire 30 is shown positioned in a feed chute apparatus 32 for delivery into the kiln. In operation, the timing of the release of the fuel from the feed chute should be coordinated with the opening of the doors 12a and 12b when in the proper position to receive the fuel. In this regard, it will be appreciated that it is important that the tires not be released from the feed chute apparatus until the feed doors on the kiln are in position and opened to receive the tires. In addition, to ensure that the tires will be gravity fed into the kiln, the feed chute is oriented on the support frame such that the plane of the internal ramp (bottom wall) has an angle of inclination between approximately 33 degrees and approximately 60 degrees, and preferably 47 degrees. The feed chute apparatus with rate regulation capability described in detail in co-pending application Ser. No. 09/448,570 filed on Nov. 23, 1999, which is incorporated herein by reference, can be used for this purpose. It will be appreciated, however, that the feed door assembly of the present invention can also be used with other feed mechanisms known in the art that actively inject the fuel into the kiln without the assistance of gravity.

[0044] Referring also to FIG. 3, the preferred embodiment of the warp resistant feed doors are shown in greater detail. It will be appreciated that the various components described herein can be attached using conventional fastening techniques, such as welding, bolts, pins or the like, as appropriate for the type of attachment made. In the embodiment shown, doors 12a and 12b each have a pivot shaft, a plurality of support arms mounted to the shaft and a planar member secured to the arms. Specifically, door 12a includes a pivot shaft 34 which functions as a hinge and which preferably has grooves to receive splines at both ends. A plurality of arms 36, 38, 40, and 42 are oriented substantially parallel in the same direction and are securely mounted to shaft 34. Each arm preferably has a horizontal anchor 44, 46, 48 and 50, respectively, which serves as an attachment point with planar member 22a. Each horizontal anchor is supported by a vertical upright which is perpendicular to the horizontal plane of the anchor. Vertical uprights 52, 54, 56 and 58 are attached to pivot shaft 34 as well as to its respective horizontal anchor. Each vertical upright has a top plate 60, 62, 64, or 66, respectively, attached on the side opposite the anchor.

[0045] Top plates 60, 62, 64, and 66 are also attached to pivot shaft 34 providing additional strength and rigidity to the door. Further rigidity for door 12a is provided by a cross-brace or beam 68 which cross-links the vertical uprights of the anchor arms.

[0046] Each of the horizontal anchors has one or more pairs of apertures that receive bolts or the like to secure the planar members to the anchors. For example, horizontal anchor 44 has a pair of apertures 70a and 70b that have a generally oblong shape with the lengthwise portion of the oblong oriented substantially parallel to the length of shaft 34 and substantially perpendicular to the length of anchor 44. In other words, the longitudinal axis through the oblong portion of the aperture is generally aligned with the longitudinal axis of the shaft and generally offset with the longitudinal axis of the anchor by approximately ninety degrees.

[0047] Horizontal anchor 46 has two pairs of apertures 72a, 72b and 74a, 74b that are preferably disposed on either side of vertical upright 54. Apertures 72a and 72b are oversized and circular in shape. In contrast with apertures 70a and 70b, apertures 74a and 74b have a generally oblong shape with the lengthwise portion of the oblong oriented substantially perpendicular to the length of shaft 34 and generally parallel to the length of the anchor. In other words, the longitudinal axis through the oblong portion of the aperture is offset in relation to the longitudinal axis of the shaft by approximately ninety degrees and is generally aligned with the longitudinal axis of the anchor.

[0048] Apertures 76a and 76b in anchor 48 have the same oblong dimensions as apertures 74a and 74b and are oriented in the same direction generally perpendicular to the length of the shaft 36 and aligned with the length of the anchor. Likewise, apertures 78a and 78b are circular and preferably have the same dimensions as apertures 72a and 72b.

[0049] Anchor 50 has apertures 80a and 80b which are oblong oriented in a direction substantially parallel to the direction of length of shaft 34 and substantially perpendicular to the length of the anchor. Preferably, apertures 80a and 80b have the same dimensions as apertures 70a and 70b in anchor 44.

