Method and apparatus for the sorting of refuse, and handling robot for this purpose.
Background of the invention
The invention concerns a method of the kind disclosed in the preamble to claim 1 and an apparatus of the kind disclosed in the preamble to claim 4, primarily for the sorting of refuse such as household refuse collected in bags or sacks, and a handling robot for this purpose as disclosed in the preamble to claim 7.
The sorting of items, e.g. refuse bags in accordance with a given optical characteristic, e.g. a certain colour, is commonly known, among other things in the manual sorting of items which are transported on a conveyor. A manual sorting is not particularly expedient, in that the personnel are burdened by monotonous work and extensive use of safety and protection equipment is required so that the working environment becomes acceptable. Moreover, manual sorting is not particularly suitable due to the large amounts of household refuse collected.
In the sorting of refuse, e.g. household refuse, where that part which is desired to be sorted out is that which can be composted, there are great environmental problems because the refuse is already partly decomposed and is often mixed with other refuse, which can involve risks for the personnel because the refuse can emit dust and gases which are dangerous etc.
In many areas, the daily refuse is sorted at source, i.e. use is made of a refuse system with e.g. two differently-marked bags. Use is often made of green and black bags, so that the refuse, which can be composted, is
placed in the green bag and the remainder in the black bag. This system can also be extended with more than two kinds of bags. Hereafter, the collected bags are sorted centrally and the refuse, which can be composted, is composted and recycled.
It would be more advantageous if the bags were collected individually, i.e. if the sorting of the bags took place at the consumer. Since in practice, however, it has proved to be very difficult and uneconomic to carry out a sorting of the bags in accordance with colour at the same time that they are collected, there is normally effected a central, mechanical sorting of the bags. The sorting must be able to be effected mechanically, either by means of an unmanned sorting apparatus or by an apparatus, which is remote controlled, so that the sorting takes place in a correct manner from the point of view of safety and the environment. Furthermore, it is important that the sorting is effected quickly and at the lowest possible cost.
From Danish patent no. 168.151 (= EP patent no. 0.554.207), there is known a sorting plant for refuse in bags whereby bags of a certain colour, e.g. green bags containing material which can be composted, are sorted mechanically from a mixture of bags of several colours. The sorting is effected by optical identification of those bags, which shall be sorted out, whereby from an incoming conveyor where they are mixed with other bags they are transferred to a conveyor solely for green bags. Hereafter, the green bags must either be opened so that contents can be sent for composting, or the bags must be comminuted and allowed to form part of the compost mass. In many cases the latter is undesirable, and is thus not a realistic possibility. Moreover, with comminution there is no possibility of being able to subsequently check whether the users have sorted correctly. If the bags are comminuted and mixed with the refuse which can be composted, this mixture can not be used for biogas systems, but solely for
composting, the reason being that the bag material (polyethylene) stops the bio gasification process.
From international application no. WO 90/11142 (PCT/SE 90/00180), there is known a sorting plant for refuse in bags whereby bags with a certain colour are sorted out by optical identification. Those bags, which contain materials, which can be composted, can thus be sorted out, in that the incoming amount of bags with refuse is divided into two piles. Neither in this plant is there any opening of the bags, which must therefore be carried out afterwards, or the bags may form part of the composting process, which is often undesirable.
For the known plants, cf. the above, it is possible to make use of bags made of bio-decomposable materials. If, for example, the green bags are of bio-decomposable material, they can directly form part of the composting, and be comminuted at the same time that the refuse is comminuted. However, bags of this kind are very costly, and the recycling process is hereby made considerably more expensive, in that use is made of a very great number of bags. Consequently, this solution is almost never used today because of the costs involved. Moreover, with this method the possibility of being able to check the contents of the bags is lost, and it cannot be currently evaluated whether the users maintain the sorting at source as desired. It is also difficult in practice to use bags of bio- decomposable material, in that the decomposition usually starts as soon as the bags are exposed to moisture, and therefore the collections must be made frequently. Bio-decomposable bags also have other disadvantages.
Advantages of the invention
By a method as characterized in claim 1 , e.g. while using an apparatus as characterized in claim 4, in comparison with the known systems it is achieved that the items are not only sorted quickly, but also that the bags or the sacks are opened. It is thus achieved that the bags or the sacks are both moved and opened in substantially one working operation, and a significant step further forward in the central sorting process is hereby attained.
Moreover, by a method as characterized in claim 2, e.g. while using an apparatus as characterized in claim 5, further advantages are achieved, in that among other things the possibility is provided of removing the bags or the sacks from the contents. The possibility is thus now achieved of being able to effect a complete sorting.
