AU2004100287A4 - Apparatus and Process for Compressing Material - Google Patents

Description

P/00/009A Section 29

AUSTRALIA

Patents Act 1990 INNOVATION PATENT SPECIFICATION Invention Title: APPARATUS AND PROCESS FOR COMPRESSING

MATERIAL

Applicant: W McCULLOCH SON PTY LTD The invention is described in the following statement: Apparatus and Process for Compressing Material Field of the Invention The present invention relates to an apparatus and process for compressing material. The apparatus and process of the present invention are particularly suitable for use in compressing low density material to a much greater density, such as grasses, hays, waste paper and recycled material. It will be convenient to hereinafter describe the invention in relation to that particular application, however it should be appreciated however that the invention could have wider application.

Background of the Invention When loose material such as hay needs to be transported, it is preferred that the material is compressed to remove excess air and to thereby reduce the volume and increase the density. When compressing loose materials such as hay, a non-linear relationship exists between the density of the compressed material and the force required to compress it to that density. That is, the force required to increase the density of such material increases in a non-linear manner as the density of the material increases.

The force/density relationship can be described as non-linear -such that very little force is required to achieve initial compression (at low density), but substantial force is required to achieve higher compression, with additional increasing force yielding very little additional compression. Alternatively, this relationship can be described as follows: that as the density of the compressed material increases the force required to achieve that density increases exponentially. A practical limit of material compressibility is reached when the force required to compress the material further cannot be efficiently achieved.

The above discussion is illustrated in attached Chart 1, which represents tests performed to determine the compressibility of a material with applied pressure plotted against achieved material density.

W:\MaryO\Davin\Speci\nnovation of IRN 690933.doc Conventional machinery used to compress loose material of the above described kind, generally utilise a system whereby a piston like rod compresses the material against fixed surfaces. Because of the variable relationship of the force required to compress such material at high densities,it is common thatthe power system driving the compression rod must either be geared for the maximum compression force requirement, and hence operate at that maximum force requirement throughout the compression stroke, or alternatively, the power system must be staged to progressively increase the force applied to the material at stages through the compression stroke. In addition, the compression stroke is performed at a constant rate of travel, provided there is a a constant supply of energy.

The main disadvantage associated with the above type of system is the difficulty to efficiently provide a high compression speed early in the compression stroke, when only low compression force is required. Early high compression speed is important to reduce press cycle times. Increasing the speed of early compression in known systems generally involves driving the compression rod faster, but still at maximum force, but this is extremely inefficient, and wasteful and represents a significant portion of the energy resources needed for the. full compression stroke.

It would be desirable to provide a compression system that more efficiently compresses loose material. It would also be desirable to provide a compression system that uses less energy than prior devices. It would also be desirable to produce a compression system that has a reduced cycle time compared with prior systems.

Summary of the Invention According to a first aspectthe present invention provides an apparatus for compressing material including: a receiving station for receiving the material to be compressed; a compression member for compressing said material in said receiving station; WAMaryO\Davin\SpeRInnovation of IRN 690933.doc 4 a driving member having a driving stroke for driving said compression member via an assembly which connects said driving member and said compression member, wherein drive of said driving member through said drive stroke is operable to drive said compression member through a compression stroke having a first stage and a second stage,wherein in the first stage, the compression member provides a relatively low compression force, and in the second stage, the compression member provides a relatively higher compression force; and wherein movement of the compression member through the first stage being faster than through the second stage.

In at least one preferred embodiment, in the first stage, the force being applied by the driving member to the assembly is greater than that applied by the compression member to the material, and in the second stage, the force being applied by the driving member to the assembly is less than that applied by the compression member to the material.

Apparatus that operates according to the above description is operable to compress the material through the early or first stage of the compression stroke at high velocity. This is acceptable, because the force required to compress the material in the early stage is low. The force required however increases through the first stage progressively into the second or later stage, whereby the velocity of the compression stroke is reduced with a corresponding increase of the compression force applied to the material in the later stage of the compression stroke. The force applied to the material increases through the compression stroke, whereby initially (in the first stage) there is negative mechanical advantage which progressively transitions into positive mechanical advantage later (in the second stage) of the compression stroke. That is, by virtue of the assembly, in the first stage the output force of the driving member is greater than that of the compression member resulting in a negative mechanical advantage, whereas in the second stage the output force W:\MaryO\Dain\SpeRAflnovaiof of IRN 690933.doc compression member is greater than that of the driving member resulting in a positive mechanical advantage. In addition, the overall cycle time of the.

compression stroke is minimized, while the required force applied to the material is optimised through the compression stroke, so that the material is still compressed to the maximum density required.

