APPARATUS AND METHOD FOR SORTING NON-FERROMAGNETIC PARTICLES
Technical Field
This invention relates to an eddy current separator and a separation method having improved efficiency for separating non-ferromagnetic particles.
Background Art
Eddy current separators have previously been known for separating non-ferromagnetic particles such as disclosed by U.S. Patent Nos . 4,834,870 Osterberg et al . and 4,869,811 olanski et al . Such separators generate a rapidly changing high flux density primary magnetic field through which the non-ferromagnetic particles are conveyed. This changing magnetic flux induces eddy current flow in electrically conductive particles and thereby generates particle magnetic fields repelled by the primary magnetic field. For ferromagnetic particles, the ferromagnetic attraction is stronger than the eddy current repulsion and such particles are thus attracted to the separator. However, non-ferromagnetic particles, after passing through the primary magnetic field, are propelled varying distance depending upon the electrical resistance thereof and consequent electrical flow that divides different levels of particle magnetic fields for the different materials.
Other separators for separating non-ferromagnetic particles are disclosed by German Offenlegung- sschrift DE 3416504 Wagner and European patent publica-
tion 83445 Steinert Electromagnetbau GmbH. These additional disclosures disclose such separation with falling particles.
Many conventional eddy current separators utilize a rotor having permanent magnets that generate the rapidly changing high flux density primary magnetic field. While new rare earth magnetic materials such as Neodymium- Iron-Boron and new rotor designs permit achievement of higher magnetic fields and higher rates of change of the flux than is possible with prior designs, only a small fraction of the primary magnetic field potential is actually utilized to propel the metallic particles. This is because as the particles enter the primary magnetic field, the repulsive eddy current force lifts the particles and prevents them from entering the stronger portions of the magnetic field. More specifically, conventional eddy current separators have the particles approaching the primary magnetic field generator angularly on the surface of a conveyor belt. The particles are thus conveyed into the primary magnetic field by their momentum and are held down by the force of gravity. Due to the laws of physics, the maximum force that the primary magnetic field can exert on the metallic particles is limited to that required to overcome gravity and change the particle momentum. The net result is that the particles lift off the conveyor belt before reaching the strongest location of the primary magnetic field and hence do not experience the full potential of the primary magnetic force that could be applied to them.
Disclosure Of The Invention
One object of the present invention is to provide an eddy current separator having improved efficiency for separating non-ferromagnetic particles.
In carrying out the above object, the separator for separating non-ferromagnetic particles according to the invention includes a magnetic field generator for generating a rapidly changing high flux density primary magnetic field. A conveyor of the separator conveys the particles along a direction of conveyance adjacent the magnetic field generator. Different embodiments of the separator are constructed with different means for: (a) engaging the conveyed particles to force the particles into the primary magnetic field to increase the induced eddy current flow in the particles to generate higher particle magnetic fields repulsed by the primary magnetic field of the generator; and (b) thereafter releasing the particles to allow the repulsion between the particle magnetic fields and the primary magnetic field to propel the particles distances that vary for different metals having different electrical resistances, densities, shapes, and sizes.
The engagement of the particles and forcing thereof into the primary magnetic field induces a greater eddy current flow in the particles to generate larger particle magnetic fields than have previously been possible and consequently a greater propulsion and distance of travel so as to provide better separation between particles of different materials.
In the preferred construction, the separator includes an adjuster for adjusting the position along the direction of conveyance where the particles are released to be propelled by the magnetic fields.
In one construction, the conveyor includes an endless belt and a pair of rotary pulleys that support the endless belt.
Certain embodiments of the separator have the conveyor including a conveyor member having an upwardly facing surface on which the particles are conveyed and have the magnetic field generator located below the upwardly facing surface of the conveying member as well as having the means for engaging and thereafter releasing the particles being located above the upwardly facing surface of the conveying member to engage and thereafter release the particles.
In one construction, the means for engaging and thereafter releasing the particles comprises an inclined engagement member that extends downwardly along the direction of conveyance toward the upwardly facing surface of the conveying member. The inclined engagement member has a distal end at which the particles are released for the propulsion thereof by the magnetic fields. In addition, the separator has an adjuster for adjusting the location of the inclined engagement member to adjust the position of its distal end. Furthermore, the inclined engagement member in one construction has an upper mount that provides pivotal mounting thereof about an axis above the upwardly facing surface of the conveying member. In another construction, the inclined engagement member is made of a flexible material that
permits flexing of the distal end thereof during use. This flexible construction of the inclined engagement member is disclosed as including laterally spaced portions that cooperatively define the distal end thereof and that can flex independently of each other. A further construction of the inclined engagement member includes a brush having bristles that define the distal end thereof for engaging the particles.
