EP2759989A1

EP2759989A1 - Recycling station

Info

Publication number: EP2759989A1
Application number: EP14152937.0A
Authority: EP
Inventors: Henrik Als; Benny Steen Rasmussen
Original assignee: Dansk Retursystem AS
Current assignee: Dansk Retursystem AS
Priority date: 2013-01-28
Filing date: 2014-01-28
Publication date: 2014-07-30
Also published as: EP2759988A1

Abstract

The present invention relates to a recycling station (1) comprising:
- a deposit unit (20) for receiving packaging receptacles (70),
- a handling unit (30) for distributing packaging receptacles (70) received in the deposit unit (20) to a batch collector (34), and
- a grabbing unit 40 for transferring packaging receptacles (70) to a collecting container (60),

wherein the recycling station (1) is provided with a buffer storage (80) for storing packaging receptacles (70), the grabbing unit (40) being adapted may transferring packaging receptacles (70) selectively to a collecting container (60) and the buffer storage (80).

Description

The present invention relates to a recycling station and an automated recycling system for collecting consumer packaging such as bottles, cans, boxes bottle cradles and more. More particularly the present invention relates to a recycling station of the kind where cans and bottles are received in packaging receptacles in the form of bags and optionally also in bottle cradles, and where the content of the packaging receptacles are sorted and processed in a location different than the recycling station.

Background of the invention/Background art

In the prior art recycling stations, e.g. in the form of so called reverse vending machines are known, the return vending machines making it possible to return recyclable bottles and cans, which are emptied from beverages or the like, and get a deposit for the bottle or can returned, based on the number and type of the bottles or cans inserted into the machine.
Such return vending machines are often configured to receive one bottle or can at a time.
Also known in the art are reverse vending machines where a user may return a batch of cans or bottles packed in a packaging receptacle, such as a back (or sack) or in e.g. a bottle crates. Some prior art reverse vending machines allows both the return of individual bottles or cans and bottle crates. Such bottle crates are typically standard crates with individual compartments, each for holding a bottle of an exact type or size of bottle.
Reverse vending machines are often placed at narrow passageways at a supermarket, why a queue of people trying to hand in their deposit cans or bottles forms quickly. Therefore large automated systems for collecting cans and bottles in bags and crates in large quantities have been developed. Such a systems where the cans and/or bottles placed in bags may be received via a user interface in the reverse vending machine, and place the bags with bottles and cans in a collecting container adapted for transport of the bags to a regeneration or destruction facility is known from EP2319777 . This reverse vending machine is intended for location in a central place e.g. at a car park, and preferably a car park near to a shopping centre, larger consumer goods store or the like.
In this in the reverse vending machine a user delivers a number of deposit cans or bottles to a collecting container and when handing in the deposit cans or bottles, they are placed in bags or boxes, which bags or boxes are marked by a marking unit in such a way that each bag or box through the marking can be attached to information on the user, by applying a unique code, image or identification chip or tag to a bag or box for deposit cans or bottles, where the user information is derived from an identification card, a credit card or a debit card.
The bags or boxes are then placed in a collection container, which is transported to another facility where the cans and bottles contained therein are sorted, and the number and type are recorded. Based on the number of bottles and cans the accumulated deposit may be returned to the user, e.g. electronically transferred to the account of the user who delivered the bottles and cans to the reverse vending machine.
Other types of reverse vending machines are disclosed in WO 2011/066839 and US 2004/0020377 .
A problem with this type of reverse vending machines is that the logistics of transporting collection containers between the reverse vending machines and the sorting and processing facility, requires scheduled replacement of the collection containers in such a way, that it is often necessary to transport only partly filled collection containers, thus increasing costs and the environmental impact of recycling the cans and bottles. It is also a problem that if the storage capacity of the reverse vending machine is reached before the collection container is replaced, the reverse vending machine may need to be closed.

