REFUSE COMPACTOR
United States Patent 3752061
A refuse compactor suitable for handling a large volume of refuse, such as from an apartment house, in which: a ram is driven mechanically to apply vertical, high load compaction by means of a jack screw assembly and the refuse is fed to the ram by means of a pivoting pushbar platform. Electrical circuitry actuates the machine automatically when a full load of refuse has been accumulated.
US Patent References:
Press
Snyder - July 1928 - 1675669
APPARATUS FOR COMPACTING REFUSE
Lombard et al. - September 1972 - 3693541
APPARATUS FOR COMPRESSING GARBAGE
Smolka et al. - July 1970 - 3521553
STATIONARY REFUSE PACKER
Carter - February 1972 - 3643589
WASTE COMPACTING DEVICE
Boje - September 1971 - 3604345
Press
Snyder - July 1928 - 1675669
APPARATUS FOR COMPACTING REFUSE
Lombard et al. - September 1972 - 3693541
APPARATUS FOR COMPRESSING GARBAGE
Smolka et al. - July 1970 - 3521553
STATIONARY REFUSE PACKER
Carter - February 1972 - 3643589
WASTE COMPACTING DEVICE
Boje - September 1971 - 3604345
Application Number:
05/151814
Publication Date:
08/14/1973
Filing Date:
06/10/1971
View Patent Images:
Export Citation:
Assignee:
TCI Inc. (Benson, MN)
Primary Class:
Other Classes:
100/215, 100/139, 100/98R, 100/289, 100/295, 100/216, 100/99, 100/52, 100/45, 100/73, 100/256, 100/189
International Classes:
B30B9/30; B30B9/00; B30B15/14
Field of Search:
198/61 100/45,49,215,216,98,139,73,99,52,53,289,256,179,189,295
US Patent References:
Primary Examiner:
Wilhite, Billy J.
Claims:
What is claimed is
1. A refuse compactor comprising:
2. A refuse compactor, as defined in claim 1, and further comprising a torsion assembly to eliminate twisting movement in the jack screw assembly, said torsion assembly comprising:
3. A refuse compactor as defined in claim 1 in which the feed means assembly comprises:
4. A refuse compactor as defined claim 3 and further comprising an override spring fitted on the pushbar linkage to prevent the pushbar platform from jamming as a result of solid refuse becoming lodge between the pushbar platform and an inner side wall of the hopper compartment.
5. A refuse compactor as define d in claim 1, in which the means for actuating the compaction cycle comprise:
6. A refuse compactor as defined in claim 5 in which the electrical circuitry further comprises:
7. A refuse compactor as defined in claim 1 in which the ram comprises:
8. A refuse compactor as defined in claim 1 in which the lead screw and follower nut arrangement of the jack screw assembly further comprises a set of independent rollers and needle bearings.
9. A refuse compactor comprising:
1. A refuse compactor comprising:
2. A refuse compactor, as defined in claim 1, and further comprising a torsion assembly to eliminate twisting movement in the jack screw assembly, said torsion assembly comprising:
3. A refuse compactor as defined in claim 1 in which the feed means assembly comprises:
4. A refuse compactor as defined claim 3 and further comprising an override spring fitted on the pushbar linkage to prevent the pushbar platform from jamming as a result of solid refuse becoming lodge between the pushbar platform and an inner side wall of the hopper compartment.
5. A refuse compactor as define d in claim 1, in which the means for actuating the compaction cycle comprise:
6. A refuse compactor as defined in claim 5 in which the electrical circuitry further comprises:
7. A refuse compactor as defined in claim 1 in which the ram comprises:
8. A refuse compactor as defined in claim 1 in which the lead screw and follower nut arrangement of the jack screw assembly further comprises a set of independent rollers and needle bearings.
9. A refuse compactor comprising:
Description:
BACKGROUND OF THE INVENTION
Handling and disposal of household and commercial refuse is a growing problem, particularly in urban areas. Incineration is becoming impractical as a result of its contaminating effect on the atmosphere and environment. Loose, non-compacted refuse is inconvenient to handle, expensive to transport and is rapidly filling available dumping areas. Compacting, to reduce the bulk volume of refuse, has become desirable to allow more efficient transport and disposal of such refuse. Thus, there is a growing need for compacting machines, particularly those which are simple and economical to build and maintain; versatile as to the amount and type of refuse which can be handled; small enough to be installed in existing buildings without requiring a prohibitively large amount of space, yet large enough to handle the refuse volume of a multi-level apartment building, factory, store or restaurant; and sophisticated enough to be capable of automatic operation day or night, without the continuous attendance of maintenance personnel.
In general, there are two basic types of compacting machines for use in buildings such as apartment houses. One type operates on the principle of extrusion with raw refuse entering a hopper and then coming to rest in front of a hydraulically driven ram. The ram is activated to compress the refuse into a compaction chamber. After completion of its forward stroke, the ram is returned to its rearward position, leaving space for new refuse to enter the cavity which is forward of the ram. With each forward stroke of the ram, more refuse is compacted into the chamber and subsequently driven out through the nozzle opening at the front end of the machine, having been compacted in the reducing cross section of the nozzle. The output of the machine is a continuous cylinder of compacted refuse.