[0050] One skilled in the art will appreciate the symmetry of the placement of apertures 70a through 80b. While this symmetry is preferred, other combinations and placements are anticipated. The orientation and placement of the apertures 70a through 80b allow the expansion and contraction of planar member 22a due to the high temperature gradients associated with opening and closing the doors to occur without causing significant deformation to the door assembly. In addition, appropriately sized bushings may alternatively be placed in the apertures to further reduce stresses. Thus, expansion and contraction of the inventive door assembly from exposure to extreme temperatures does not create sizeable stresses in the door assembly causing warping and a loss of door seal to escaping combustion gases.

[0051] Kiln feed door 12b has essentially the same structure as feed door 12a as can be seen in FIG. 3. Pivot shaft 82 preferably has four mounting arms 84, 86, 88, and 90 which are secured to pivot shaft 82. Each arm has horizontal anchors 92, 94, 96, and 98, respectively, which are ultimately secured to planar member 22b. Each anchor has a vertical upright 100, 102, 104 and 106, respectively, mounted radially to shaft 82 and perpendicularly to horizontal anchors 92, 94, 96, and 98, respectively. The vertical uprights are preferably cross-linked by beam 108 to provide strength to the mounting arm assembly. Top plates 110, 112, 114 and 116 are mounted to the vertical uprights on the side opposite the horizontal anchor as well as shaft 82 providing further rigidity to the assembly as shown in FIG. 1. Note that cross beam 108, cover 130 and top plates 110, 112, 114 and 116, can be seen in FIG. 1, but have been omitted from FIG. 3 for clarity.

[0052] The apertures in the horizontal anchors of arms 92, 94, 96 and 98 share the same shape, symmetry, placement and orientation as those apertures in anchors 44, 46, 48 and 50 of door 12a. Apertures 118a and 118b in anchor 92 are oblong shaped with the lengthwise portion of the oblong oriented in the direction of the length of shaft 82. Apertures 120a, 120b and 122a and 122b are disposed in anchor 94. Apertures 120a and 120b are circular in shape, and apertures 122a and 122b are oblong in shape with the lengthwise portion of the oblong perpendicular to the length of shaft 82.

[0053] Horizontal anchor 96 has apertures 124a and 124b which are oblong in shape and 126a and 126b which are circular in shape disposed on either side of upright 104. The lengthwise portion of oblong apertures 124a and 124b is perpendicular to the length of shaft 82.

[0054] Anchor 98 has apertures 128a and 128b which are oblong in shape and oriented so that the lengthwise portion of the oblong is parallel to the length of shaft 82. As can be seen, therefore, door 12b preferably maintains the same symmetry with respect to the apertures as door 12a as seen in FIG. 3.

[0055] Referring to FIG. 1, FIG. 4 and FIG. 5, there is a cover 130 that is attached to the outer edge of planar member 22b and covers the gap between planar members 22a and 22b when doors 12a and 12b are in the closed position. Cover 130 acts to seal the gap between the doors to prevent the escape of significant amounts of combustion gases and heat from the kiln.

[0056] The door assembly of the present invention has a front or drive side as seen in FIG. 4 and a rear side as shown in FIG. 5. In the embodiment shown, the ends of pivot shafts 34 and 82 rotate in high temperature pillow block bearings 132a, 132b and 134a, 134b, respectively. The pillow block bearings 132a, 132b, 134a and 134b are preferably mounted on baseplate 20.

[0057] Doors 12a and 12b are preferably counterweighted to create a zero lift weight and reduce the stress on the door actuating mechanisms. Shaft 34 has a counterweight 136a on the drive side and a counterweight 136b on the rear side of the apparatus. Similarly, shaft 82 has a counterweight 138a on the drive side and a counterweight 138b on the rear side of the shaft. The counterweights are preferably placed on the shaft such that the pillow block bearings are between the door and the counterweight.