Disclosure of the invention

On this background, it is an object of the present invention to provide a recycling station that overcomes the problem of the prior art, reduces the amount of transport of collecting containers, and provides an alternative to known recycling stations.
This object is achieved by providing a recycling station comprising a deposit unit for receiving packaging receptacles, a handling unit for distributing packaging receptacles received in the deposit unit to a batch collector, a grabbing unit for transferring packaging receptacles to a collecting container, at least one docking bay for storing a removable collecting container, and a control system, wherein the recycling station is provided with a buffer storage for storing packaging receptacle, wherein control system is adapted to control the grabbing unit to transfer packaging receptacles selectively to a collecting container or the buffer storage, and wherein the control system is further adapted to control the grabbing unit to transfer packaging receptacles from the buffer storage to the removable collecting container.
In an embodiment the recycling station further comprises a housing, the buffer storage being provided in said housing.
Preferably, the buffer storage has flexible capacity.
In a further embodiment the buffer storage may comprise a shelve system.
In a further embodiment the shelve system has at least two shelves arranged one above the other, and wherein at least the upper shelve is pivotally mounted in the housing to allow two positions of the pivotally mounted shelve, and to allow easy access to a shelve below the pivotally mounted shelve.
In a further embodiment the shelve system has at least two shelves arranged one above the other, and where a lower shelve is wider than an upper shelve.
In a further embodiment the handling unit is adapted for collecting packaging receptacles in batches, and the grapping unit is adapted for transferring the packaging receptacles in the batches collected by the handling unit. This feature will save operations of the grabber unit, thereby increasing the flexibility and speed of the system, and further reduce wear on the grabber unit. Also, this will allow for more efficient packaging of the packaging receptacles on the shelves and in the collecting container.
In a further embodiment the handling unit comprises a conveyor extending from the deposit unit to the batch collector, an end stop arranged at an end of the conveyor opposite from the deposit unit. The end stop is operable between a closed and an open position, and the system is adapted to collect a batch of packaging receptacles on the conveyor, when the end stop is in the closed position, and to instruct the conveyor to transfer the batch of packaging receptacles to the batch collector, by opening the end stop.
In a further embodiment, the deposit unit is provided with sensor means allowing a controller connected with the sensor means to distinguish between types of packaging receptacles, and the controller is adapted to control the handling unit such that a first type of packaging receptacles is transferred to the batch collector and a second type of packaging receptacles is transferred to a second storage.
In a further embodiment, the buffer storage is arranged above the second storage.
In a further embodiment, the second storage comprises at least on roller lane, sloping downward away from the deposit unit.
In a further embodiment, the first type of packaging receptacles comprises bags, and the second type of packaging receptacles comprises bottle cradles.
In a further embodiment, a controller is associated with the recycling station and adapted for controlling the grabbing unit, and the controller is adapted to load packaging receptacles to a lower shelve and fill this shelve with packaging receptacles before loading packaging receptacles on an upper shelve.
The objects of the invention is further obatained by a method of operating a recycling station, the recycling station comprising: a deposit unit for receiving packaging receptacles, a handling unit for distributing packaging receptacles received in the deposit unit to a batch collector, a grabbing unit for transferring packaging receptacles to a collecting container from the batch collector, at least one docking bay for storing a removable collecting container, and a control system; wherein the recycling station is further provided with a buffer storage for temporarily storing packaging receptacles, wherein the control system actuates the grabbing unit to transfer one or more packaging receptacles from the batch collector to a removable collecting container if there is space for the one or more packaging receptacles in the removable collecting container, or actuates the grabbing unit to transfer the one or more packaging receptacles from the batch collector to the buffer storage, if there is no space for the one or more packaging receptacles in the removable collecting container; and wherein the control system actuates the grabbing unit to transfer packaging receptacles from the buffer storage to the removable collecting container, when space for the one or more packaging receptacles becomes available in a removable collecting container.
Further objects, features, advantages and properties of the recycling station according to the invention will become apparent from the detailed description.
Throughout the description the term packaging receptacle is used. By this is meant a bag or sack or box or bottle crate, or can crate, containing individual consumer packaging items, such as beverage containers or other containers, e.g. aluminium cans and other metal cans, steel cans, bottles, glass bottles, glass jars, and plastic bottles (e.g. PET bottles), and the like. The containers may be reusable/refillable or disposable (for final deposit or for reusing material). A packaging receptacle may further be a box or crate for reusable containers/packaging, such as bottles or cans. Such boxes or crates may often be formed in a durable hard plastic. Typical bottle crates are adapted for receiving 12, 24 or 30 bottles.

Brief description of the drawings

In the following detailed portion of the present description, the invention will be explained in more detail with reference to the exemplary embodiments shown in the drawings, in which:

Fig. 1 shows a recycling station according to one embodiment of the invention, and where Fig. 1A shows the recycling station in a side view, Fig. 1B, in a diagrammatic depiction, shows a plan (top view) of the recycling station, and Fig. 1C shows a section C-C through the recycling station in Fig. 1B;
Fig. 2 shows a detailed view of the recycling station in Fig. 1A;
Fig. 3 shows a detailed view of the recycling station in the plan view of Fig. 1B;
Fig. 4 shows a detailed view of an deposit unit of the recycling station in Fig. 3;
Fig. 5, in a top or plan view, shows a recycling station according to another embodiment of the invention;
Fig. 6 shows a detailed view of an deposit unit of the recycling station in Fig. 5;
Fig. 7 shows a detailed view of the recycling station in Fig. 1C; and
Fig. 8 shows a diagram representing a control system for controlling a recycling station according to the invention.