Preferably, the driving member is a piston or rod which is driven at a constant velocity or unit displacement. In this arrangement, it is the assembly that converts the constant velocity drive of the driving member to the variable io velocity drive applied to the compression member. The assembly is able to provide a negative or positive mechanical advantage as required during the compression stroke.

In at least one preferred embodiment, the ratio of the driving member velocity to the compression member velocity in the first and second stages is determined according to the compression characteristics of the material to be compressed. In addition, it is preferred that the duration of the first and second stages of the compression stroke is determined according to the compression characteristics of the material to be compressed.

One such material that the apparatus of the present invention is suitable for is hay. For hay, the ratio of the compression member velocity to the driving member velocity is very high, and progressively reduces towards the end of the compressions stroke. In addition, for hay, the first stage comprises about 4/5 of the compression stroke, and the second stage comprises about 1/5 of the compression stroke.

In at least one further preferred embodiment the compressive pressure required to compress the material increases from the first stage of the compression stroke to the second stage of the compression stroke. Preferably the pressure applied to the material in the first stage increases through the compression stroke of the first stage from 0 to about 425 Tonnes/m 2 while the pressure applied to the material in the second stage increases through the compression stroke of the second stage from about 425 to about 950 W:\MaryO\Davi\Spec\I~lnnovation of IRN 690933.doc Tonnes/m 2 Thus, from the first through to the second stage, there is a progressive increase in forceapplied to the material, as the assembly changes from a negative to a positive mechanical advantage, It is preferred that the receiving station includes a base and side walls, the material being located between the sidewalls and the base, the receiving station further including a side opening through which the compression member enters to compress the material. Preferably, the receiving station also includes an outlet, and an ejection port opening, whereby an ejector mechanism is io operable through the ejection port opening to eject the material in the receiving station out through the outlet after compression.

In at least one preferred embodiment, the apparatus also includes a support frame for supporting the receiving station, the compression member and the assembly. Preferably, the support frame includes linear bearings for guiding the movement of the compression member into the receiving station.

More preferably, the compression member includes a compression plate for transferring the compression force to the material being compressed.

The driving member, through the assembly is designed to provide a variable force in excess of the force required for compressing the material.

Advantageously, the assembly between the driving member and the compression member can be arranged to vary the mechanical advantage provided to the main compression member. The level of mechanical advantage is preferably to match the specific compression characteristics of the handled material.

In order to achieve the mechanical advantage described, in one preferred embodiment the assembly includes: an assembly frame, a compression link, a tension link and a bell crank, the assembly frame having: a first frame pivot connection for connection of the assembly frame to the support frame; W:\MaryO\Davi\SpeFIlnnovatio of IRN 690933.doc a second frame pivot connection for connection of the assembly frame to the driving member via the bell crank; a third frame pivot connection for connection of the assembly frame to the compression member; the compression link pivotably connecting the third frame pivot connection of the assembly frame to the compression member; the bell crank having 3 crank pivot connections, a first crank pivot connection for connection of the bell crank to the second frame pivot of the assembly frame; a second crank pivot connection for connection of the bell crank to the driving member; a third.crank pivot connection for connection of the bell crank to the tension link, the tension link pivotably connecting the third crank pivot of the bell crank to the position at which the compression member and the compression link are also pivotably connected, wherein upon the activation of the driving stroke, the driving member is operable to rotate the bell crank about its first pivot connection, causing a pull force in the tension link and a compression force in the compression link to cause the compression member to perform its compression stroke.

It is preferred that the assembly frame includes two side plates and each of the driving member, bell crank; compression link, and tension link being mounted between the respective side plates. Preferably, these respective components can rotate about their respective pivots relative to the housing, via connection pins extending either between the side plates of the assembly frame, or merely between the components as required.

In at least one preferred embodiment, the driving member is housed in a drive member housing that is connected to a power source, the power source providing the movement of the driving member relative to the drive member housing so as to perform a driving stroke. Preferably, the drive member housing is mounted in the assembly frame to a mounting plate between the respective side plates. It is preferred that the movement of the driving member W:MaryO\DavinSpecNnnovaton of IRN 690933.doc 8 is hydraulically powered. Furthermore, it is preferred that that driving member extends and retracts telescopically relative to the drive member housing.