A second type of compacting machine compresses the raw refuse into a chamber until it is full. A door is then opened, following which the formed slug of compacted refuse is ejected into a bag or other receptacle.
Since the machines described above have generally been driven hydraulically, they have exhibited several drawbacks. Because of the requirement for motor, pump, fluid reservoir, valving, piping, filtering, temperature and pressure limitation, etc., these machines are costly to build and maintain. Also, the presence of fluid in the reservoir, and under pressure in the lines and components tends to develop leaks and other mechanical failures. In addition, the overall arrangement of these systems results in excessive weight and volume.
SUMMARY OF THE INVENTION
This invention relates to an improved refuse compactor. Although not limited thereto, it is particularly suitable for handling a large volume of refuse of various types, such as the daily garbage from the many kitchens in a multi-level apartment building or from the kitchen of a restaurant or refuse from a store or factory, particularly those which handle food products and wrappings. The ram of the compactor is driven mechanically, rather than hydraulically, which simplifies the machinery involved and thereby reduces the size of the compactor. The basic drive system uses a motor driven jack screw assembly which directly drives the compacting ram. The principle of the jack screw is well known and has been applied to ram devices before. However, application of the jack screw in the assembly described herein has important advantages.
High load compaction is applied vertically, rather than horizontally, which results in more efficient operation and avoids the tendency of other compacting machines having a horizontal stroke to accumulate bits of refuse between the ram and the side walls of the refuse chamber. This vertical arrangement reduces the necessity for cleaning and other maintenance costs. High load compaction is accomplished by means of a jack screw arrangement in which the follower nut is closest to the power source of the motor at the time of heaviest load. This reduces vibration along the jack screw and binding of the ram structure, thereby prolonging the life of the compactor. The high load capacity allows this invention to handle the large volume of refuse from an apartment house, rather than the comparatively small volume of refuse handled by other compactors designed for use under the countertop in the kitchen of a dwelling.
A pushbar platform assembly is used to push the refuse into the compaction chamber by positive action. This prevents refuse, such as a box or a length of wood, from bridging across the ram opening or otherwise becoming stuck in the machine and thereby causing the machine to cycle continuously without receiving or discharging refuse.
A photocell sensor is used to initiate automatic operation of the compactor only after it has accumulated a full load of refuse This achieves economy of operation by avoiding a separate compaction cycle each time the compactor receives a few bits of refuse. There is also a deodorant and disinfectant spray pump assembly which is actuated automatically and a fire sprinkler with thermostatic control.
This invention is designed to handle all types of household refuse. It is not restricted to handling only certain types of household refuse, such as tin cans or paper towels.
The principal object of this invention is to provide an improved overall arrangement and drive system for a compacting machine which is less costly to build and less expensive and less troublesome to maintain than present systems.
It is a further object of this invention to provide a machine which has a high load capacity and yet occupies less floor space than existing compactor machines.
Other objects and advantages of this invention will be apparent from the drawings and description.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of the machine, in one stage of operation and with part of the outer wall broken away to reveal interior components.
FIG. 2 is a side elevational view of the machine, in another stage of operation and with part of the outer wall broken away to reveal interior components.
FIG. 3 is an enlarged side elevational view of FIG. 1, with additional parts being broken away to reveal additional interior components.
FIG. 4 is a sectional view taken along the lines 4--4 in FIG. 1 and in the direction of the arrows in FIG. 1.
FIG. 5 is a sectional view taken along the lines 5--5 in FIG. 1 and in the direction of the arrows in FIG. 1.
FIG. 6 is a sectional view taken along the lines 6--6 in FIG. 3 and in the direction of the arrows in FIG. 3.
FIG. 7 is a fragmentary side elevational view in the direction of the arrows 7--7 in FIG. 3.
FIG. 8 is a simplified elevational view of the machine in the same stage of operation as FIG. 1.
FIG. 9 is a simplified elevational view of the machine in the same stage of operation as FIG. 2.
FIG. 10 is an electrical schematic of the circuitry for the machine.
FIG. 11 is an additional electrical schematic of part of the circuitry in FIG. 10.
DETAILED DESCRIPTION
Mechanical Operation
Referring to FIGS. 1, 2 and 3, the compactor consists of a hopper module, designated generally by reference number 1, and a press module, designated generally by reference number 3. The hopper module 1 contains a hopper compartment 5 and a pushbar platform assembly consisting of a pushbar platform 7, pushbar linkage 9 and deflector plate 35. The press module 3 contains a ram 11, a ram chamber 13, a drive motor and gear reducer 15, a jack screw assembly designated generally by reference number 17 and a nozzle chamber 19. Refuse enters the compactor either through door 21 or through a chute, not shown, which is connected to the top of the hopper module at doors 22, shown in FIG. 3.