Detailed description of selected embodiments

In the following detailed description of the recycling station 1 according to the invention will be described by the preferred embodiments. A system for receiving and processing deposit bottles, cans and the like in bags, boxes or crates is also disclosed.
The construction and operation of recycling stations 1 is as such well-known and should not require further explanation in the present context. Further details regarding the operation of recycling stations 1 are provided below.
Figs. 1A-C show a first exemplary embodiment of a recycling station 1 which is particular suitable for reducing transport of materials to be recycled, and for easing the sorting of the materials to be recycled. Figs. 1A-C show a recycling station 1 according to an embodiment of the invention the invention in a side view in Fig. 1A, a top plan view in Fig. 1B and a front sectional view in Fig. 1C. The recycling station comprises a housing 10, a deposit unit 20 for receiving and initially registering packaging receptacles 70, a handling unit 30, for distributing packaging receptacles received in the deposit unit 20 to other parts of the recycling station 1; a grabbing unit 40 (crane / claw), a docking bay 50 for a collecting container 60, and a buffer storage 80 for temporarily storing packaging receptacles 70, as described in further detail below.
In the embodiments of the recycling station 1 shown in the figures, the housing 10 may be in the form of a building. In other embodiments the housing 10 may a more temporary structure, such as a shed. In other not shown embodiments the deposit unit 20, the handling unit 30, the grabbing unit 40 and the buffer storage 80 may be formed in a mobile unit, such that a collecting container 60 may reachable by the grabbing unit 40, when the collecting container 60 is placed next to the mobile unit. In this case the concept of a docking bay 50 should be understood widely. In any case the docking bay should allow for a predetermined fixed position relative to the grapping unit 40, so that packaging receptacles 70 can be accurately placed in a collecting container 60 located in the docking bay 50 by the grapping unit 40.
The housing has a front wall 11 where the deposit unit 20 is located. Opposite to the front wall back wall 12 is provided. Between the front and back walls 11 and 12, side walls 13 and 14 are provided. The housing preferably further comprises a roof to define a closed space, for containing functional parts of the recycling station 1.
In the shown embodiments, the housing 10 has a docking bay 50 for receiving a collecting container 60. In the embodiments shown in the figures there is one docking bay 50. However, in other, not shown embodiments, there may be two or three docking bays 50 each for receiving a collecting container 60. In these cases the grapping unit is arranged so that it may access all of the collecting containers 60. Although, embodiments with more than one collecting container 60 could thus be conceived in order to increase the capacity of the recycling station 1, the present invention allows an increased capacity of the recycling station 1 using just a single collecting container 60.
The docking bay(s) 50 may be accessed via a gate/gates 51 provided in a back wall of the housing 10.
A collecting container 60 is preferably a standard 20 or 40 foot standard container of the type having an open top so that the container may be loaded from above. The size of the collecting container 60 needed at a particular recycling station 1 can be determined by statistical data collected over time, the data showing the quantity of deposit cans of bottles handed in at the particular location of the recycling station.
In the front wall 11 of the housing 10, at least one deposit inlet 21 is/are defined as openings through the front wall 11.
Near the deposit inlet 21 a slot (not shown) for insertion of a card (not shown) for identification of the user depositing a packaging receptacle 70 (bag or crate), may be provided. Other kind of card readers could be used. The type of card reader is not essential, but a type of card reader which is not easy to break or ravage is preferred. The card may be a special card issued from the organisation handling deposit goods/recyclable items, a card issued by one or more chains of shops, a credit card or a debit card.
A keyboard or keypad (not shown) may further be provided in the vicinity of the one or each of the deposit inlets 21, the keypad making it possible for a user to type a code or type a cell phone number on order to receive a SMS or the like containing information, which information could be that the amount of money relating to the handed in deposit cans or bottles is deposited on the users account.
When the card is inserted in the slot or otherwise read by a card readers, a screen (not shown), also located in the vicinity of the one or each of the deposit inlets 21, may present information about handling of the packaging receptacle 70. A door at each deposit inlets 21 will provide access to the interior of the deposit unit 20, i.e. allowing entering packaging receptacles 70 into the deposit unit 20.
A packaging receptacle 70 is placed in the deposit inlets 21 on a tray or plate for handing in the packaging receptacle 70, and the user may be asked if he or she wants to hand in the packaging receptacle 70, e.g. through information on the display. The tray or plate may be connected to means for weighing a content (packaging receptacle 70) placed on the tray or plate.
Typical information from the display when the card is read could be: "Please place a bag or crate on the tray". Detection means for detecting the presence of a packaging receptacle 70 on each tray of the deposit inlets 21 is provided. When a packaging receptacle 70 is detected in a deposit inlet 21, the user is asked if he or she wants to hand in the packaging receptacle 70.