According to a second aspect, the present invention provides a process for compressing material including the steps of: receiving the material in a receiving station; activating a driving member having a driving stroke for driving a compression member via an assembly which connects said driving member and said compression member, compressing said material in said receiving station via said compression member; wherein drive of said driving member through said drive stroke is operable to drive said compression member through a compression stroke having a first stage and a second stage, wherein in the first stage, the compression member provides a relatively low compression force, and in the second stage, the compression member provides a relatively higher compression force; and wherein movement of the compression member through the first stage being faster than through the second stage.

Preferably, the driving member is driven at a constant velocity._ Advantageously, the present invention in one or more preferred forms is able to provide an apparatus and process that at the start of the compression stroke, the compression member moves with maximum velocity (and correspondingly lowest force) to reduce the press system cycle time efficiently, while at the end of the compression stroke the compression member moves with the maximum force (and correspondingly lowest velocity) being applied.

Another advantage is that a less powerful driving member is required by the one or more preferred forms of the apparatus and process of the present invention, because of the mechanical advantage gained by the assembly.

Accordingly a lower powered device, such as a device rated to 200bar can be W:MaryO\Davin\SpeCi\nnovatio of IRN 690933.doc used, which means that all the associated valves and fittings can also be rated at a lower pressure. This is particularly advantageous, as lower rated valves, fittings and hoses translate into lower priced components and overall cost savings. In addition, lower rated components also have lower power requirements hence reducing electricityusage and providing additional cost savings. Prior art devices required pressures above 200 bar to generate the required compression forces with direct cost implications to the driving merifber and consequential costs associated with the valve and related fittings.

0io Description of Drawings The above and other features of the invention will be evident from the following detailed description of the preferred embodiment with reference to the accompanying drawings, in which: Figure 1 is a perspective view of a preferred embodiment of the present invention; Figure 2 is a side view of the preferred embodiment of the present invention; Figure 3 is a perspective of the assembly of the preferred embodiment of the present invention; Figure 4 is a top view of the assembly of the preferred embodiment of the present invention.

Figure 5 is a side view along Section B-B of Figure 4 of the components of the assembly of the preferred embodiment of the present invention.

Figure 6 is a perspective view along Section B-B of Figure 4 of the components of the assembly of the preferred embodiment of the present invention.

Figures 7 to 11 are a series of screen shots of an animation of the preferred embodiment of the present invention in operation during the compression stroke.

Figure 12 is a graph showing an example of the forces associated with one example of the present embodiment of the present invention.

W:\MaryO\Davin\Speci\Ilnnovation of IRN 690933.doc Detailed Description The preferred embodiment of the present invention is exemplified by reference to the compression of hay. It is noted that hay is provided as a mere example, and it is foreseeable that various different types of materials may be compressed according to the present invention, and that various alterations, modifications and/or additions may be introduced into the apparatus and process described without departing from the spirit or ambit of the invention.

Hay is a material that is gathered in paddocks, often in bales. Hay is used as a feed stock for animals such as cattle and the present invention can provide an efficient way to transport hay material by reducingthe volume of the feed stock, thereby reducing the cost of distributing the hay.

Under traditional processes, bales of hay or uncompressed bales of hay are inserted into a chamber where the hay undergoes a process called "fluffing".

Fluffing involves teasing and tickling the hay using rotating shafts having knives and.fingers in order to loosen the hay material.

Once the hay has been fluffed, it is dropped onto a conveyor belt into a baling machine which compacts the hay material to form an elongate "sausage" of hay. The sausage of hay is cut according to a desired weight of hay required.

The desired weight of hay is inserted into the receiving station of the apparatus in the present invention for compression as will now be described with reference to the preferred embodiment in Figures 1 to 4.

Apparatus 10 has a support frame 12 which supports a receiving station 14, an assembly 16, a driving member 18 and a compression member The receiving station 14 is where the hay material is compressed (not shown in these views), and includes a base 19, a side wall 23, an ejector mechanism 24, an ejector chute 25, and an upper wall 26. Base 19 is moveable relative to other parts of the station 14, and is lowered to receive the "sausage" of hay which it supports. The base 19 is then raised into position where the hay is surrounded by side wall 23 and compression member 20, ejector mechanism W:VMiaryO\Davn\Speci nnovat on of IRN 690933.doc 24 and ejector chute 25, base 19 and the upper wall 25. Once the hay has been compressed, operation of the ejector mechanism 24 can eject a compressed bale of hay out of receiving station 14 through ejector chute The assembly 16 is connected to the support base 12 via pivot connection plates 28 and 29 which facilitate pivoting movement of the assembly 16, which is positioned between the respective pivot connection plates.

