GB2467786A - Crushing machine - Google Patents

Abstract

A crushing machine has a delivery chute, rotating paddle (504,fig.5), an impaction chamber 103, a drive system (501,502,503,fig.5), and a framework 109 which can accommodate a removable collection receptacle. In this manner the main workings of the machine are all housed above a plate 101, which can be pressed down into a sealed relationship with the top of a suitable container, during crushing. The device may find particular application in the crushing of glass bottles, at licensed premises, into well known bin types, such as a "wheelie bin".

Description

EKKO GLASS CRUSHING MACHINE -MODEL GJK 121

FIELD OF THE INVENTION

This invention is a machine to break glass bottles into small fragments or cullet' which facilitates the simple and economic disposal of the waste product by substantially reducing its volume.

BACKGROUND

Many licensed premises struggle to find adequate storage space for their waste products and since empty bottles take up an unnecessarily vast amount of space, overflowing bins can be seen in lanes and alleys all over town and city centres. Even once the bins have been emptied by private contractors, a large number of glass bottles simply end up in landfill sites instead of being recycled. When the total cost of collecting and dumping this waste is taken into account, our society spends millions of pounds just to hide this problem without actually dealing with it.

In October 2008 the British Government passed legislation stating that all licensed premises must segregate their waste. Significant penalties now apply to offending premises and Local Authorities are penalised when they do not meet recycling targets.

Against this background, glass cullet is becoming popular as a raw material, not only in the manufacture of new glass containers, but also in a number of other applications. To facilitate the recycling process EKKO Glass Limited has formulated the EKKO System consisting of a method and an apparatus, for the processing of this glass waste.

SUMMARY

To help overcome the problem, this invention proposes an integrated machine which will break glass bottles into cullet resulting in a reduction in volume of around 80%. Empty glass bottles will be loaded into the machine by hand, one at a time but with no limitation on how quickly (other than operator speed) down an elongated delivery chute. The bottle will then drop onto a rotating steel paddle contained within an impaction chamber and driven by an electric motor where the impact of the hardened edge of the steel paddle will cause the bottle to shatter by fast fracture into cullet. This cullet will then drop into a collection receptacle securely located in the base frame. The collection receptacle will be easily maneouverable and could be similar to the standard wheelie bins' available worldwide.

The delivery chute, electric motor and impaction chamber containing the rotating paddle will be combined onto a steel framework which will be attached with hinges to the base. This base unit can be designed to accommodate a suitable wheelie bin (with its lid open) or could be adjustable to accommodate a variety of collection receptacles and will be such that when the top plate is down it encloses the opening ensuring all the glass cullet falls within the receptacle.

Because the apparatus runs from an electric motor and its compact design results in a small footprint, it could be powered from a power pack in the back of a van or truck for remote and transportable beneficiation and disposal services.

A number of types of machine exist to carry out the early stages of beneficiation but they tend to be larger, less reliable, more labour intensive and far more costly. They also tend to be more complicated in design and thus require more maintenance than the proposed invention. Because of the mechanical simplicity and the relatively small number of components used it would be possible to produce this machine at a considerably lower cost to the end user. The simplicity of the machine also adds to its robustness and durability.

Another advantage of this machine is its relatively small footprint, able to be comfortably sited within confined spaces such as drinks cellars, whilst still being robust enough to withstand external siting. The versatility and adaptability of the frame design and the simplicity of the delivery system allows the machine to be modified to suit specific site requirements. As long as there is some kind of elongated delivery system the machine can operate safely.

The fact that the cullet is smashed and deposited directly into a suitable collection receptacle means the collection service for the waste glass would be simplified as far as possible due to the easy maneouverability of wheelie bins. In addition, standard vans with a simple tail-lift modification could be used for the collection rather than dedicated bin lorries. This means the collection vehicles would be considerably more mobile within busy city centres and environmentally friendly. Standard diesel vans can achieve three times the mileage that a standard bin lorry can travel for every gallon of fuel.

The apparatus uses the high rotational velocity of an object of a reasonably large mass and thus with a high inertia to shatter the glass, by utilising the impulse at impact against the glass bottle to instigate brittle fracture within the glass. This allows the machine to use a relatively small amount of electrical energy in order to achieve the cullet. A number of machines exist which are much larger and tend to compress the bottles to crush the glass, which because of the relatively high compressive strength of glass requires a greater energy input to achieve a similar result, making them less energy efficient.