Furthermore, by a method as characterized in claim 3, e.g. while using an apparatus as characterized in claim 6, the complete sorting is achieved so that the collected refuse bags with contents which can be composted are separated from the remaining bags, and the bags sorted are divided into the contents of the bags, the so-called percolate, and in empty, used bags.
The latter will be able to be sent for incineration or other destruction.
Hereafter, it will also be possible to continuously inspect the percolate, e.g. via a camera and a screen which is held under surveillance by the personnel or by automatic monitoring equipment, so that it can be checked whether the percolate contains undesired material.
The complete sorting can thus be effected in one operation, which will reduce costs considerably in relation to the costs of the known systems.
Moreover, the invention also comprises a specially configured handling robot as characterized in claim 7. This handling robot or handling mechanism will be able to undertake that handling which is necessary for the methods and apparatus described above, but will also be able to be used for many other methods and in many other plants. For example, it will be able to be used in all places where it is desired to empty the materials from the bags or sacks, and where the empty bags or sacks are placed at a distance from these materials, e.g. the emptying of sacks with powdered or granulated contents. Finally, the handling robot according to the invention can be configured as characterized in the independent claims 8 - 10, so that the resulting robot is one which both quickly and effectively, and hereby cheaply, effects the desired processes so that a complete sorting can be achieved.
The drawing
The invention will now be explained in more detail with reference to the example embodiment shown in the drawing, where
fig. 1 shows the sorting principle seen from above and with a number of handling robots according to the invention,
fig. 2 shows a handling robot according to the invention, seen directly from the front and in the direction ll-ll in fig. 1 ,
fig. 2A-F shows a handling robot in principle and seen in the swing plane for the illustration of the functions and working mode of the robot,
fig. 3 shows a plane section in the robot at right angles to the swing plane,
fig. 4A and B show parts of the robot for the illustration of the function and the movement of the gripping elements,
fig. 5A and B show parts of the robot for the illustration of the function and movement of the gearbox for the gripping elements, and
fig. 6A and B shows parts of the robot for the illustration of the function and movement of the bag-cutting device.
Description of the example embodiment
In fig. 1 is seen an example of a sorting plant with three handling robots H in connection with a conveyor system. Bags or sacks containing refuse are sorted, in that use is made of green bags G for material, which can be composted and black bags S for other refuse. A sorting at source has previously been effected at the consumers, but the bags are collected using a common refuse container. There is thus collected a mixture of green and black bags which must now be divided into two groups, i.e. the black bags which must be disposed of, destroyed or incinerated, and the green bags which must be opened and emptied so that the contents can be composted and the bags destroyed, e.g. incinerated.
The plant comprises a number of conveyors TR1.TR2 and TRS + TRG, and three successively arranged handling robots H, which are suspended in portals P above the conveyors. Each handling robot comprises a frame
R with transverse axles T and support rollers B in which the individual parts of the robots are mounted, so that it is a quick and simple matter to replace a robot for service or repair and adjustment etc. Each sorting robot also comprises a camera C which is directed towards the conveyor on which the bags arrive for sorting, and a cam-disk arrangement K, which parts are
explained in more detail later. Each sorting robot is thus a completely independent unit, which works independently, as will be explained later. There is hereby achieved not only an optimum and service-friendly construction, but also that the sorting plant can be extended or reduced in a simple manner in accordance with requirements, i.e. by changing the number of robots.
Bags G and S are fed forward in random sequence on the incoming conveyors TRG +TRS, but so that the bags are conveyed in succession arranged in one row and with a minimum distance between neighbouring bags. The minimum distance between the bags must merely be so great that the handling robots, which are discussed later, can grip a bag without affecting the neighbouring bags. The feeding speed, and herewith the sorting speed, naturally depends on how many handling robots H are used, or conversely the number of handling robots which must be used depending on the desired sorting speed and amount.
When the bags on the incoming conveyor pass the handling robots H, the green bags are gripped individually by the robots, the bags are secured, opened and emptied, so that the contents of the bags are placed on the conveyors TR2 and the empty bags are placed on the conveyors TR1. Hereafter, the conveyor TRG + TRS feeds only the black bags, as will appear from fig. 1 , where hereafter the conveyor is designated TRS. The arrows on the conveyors show the feeding directions.
If, for example, use is made of five handling robots arranged in succession in a sorting plant, and it is desired to sort approx. 40 tons of refuse per hour, and it is expected that approx. a half part comprises green bags, i.e. approx. 20 tons, the speed of the incoming conveyor TRG+TRS must be approx. 5m/second when there is approx. one bag per meter on the
conveyor, if each bag on average weighs approx. 1.2 kg, i.e. approx. 5 bags per second are sorted. Put in another way, each handling robot has an average of approx. 1 second in which to grip, open, move and place the contents and bags correctly, and thereafter be ready to handle the next bag.