[0058] Referring more particularly to the drive side of the apparatus as shown in FIG. 4, armature 146 is connected to an output shaft 150 (FIG. 5) of gearbox 152 and rotated by the output shaft at a desired speed. Output shaft 150 and gearbox 152 are preferably driven by an electric motor 154. The proximal end of push rod 142 is rotatably connected to rotating arm 146 by bearing 148. The distal end of push rod 142 is pivotally coupled to actuating arm 140 by bearing 144. Thus, it will be seen that the rotation of armature 146 and movement of push rod 142 forces actuating arm 140 to oscillate. Consequently, the force applied to actuating arm 140 will cause pivot shaft 34 to rotate around its axis in block bearings 132a and 132b preferably to a point that door 12a is opened to a vertical position.

[0059] Push rod 142 is preferably coupled to a resistive plunger or spring assembly 156 that will allow the length of pushrod 142 to compress or shorten slightly while resisted by spring assembly 156. This serves to temper the force applied to arm 140 and shaft 34 by pushrod 142 when door 12a is opened or closed.

[0060] In one embodiment, the spring assembly 156 includes a spring loaded cylinder with one end of pushrod 142 fixed to actuating arm 140 and the other end of pushrod 142 sliding within the cylindrical body of assembly 156 and resisted by a spring within the body (not shown). The fixed end of the cylindrical assembly 156 is connected to the rotating arm 146 on the output side of the gear box 152 and the sliding pushrod 142 is connected to the actuating arm 140 on the lower kiln door. Thus, when the fixed end shaft of the cylindrical assembly is pushed, the sliding end of pushrod 142 preferably bottoms at the opposite end of the cylindrical body of assembly 156 creating a full positive force. Additionally, when the fixed end of the cylindrical spring assembly 156 is pulled the sliding end of rod 142 extends, thereby compressing the cylinder spring. The strength of the spring determines the force created. Preferably, an internal sleeve on the sliding pushrod 142 limits its travel (not shown).

[0061] Motor 154 may be activated by any number of timing mechanisms known in the art that allow the doors to be opened at the proper position to receive fuel during rotation of the kiln. The opening and closing of the feed doors can be timed for every cycle of rotation of the kiln or for alternate cycles. Alternatively, the doors may be opened more than one time during any one rotation of the kiln. Thus, it will be seen that a kiln mounted, low voltage electrical motor and linkage allows total operational flexibility to control when and where the doors are open and the duration of closure thereby eliminating cumbersome mechanical linkages known in the art.

[0062] Referring now to FIG. 5, the rear side of the inventive apparatus is shown. A transfer arm 158 is mounted to pivot shaft 34 and rotates with shaft 34 in pillow bearings 132a and 132b when the shaft is rotated by actuating arm 140. Transfer arm 158 is pivotally connected to one end of transfer rod 160 by transfer arm bearing 162. The other end of transfer rod 160 is pivotally connected to arm 164 through bearing 166. When shaft 34 is rotated, counterweight 136b rotates downwardly, transfer arm 158 moves upwardly about the axis of shaft 34 and transfer rod 160 forces arm 164 to rotate pivot shaft 82. Rotation of shaft 82 causes door 12b to open upwardly and counterweight 136b to rotate downwardly around the axis of shaft 82. It is preferred that door 12b open beyond vertical to approximately one hundred and ten degrees from horizontal.

[0063] In operation, the opening of doors 12a and 12b is preferably coordinated with the release of fuel from feed chute 32. It is also preferred that the doors do not open when the assembly is below forty degrees from horizontal.

[0064] Referring also to FIG. 2 and FIG. 6, in operation a tire 30 is placed on feed chute 32 either manually or by using an auxiliary mechanical feed mechanism (not shown). As kiln 16 rotates, sensor 168, which is a conventional photosensor or the like, senses an actuator key such as tab 170 and activates motor 154 thereby opening doors 12a and 12b. As rotation continues, the doors completely open and fuel guide 26 and feed opening 14 comes into alignment with feed ramp 32, fuel control sensor 172 detects tab 174 and sends a control signal to feed chute 32. The tire or other combustible material is timed to slide down the feed chute, along fuel guide 26 and planar member 22a, and into the kiln since the angle of inclination is sufficient to allow the material to be gravity fed out of the end of the feed chute.

[0065] The number of times that doors 12a, 12b open and close may be controlled and coordinated with the release of fuel by feed chute 32 to meter the amount of material injected into the kiln by sensor controllers at the door and feed chute assemblies. (not shown). Accordingly, the door assembly can remain closed until the kiln completes one or more full rotations.