Different embodiments of the separator also have the means for engaging and thereafter releasing the particles constructed as a roll located above the conveyor. In one embodiment, the roll also includes a rotary mount that rotatably mounts the roll while permitting vertical movement of the roll and may also be provided with a resilient outer surface that engages the particles. In another embodiment, the roll comprises a rotary brush having bristles that engage the particles. Both of the roll embodiments of the separator include an adjuster that adjusts the position of the roll.
Another embodiment of the separator has the means for engaging and thereafter releasing the particles constructed as an upper auxiliary conveyor located above the first mentioned conveyor. This upper auxiliary conveyor is disclosed as including a conveying member having a reach that has a downwardly facing surface inclined downwardly along the direction of conveyance. This embodiment includes an adjuster for adjusting the position of the upper auxiliary conveyor.
In another construction, the magnetic field generator is located above the conveyor and the conveyor includes a conveying member that has an upwardly facing
surface on which the particles are conveyed and that embodies the means for engaging and thereafter releasing the particles. In one embodiment of the separator having this construction, the conveying member is embodied by an endless belt and the conveyor includes a pair of rotary pulleys that support the endless belt with one of the pulleys being hollow and receiving the magnetic field generator. In another embodiment of the separator having this construction, the conveyor includes a vibratory conveying member that has an upwardly facing surface on which the particles are conveyed. Both of these embodiments include an adjuster that adjusts the position of the magnetic field generator .
In other constructions, the conveyor of the separator is embodied by a downwardly inclined gravity slide. One construction of the gravity slide includes a lower end below which the magnetic field generator is located and generates the primary magnetic field about a horizontal axis, and the means for engaging and thereafter releasing the particles is an inclined engagement member located above the lower end of the gravity slide. In another construction, the gravity slide is an inclined trough of a curved shape and the magnetic field generator is located within the curved shape of the inclined trough such that the particles are propelled therefrom in a sideways direction.
Another object of the present invention is to provide an improved method for separating non-ferromag- netic particles.
In carrying the immediately preceding object, the method for separating non-ferromagnetic particles according to the invention is performed by generating a rapidly changing high flux density primary magnetic field and conveying the particles along a direction of conveyance adjacent the primary magnetic field. The conveyed particles are engaged to force the particles into the primary magnetic field to increase the induced eddy current flow in the particles to generate particle magnetic fields repulsed by the primary magnetic field. Thereafter, the conveyed particles are released to allow the repulsion between the particle magnetic fields and the primary magnetic field to propel the particles distances that vary for different metals having differ- ent electrical resistances, densities, shapes and sizes.
In one practice of the method, the particles are conveyed above the primary magnetic field and engaged from above by a distal end of a pivotal engage- ment member, a rotating roll, or an upper auxiliary conveyor .
In another construction, the particles are conveyed below the primary magnetic field and engaged by a conveying member of a conveyor that conveys the particles. In one practice, the conveying member is moved over a pair of pulleys and conveys the particles on an upper reach thereof above which the primary magnetic field is generated. In another practice, the conveying member is vibrated to convey the particles below the primary magnetic field.
The method is also performed by conveying the particles on an inclined gravity slide. In one prac-
tice, the particles are propelled by a magnetic field generated below a lower end of the gravity slide. In another practice, the particles are propelled sideways from the inclined gravity slide by a magnetic field generated within a curved shape of the gravity slide.
The objects, features, and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.
Brief Description Of The Drawings
FIGURE 1 is an elevational view that illustrates one separator constructed according to the invention to perform the method thereof utilizing an inclined engagement member.
FIGURE 2 is a perspective view illustrating another construction of the inclined engagement member which is flexible and has laterally spaced portions.
FIGURE 3 is a perspective view a further construction of the inclined engagement member which is embodied by a brush having bristles.
FIGURE 4 is a partial view similar to Figure 1 illustrating another embodiment of the separator that utilizes a vertically movable roll for engaging the particles.
FIGURE 5 is a view similar to Figure 4 of another embodiment of the separator that includes a roll
constructed as a rotary brush for engaging the particles .