The operation of the compactor is illustrated in simplified form in FIGS. 8 and 9. The refuse is deposited in hopper compartment 5 of the hopper module 1. At this time the pushbar platform 7 and the ram 11 are each in their down position, as shown in FIG. 9. When sufficient refuse has accumulated in the hopper compartment 5, the ram 11 is raised to its upper position, as shown in FIG. 8 and the pushbar platform 7 pivots upwardly to urge the refuse into the ram chamber 13. Then, during the compaction cycle, the ram 11 is lowered to compact the refuse during the travel of the ram 11 through the ram chamber 13 and in the nozzle chamber 19, resulting in extrusion of the refuse through the nozzle chamber 19.
Referring to FIGS. 1, 2 and 3, loose uncompacted refuse entering the hopper module 1 passes through the light beam of a photosensor 23, shown in FIG. 3. The refuse strikes the leading face 6 of pushbar platform 7 at a time when the pushbar platform 7 is in its lower position, as shown in FIG. 2, when the leading face 6 is approximately 30° above the horizontal. As refuse accumulates, it gradually reaches the level of the photosensor 23. The photosensor 23 is provided with a time delay mechanism, such that it will close a switch to actuate the compaction cycle only when the light beam is interrupted for more than a minimum of several seconds. For this reason, the passage of small batches of refuse through the light beam will not actuate the compaction cycle until a full load of refuse has accumulated. This achieves efficiency and economy by reducing the number of cycles of compactor operation to a minimum, reducing consumption of power, and reducing machine wear, as compared to total volume of refuse compacted.
When a full load of refuse has accumulated in the hopper compartment 5, the photosensor 23 causes the motor and gear reducer 15 to energize. At this point in the cycle the ram 11 and jack screw assembly 17 are in their down position as shown in FIG. 2. The motor and gear reducer 15 rotate a lead screw 25 which, in turn, drives a follower nut 27. The follower nut 27 moves axially along stationary lead screw 25. Preferably, this arrangement includes sets of independent rollers 28 and needle bearings 30, one set of which is shown in FIG. 3. This arrangement is not as susceptible to the extent of damage caused by contaminents in ball screw arrangements. Follower nut 27 is connected to ram 11 by vertical supports 31. This embodiment uses three vertical supports 31, most clearly shown in FIG. 6. When motor and gear reducer 15 are energized, they drive the follower nut 27 and ram 11 upward along lead screw 25 from the down position of the ram 11 shown in FIG. 2 to the up position of the ram shown in FIG. 1. During this upward stroke, there is relatively low load on the machine since the drive motor and gear reducer 15 must only overcome the weight of the ram 11 and jack screw assembly 17 and the friction in the system.
As the ram 11 and jack screw assembly 17 are driven upward, the ram 11 passes through the ram chamber 13 and the raising of the ram shield 43, shown in FIG. 3, exposes a passageway located on the inside wall 33 common to both the ram chamber 13 and the hopper compartment 5. As a result, loose uncompacted refuse which has accumulated in the hopper compartment 5 with pushbar platform 7 in the down position, as shown in FIG. 2, is allowed to spill over from the hopper compartment 5 into the ram chamber 13 through this passageway. When the ram 11 and jack screw assembly 17 near the top of their stroke, the jack screw assembly 17 engages the pushbar linkage 9, shown in FIGS. 1 and 2, which is directly connected to the pushbar platform 7. During the last few inches of the upward stroke of the ram 11 and jack screw assembly 17, the pushbar linkage 9 pivots the pushbar platform 7 approximately 60° in a vertical plane on pivot point 44 from a lower position of the pushbar platform 7, as shown in FIG. 2, to an upper position of the pushbar platform 7, as shown in FIG. 1, with the leading face 6 in a vertical position. When the pushbar platform 7 pivots upwardly it pushes the refuse which has accumulated in the hopper compartment 5 into the ram chamber 13. A deflector plate 35 is mounted within the hopper compartment 5 adjacent to the hollow pushbar platform 7 to deflect falling refuse on to the leading face of the pushbar platform 7, when in its lower position as shown in FIG. 2.
The pushbar platform 7 is defined by a leading face 6 which is a flat surface, an arcuate face 10 having a curving surface, and structural supports for these surfaces. In the side view of FIGS. 1, 2 and 3, the pushbar platform 7 presents a pie-shaped appearance, such pie-shape being formed by the leading face 6, the arcuate face 10 and the bottom structural supports 12. Other than structural supports 12, the bottom of the pushbar platform 7 is not enclosed. Similarly, other than structural supports, the pie-shaped sides 8 are not enclosed. The portions of the pushbar platform 7 which are enclosed are the leading face 6 and the arcuate face 10. The radius of the arcuate face 10 is equal to the length of the bottom structural supports 12 and equal to the length of the leading face 6. The radius of the arcuate face 10 provides a close clearance with the lower edge of the deflector plate 35. Thus, little or no refuse will be able to slip down between the arcuate face 10 of the pushbar platform 7 and the lower edge of the deflector plate 35. A similar close clearance exists between the sides 8 of pushbar platform 7 and side walls 16 of the hopper compartment, as shown in FIG. 6, thus allowing little or no refuse to slip between the sides 8 of the pushbar platform 7 and the side walls 16 of the hopper compartment. This close clearance between the pushbar platform 7 and the walls 16 and the deflector plate 35 minimizes the amount of cleaning and attention required by this machine.