[0066] Referring now to FIG. 7, an alternative embodiment of the actuating mechanism for opening the kiln feed doors 12a, 12b is generally shown. In the embodiment shown, the gearbox 152 has an additional mechanism for regulating the activity of the motor through the cycle of the opening and closing of the kiln doors 12a, 12b.

[0067] The activity of the motor 154 is regulated during various times of the cycle of the rotation of the gearbox armature 146 by sensors thereby regulating the rate of movement of the door actuating pushrod 142. Preferably the motor 154 is momentarily turned off just before the doors are fully closed or opened thereby reducing the stress on the seals, doors and linkage from the impact of the doors against the kiln opening that occurs under power.

[0068] Gearbox 152 has a shaft 176 disposed on the side of the gearbox opposite shaft 150 and armature 146 preferably rotates at the same rate as shaft 150. A rotating disk 178 is coupled with shaft 176 and includes sensor tabs 180 near the periphery of the disk. Detectors 182 are aligned over sensor tabs 180 and activate and deactivate the motor 152. The input from detectors 182 is preferably coordinated with the input from sensors 168 and 172.

[0069] Low voltage motor 154 causes armature 146 to rotate and force pushrod 142 to move actuating arm 140 and open the kiln feed doors 12a, 12b. This may be considered the positive stroke of the door actuating mechanism. When the armature 146 on the gearbox 152 has rotated one hundred and eighty degrees, the lower door 12a is preferably perpendicular to the center of the kiln and parallel to the feed chute 32 at the time of material release. It is preferred that a few degrees before one hundred and eighty the disk sensor tab 180 on the disk 178 gear box output shaft 176 align with the detector 182 signifying the proper position. The detector 182, or other control mechanism associated with the detector, preferably cuts power to the drive motor 154. As the motor 154 slows to a stop, the doors 12a, 12b continue to open to the set position and the disk 180 rotates to one hundred and eighty degrees. The doors 12a, 12b remain in this position until they have aligned with the feed chute 32 and the materials are fed to the kiln.

[0070] Once the materials have been fed to the kiln 16, it is preferred that the power to the motor 154 be regained and armature 146 continue rotating clockwise back one hundred and eighty degrees, creating a pulling action on the pushrod 142 and thus closing the doors. This may be considered the negative stroke of the cycle. The linkage is preferably adjusted so that when the armature 146 on the gearbox 152 has reached a few degrees before one hundred and eighty degrees, the sensor tabs 180 on disk 176 aligns with a detector 182 and cuts power to the motor 154. Consequently the motor 154 is not active when doors 12a, 12b are in the fully closed position and stresses on the doors and linkage are greatly reduced.

[0071] Accordingly, it will be seen that this invention provides a simple and effective way of introducing combustible materials such as tires into a rotating kiln using gravity feed or affirmative injection which can skip one or more revolutions of the kiln. The structure of the fuel feed doors allow for exposure to extreme temperatures and inconsistent expansion and contraction without warping, fracturing the bearings, shaft distortion, jamming or significant release of heat or combustion gases. Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. Thus the scope of this invention should be determined by the appended claims and their legal equivalents.

Claims

1. A fuel feed door apparatus for a high temperature combustion chamber, comprising: (a) a warp resistant feed door assembly; (b) a door opening mechanism associated with said feed door assembly; and (c) a control mechanism coupled to said door opening mechanism and configured to activate said door opening mechanism when said feed door assembly is aligned with a fuel delivery platform.

2. An apparatus as recited in claim 1, further comprising a fuel guide mounted adjacent to said feed door assembly, said fuel guide having at least one planar surface.

3. An apparatus as recited in claim 1, wherein said feed door assembly comprises a pair of opposing doors.

4. An apparatus as recited in claim 3, wherein each said feed door comprises: (a) a plurality of support arms; (b) each said support arm including at least one anchor arm; (c) a door plate; and (d) a plurality of fasteners coupling said door plate to said anchor arm.

5. An apparatus as recited in claim 4, wherein said anchor arms include a plurality of bores, and wherein said fasteners are disposed in said bores.