The user may select yes or no. If "YES" is selected the door will be closed and the packaging receptacle 70 is marked with an individual code or image or an identification chip or tag by a marking unit (not shown). The code, image, identification chip or tag makes it possible to recognise the exact same packaging receptacle 70 when the packaging receptacle 70 is later emptied at a remote processing facility, and the information from the card is linked together with the code or image from the packaging receptacle 70 handed in by the card holder. Thereby it is possible later to deposit the correct amount of money to an account of the user. Alternatively or additionally, (standardized) packaging receptacles 70 being provided with marks comprising e.g. an individual code or an identification chip could be registered at the deposit inlet 21 and linked with the personal information on the card.
After the packaging receptacle 70 is marked/registered it is transferred to a conveyor 31 forming a part of the handling unit 30 and transported into the housing 10 for further processing. This further processing will be described in further detail below, however eventually the packaging receptacles 70 handed in at the deposit station 20 are transferred to a collecting container 60 for subsequent transport to e.g. a sorting facility, where the content of the packaging receptacle 70 may be sorted and counted to allow the user to receive his/her deposit, via the information registered regarding that user.
If the user selects "NO", the user may be instructed by the display to remove the packaging receptacle 70 from the deposit inlet 21.
After a packaging receptacle 70 is handed in, the display may make it possible for the user to select handing in more packaging receptacles 70. If "YES" is selected the door closes and the process described above reiterates, though the user only needs to identify him or herself once. If "NO" is selected, the display may ask if the user wants to receive a SMS, when the deposit amount is transferred to the users account. If "YES" is selected in response to the latter question, it will be possible for the user to type a cell phone number for receiving the SMS. The number can be typed directly on the display or at a keyboard or keypad, preferably located close to the display. Finally the user may select on the display, if he or she wants a receipt (not shown) for the handed in packaging receptacle(s) 70. Such a receipt can contain information about the user identity, the number of packaging receptacles 70 have been handed in, the location of the recycling station 1, etc. If the user selects "NO" to a receipt or after a receipt is printed out, a control system prepares for the next user.
When a collecting container 60 is full, it is preferably picked up and transported to the nearest authorized handler of deposit cans or bottles or similar consumer packaging, which is typically located at facility remote from the recycling station.
The packaging receptacles 70 are identified, which identification is used i.e. when a user wants information about where in the deposit flow the individual packaging receptacles 70 are, and when the deposit amount is expected to be transferred to the users account.
When the packaging receptacles 70 are counted/treated at the remote facility, the packaging receptacles 70 automatically will be identified by the code, image, identification chip or tag, on each packaging receptacle 70, thereby making it possible to determine and prove which packaging receptacles 70 belongs to each return delivery, and more particularly to which user it belongs, so that he/she may receive the correct refund.
If the user selected that he or she wants an SMS, the SMS is sent when the deposit cans or bottles are counted at the remote facility, and tells the user when the deposit amount will be transferred to the users account.
It is possible to design the system in such a way that information such as name and address of the user will not be displayed to the authorized handler of deposit goods.
The deposit unit 20 is adapted for receiving packaging receptacles 70, preferably in the form of bags, boxes or bottle crates. The deposit unit 20 is formed at one end wall of the housing 10, typically a front end 11. The deposit unit 20 comprises one or more depositing inlets 21 for delivering packaging receptacles 70.
In the embodiment shown in the figures, there are two depositing inlets 21, where users may deliver empty packaging packed in packaging receptacles 70. In other embodiments, there may be only a single depositing inlet 21, or there may be more than two depositing inlets 21, e.g. 3, 4, 5 or 6 depositing inlets 21. In the embodiments, where there are two or more depositing inlets 21 (as shown) users may deliver packaging receptacles independently of each other at the same time.
At each depositing inlet 21 of the deposit unit, means are provided for registering the users ID, e.g. via a credit card, a debit card, a coded account, communication with uses cell/mobile phone or in other similar manner.
When, one or more packaging receptacles 70 is deposited through a depositing inlet 21 by a user, data regarding the packaging receptacle is recorded, by suitable means provided in the deposit unit 20. If the packaging receptacles 70 are bags, an RFID tag (or similar) of each bag is recorded, along with the weight of the bag and a picture of the bag. The data is stored for use in the further processing of the packaging receptacle 70. In the case where the packaging receptacles 70 are standard bottle crates, the weight of each box/crate and a picture of each bottle crate is recorded and stored for the subsequent processing.