When the ram 11 and jack screw assembly 17 reach the upper end of their stroke, the motor and gear reducer 15 are stopped and then reversed, which starts the downward stroke of the ram 11. During the first few inches of the downward stroke, the pushbar linkage 9 is again actuated to restore the pushbar platform 7 to its lower position, as shown in FIG. 2, with the leading face 6 approximately 30° above the horizontal. Return of the pushbar platform 7 to its lower position provides additional space for more refuse to enter the hopper compartment 5. The ram 11 and jack screw assembly 17 continue their downward movement, and ram shield 43, shown in FIG. 3, closes the passageway located on the wall 33 of both the ram chamber 13 and the hopper compartment 5.
As the ram 11 moves downwardly through the ram chamber 13 it drives the refuse in the ram chamber 13 before it, pushing and compacting the refuse into the nozzle area 19, resulting in extrusion of the refuse through the nozzle chamber 19. The ram 11 penetrates several inches into the nozzle chamber 19, as shown in FIG. 2.
Referring to FIG. 3 an upper shearing bar 39 is mounted on the lower face of the ram 11. A lower shearing bar 41 is mounted on the inside wall of the ram chamber. The edge of upper shearing bar 39 is pointed downwardly and the edge of lower shearing bar 41 is pointed upwardly so that the two shearing bars 39 and 41 cooperate to shear any refuse material which is across the opening between the hopper compartment 5 and the ram chamber 13. FIG. 3 shows the ram 11 in its upper position, but shows ram shield 43 in dotted line in its downward position covering the passageway located on the inside wall of both ram chamber 13 and hopper compartment 5. Ram shield 43 covers this passageway during the downward stroke of ram 11 and exposes this passageway during the upward stroke of ram 11 to allow refuse to pass from hopper compartment 5 into ram chamber 13.
Pushbar platform 7 provides the following advantages: It takes an accumulation of refuse which has entered the hopper compartment 5 without obstructions and pushes the refuse positively into the ram chamber 13. This positive action prevents refuse material such as a box or length of wood 14, shown in FIG. 8, from bridging across the passageway located on the inner wall 33 of both the ram chamber 13 and the hopper compartment 5. In previous machines, not having such a pushbar platform 7, this condition has caused the machine to cycle continuously without receiving or discharging refuse. The pushbar platform 7 also provides a measure of precompaction to the system during the upward stroke of the ram 11 when power is not needed for compaction by the ram 11. This precompaction produces a full charge of refuse in the ram chamber 13 and nozzle chamber 19 when compaction by the ram 11 occurs later in the cycle. The pivoting movement of pushbar platform 7 about pivot point 44 is accomplished by a mechanical pushbar linkage 9, without any electrical or hydraulic components.
Referring to FIGS. 1 and 2, the pushbar linkage 9 is fitted with an override spring 45 which prevents jamming of the pushbar platform 7 if solid objects become stuck between the pushbar platform 7 and any of the inside walls of the hopper compartment 5. If refuse material such as a box or length of wood become lodged between an inside wall of the hopper compartment 5 and the pushbar platform 7 (FIG. 9), the complimentary motions of the ram stroke and the pushbar platform stroke will eventually dislodge the material.
To eliminate twisting moments from the ram 11, a torsion assembly 47 may be used as an optional feature. The follower nut 27 of the jack screw assembly 17 is fitted with a torsion roller 49 which rides on two torsion supports 51, shown in FIGS. 4 and 5. The torsion supports 51 are affixed to and integral with motor and gear reducer 15 and vertical supports 31 of the jack screw assembly 17. This torsion assembly 47 balances any torsional moments which would otherwise be transmitted to the ram 11 and leaves the ram 11 free to move in the ram chamber 13 with no twisting movements which would cause undue wear. This optional torsion assembly 47 may be omitted where heavy loads are not present.
The hopper module 1 and the press module 3 are both enclosed units, for safety reasons and to prevent tampering with the machine.
Electrical Operation
Referring to FIG. 10, three phase, 60 cycle power is applied to the compactor by the on/off switch S1 through transformer T1. Transformer T1 has two secondary windings. One secondary winding provides 115 volts. The second provides 6.3 volts. The 115 volts is used for all control and indication functions. The 6.3 volts is used to provide power for all logic and sequencing functions through a regulated 5 volt dc power supply consisting of a full wave bridge 55, filter capacitor C1, and series regulator Z12. These logic and sequencing functions are described below.
The 6.3 volt input power is half wave rectified by diode CR5 and converted into a pulse train by amplifier Q1 and resistors R1, R2 and R3 and inverter Z1A. This pulse train is applied to a six bit binary counter consisting of four bit binary counter Z2 and dual flip-flop Z3. This six bit counter provides an output frequency of 0.9375 cycles which is used for the time controlled functions of the machine. This signal is fed to a two stage binary counter (Z6), and a twelve bit binary counter (Z4, Z5 and Z7). The twelve bit counter provides pulses at 72.8 minute intervals, except when reset. A reset input inhibits further counting, and resets the counter to zero, thereby causing the 72.8 minute time interval to begin again after the reset is removed.