The axis of rotation of the smashing apparatus will be horizontal, and perpendicular to the longitudinal axis of the delivery chute, thus maximising the ability to fracture and hence enhance the efficiency of the machine. This is possible by utilising the increased impulse acting on the glass bottle due to the fact that upon impact, the reaction is acting at an angle normal to the paddle surface. This differs from certain existing machines whereby the crushing apparatus rotates on the same longitudinal axis as the delivery apparatus.

This effectual uni-directional reaction that takes place resulting from the cross-directional axes of movement between the bottle and paddle results in the very efficient operation of the machine. And since the purpose of the apparatus is to aid recycling, reduce wastage and generally benefit the environment, energy efficiency should be a consideration when designing a machine fit for purpose.

Whereas it has been stated that the proposed invention is designed to process waste glass bottles it should not be assumed that the operation is limited solely to the processing of waste glass bottles. Any glass object that is able to be inserted into the chute could experience at least the early stages of beneficiation using the said apparatus.

DETAILED DESCRIPTION

The invention and operation of such will now be described by way of example and with reference to the accompanying drawings in which: Figure 1 shows one embodiment of the apparatus, with a wheelie bin secured within the steel frame and under the top plate.

Figure 2 shows another embodiment of the apparatus with a different drive configuration and the addition of side panels.

Figure 3 shows one embodiment of the top plate arrangement without the chute portion and indicating the position of the paddle and the direct drive from the electric motor.

Figure 4 shows one embodiment of the impaction chamber mounted on a steel framework with the motor mounted on a hinged plate to the rear.

Figure 5 shows an embodiment of the belt-drive configuration.

Figure 6 shows an embodiment of the paddle which contains six steel blades.

Figure 7 shows a cross-sectional view of one embodiment of the impaction chamber, screen mesh, paddle and motor through the plane A-A (Figure 4).

Figure 8 shows an embodiment of the delivery chute with the protective rubber flaps.

Figure 9 shows an embodiment of the bin-out' switch.

Figure 10 shows one embodiment of a height adjustable framework.

Figure 11 shows a simplified circuit diagram for the machine.

Figure 12 shows a flow chart illustrating the operation of the apparatus.

To operate a machine employing the EKKO concept, firstly the top plate (101) must be raised. Depending on the configuration of the top plate this may be aided by pneumatic lift-assisters (102) or alternatively the top plate will be configured with the motor (201) mounted behind the impaction chamber (103) such that the centre of gravity lies close to the back of the lid, thus significantly reducing the effort required to raise the lid. The locking stays (104) would then slot into the locators (105) to lock the lid in the upright position.

A suitable coUection receptacle (106) with lid open could then be pushed onto the base plate (107) to sit underneath the top plate. The receptacle would be directed in Situ by the guide vanes' (108) on either side of the frame (109). The top plate could then be lowered by disengaging the locking stays using the handle on the arms. The stays could be linked so to work dependently allowing both to be raised using one handle for ease of operation.

Once lowered, the top plate could be secured in place using the locking pins (202) on either side, through the lid lock-mount (203) and the stand lock-mount (204). This would ensure that the top plate would form a tight seal around the top of the open collection receptacle. The locking pins could be attached to the lid lock-mounts by way of a welded chain (not shown), such that they would always be close to hand and available to lock the machine lid in place.

A base plate possibly made of steel plate or similar would ensure that regardless of the ground surface that the machine is installed upon (i.e. uneven ground/cobbled street) the collection receptacle would be in the correct position to form a tight seal with the top plate. Floor-mounting brackets (205) and wall-mounting brackets (206) would allow the stand to be securely fixed in situ to eliminate the risk of the movement caused by vibration. Insulated side panels (207) could be fitted to the side of the frame to effect sound-reduction and reduce the noise level of the machine during operation.

Once the bin is securely located and the lid is locked in place, glass bottles can be hand fed into the delivery chute (208). The delivery chute will be elongated to prevent any possibility that the operator could reach the rotating paddle (301) during operation, and to reduce the chance of material ejection through the end of the chute. The delivery chute and impaction chamber can be lined internally with a heavy duty rubber to act as another sound-reduction device.

The machine will then break the bottles into cullet which will fall into the collection receptacle below. A viewing panel (302) would allow the operator to gauge when the level of cullet reaches the requisite level.

The viewing panel could be made from toughened glass, a suitable acrylic glass or similar hardened transparent material, and sealed and bolted onto the steel top plate. The tight seal formed by the steel top plate completely enclosing the bin opening would make it impossible to gain access to the rotating steel paddle thus eliminating risk of accidental injury to the operator.