With reference to figs. 2-6 of the drawing, it will now be explained in more detail how the handling robot according to the invention functions.
Fig. 2 shows a handling robot seen directly from the front, and also indicates the conveyors, which were discussed in connection with fig. 1. In the shown embodiment, the robot has two movable arms 1a and 1 b. These arms are also called the pendulum because they can swing in the manner of a pendulum transversely over the conveyors, as shown in the drawing, in that the two arms 1a and 1 b are firmly coupled together and in that they are firmly coupled to a pendulum axle 4 which, via a connecting rod 35, is driven by a geared motor 36. The two arms 1 a and 1 b are disposed in the same swinging plane, but displaced at an angle in relation to each other, e.g. 30° to 50°, preferably approx. 40°, so that a suitable distance is achieved between the gripping elements 6a and 6b, which will be discussed later. The speed of the output shaft on the geared motor is in the order of approx. 30 rpm. For the same parts as those shown in fig. 1 , the same reference designations are used. The construction and configuration of the frame R with transverse axles T and support rollers B are also seen clearly in the drawing. On or at the frame R there is mounted a camera C which can be a video camera or the like and of a commonly known kind, and which is coupled to an electronic control circuit, e.g. a computer. The camera is directed towards the conveyor TRG+TRS, and it detects or reads the colour of the next bag on the conveyor. If the next bag is of a colour, which denotes that it must be removed from the conveyor, the robot
will do this if it is ready to do so. If it is not ready for this, it lets the bag pass and one of the subsequent robots will remove the bag. The manner in which the camera and the computer function and in detail control the handling robot does not form part of the present invention, and therefore this will not be explained further
In addition, the two arms 1a and 1 b are controlled by a cam-disk arrangement K, which will be explained later.
At the free end of each arm there is a gearbox 2a and 2b, these gearboxes being identical. Each gearbox controls gripping elements 6a and 6b, which can grip and hold a bag. In fig. 2 it is seen that the arm 1a is ready to grip the bag 17a, and that the arm 1 b is holding a bag 17b. It is also seen that the gearbox 2a has rotated and holds the bag 17a upwards. For weight- balancing purposes, the two arms could comprise an upwardly extending weight or mass 34.
Under the swingable but firmly coupled-together arms 2a and 2b there are funnel-shaped elements A1 and A2, so that the contents of the green bags and the empty green bags are more easily transferred to the underlying conveyors. In this embodiment, each of the handling robots thus comprises two arms and can therefore handle two green bags at a time, as will be explained later in connection with figs. 2A - 2F.
Figs. 2A - 2F are principle drawings which shall serve to illustrate the functions of the robot, and therefore there are a number of parts which are not shown or which are shown schematically. How the robot can be configured in practice is shown and explained later in connection with figs. 3 - 5.
Fig. 2A shows the robot in a position which can be called the start position. The arm 1A has swung 15° to the left in relation to the vertical. If this side is looked upon as being negative, and the opposite side as being positive, the arm has thus swung -15°. The arm 1a has its gripping elements 6a open and ready to grip the bag 17a, in that from the start position the arm moves towards the vertical as shown by the curved arrow. The arm 1 b is firmly connected to 1 a and is in its uppermost position and is about to empty the bag 17b. The bag 17b has been cut open by a cutting device built into the robot, which is explained later. The emptying begins by the gripping elements 6b, which are holding the bag being loosened slightly. At the same time herewith, suction is applied to the gripping elements through holes in the elements, so the green plastic bag is secured and opened slightly. The contents of the bag fall down into the funnel A2 and down on the underlying conveyor TR2.
Fig. 2B shows that the arms have now swung 15° in the direction of the curved arrow and the arm 1a is standing vertical, and it is seen that the gripping elements are closed around the bag 17a. The gripping elements 6b now shake the bag so that its remaining contents are emptied during the movement from fig. 2A to 2B. The contents fall down into the funnel A and further down on to the conveyor TR2. It can also be seen that the gripping elements 6b and the bag 17b are turned slightly in relation to fig. 2A. This turning and herewith also the manoeuvring of the gripping elements are executed because the gearbox 2b, on which the elements are mounted, is turned. The gripping elements 6a are similarly mounted on a rotary gearbox 2a. The two gearboxes 2a and 2b are preferably completely identical.