FIGURE 6 is a partial view similar to Figure
1 of another embodiment of the separator that includes an upper auxiliary conveyor for engaging the particles .
FIGURE 7 is a partial view that illustrates another embodiment of the separator where a primary magnetic field is generated above the conveyor on which the particles are conveyed.
FIGURE 8 is a view of another embodiment of the separator that includes a vibratory conveyor for conveying the particles below a magnetic field generator utilized in the separation.
FIGURE 9 is a view of another embodiment of the separator whose conveyor is an inclined gravity slide and whose magnetic field generator is located below a lower end of the gravity slide.
FIGURE 10 is a view of another embodiment of the separator whose conveyor includes an inclined gravity slide of a curved shape in which the magnetic field generator is located such that the particles are propelled therefrom in a sideways direction.
Best Modes For Carrying Out The Invention
With reference to Figures 1-10 of the draw- ings, different embodiments of the separator constructed in accordance with the present invention are respectively identified by 10, 10a, 10b, 10c, lOd, lOe, lOf and
lOg as is hereinafter more fully described. The construction of these embodiments of the separator and the method of operation thereof in accordance with the invention will be described in an integrated manner to facilitate an understanding of the different aspects of the invention.
With reference specifically to Figure 1 of the drawings, the separator 10 illustrated includes a hopper 12 that receives non- ferromagnetic particles 14 to be separated. A conveyor, generally indicated by 16, receives the metallic particles 14 from the hopper 12 for conveyance along a direction of conveyance, as illustrated by arrows 18. The conveyor 16 illustrated is of the type including an endless belt 20 and a pair of pulleys 22 and 24 that support the belt 20 with an upper reach 26 thereof having an upwardly facing surface 28 on which the conveyed particles 14 are supported and moved toward the right. The left pulley 22 is driven by a suitable motor 29 through a drive belt 30. The other pulley 24 is a hollow non-metallic sleeve whose ends are rotatably supported in any suitable manner and that receives a magnetic field generator 32 of the separator. This magnetic field generator 32 generates a rapidly changing high flux density primary magnetic field 34 that is illustrated by the petal-shaped phantom line indicated flux representations. In the specific construction illustrated, the magnetic field generator 32 is shown as a permanent magnet rotor that is rotatably driven by a motor 36 through a drive belt 38. Rapid rotation of the rotor generates the rapidly changing flux patterns that generate eddy current flow of electricity in the non-ferromagnetic particles 14 upon being conveyed adjacent the generator 32 toward the right on
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the upwardly facing surface 28 of the belt reach 26. Such eddy current flow in the particles 14 generates particle magnetic fields that are repelled by the primary magnetic field of the generator to initiate a force that propels the particles as shown by the trajectories 40a, 40b, and 40c.
With continuing reference to Figure 1, the separator 10 also includes an inclined engagement member 42 that provides a means for engaging the conveyed particles 14 upon movement toward the right to force the particles into the primary magnetic field 34 against the repulsive force of the initially generated particle magnetic fields as the particles first approach the primary magnetic field from the left. Specifically, the initial generation of the particle magnetic fields can cause the particles to move upwardly off the belt before reaching the right end of the belt and being propelled along one of the trajectories depending upon the extent of the particle magnetic field generated which varies according to the electrical resistance of the material of which the particle is composed, the particle densities, shapes and sizes. However, the engagement member 42 forces the particles deeper into the primary magnetic field 34 so as to create higher flux density particle magnetic fields and a consequent greater propulsion force and a greater separation between the materials so as to provide improved efficiency in the material separation. Specifically, the separating members 44 and 46 provide separation between three different ranges of trajectories of the particles 14. Thus, after the particles 14 have moved sufficiently toward the right so as to be released from the engagement member 42, the conveying momentum and the magnetic field propulsion
provides the particle trajectory with a distance that varies according to electrical resistance, density, size, and shape of the particle.
It should be appreciated that whereas the magnetic field generator is illustrated as a permanent magnet rotor as previously mentioned, it is also possible to generate a rapidly changing high flux density magnetic field with stationary coils electrically driven so as to provide flux field rotation in a similar manner to that achieved by the permanent magnet rotor.
With continuing reference to Figure 1, it will be noted that the inclined engagement member 42 includes a suitable adjuster 48 that is schematically illustrated by arrows and that is movable: (a) to the left and the right to adjust the position along the direction of conveyance where the particles are released for the propulsion as previously described; (b) up and down to adjust the inclination; and (c) laterally with respect to the direction of conveyance.