Assembly 16 is seen in isolated views in Figures 3 and 4.

The assembly 16 includes two side plates 30and 32 which enclose the various components of the assembly and which also facilitates linkage of those components and which further also facilitates connection to the support stand 12 and the receiving station 14. Each side plate 30, 32 has a number of pivotable connection points 34, 36 and 38 whichfacilitate the rotation of various components of the assembly. First pivot connection 34 on side plates 30 and 32 provides connection with pivot connection plate 28 and 29 of the support frame via respective connection pins 39 and 40. -Located between the respective side plates at the location where pivot connection plate 28 and 29 connect to the assembly, there is also included a linear bearing 42 which is also connected to the support stand 12. Linear bearing 42 is located between the respective side plates 30 and 32 and provides guidance for movement of compression member 20 as it enters the receiving station (described later).

Second pivot connection 36 on side plates 30 and 32 provide connection to compression link 44 and are connected to each other via a pivoting pin which passes through compression link 44, so that compression link 44 can rotate about second pivot connection 36. Compression link 44 also connects to compression member 20 and tension link46 via external pivot connection 48 by pin 50. Pin 50 pivotably connects the side walls of compression link 44, tension link 46 and compression member 20 together.

Third pivot connection 38 is located at the top of the assembly 16 and connects both side plates 30, 32 via pin 54 which passes through bell crank 56.

Bell crank 56 includes pivot connections 60, 62 and 64. Pivot connection 60 is W:MaryO\Davin\Speci\Innovation of IRN 690933.doc 12 rotatable relative to the assembly side walls 30 and 32 about pin 54 at third pivot connection 38. Second crank pivot 62 connects to the driving member 18.

At third crank pivot connection 64, there is a pivotal connection with tension link 46 via a connection pin 65. This completes the linkage from the driving member 18 through the bell crank 56, the tension link 44 and the compression link 46 to the compression member Driving member 18 is mounted within a drive member housing 70 and drive member housing 70 is mounted between the respective side plates 30 and 32 of assembly 16. Driving member 18 is connected to second crank pivot 62 with a male clevis rod end. Drive member housing 70 is connected to a force generation system (or external power system) that telescopically extends retracts driving member 18 relative to drive member housing Compression member 20 is an elongate member that is constrained to move horizontally into receiving station 14. Compression member 20 is connected at external pivot 48 to the assembly 16, and at its free end that enters receiving station 14, it has a compression plate or monkey 21. The monkey 21 transfers-the force in the system into the material to be compressed.

It also functions as a vertical and horizontal guide for the mechanism as it travels into the receiving station 14.

It will now be convenient to describe the operation of apparatus 10 and assembly 16.

Base 19 of receiving station 14 is lowered from its operating position to receive a sausage of hay material. The base is then raised and restrained in position so that the hay is now secured in receiving station 14.

Under the action of an external power source, driving member 18 can extend beyond drive member housing 70. The extension of driving member 18 beyond the housing 70 is able to cause rotation of bell crank 56-about pivot connection 38. The rotation of bell crank 56 results in third bell crank pivot connection 64 moving upwardly away from the support base 12, applying W:WMaryO\DavinSpedA\Innovaion f RN 690933.doc tension through tension link 46. The force transferred through tension link 46 is transferred at external pivot connection 48 via compression link 44 and results in the horizontal movement of compression member 20 through linear bearing and into receiving station 14. The compression link 44 constrains the movement of the assembly 16 relative to the compression member 20. This balances the vertical forces generated by the driving member 18 at the external pivot connection 48 and directs the applied force into the compression member 1o As driving member 18 extends into its driving stroke, the resultant movement of compression member 20 into its compression stroke results in the rocking or rotation of assembly 16 about pivot connection 34 because of the constraining relationship of compression link 46 and tension link 44 in the assembly. At the end of the driving stroke, the driving member is returned within housing 70 and the compression member retracts from the receiving station back to its start position, and the assembly 16 rotates back to its original position also.