Fig. 2C shows that the arm 1a is now about to remove the bag 17a from the conveyor, and this means that the not-shown cutting device, which is
explained later, now begins to cut the bag 17a so that it can be emptied later. The arm 1 b is now about to turn back towards the vertical position, so that the now empty bag can soon be dropped into the funnel A1. The arm 1a now stands in a position, which is +7.5° in relation to the vertical.
Fig. 2D shows the same as in fig. 2C but 7.5° later, i.e. with the arm 1a in a position of +15°. The cutting device has now finished cutting the bag 17a, and the gearbox 2a starts to turn as shown by the curved arrow on the gearbox. The empty bag 17b has now been turned almost all the way back.
Fig. 2E shows that the bag 17a has now been turned almost all the way up for emptying, and the suction function is started in order to secure the bag. The bag 17b continues to be turned, but the suction function is now changed to a blowing function so that the empty bag is delivered into the funnel A1 and falls down on the conveyor TR1. In the drawing there is sketched an intermediate position, i.e. where the gripping elements release the empty bag 17b. The gripping elements 6b are now fully open, and thus the arm can pass the incoming conveyor TRG+TRS without colliding with a bag 17 which is possibly lying on the conveyor. The arm 1a is in a position of +40°, and the arm 1 b is in the vertical position. The bag 1 b is now both open and empty and the empty bag is delivered. Moreover, the gripping elements are now already in the start position and ready to grip and hold a new green bag, but this does not happen until the arm 1 b swings back.
Fig. 2F shows the arm 1a in a position of +55°, i.e. at maximum swing, and the robot is thus in its second start position, i.e. opposite the start position in fig. 2A. The bag 17a is now ready to be emptied, and the gripping elements 6a are loosened slightly and suction is applied in order to secure the bag itself. The gripping elements are now shaken in order to ensure that the bag is completely emptied. The gripping elements 1b are now quite
ready to grip the next possible bag 17 on the incoming conveyor during the return swing of the robot. During the return movement, all of the functions as explained above are executed, but in the reverse order.
Fig. 3 shows in detail how a handling robot can be arranged. Only the one pendulum arm 1a is seen, but as will be seen in the figure this consists of two parts, i.e. one part to the left and one part to the right, and all of the movable parts of the pendulum arm are disposed between them. Uppermost, the arm parts 1a are firmly mounted on a common axle 4, and via bearings or bearing blocks 12 and an axle holder 13 they are secured on the frame R mentioned earlier. The handling robot is suspended on the portals P, see fig. 1 , via transverse axles T, which are shown only in fig. 1. Between the tops of the arm parts 1a there is a connection arm with which the connecting rod 35 on the geared motor is in driving engagement. In addition, the robot comprises push rod/draw rod 14 and a push rod/draw rod 22 for the function of the gripping elements and the gearbox 2a respectively. The gearbox 2a' is an "empty" gearbox without push/draw rods, in that it is merely required to follow the movements of the gearbox 2a. In the centre is seen a further push/draw rod 30 for the operation of the cutting device 26. The gearbox 2a and the "empty" gearbox 2a' are in engagement with the arms 1 a via bearing elements 34, and are also in engagement with the rods 14 and 22. It will also be seen that planet spindles 5 on the gearboxes 2a and 2a' are in engagement with the gripping elements 6a. These gripping elements also each comprise a plate 7a for the firm clamping of a refuse bag.
As discussed earlier, the gripping elements and also the plates 7a have holes through which suction or blowing air can be applied, cf. the earlier explanation concerning figs. 2E and 2F. This air coupling is effected in a
commonly known manner via the pipe 18 and hollow axles in the gearbox 2a, and thus will not be explained in more detail.
The function and working mode of the handling robot will now be explained in more detail with reference to figs. 4, 5 and 6, in that the same reference designations are used in these figures as for the same parts in earlier figures.
Figs. 4A and B show the function of the gripping elements, i.e. opening and closing, which is controlled by cam-disks by means of the movement of the pendulum arm while this swings from the left position in fig. 4A to the right position shown in fig. 4B. The relative movement is seen between the gearbox 2a and its central axle 3 when the arm 1 a swings around the axle
4 in the angle interval of -15° to +55°. In this embodiment, the gearbox is arranged in such a manner that an angular turning of the axle 3 gives rise to the double angular turning of the planet spindles 5. With reference to fig. 3, it will be seen that the gripping elements 6a with the plates 7a are secured to the spindles 5, whereby a relative angular turning between the axles 3 and spindles 5 results in the gripping elements 6a with the plates 7a,7b moving towards or away from each other.