The recycling station may further be adapted for receiving return of bottles in other receptacles than bags and standard bottle crates. Such receptacles may for instance be cardboard boxes. Such irregular receptacles may in one embodiment be transferred to the crate storage, where they can be subsequently handled by service personnel. However, in another embodiment, filled cardboard boxes may be handled in the first storage, much in the same way as when the receptacles are bags. In order to handle irregular size bags or cardboard boxes, the recycling station may further be adapted to estimate the size of each bag or cardboard box handed in at the inlet. This may be done by suitable sensors, or by a camera connected to the controller and suitable image analysis program. Such a camera may be the same camera that records images of the handed receptacles for documentation and identification, or it may be an additional camera. The size estimation sensors or cameras may be located at the inlet or they may be located near or overlooking the conveyor 31.
After depositing and control of the deposited packaging receptacles 70, the packaging receptacles are transferred to a conveyor belt 31 of a handling section 30, the packaging receptacles 70 are transported from the deposit unit 20 and into the recycling station 1.
In the handling section 30, the deposited packaging receptacles 70 are treated in two different ways depending on the packaging receptacle 70 being a bag 70' or a bottle crate 70". Bags are transported on the conveyor 31 to an end stop 32, thereof. The end stop 32 is arranged at an end of the conveyer 31 facing away from the deposit unit 20 and the front wall 11, such that the bags 70' may be collected in batches of bags. A preferred batch of bags could for example be four to six pieces, depending on the content of the bags. Thereby, if a user deposits bags 70' which are not fully filled, more bags can enter into a batch. Thereby, storage space and the number of further transports of batches by the grabbing unit 40 may be reduced, and a desired batch size may be approximated more closely to obtain a more optimized packaging in the collecting container 60. The batches of bags are subsequently moved either to a collecting container 60 or to a buffer storage 80 by a grabber 41, for further details see below.
Arranging the bags in batches improves the utilization of the capacity (number of bags per time unit) of the grabber 41, since it may be operated only when its full load capacity is present on the conveyor belt 31.
In the handling section 30, standard bottle crates 70" are sorted out at the an end 33 of the conveyor belt 31, proximal to the deposit unit 20, and transferred from the conveyor belt 31 to separate second roller lanes 95 of a crate storage 90, which is one example of a second storage, see below.
When a batch of e.g. four-six bags 70' are lined up on the conveyor 31, towards the end stop 32, the end stop 32 is opened and all the bags 70' of the batch are thereby transferred to a batch collector 34, preferably in the form of a first roller lane arranged in extension of the conveyor 31. The batch collector 34 is formed such that a grabber 41 can grab the bags 70' of the batch and lift these to transport them to another destination, see below.
The 4-6 bags 70' on the batch collector 34 are simultaneous lifted by the grabber as a batch. The batch of packaging receptacles 70/bags 70' is preferably transferred to a collecting container 60 located in the docking bay 50, as long as there is still room therein, or as long as the batch can be fitted into the collecting container 60 in a way that optimum packaging capacity is provided. The packaging receptacles (bags 70') are packed in the collecting container 60 such that the collecting container 60 packing is optimized for transport of collecting containers 60, i.e. such that the collecting container contains the largest possible number of bags 70'. The number of bags 70' and the weight of the bags 70' transferred to the container 60 are recorded by a controller 100, whereby it is possible to keep track of the need for replacing the collecting container, when it is filled. Preferably, the controller is linked to communication means, e.g. wireless communication means, and provided with a programming such that the controller 100 may be request replacement of the collecting container 60 when it is filled, or when it is closed to being filled.
Alternatively or additionally, the controller 100 may be accessed from a remote location and prompted for a status on the capacity in the collecting container 60. Such control may be done in regular intervals and in an automated way.
If the collecting container 60 is full of if the batch cannot be packed into the collecting container in a way that allows optimal compactness at that time, the packaging receptacles 70/bags 70', are moved from the batch collector 34 to a buffer storage 80 instead of to the collecting container 60, until the collecting container 60 is picked up and replaced by a new empty collecting container 60, see below, or until the batch can be placed in a collecting container in a way that allows optimal packaging of the collecting container 60.
In on one embodiment the buffer storage 80 may be a second collecting container (not shown) removable or permanent, either provided in a second docking bay (not shown) or in a space in the housing 10, or the buffer storage 80 may simply be a space provided in the housing 10.
The buffer storage 80, in a preferred embodiment is a flexible capacity buffer storage, i.e. it comprises a variable area available for temporarily storing the packaging receptacles 70/bags 70'
The buffer storage 80, in the preferred embodiment shown in the figures comprises a shelve system 81. The shelve system 81 comprises a bottom shelve 82 which is fixed. The bottom shelve is arranged above the above mentioned second roller lanes 95. In other embodiments of the invention the second storage 90/second roller lanes 95 may be left out. The bottom shelve 82 is preferably sized to have room for three rows of (fully filled) (standard size) bags 70', the rows being arranged in a direction parallel to the side wall 14 of the housing 10 and parallel to the conveyor 31.