This movement can be seen from the animation screenshots shown in 2o Figures 7 to 11 showing the driving member performing the driving stroke, causing the compression member to perform the compression stroke, progressively from start to end. When the driving member 18 retracts within drive member housing 70, the movement of the respective components of the assembly is reversed, ie movement of the assembly and its components is from Figures 11 to 7. In this movement, the compression member moves quickly at the start of the compression stroke through first stage which progressively slows through the second stage of the stroke. It needs to be understood that the references to first and second stage are not intended to indicate an abrupt switch in force and/or velocity of the compression member between different parts of the compression stroke, but rather a smooth transition between the respective stages.

The compressed bale of hay is then ejected from receiving station 14 by action of ejector mechanism 24 which ejects the hay through chute 25, where it W:\MaryO\Davin\SpecfOvan of IRN 690933.doc is held between arms 74 and 76. When the hay is in between arms 74 and 76, it can be strapped using a conventional strapping machine for easier handling, storage and distribution.

The cycle repeats itself with a new "sausage" of hay being placed on the lowered base 19 of the receiving station 14.

Example One Trial tests of the preferred embodiment have yielded particularly favourable results as will be shown in reference to the following example.

An apparatus using a driving member powered at 200 bar is able to generate a force in the driving stroke of 65 tonnes. This force is applied constantly through the driving stroke. In the apparatus, the compression stroke has a length of 1.25 metres from the initial position to its final position.

Figure 12 shows a graph which illustrates the relationship of the forces required to compress hay and the forces that are provided by the assembly in this example.

As can be seen in this graph, the force applied to the material by the compression member is less than the force provided by the driving member in the first stage. This is the region of negative mechanical advantage.

Additionally, in this region the compression member is moving at a higher velocity than that of the driving member. However, during the progression from the first stage to the second stage of the compression stroke which occurs in the region marked R, the mechanical advantage also transitions from negative to positive. In the second stage, the constant force of the driving member is far exceeded by that of the compression member. The transition occurs as the velocity of the compression member decreases which is then less than that of the driving member. Accordingly, in the first stage, the velocity of compression member is faster than the velocity of the driving member, while the force applied by the compression member is lower than that applied by the driving member.

W:\MaryO\Davin\Speci\Innovaton of IRN 690933.doc Conversely, in the second stage, the velocity of compression member is slower than the velocity of the driving member, while the force applied by the compression member is greater than that applied by the driving member.

Thus, the apparatus and process of the present invention provides an apparatus and process having a faster cycle times and better energy efficiency for compressing material than prior devices and processes.

Finally, it is to be understood that various alterations, modifications 0o -and/or additions may be introduced into the apparatus and process previously described without departing from the spirit or ambit of the invention as outlined herein.

W:\MaryO\Davin\SpedInnovtion of IRN 690933.doc

Claims (4)

1. An apparatus for compressing material including: a receiving station for receiving the material to be compressed; a compression member for compressing said material in said receiving station; a driving member having a driving stroke for driving said compression member via an assembly which connects said driving member and said compression member, wherein drive of said driving member through said drive stroke is operable to drive said compression member through a compression stroke having a first stage and a second stage, wherein in the.first stage, the compression member provides a relatively low compression force, and in the second stage, the compression member provides a relatively.higher compression force; and wherein movement of the compression member through the first stage being faster than through the second stage.

2. An apparatus for compressing material according to claim 1, wherein in the first stage, the force being applied by the driving member to the assembly is greater than that applied by the compression member to the material, and in the second stage, the force being applied by the driving member to the assembly is less than that applied by the compression member to the material.

3. An apparatus for compressing material according to claim 1 or claim 2, wherein the driving member is driven at a constant velocity or unit displacement.

4. An apparatus, for compressing material according to any one of the preceding claims, wherein the compressive pressure required to compress the material increases from the first stage of the compression stroke to the second stage of the compression stroke. W:\MaryO\Davin\SpeRInnovation of IRN 690933.doc An apparatus for compressing material according to claim 4, wherein the pressure applied to the material in the first stage increases through the compression stroke of the first stage from 0 to about 425 Tonnes/m 2 while the pressure applied to the material in the second stage .increases through the compression stroke of the second stage from about 425 to about 950 Tonnes/m 2 Dated: 15 April 2004 PHILLIPS ORMONDE FITZPATRICK Attorneys for: W. MCCULLOCH SON PTY. LTD. W:WMaryO\Davin'Specdnnovafion of IRN 690933.doc