A rocker arm 8, which is mounted on a rocker arm axle 11 , is mounted in the axle holder 13, and has a cam roller 9, which under spring pressure rests against the roller track on a cam-disk 10. The cam-disk 10 is firmly mounted on the axle 4 and follows this, and herewith also follows the movement of the pendulum arm, so that the turning angle for the pendulum arm is always the same as for the cam-disk 10.
On the rocker arm 8, but opposite the cam roller, a push/draw rod 14 is mounted via a hinge link 15. The opposite end of the rod 14 is pivotally
fastened to an arm 16, which is in firm connection with the centre axle of the gearbox 2. The effect of this is that a turning of the pendulum arm 1a results in the same turning of the cam-disk 10 and herewith a turning of the rocker arm 8, which via the rod 14 in turn results in an angular turning of the centre axle 3 of the gearbox. It is not until the gearbox 2a and its centre axle 3 are moved relatively in relation to each other that an angular turning of the planet spindles 5 in the gearbox takes place, consequently with movement of the gripping elements.
When the pendulum arm 1a is in the start position (fig. 4A), the plates 7a are open (see figs. 2A and 3). At the position 0°, i.e. with the arm vertical, the cam-disk 10 permits a turning angle of the centre axle in the gearbox of 36°, and herewith a turning angle of 72° for the gripping elements, which results in an immediate closing of the plates 7a around a refuse bag 17, because the gearbox 2, which will be seen later in figs. 5A and B, is not turned at an angle before the pendulum arm 1 a is in the position +20°. The curved line in fig. 4A and B, and later in figs. 5A and B, shows the angular turning of the gearbox arm 16 for different positions of the pendulum arm 1a, and the drawing has been provided with the degree of angular turning in typical positions.
Figs. 5A and B show how the gearbox 2a rotates during the angular turning of the pendulum arm 1a, controlled by a cam-disk 20, a rocker arm 21 and the push/draw rod 22, following the same principle as explained with reference to figs. 4A and B in connection with the rotation of the gripping elements, in that like the cam-disk 10, the cam-disk 20 is secured to the axle 4.
From figs. 6A and 6B it will be seen how a cutting device, e.g. a saw 26, is controlled vertically by a cam-disk 27 which is also anchored on the axle 4,
via track roller 28 and a rocker arm 29 and the push/draw rod 30. The rocker arm 29 and the rod 30 are coupled together via a hinge link 15. This control functions as discussed earlier under figs. 4 and 5. The effect of cam-disk 27 is that the cutting device 26, in the angle interval from 0° to +7.5°, is lowered towards the bag in which it effects a cut, for example a U- shaped cut. In the angle interval of 7.5° to +15°, the cam-disk 27 causes the cutting device to be lifted again and led away from the filled and now cut-open bag.
When comparing figs. 4A and B with figs. 5A and B, it is seen that the gearbox 2 in fig. 5 and its centre axle 3 in fig. 4 are rotated the same amount in the angle interval from +20° to +40°, the consequence being that the closed gripping element 7a with bag 17 is turned 128° plus the turning of the pendulum arm of 40°, a total of 168°. In the remaining 15°, the cam- disk 10 describes a relative angular turn of +/-10°, which means that the gripping elements 7a shake the bag 17 by vibration. That this is possible is due to the fact that vacuum is applied to the pipe 18 (see fig. 3) through the tubular axles of the gearbox etc. to gratings or perforations in the plates 7a of the gripping elements. The fact that the bag 17 is sucked towards the plates 7a makes it possible to effect the shaking function, which eases the emptying of the filled, cut-up bag down into the funnel A2.
When during its return swing the pendulum arm 1a passes the +40° point, the vacuum function is changed by means of a shutter or the like to a blowing function, which frees the now empty bag from the gripping elements, and the bag is now dropped down into the funnel A1 and down on the underlying conveyor.
When the pendulum arm 1a reaches the +40° position, a shadow cam-disk 23 (fig. 4) makes contact with the underside of the mounting plate 24 by
which the parts are supported. The shadow cam-disk 23 is secured to the axle 4 by means of a not-shown friction hub, which allows that this cam- disk is not turned during the last 20° of movement. With this angular turning, the shadow cam-disk 23 is brought closer to the cam-disk 10 so that a new cam path is formed, and which has the characteristic that the plates 7a on the gripping elements 6a are opened before the arm 1a passes +15°. It is hereby ensured that the pendulum arm always passes the 0° point with open plates during the return swing. When during its return swing the arm reaches +5°, the shadow cam-disk 23 establishes contact with the upper side of the mounting plate 24, and is back in its start position when the arm has reached the +15° position.
The mechanical solution described above is duplicated on the second pendulum arm of the robot 1 b by turning around a centre plane. The capacity of the robot is hereby doubled in relation to a robot with one arm.