The next shelve above the bottom shelve 82, the second shelve 83, has a width suitable for two rows of bags 70'. This shelve 83 is pivotally mounted on an inner surface the side wall 14 of the housing 10 or on a rack (not shown) provided in the housing 10. The pivotal mounting allows the shelve second 83 to be placed in two different positions, a closed, substantially vertical position (parallel to the sidewall 14), and a second open position, where the shelve is horizontal, and ready to receive bags 70'. The second shelve 83 is only unfolded/opened, when the bottom shelve has been filled with bags 70'.
Above the second shelve 83 a third or upper shelve 84 is arranged. This shelve is also pivotally mounted on the side wall 14 of the housing 10 or on a rack (not shown) in the housing 10. The third shelve 84 is only unfolded/opened, when the second or middle shelve 83 has been filled with bags.
In Fig. 7 the second shelve 83 and the third shelve 84 are shown in the open or unfolded position, with bags 70' lying on the shelves 83, 84. In dashed lines the second and third shelves are shown in the folded, upright or closed positions 83', 84' as well.
In other embodiments, there may be more or less space on the shelves 82, 83, 84 (different number of rows). Also the number of layers of shelves 81 above each other may be varied. However, the shelves widths should preferably decrease by one row for every shelve moving upwards. This arrangement allows the grabber 41 to be able to access the shelves 81 when the underlying shelve has been filled with bags 70' without interfering with the bags 70' already on the shelves.
The control system controls the grapper 41 to place the bags 70' in the collecting container 60 based on an algorithm, the algorithm using input on the collecting container size 60, the batch size, the weight/size of the bags 70' and/or the number of bags 70'.
The docking bay 50 may be adapted for receiving different sizes of collecting containers 60. The docking bay 50 may be provided with means for determining the size of a collecting container 60 loaded into the docking bay 50, the collecting container 60 for example being tagged or otherwise equipped with machine readable identification means, such as bar codes or the like. Alternatively, or additionally the collecting container 60 size information could be entered manually into the control system, either on location (via a suitable user interface) or remotely.
Collecting containers 60 are filled gradually as users deliver packaging receptacles 70 in the form of bags 70'. When a collecting container 60 has been filled, it must be picked up by an operating crew, for transport to a facility for further processing, e.g. cleaning, disinfection, refilling, etc. A picked-up collecting container 60 must be replaced by an empty collecting container 60.
In order to optimize the transports of collection containers 60 between one or more recycling stations 1 and remote facility (not shown) for handling the content of packaging receptacles 70, bags 70' may be stored in the buffer storage 80, when the collection containers 60 in the docking bay 50 is full.
Thereby, the recycling station 1 may be kept operational, even during the replacement of collecting containers. Further, the temporary storage of bags 70' in the buffer storage allows a total filling of each collecting container, whereby the need for transporting half-filled containers is avoided or reduced.
The controller 100 may further access stored historical data from a memory 101 remote or local to the recycling station 1 to provide statistics on the delivery of packaging receptacles 70 at that particular or similar locations, in order to anticipate peak load periods where the collecting container 60 and the buffer storage 80 could be at risk of being fully occupied, without being able to be replace the collecting container 60, such as in connection with holydays, etc., where transport of the collecting containers 60 may not be possible.
The shelves of the bag buffer storage are packed from the bottom and upwards. Fist the bottom shelve, the second shelve, then the third, (etc. if there are more than three shelves). After a shift of collecting container 60, the buffer storage 80 is emptied by transferring the bags 70' to the new collecting container 60, by use of the grabber 41, on the basis of stored data on the location of the bags in the bag buffer storage 80. The grabber 41 is controlled such that transport of bags 70' from the handling unit (the first roller lane/the batch collector 34), is prioritized over the bags to be moved from the buffer storage 80, to the collecting container 60. Thereby, it is ensured that a user will never or rarely experience that the deposit of packaging receptacles 70 at the deposit station 20 is delayed.
Preferably, the bags 70' are placed in the collecting container 60 using an optimizing algorithm, to maximize the capacity utilization (the more bags the better).
In a preferred embodiment of the invention, and as shown in the figures, the recycling station further has a second storage 90/crate storage 90 for (standardized) bottle crates 70".
On reception of packaging receptacles 70 data (RFID/weight/photo) is measured/read for each packaging receptacle 70 and the type is determined, i.e. if it is a bottle crate 70" or a bag 70'.
The measured and/or read data are used at least for sorting of bottle crates 70" and bags 70', crates 70" are transferred to the crate storage 90, and bags 70' are transferred to either the collecting container 60 or the buffer storage 80.