As previously mentioned, the conveyor 16 shown in Figure 1 includes the endless belt 20 and the pair of rotary pulleys 22 and 24 that support the belt for the conveying movement. The upper reach 26 of the belt effectively embodies a conveying member having the upwardly facing surface 28 previously mentioned on which the particles 14 are conveyed from the left toward the right as illustrated. The magnetic generator 32 located within the pulley 24 is thus located below the upwardly facing surface 28 of the belt reach 26 embodying the conveying member, and the inclined engagement member 42
that engages and thereafter releases the particles 14 is located above the upwardly facing surface 28.
As shown by continued reference to Figure 1, the inclined engagement member 42 extends downwardly to the right along the direction of conveyance in a direction toward the upwardly facing surface 28 of the belt reach 26 that embodies the conveying member on which the particles 14 are conveyed. The inclined conveying member 42 has a distal end 50 at which the particles 14 are released for the propulsion thereof by the magnetic fields as previously described. An upper pivotal mount 52 of the inclined engagement member 42 is supported by the adjuster 48 previously described and pivotally mounts the inclined conveying member so that its distal end 50 is moved downwardly under the force of gravity against the upwardly facing conveyor surface 28 of the upper belt reach 26. Adjustment of the adjuster 48 to the left and the right thus adjusts the position of the distal end 50 to adjust the location at which the particles 14 are released. The axis about which the inclined engagement member 42 is pivoted is thus located above the belt reach surface 28 on which the conveyance takes place. . It is also possible for the inclined engagement member 42 to have a stop that limits its downward movement so that the distal end 50 does not slide along the upper belt reach 26 of the conveyor belt. Adjuster 48 also has provision for vertical adjustment such that with such a stop, the vertical spacing between the distal end 50 and the upper belt reach 26 can be adjusted.
With reference to Figure 2, another construction of the inclined engagement member 42' is made of a
flexible material that can flex to permit passage of the particles below its distal end 50. More specifically, this construction of the inclined engagement member 42' includes laterally spaced portions 43 that can flex independently of each other across the lateral width of the conveyor when different portions thereof engage particles of different heights.
With reference to Figure 3, a further embodiment of the inclined engagement member 42'' is embodied by a brush having bristles 45 that define its distal end 50 and that flex as the particles pass beneath the brush during the separation operation.
With each of the embodiments of Figures 2-3, an upper mount can fixedly mount the associated inclined engagement member 42' or 42'' without the need for any pivotal movement in view of the flexing achieved. Nevertheless, a suitable adjuster 48 can be utilized to provide adjustment along the direction of conveyance, up and down, and laterally with respect to the direction of conveyance as required.
With reference to Figures 4 and 5, the further embodiments 10a and 10b of the separator each includes a roll 54a, 54b that engages the particles 14 to force the particles deeper into the primary magnetic field 34 and that thereafter releases the particles for propulsion along the trajectories 40a, 40b, and 40c as previously described. In each embodiment, the roll 54a, 54b is located above the conveyor 16 on which the particles 14 are conveyed by the upper belt reach 26 as previously described.
With specific reference to Figure 4, the roll 54a is illustrated as having a rotary mount 56 that rotatably mounts the roll while permitting vertical movement of the roll upwardly and downwardly so as to accommodate particles 14 of different sizes. The roll 54a also has an outer annular foam layer 58 having a resilient outer surface 60 that also accommodates for different size particles 14. An adjuster 48 provides adjustment of the location of the rotary mount 56 along the direction of conveyance to thus control the location at which the roll 54a releases the particles 14 for the propulsion along their trajectories by the magnetic fields as previously described. This adjuster 48 can also provide vertical adjustment that can be utilized to limit the downward movement so as to maintain the roll 54a spaced above the upper reach 26 of the conveyor belt 20. In addition, the adjuster 48 can also provide lateral adjustment of the roll 54a are required.