The reset signal is generated by the two stage counter Z6. Counter Z6 is enabled (allowed to count) by a cycle command. A cycle command signal is obtained whenever the photo detector (FIG. 11) senses a minimum refuse input. If this input is maintained sufficiently long to allow Z6 to receive three pulses (between 2.13 and 3.20 seconds) the twelve bit counter will be reset. If the cycle command does not remain long enough, counter Z6 resets to zero and remains there until the next cycle command is received.
The outputs of both the twelve bit counter (Z4, Z5 and Z7) and two bit counters Z6 are then applied to set flip-flop Z8A and Z9A which turns on relay K1. Contact K1A turns on the reversing contactor (RVS) 57, which causes the motor to drive in reverse, thereby retracting the ram. The ram continues to retract until it reaches a limit switch S7 (maximum pull-back limit switch), shown in FIG. 11. When switch S7 closes, the Z8A - Z9A flip-flop is reset, turning off K1 and the reversing contactor 57.
Contact K1B turns on the chemical dispenser, which sprays deodorant, insecticide or any other suitable chemical, as selected. Contact K1C turns on neon indicator DS 3 indicating the machine is compacting. Switch S6 is for manual start of the compactor.
Closing of S7 also sets a second flip-flop (Z8B and Z9B), shown in FIG. 10, lower left. This activates relay K2, which causes the ram to compress the refuse in the hopper. Referring to FIG. 11, as the ram compresses the refuse, it moves past a second limit switch S9 (minimum position limits switch). This position represents the minimum acceptable ram stroke. The ram continues past S9 until either one of two possibilities occurs. One possibility is that the ram reaches limit switch S8 (maximum position limit switch). Switch S8 is located at the point of maximum downward ram travel. It resets flip-flop Z8B and Z9B, turning off relay K2. The other possibility is that the ram encounters sufficient physical resistance from the refuse to cause the motor current to rise beyond the setting of the Instantaneous Trip Current Relay K4. This also resets flip-flop Z8B and Z9B, turning off relay K2.
In the event that an object in the ram chamber 13 cannot be cut by the shearing blades, the Instantaneous Trip Current Relay K4 will be activated before the ram reaches S9. If this condition occurs, the machine cycle is reinitiated by inverter Z1D and gate Z8C, which sets flip-flop Z8A and Z9A. Gate Z8D also monitors this condition and feeds an input pulse to the clock input (CP) of two stage binary counter Z10, causing it to advance. If Z10 reaches the count of three, signifying that K4 has been actuated three times in succession without S9 closing, Z11A actuates K3, which interrupts the control power and turns on Jam Indicator DS2. Thus, the drive system will make three strokes to shear the object or move it through the ram chamber 13. If it cannot handle the object in this manner, the machine is stopped and a jam is indicated.
Four system interlocks are provided, any one or more of which interrupts control power shutting down the machine when the switch is open. The interlocks are: Access Door No. 1, S2; Access Door No. 2, S3; Shutoff Door, S4; and Bag End Switch (released when no bag is available to receive refuse), S5. Z1 is a hexode inverter; Z8 is a quad two input gate; and Z9 and Z11 are dual buffers.
Handling and disposal of household and commercial refuse is a growing problem, particularly in urban areas. Incineration is becoming impractical as a result of its contaminating effect on the atmosphere and environment. Loose, non-compacted refuse is inconvenient to handle, expensive to transport and is rapidly filling available dumping areas. Compacting, to reduce the bulk volume of refuse, has become desirable to allow more efficient transport and disposal of such refuse. Thus, there is a growing need for compacting machines, particularly those which are simple and economical to build and maintain; versatile as to the amount and type of refuse which can be handled; small enough to be installed in existing buildings without requiring a prohibitively large amount of space, yet large enough to handle the refuse volume of a multi-level apartment building, factory, store or restaurant; and sophisticated enough to be capable of automatic operation day or night, without the continuous attendance of maintenance personnel.
In general, there are two basic types of compacting machines for use in buildings such as apartment houses. One type operates on the principle of extrusion with raw refuse entering a hopper and then coming to rest in front of a hydraulically driven ram. The ram is activated to compress the refuse into a compaction chamber. After completion of its forward stroke, the ram is returned to its rearward position, leaving space for new refuse to enter the cavity which is forward of the ram. With each forward stroke of the ram, more refuse is compacted into the chamber and subsequently driven out through the nozzle opening at the front end of the machine, having been compacted in the reducing cross section of the nozzle. The output of the machine is a continuous cylinder of compacted refuse.
A second type of compacting machine compresses the raw refuse into a chamber until it is full. A door is then opened, following which the formed slug of compacted refuse is ejected into a bag or other receptacle.