The crate storage 90, in the shown embodiments, is fixed in the housing 10, and comprises second roller lanes 95. The second roller lanes 95 are arranged with a slight downward slope towards the rear wall 12 (opposite to the deposit unit 20) of the housing 10. Thereby the bottle crates 70" passively are transported to the back of the housing where they may be removed from the crate storage 90 through a gate 15 arranged in the rear wall 12 of the housing 10.
In a further embodiment (not shown), the bottom shelve 82 of the buffer storage 80 shelve system 81, may also be pivotally mounted to the side wall 14 of the housing 10 or to a rack (not shown). This will provide easier access to the space below the bottom shelve 82, i.e. the second roller lanes 95, e.g. for service, maintenance or cleaning purposes.
The arrangement with a buffer storage 80 for the bags 70' over a crate storage 90, allows for a compact design of the recycling station 1.
In one embodiment, and as shown in Fig. 4, the deposit unit 20 may be equipped with a sideways conveyor 25 for transferring packaging receptacles 70 from the deposit inlets 21 to the conveyor 31 of the handling unit 30. A packaging receptacle 70 is placed through a deposit inlet 21. When registering of the packaging receptacle70 is done the packaging receptacle 70 is loaded either directly on to the main conveyor 31 (the packaging receptacle 70 in the leftmost deposit inlet 21 in Fig. 4) or on to the sideways conveyor 25 (the packaging receptacle 70 in the rightmost deposit inlet 21 in Fig. 4), which in turn will load the packaging receptacle 70 onto the main conveyor 31.
In another embodiment, and as shown in Fig. 6, the deposit unit 20 may be equipped with pushing means 26 for pushing transferring packaging receptacles 70 from the deposit inlets 21 sideways onto to the conveyor 31 of the handling unit 30, which in this embodiment extends all the way to the front wall 11.
In a further embodiment (not shown), the deposit unit 20 may further comprise a deposit inlet 21 having a holder for a bag. The bag on the holder may be filled with cans and bottles by a user. When the user is done he/she may prompt the closing of the bag, via suitable closing means provided at that deposit inlet 21. When the bag is closed, the bag may be automatically registered as in the other types of deposit inlets 21 described above and transferred to the conveyor 31.
In the following the grabbing unit 40 is described with reference to Figs. 3, 5 and 7. The grabbing unit 40 has a claw or grabber 41 that may be moved in the housing 10 of the recycle station 1 to transport the packaging receptacles 70. The claw or grabber 41 may be moved in the vertical plane, up and down, and in the horizontal plane, back and forth as well as sideways in the housing 10. In a preferred embodiment the claw or grabber 41 is arranged on a cart 42 being movable on sideways extending (between the side walls 13, 14 of the housing 10) cross rails 43, forming a frame. The frame formed by the cross rails 43 is movable along a longitudinal rails 44, extending in a longitudinal direction of the housing 10.
The grabber 41 comprises two sets of arms 45', 45" arranged pivotably at least to the cart 42 such that the two set of arms 45', 45" may be moved away from and towards each other to grab packaging receptacles 70. The two set of arms 45' 45" each comprise two or more arms spaced apart at suitable intervals. These spaced apart arms 45', 45" are arranged to cooperate with a spacing between rollers of the batch collector 34, such that the arms 45', 45" can grab under the packaging receptacles 70 when located on the batch collector 34.
Preferable, the shelves 82, 83, 84 of the shelve system 81 are also formed such that they comprise spaced apart parallel ribs - arranged perpendicular to the side wall 14, and such that the spaced apart arms 45', 45" can grab under the packaging receptacles 70 when located on a shelve 82, 83, 84.
Fig. 8, in diagram form, shows a control system 100 for a controlling at least the grabbing unit 40 a recycling station 1 according to the invention. The control system comprises a control unit 101. The control unit 101 receives information from various sensors (may also be called sensor means) or subsystems 201, 202, 203, providing information about the number, weight, size, etc. of packaging receptacles 70 that have been transferred to the batch collector. These sensors or subsystems 201, 202, 203 may be provided in the deposit unit 20 as described above. In further embodiments a subsystem 204 e.g. comprising a camera overviewing the batch collector 34 and means for calculating the size of a batch of packaging receptacles 70 located on the batch collector 34 may provide input to the control unit 101. The control unit 101 receives information from a sensor/subsystem 205 regarding the size/type of the collecting container 60 placed in the bay. Based on the information received from the sensors/ subsystems 201, 202, 203, 204, 205 the control unit 201 distributes the packaging receptacles 70 located on the batch collector 34 to either the collecting container 60 or the buffer storage 80, or from the buffer storage 80 to the collecting container 60 as described above. This is done by the control unit 101 being connected to a grabber unit control unit 40'. The control unit further communicates with or comprises a memory 102 to store information received from the sensors/subsystems etc.
Although the teaching of this application has been described in detail for purpose of illustration, it is understood that such detail is solely for that purpose, and variations can be made therein by those skilled in the art without departing from the scope of the teaching of this application.
The term "comprising" as used in the claims does not exclude other elements or steps. The term "a" or "an" as used in the claims does not exclude a plurality. The single processor or other unit may fulfill the functions of several means recited in the claims.