With specific reference to Figure 5, the roll 54b is embodied by a rotary brush having bristles 62 that engage the particles 14 and thereafter release the particles for the magnetic field propulsion. The bristles 62 deflect so as to thereby eliminate the necessity for vertical movement of the rotary brush in order to accommodate particles 14 of different sizes. A schematically illustrated adjuster 48 provides adjustment of the rotary brush along the direction of conveyance so as to thereby adjust the position at which the brush releases the particles 14 for the magnetic field propulsion. The adjuster 48 also provides vertical adjustment of the roll 54b to control the spacing between the roll bristles 62 and the upper reach 26 of the conveyor belt 20. In addition, the adjuster 48 can
also provide lateral adjustment of the roll 54b as required.
With reference to Figure 6, another embodiment of the separator 10c includes an upper auxiliary convey- or 64 that engages and thereafter releases the particles 14 for the magnetic field propulsion. This upper auxiliary conveyor 64 is disclosed as including a pair of rotary pulleys 65 that receive an endless belt 66 having a lower reach 67 that has a downwardly facing surface 68 inclined downwardly along the direction of conveyance. The pulleys 65 are rotated counterclockwise so as to thus move the belt reach 67 downwardly toward the right to engage the particles 14 and force the particles into the primary magnetic field 34 prior to being released for the magnetic field propulsion toward the right as previously described. An adjuster 48 rotatably supports each of the pulleys 65 so as to thereby adjust: (a) the location at which the upper auxiliary conveyor 64 releases the particles for the magnetic field propulsion toward the right; (b) the spacing between the upper auxiliary conveyor and the conveyor 16; and (c) lateral positioning.
With reference to Figures 7 and 8, each embodiment lOd and lOe of the separator has the magnetic field generator 32 located above the associated conveyor 16, 16' . Each construction of the conveyor 16, 16' includes a conveying member 26, 26' that defines the associated upwardly facing conveying surface 28, 28' and constitutes the means for engaging and thereafter releasing the particles 14 for the magnetic field propulsion.
With specific reference to Figure 7, this embodiment of the separator lOd has the conveyor 16 constructed to include the endless belt 20 previously described in connection with Figure 1 such that the conveying member provided by its upper reach 26 forces the particles 14 deeper into the magnetic field 34 of the magnetic field generator 32 located above the conveyor. Upon sufficient movement of the particles 14 toward the right, the particles 14 are released for the magnetic field propulsion. A suitable adjuster 48 of the magnetic generator 32 provides adjustment of the location along the direction of conveyance at which the particles are released for the magnetic field propulsion, as well as providing vertical and lateral adjust- ment as required.
With specific reference to Figure 8, this embodiment of the separator lOe is the same as the embodiment of Figure 7 except that the conveyor 16' is constructed as a vibratory conveyor including a convey- ing member 26' that is vibrated so that its upper surface 28' on which the particles 14 are conveyed are moved in a vibratory manner toward the right . The conveying member 26' thus engages the particles 14 and forces the particles into the primary magnetic field 34 of the magnetic generator 32 prior to being conveyed sufficiently toward the right so as to be released for the magnetic field propulsion. An adjuster 48' adjusts the location of the magnetic field generator 32 along the direction of conveyance to adjust the position at which the particles 14 are released, as well as providing vertical and lateral adjustment as required.
With reference to Figures 9 and 10, further embodiments of the separator lOf and lOg each include the conveyor 20 constructed as a downwardly inclined gravity slide respectively identified as 70 and 72. In the embodiment of Figure 9, the gravity slide 70 includes a lower end 74 below which the magnetic field generator 32 is located. Above the lower slide end 74, the means that engages and thereafter releases the particles 14 is located and illustrated as the upper auxiliary conveyor 64 previously described in connection with Figure 6. Adjusters 48 provide for adjustment along the inclined direction of conveyance, between the upper auxiliary conveyor 64 and the gravity slide 70 and laterally with respect to the direction of conveyance as required. It should be appreciated that the inclined engagement members 42, 42' and 42'' of Figures 1, 2 and 3, and the rolls 54a and 54b of Figures 4 and 5 can also be used with this embodiment lOf of the separator to force the particles 14 deeper into the primary magnetic field.
With reference to Figure 10, the embodiment of the separator lOg has its gravity slide 72 constructed as an inclined trough of a curve shape. Furthermore, the magnetic field generator 32 is located within the curved shape of the inclined trough such that the particles 14 are propelled therefrom in a sideways direction. Suitable adjusters 48 supporting the magnetic field generator 32 and the drive motor 38 control the spacing between the magnetic field generator and the inclined trough of the gravity slide 72.
While the best modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative ways of practicing the invention as defined by the following claims.