An alternative arrangement would include a method for detecting the level of cullet through the use of a weighing mechanism or ultrasonic detector which would eliminate the risk of operator error by disabling operation of the motor once the cullet reached the requisite level.

The steel paddle which will rotate at high speed to smash the glass will be driven, either directly or belt-driven, by an electric motor which could be turned on/off with an externally rated toggle switch mounted on the motor and the operation of which would be governed by a series of safety cut-out devices. The motor will have a thermal cut-out switch to prevent overheating which can be reset by a push switch on the side of the motor.

In the embodiment where the paddle-shaft is directly driven the motor would be securely fixed/bolted onto the base plate and perfectly aligned with the centreline of the paddle shaft (303) to avoid vibration and increased wear. The output of the motor (the driveshaft) (304) would be connected to the paddle shaft by way of a drive coupling' which can be rubber cushioned to absorb some of the impact upon contact with bottles. A coupling housing (305) would fully enclose this coupling and the ends of the driveshaft and paddle shaft which would otherwise be exposed outside the motor and the impaction chamber, thus eliminating the inherent dangers of the fast-rotating parts.

In another embodiment where the paddle-shaft is belt-driven, the motor will be securely mounted onto a hinged plate (401) which will be located behind the impaction chamber and which will be hinged close to the bottom of the impaction chamber, near the union with the top plate. At the output from the motor and the paddleshaft there will be grooved wheels (501, 502) to accommodate a rubber v-belt' (503) or similar.

The relative sizes of these wheels can be altered to provide an infinite variety of rotational speeds of the paddle. A handled grub screw (402) threaded through a fixed nut (403) on the hinged plate and fixed but able to rotate freely (404) on the impaction chamber will act as an infinitely adjustable tensioning device which allows the distance between the centerlines of the driveshaft and paddleshaft to be varied within a predefined range to accommodate a variety of different drivewheel configurations.

A bearing and housing (405) will be located on either side of the impaction chamber where the paddle shaft will pass through the chamber, to allow free rotation of the shaft while still maintaining a complete seal to the impaction chamber.

The paddle unit will be made from at least two steel blades symmetrically positioned and welded longitudinally onto a thick-walled hollowed rod which is then secured onto the grooved paddle shaft with grub screws. Because this is a rotating component it will be perfectly dynamically balanced in order to avoid vibration caused by unbalanced rotation. The leading edge will incorporate a longitudinal weld (505) which will act to both roughen and significantly harden the edge, thus improving its ability to shatter the glass upon impact and greatly decreasing the amount of wear experienced by the leading edge. It will be possible to alter the paddle design/configuration and the motor speed to vary the cullet size depending on the end use of the cullet. It follows that the higher the rotational speed of the motor, the smaller the resultant average cullet size. In one embodiment the motor will effect a rotation of the paddle (504) at 1725 RPM resulting in an average cullet size of 0.1mm -35mm. This would be suitable for further beneficiation or production of crushed glass aggregate for use in various applications.

In another embodiment, the paddle will consist of six steel blades (601) equally spaced with a longitudinal weld on the leading edge of each blade and welded onto a thick-walled hollowed rod. In this case a rotation of the paddle of around 1500 RPM will produce an average cullet of less than 6mm. This will reduce the volume of the waste considerably more than the 80% stated with the previously described configuration. In addition it can enable the resultant cullet to be used directly from the collection receptacle and as such the further stages of beneficiation to be forgone thus eliminating any the time and cost associated with additional processing.

An addition to the apparatus in this embodiment can include a removable screen mesh (701) located horizontally transversely between the union of the impaction chamber and the top plate. This mesh would have a size spacing in accordance with the desired resultant cullet size. For example a 5mm spacing would ensure that any particles greater in size than this, including bottle tops and paper labels, would be prevented from descending into the collection receptacle and contaminating the cullet. The facility would be there to periodically remove this debris by removing the screen mesh and emptying the contents into a separate crate. The resultant cullet in the collection receptacle would then be a high quality cullet with very small average particle size and the by-product taken from the screen mesh could experience further stages of beneficiation to ensure minimal wastage.