Claims

A recycling station (1) comprising:
- a deposit unit (20) for receiving packaging receptacles (70),

- a handling unit (30) for distributing packaging receptacles (70) received in the deposit unit (20) to a batch collector (34),

- at least one docking bay (50) each for storing a removable collecting container (60),

- a grabbing unit (40) for transferring packaging receptacles (70) from the batch collector (34) to a collecting container (60), and

- a control system (100),
wherein the recycling station (1) is further provided with a buffer storage (80) for temporarily storing packaging receptacles (70), the control system (100) being adapted for controlling the grabbing unit (40) to transfer packaging receptacles (70) from the batch collector selectively to a removable collecting container (60) or the buffer storage (80), and wherein the control system (100) is further adapted to control the grabbing unit (40) to transfer packaging receptacles (70) from the buffer storage (80) to the removable collecting container (60).
A recycling station (1) according to claim 2, wherein the recycling station (1) further comprises a housing (10), the buffer storage (80) being provided in said housing (10), and the buffer storage (80) comprising a shelve system (81).
A recycling station (1) according to claim 1 or 2, wherein the buffer storage (80) has a flexible capacity.
A recycling station (1) according to claim 2 or 3, wherein the shelve system (81) has at least two shelves (82, 83, 84) arranged one above the other, and wherein at least the upper shelve is pivotally mounted in the housing (10) to allow two positions of the pivotally mounted shelve.
A recycling station (1) according to any one of claims 2-4, wherein the shelve system (81) has at least two shelves (82, 83, 84) arranged one above the other, and where a lower shelve is wider than an upper shelve.
A recycling station (1) according to any one of claims 2-5, wherein the handling unit (30) is adapted for collecting packaging receptacles (70) in batches, and wherein the grapping unit (40) is adapted for transferring the packaging receptacles (70) in the batches collected by the handling unit (30).
A recycling station (1) according to claim 5, wherein the handling unit (30) comprises a conveyor (31) extending from the deposit unit (20) to a batch collector (34), an end stop (32) arranged at an end of the conveyor (31) opposite from the deposit unit (20).
A recycling station (1) according to claim 7, wherein the end stop (32) is operable to be in an open and closed position, where the recycling station (1) is adapted for collecting a batch of packaging receptacles (70) on the conveyor (31), when the end stop (32) is in the closed position, and to operate the conveyor (31) to transfer a collected batch of packaging receptacles (70) to the batch collector (34), by opening the end stop (32).
A recycling station (1) according to any one of claims 1-8, wherein the deposit unit (20) is provided with sensor means (201, 202, 203, 204) allowing a control unit (101) connected with the sensor means (201, 202, 203, 204) to distinguish between types of packaging receptacles (70), and where the controller controls the handling unit (30) such that a first type of packaging receptacles (70) is transferred to the batch collector (34) and a second type of packaging receptacles (70) are transferred to a second storage (90).
A recycling station (1) according to any one of the preceding claims, wherein the buffer storage (80) is arranged above a second storage (90).
A recycling station (1) according to claim 10, wherein the second storage (90) comprises at least on roller lane 95, sloping downward away from the deposit unit (20).
A recycling station (1) according to claim 10 or 11, wherein the first type of packaging receptacles (70) comprises bags (70'), and the second type of packaging receptacles (70) comprises bottle cradles (70").
A recycling station (1) according to any one of claims 4-12, wherein a the control system (100)is adapted for controlling the grabbing unit (40), and where the controller is adapted to load packaging receptacles (70) to a lower shelve and fill this shelve with packaging receptacles (70) before loading packaging receptacles (70) on a an upper shelve.
A method of operating a recycling station (1), the recycling station (1) comprising:
- a deposit unit (20) for receiving packaging receptacles (70),

- a handling unit (30) for distributing packaging receptacles (70) received in the deposit unit (20) to a batch collector (34),

- a grabbing unit (40) for transferring packaging receptacles (70) to a collecting container (60) from the batch collector (34),

- at least one docking bay (50) for storing a removable collecting container (60), and

- a control system (100),
wherein the recycling station (1) is provided with a buffer storage (80) for temporarily storing packaging receptacles (70), wherein the control system (100) actuates the grabbing unit (40) to transfer one or more packaging receptacles (70) from the batch collector (34) to a removable collecting container (60) if there is space for the one or more packaging receptacles (70) in the removable collecting container (60), or actuates the grabbing unit (40)) to transfer for the one or more packaging receptacles (70) from the batch collector (34) to the buffer storage (80), if there is no space for the one or more packaging receptacles (70) in the removable collecting container (60); and wherein the control system (100) actuates the grabbing unit (40) to transfer packaging receptacles (70) from the buffer storage (80) to the removable collecting container (60), when space for the one or more packaging receptacles (70) becomes available in a removable collecting container (60).