6. An apparatus as recited in claim 5, wherein said bores in said anchor arms are oblong in shape.

7. An apparatus as recited in claim 6, wherein said oblong apertures are oriented such that the length of the oblong is substantially parallel to the length of said anchor arm.

8. An apparatus as recited in claim 6, wherein said oblong apertures are oriented such that the length of the oblong is substantially perpendicular to the length of said anchor arm.

9. An apparatus as recited in claim 5 wherein said bores in said anchor arms comprise a combination of circular-shaped bores and oblong-shaped bores.

10. An apparatus as recited in claim 4, further comprising a bushing located within each of said bores, wherein said fasteners are disposed within said bushings.

11. An apparatus as recited in claim 4, further comprising a cross-brace interconnecting said anchor arms.

12. A warp resistant feed door apparatus for a high temperature combustion chamber, comprising: (a) a pair of warp resistant feed doors; (b) a door opening mechanism associated with said feed doors configured to allow the synchronous opening of said doors upon activation of the mechanism; and (c) a control mechanism coupled to said door opening mechanism configured to activate said door opening mechanism when said feed door apparatus is aligned with a fuel delivery platform.

13. An apparatus as recited in claim 12, wherein said door opening mechanism comprises: (a) a first lever arm mounted to a first end of a first pivot shaft which is rotatably mounted to a base; (b) a second lever arm mounted to a second hinge shaft which is rotatably mounted to said base; (c) a elongate push rod having first and second ends, said push rod operably connected at staid first end to said first lever arm and at said second end to said second lever arm; and (d) means for imparting rotational power to said first pivot shaft.

14. An apparatus as recited in claim 13, wherein said means for imparting rotational power comprises an electric motor.

15. The apparatus according to claim 12, wherein said control mechanism comprises a sensor and corresponding actuator.

16. The apparatus according to claim 13, wherein said elongate pushrod further comprises a dampening mechanism.

17. The apparatus according to claim 16, wherein said dampening mechanism comprises a spring.

18. The apparatus according to claim 16, wherein said dampening mechanism comprises a sensor assembly, said sensor assembly regulating said means for imparting rotational power.

19. The apparatus according to claim 16, wherein said dampening mechanism comprises a spring in combination with a sensor assembly, said sensor assembly regulating said means for imparting rotational power.

20. An apparatus as recited in claim 12, wherein each feed door comprises: (a) a shaft rotatably coupled to a base; (b) a plurality of anchor arms mounted to said shaft; (c) a door plate; and (d) a plurality of fasteners coupling said door plate to said anchor arms.

21. An apparatus as recited in claim 20, wherein each said door further comprises a counterweight attached to the shaft opposite said anchor arms.

22. A warp resistant door, comprising: (a) a pivot shaft; (b) a plurality of support arms attached to said pivot shaft; (c) each said support arm including at least one anchor arm; (d) a door plate; and (e) a plurality of fasteners coupling said door plate to said anchor arms.

23. A warp resistant door as recited in claim 22, wherein said anchor arms include a plurality of bores, and wherein said fasteners are disposed in said bores.

24. A warp resistant door as recited in claim 23, wherein said bores in said anchor arms are oblong in shape.

25. A warp resistant door as recited in claim 23, wherein said oblong apertures are oriented such that the length of the oblong is substantially parallel to the length of said anchor arm.

26. A warp resistant door as recited in claim 24, wherein said oblong apertures are oriented such that the length of the oblong is substantially perpendicular to the length of said anchor arm.

27. A warp resistant door as recited in claim 23, wherein said bores in said anchor arms comprise a combination of circular-shaped bores and oblong-shaped bores.

28. A warp resistant door as recited in claim 22, further comprising a bushing located within each of said bores, wherein said fasteners are disposed with said bushings.

29. A warp resistant door as recited in claim 22, further comprising a cross-brace interconnecting said anchor arms.

30. A warp resistant door as recited in claim 22, wherein said door further comprises a counterweight attached to the shaft opposite said anchor arms.

31. A warp resistant door as recited in claim 22, wherein said door further comprises a seal member at the periphery of said plate.