When an impact causes glass to shatter, small glass shards can be ejected in all directions and during operation of this machine, the glass bottles being smashed would produce a considerable quantity of glass shards travelling at high speed. In order for safe operation of the apparatus and to eliminate the risk to the operator these must be contained within impaction chamber and the chute. The delivery chute will contain a double layered rubber cross flap at the opening (alternately orientated crosses one (802) behind the other (801)). These heavy duty rubber flaps will act to prevent material exiting through the chute. This will be a secondary preventative measure as the main prevention will be another heavy duty rubber flap fixed about half-way along the chute. This flap could either be solid or split into hanging vertical sections to allow for greater flexibility and maneuverability. It could be fixed externally using bolts (803) and hang vertically to fill the entire cross-sectional area inside the chute. The delivery chute will be attached to the impaction chamber by bolting the flanged faces (406, 804) together. A gasket should be incorporated at this joint to provide a tight seal and prevent glass shards escaping through what would otherwise be a metal to metal joint. A gasket should also be incorporated at the flange (306) where the impaction chamber is bolted onto the top plate in a fashion similar to that by which it is bolted to the delivery chute.

In one embodiment of the apparatus the frame could be of a symmetrical design manufactured using welded steel box section or similar. It could be designed specifically to enclose a suitable collection receptacle in the centre of the base plate between the guide vanes which could be made from welded steel plate section. The bottom of the pneumatic lift-assisters could be welded or bolted (110) onto the outside of the front legs of the frame and the top (111) should later be welded or bolted onto the lid lock-mount, once the top plate has been fitted to the frame by welding or bolting the hinges onto the top horizontal member (112) at the rear of the frame.

Another embodiment would involve a stand similar in appearance to the one previously described but with the addition of an ability to adjust in height which would allow the stand to incorporate a variety of different collection receptacles. This could be effected by way of a two-part frame, where the cross-sectional area of the hollow box section in the upper component (1001) is greater than that in the lower component (1002) which lies within the upper component. The adjustment could be manual and secured using a locking pin (1003) through locator holes (1004).

Another variation of the frame would be to modify it to incorporate a 40 litre capacity crate for sites where larger bin use is impractical as this capacity would comfortably accommodate 20kg of cullet -the maximum weight that Health & Safety guidelines permit staff to be reasonably expected to lift. This could be achieved by utilising an adjustable stand or by welding runners along the sides of the fixed stand at such a height that the top plate forms a tight seal around the top of the crate. The machine operation and insertion/removal procedure for crates would be the same, other than the fact the crates would require to be changed more frequently. However because of the reduced weight of cullet involved the manual handling may be made easier.

In one embodiment, the frame could be further compacted and arranged such that the apparatus will specifically accommodate a smaller collection receptacle for situations where space is at a premium. This would improve its versatility and application for sites where space is an issue and, for example, the system requires bottles to be smashed underneath a bar.

For safety reasons it must be such that the machine is not able to run without a suitable receptacle securely located under the top plate. For this reason there will be a bin out' switch fitted to the stand. This could comprise a simple push switch (901) actuated by a hinged cover (902). When the collection receptacle is out, the switch will be open and the machine will not run. When the receptacle is located, it will force the cover onto the switch which will then close and complete its part of circuit. The cover and switch will be specifically designed and positioned such that the switch will only close once the collection receptacle is in precisely the correct location.

Similarly it must be such that the machine will not operate unless the lid is locked down in position. A similarly orientated switch (not shown) could be incorporated in the top plate, which will be open when the lid is in the up position, and will only close against the horizontal side of the stand (possibly at position 1005) once the lid is fully locked down.

In order to shatter the glass bottles into cullet the rotating paddle relies on the impact from the leading edge and not the crushing force of the paddle. As such the motor must be spinning up to full speed and if a bottle is inserted in the chute before the electric motor is turned on this may not be the case. A flap at the opening of the delivery chute would ensure no bottles could be inserted whilst the machine is not running.

A solid flap possibly made from steel, toughened glass or suitable acrylic glass, hinged at the top and connected to the top flange on the chute will completely cover the opening to the chute when the flap is in the down position. A contact switch on the flap will be included in the series circuit which will complete when the contact is broken, i.e. when the flap is in the open position. This would ensure that nothing can enter through the end of the chute unless the flap is open, in which case the machine will be on and the paddle will be spinning.

Alternatively, the flap could be located within the chute behind the first set of rubber flaps. It could be hinged such that when a bottle is inserted into the chute, the bottle causes the flap to open, which in turn actuates a push switch located within the chute which turns on the machine. Consequently, the paddle would be spinning up to the desired speed upon impact with the glass bottle. A time delay could be incorporated to ensure the machine would run for a short period of time, for example 5 seconds, after the flap is opened so that the motor is not continually being switched between the on/off states during continuous operation.

The fact that all the switch elements and cut-out devices will be connected in series with the power supply and motor mean that if any of the conditions are not met -if the bin is out, if the lid is up, if the flap is down, if the motor is overheated or if the bin is full to capacity -the machine will not run, thus alerting the user to action required.