Since the machines described above have generally been driven hydraulically, they have exhibited several drawbacks. Because of the requirement for motor, pump, fluid reservoir, valving, piping, filtering, temperature and pressure limitation, etc., these machines are costly to build and maintain. Also, the presence of fluid in the reservoir, and under pressure in the lines and components tends to develop leaks and other mechanical failures. In addition, the overall arrangement of these systems results in excessive weight and volume.
SUMMARY OF THE INVENTION
This invention relates to an improved refuse compactor. Although not limited thereto, it is particularly suitable for handling a large volume of refuse of various types, such as the daily garbage from the many kitchens in a multi-level apartment building or from the kitchen of a restaurant or refuse from a store or factory, particularly those which handle food products and wrappings. The ram of the compactor is driven mechanically, rather than hydraulically, which simplifies the machinery involved and thereby reduces the size of the compactor. The basic drive system uses a motor driven jack screw assembly which directly drives the compacting ram. The principle of the jack screw is well known and has been applied to ram devices before. However, application of the jack screw in the assembly described herein has important advantages.
High load compaction is applied vertically, rather than horizontally, which results in more efficient operation and avoids the tendency of other compacting machines having a horizontal stroke to accumulate bits of refuse between the ram and the side walls of the refuse chamber. This vertical arrangement reduces the necessity for cleaning and other maintenance costs. High load compaction is accomplished by means of a jack screw arrangement in which the follower nut is closest to the power source of the motor at the time of heaviest load. This reduces vibration along the jack screw and binding of the ram structure, thereby prolonging the life of the compactor. The high load capacity allows this invention to handle the large volume of refuse from an apartment house, rather than the comparatively small volume of refuse handled by other compactors designed for use under the countertop in the kitchen of a dwelling.
A pushbar platform assembly is used to push the refuse into the compaction chamber by positive action. This prevents refuse, such as a box or a length of wood, from bridging across the ram opening or otherwise becoming stuck in the machine and thereby causing the machine to cycle continuously without receiving or discharging refuse.
A photocell sensor is used to initiate automatic operation of the compactor only after it has accumulated a full load of refuse This achieves economy of operation by avoiding a separate compaction cycle each time the compactor receives a few bits of refuse. There is also a deodorant and disinfectant spray pump assembly which is actuated automatically and a fire sprinkler with thermostatic control.
This invention is designed to handle all types of household refuse. It is not restricted to handling only certain types of household refuse, such as tin cans or paper towels.
The principal object of this invention is to provide an improved overall arrangement and drive system for a compacting machine which is less costly to build and less expensive and less troublesome to maintain than present systems.
It is a further object of this invention to provide a machine which has a high load capacity and yet occupies less floor space than existing compactor machines.
Other objects and advantages of this invention will be apparent from the drawings and description.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of the machine, in one stage of operation and with part of the outer wall broken away to reveal interior components.
FIG. 2 is a side elevational view of the machine, in another stage of operation and with part of the outer wall broken away to reveal interior components.
FIG. 3 is an enlarged side elevational view of FIG. 1, with additional parts being broken away to reveal additional interior components.
FIG. 4 is a sectional view taken along the lines 4--4 in FIG. 1 and in the direction of the arrows in FIG. 1.
FIG. 5 is a sectional view taken along the lines 5--5 in FIG. 1 and in the direction of the arrows in FIG. 1.
FIG. 6 is a sectional view taken along the lines 6--6 in FIG. 3 and in the direction of the arrows in FIG. 3.
FIG. 7 is a fragmentary side elevational view in the direction of the arrows 7--7 in FIG. 3.
FIG. 8 is a simplified elevational view of the machine in the same stage of operation as FIG. 1.
FIG. 9 is a simplified elevational view of the machine in the same stage of operation as FIG. 2.
FIG. 10 is an electrical schematic of the circuitry for the machine.
FIG. 11 is an additional electrical schematic of part of the circuitry in FIG. 10.
DETAILED DESCRIPTION
Mechanical Operation
Referring to FIGS. 1, 2 and 3, the compactor consists of a hopper module, designated generally by reference number 1, and a press module, designated generally by reference number 3. The hopper module 1 contains a hopper compartment 5 and a pushbar platform assembly consisting of a pushbar platform 7, pushbar linkage 9 and deflector plate 35. The press module 3 contains a ram 11, a ram chamber 13, a drive motor and gear reducer 15, a jack screw assembly designated generally by reference number 17 and a nozzle chamber 19. Refuse enters the compactor either through door 21 or through a chute, not shown, which is connected to the top of the hopper module at doors 22, shown in FIG. 3.
The operation of the compactor is illustrated in simplified form in FIGS. 8 and 9. The refuse is deposited in hopper compartment 5 of the hopper module 1. At this time the pushbar platform 7 and the ram 11 are each in their down position, as shown in FIG. 9. When sufficient refuse has accumulated in the hopper compartment 5, the ram 11 is raised to its upper position, as shown in FIG. 8 and the pushbar platform 7 pivots upwardly to urge the refuse into the ram chamber 13. Then, during the compaction cycle, the ram 11 is lowered to compact the refuse during the travel of the ram 11 through the ram chamber 13 and in the nozzle chamber 19, resulting in extrusion of the refuse through the nozzle chamber 19.