The simple operation of the machine promotes versatility and as such the system could be further adapted to extend the bottle delivery system, for example by way of a pipe network from the bar, through the floor into a drinks cellar or storage room and directly into the existing delivery chute on the GJK121. A toggle switch could be wired into the series circuit and extended such it is located remotely from the machine, beside the bar, meaning the machine can be fully operated remotely with minimal disruption to staff during service.

In another embodiment which would eliminate this remote switch and hence the potential for user error, the flap arrangement could be hinged within the chute behind the first set of rubber flaps and hinged such that the flap swings inwardly within the chute. This would mean that as bottles are inserted into the pipes and travel down into the delivery chute they activate the machine as they pass the flap. A weighing mechanism could ensure the machine would not run if the level of cullet has reached the requisite level. A warning light system could also be implemented to provide the operator with a visual indication that the collection receptacle is full. In addition a more complex weighing mechanism could be developed where a series of lights convey the level of cullet in the receptacle could give an indication when the bin is almost full to provide the user with suitable notice before the cullet reaches the requisite level.

The limit to the size of bottles being smashed is governed by the size of the opening on the delivery chute.

This would accommodate any and all sizes of bottles used by typical licensed premises, right up to magnum size champagne bottles and the 40 oz 1.5 litre spirit bottles. There is no upper limit on how quickly bottles can be entered into the delivery chute.

From the foregoing, an apparatus and a method for the safe, convenient and economic disposal of waste glass bottles has been described in some detail. It will be appreciated that a number of different alterations and modifications may be made without departing from the concept of the present invention. For example one or more of the aforementioned features may be combined. Consequently the present invention has been described herein by way of illustration rather than limitation.

Claims (18)

1. CLAIMS1. An apparatus to facilitate the disposal of waste glass incorporating; a delivery chute into which waste glass objects are inserted and which then promotes their passage downward into the main body of the apparatus; a fast-rotating steel paddle located immediately below the aforementioned chute to fracture the said waste glass objects passing along the said chute and of which the paddle rotates on a horizontal axis perpendicular to the longitudinal axis of the said chute; an impaction chamber which fully encloses the said rotating steel paddle; a drive system in order to effect the rotation of the said steel paddle; a framework upon which the aforementioned can be assembled and which will accommodate a suitable collection receptacle.
2. 2. The apparatus of claim 1 where the steel paddle consists of no less than two similar steel blades symmetrically positioned to achieve perfect dynamic balance and welded onto a thick-walled hollowed rod.
3. 3. The apparatus of claim 2 whereby the thick-walled hollowed rod is attached to the paddleshaft using grub screws.
4. 4. The apparatus of claim 2 whereby each steel blade incorporates a longitudinal weld along its leading edge.
5. 5. The apparatus of claim 1 in which the drive system may be direct or belt-driven.
6. 6. The apparatus of claim 1 in which the said delivery chute contains protective rubber flaps in at least two locations along its longitudinal axis to prevent material ejection.
7. 7. The apparatus of claim 1 whereby the apparatus described in claim 2, claim 5 and claim 6 are combined in an integral rnoveable top plate.
8. 8. The apparatus of claim 7 where the movement of such is pneumatically or spring assisted, and is designed such that the apparatus can accommodate a variety of different sizes of collection receptacles.
9. 9. The apparatus of claim 7 where locking stays are employed to secure the apparatus in the upright position.
10. 10. The apparatus of claim 1 where the framework incorporates guide vanes to direct a suitable collection receptacle into place.
11. 11. The apparatus of claim 7 in which a transparent viewing panel is incorporated.
12. 12. The apparatus of claim 1 where the speed of rotation and design of the paddle determines the resultant average cullet size, and which can be altered to suit the end use prior to distribution.
13. 13. The apparatus of daim I whereby the freestanding framework is designed to accommodate and secure a suitable collection receptacle.
14. 14. The apparatus of claim 6 in which a flap arrangement is employed to prevent insertion of objects into the aforementioned chute at times other than when the machine is running.
15. 15. The apparatus of claim 1 in which the delivery chute is able to be extended such that the machine can be loaded remotely.
16. 16. The apparatus of claim 10 whereby the framework is adjustable to accommodate collection receptacles of different sizes.
17. 17. The apparatus of claim 1 whereby the frame incorporates insulated panels to effect sound-reduction.
18. 18. The apparatus of claim 1 whereby the impaction chamber and delivery chute are insulated to effect sound-reduction.