Referring to FIGS. 1, 2 and 3, loose uncompacted refuse entering the hopper module 1 passes through the light beam of a photosensor 23, shown in FIG. 3. The refuse strikes the leading face 6 of pushbar platform 7 at a time when the pushbar platform 7 is in its lower position, as shown in FIG. 2, when the leading face 6 is approximately 30° above the horizontal. As refuse accumulates, it gradually reaches the level of the photosensor 23. The photosensor 23 is provided with a time delay mechanism, such that it will close a switch to actuate the compaction cycle only when the light beam is interrupted for more than a minimum of several seconds. For this reason, the passage of small batches of refuse through the light beam will not actuate the compaction cycle until a full load of refuse has accumulated. This achieves efficiency and economy by reducing the number of cycles of compactor operation to a minimum, reducing consumption of power, and reducing machine wear, as compared to total volume of refuse compacted.
When a full load of refuse has accumulated in the hopper compartment 5, the photosensor 23 causes the motor and gear reducer 15 to energize. At this point in the cycle the ram 11 and jack screw assembly 17 are in their down position as shown in FIG. 2. The motor and gear reducer 15 rotate a lead screw 25 which, in turn, drives a follower nut 27. The follower nut 27 moves axially along stationary lead screw 25. Preferably, this arrangement includes sets of independent rollers 28 and needle bearings 30, one set of which is shown in FIG. 3. This arrangement is not as susceptible to the extent of damage caused by contaminents in ball screw arrangements. Follower nut 27 is connected to ram 11 by vertical supports 31. This embodiment uses three vertical supports 31, most clearly shown in FIG. 6. When motor and gear reducer 15 are energized, they drive the follower nut 27 and ram 11 upward along lead screw 25 from the down position of the ram 11 shown in FIG. 2 to the up position of the ram shown in FIG. 1. During this upward stroke, there is relatively low load on the machine since the drive motor and gear reducer 15 must only overcome the weight of the ram 11 and jack screw assembly 17 and the friction in the system.
As the ram 11 and jack screw assembly 17 are driven upward, the ram 11 passes through the ram chamber 13 and the raising of the ram shield 43, shown in FIG. 3, exposes a passageway located on the inside wall 33 common to both the ram chamber 13 and the hopper compartment 5. As a result, loose uncompacted refuse which has accumulated in the hopper compartment 5 with pushbar platform 7 in the down position, as shown in FIG. 2, is allowed to spill over from the hopper compartment 5 into the ram chamber 13 through this passageway. When the ram 11 and jack screw assembly 17 near the top of their stroke, the jack screw assembly 17 engages the pushbar linkage 9, shown in FIGS. 1 and 2, which is directly connected to the pushbar platform 7. During the last few inches of the upward stroke of the ram 11 and jack screw assembly 17, the pushbar linkage 9 pivots the pushbar platform 7 approximately 60° in a vertical plane on pivot point 44 from a lower position of the pushbar platform 7, as shown in FIG. 2, to an upper position of the pushbar platform 7, as shown in FIG. 1, with the leading face 6 in a vertical position. When the pushbar platform 7 pivots upwardly it pushes the refuse which has accumulated in the hopper compartment 5 into the ram chamber 13. A deflector plate 35 is mounted within the hopper compartment 5 adjacent to the hollow pushbar platform 7 to deflect falling refuse on to the leading face of the pushbar platform 7, when in its lower position as shown in FIG. 2.
The pushbar platform 7 is defined by a leading face 6 which is a flat surface, an arcuate face 10 having a curving surface, and structural supports for these surfaces. In the side view of FIGS. 1, 2 and 3, the pushbar platform 7 presents a pie-shaped appearance, such pie-shape being formed by the leading face 6, the arcuate face 10 and the bottom structural supports 12. Other than structural supports 12, the bottom of the pushbar platform 7 is not enclosed. Similarly, other than structural supports, the pie-shaped sides 8 are not enclosed. The portions of the pushbar platform 7 which are enclosed are the leading face 6 and the arcuate face 10. The radius of the arcuate face 10 is equal to the length of the bottom structural supports 12 and equal to the length of the leading face 6. The radius of the arcuate face 10 provides a close clearance with the lower edge of the deflector plate 35. Thus, little or no refuse will be able to slip down between the arcuate face 10 of the pushbar platform 7 and the lower edge of the deflector plate 35. A similar close clearance exists between the sides 8 of pushbar platform 7 and side walls 16 of the hopper compartment, as shown in FIG. 6, thus allowing little or no refuse to slip between the sides 8 of the pushbar platform 7 and the side walls 16 of the hopper compartment. This close clearance between the pushbar platform 7 and the walls 16 and the deflector plate 35 minimizes the amount of cleaning and attention required by this machine.
When the ram 11 and jack screw assembly 17 reach the upper end of their stroke, the motor and gear reducer 15 are stopped and then reversed, which starts the downward stroke of the ram 11. During the first few inches of the downward stroke, the pushbar linkage 9 is again actuated to restore the pushbar platform 7 to its lower position, as shown in FIG. 2, with the leading face 6 approximately 30° above the horizontal. Return of the pushbar platform 7 to its lower position provides additional space for more refuse to enter the hopper compartment 5. The ram 11 and jack screw assembly 17 continue their downward movement, and ram shield 43, shown in FIG. 3, closes the passageway located on the wall 33 of both the ram chamber 13 and the hopper compartment 5.
As the ram 11 moves downwardly through the ram chamber 13 it drives the refuse in the ram chamber 13 before it, pushing and compacting the refuse into the nozzle area 19, resulting in extrusion of the refuse through the nozzle chamber 19. The ram 11 penetrates several inches into the nozzle chamber 19, as shown in FIG. 2.
Referring to FIG. 3 an upper shearing bar 39 is mounted on the lower face of the ram 11. A lower shearing bar 41 is mounted on the inside wall of the ram chamber. The edge of upper shearing bar 39 is pointed downwardly and the edge of lower shearing bar 41 is pointed upwardly so that the two shearing bars 39 and 41 cooperate to shear any refuse material which is across the opening between the hopper compartment 5 and the ram chamber 13. FIG. 3 shows the ram 11 in its upper position, but shows ram shield 43 in dotted line in its downward position covering the passageway located on the inside wall of both ram chamber 13 and hopper compartment 5. Ram shield 43 covers this passageway during the downward stroke of ram 11 and exposes this passageway during the upward stroke of ram 11 to allow refuse to pass from hopper compartment 5 into ram chamber 13.
Pushbar platform 7 provides the following advantages: It takes an accumulation of refuse which has entered the hopper compartment 5 without obstructions and pushes the refuse positively into the ram chamber 13. This positive action prevents refuse material such as a box or length of wood 14, shown in FIG. 8, from bridging across the passageway located on the inner wall 33 of both the ram chamber 13 and the hopper compartment 5. In previous machines, not having such a pushbar platform 7, this condition has caused the machine to cycle continuously without receiving or discharging refuse. The pushbar platform 7 also provides a measure of precompaction to the system during the upward stroke of the ram 11 when power is not needed for compaction by the ram 11. This precompaction produces a full charge of refuse in the ram chamber 13 and nozzle chamber 19 when compaction by the ram 11 occurs later in the cycle. The pivoting movement of pushbar platform 7 about pivot point 44 is accomplished by a mechanical pushbar linkage 9, without any electrical or hydraulic components.
Referring to FIGS. 1 and 2, the pushbar linkage 9 is fitted with an override spring 45 which prevents jamming of the pushbar platform 7 if solid objects become stuck between the pushbar platform 7 and any of the inside walls of the hopper compartment 5. If refuse material such as a box or length of wood become lodged between an inside wall of the hopper compartment 5 and the pushbar platform 7 (FIG. 9), the complimentary motions of the ram stroke and the pushbar platform stroke will eventually dislodge the material.
To eliminate twisting moments from the ram 11, a torsion assembly 47 may be used as an optional feature. The follower nut 27 of the jack screw assembly 17 is fitted with a torsion roller 49 which rides on two torsion supports 51, shown in FIGS. 4 and 5. The torsion supports 51 are affixed to and integral with motor and gear reducer 15 and vertical supports 31 of the jack screw assembly 17. This torsion assembly 47 balances any torsional moments which would otherwise be transmitted to the ram 11 and leaves the ram 11 free to move in the ram chamber 13 with no twisting movements which would cause undue wear. This optional torsion assembly 47 may be omitted where heavy loads are not present.
The hopper module 1 and the press module 3 are both enclosed units, for safety reasons and to prevent tampering with the machine.
Electrical Operation
Referring to FIG. 10, three phase, 60 cycle power is applied to the compactor by the on/off switch S1 through transformer T1. Transformer T1 has two secondary windings. One secondary winding provides 115 volts. The second provides 6.3 volts. The 115 volts is used for all control and indication functions. The 6.3 volts is used to provide power for all logic and sequencing functions through a regulated 5 volt dc power supply consisting of a full wave bridge 55, filter capacitor C1, and series regulator Z12. These logic and sequencing functions are described below.
The 6.3 volt input power is half wave rectified by diode CR5 and converted into a pulse train by amplifier Q1 and resistors R1, R2 and R3 and inverter Z1A. This pulse train is applied to a six bit binary counter consisting of four bit binary counter Z2 and dual flip-flop Z3. This six bit counter provides an output frequency of 0.9375 cycles which is used for the time controlled functions of the machine. This signal is fed to a two stage binary counter (Z6), and a twelve bit binary counter (Z4, Z5 and Z7). The twelve bit counter provides pulses at 72.8 minute intervals, except when reset. A reset input inhibits further counting, and resets the counter to zero, thereby causing the 72.8 minute time interval to begin again after the reset is removed.
The reset signal is generated by the two stage counter Z6. Counter Z6 is enabled (allowed to count) by a cycle command. A cycle command signal is obtained whenever the photo detector (FIG. 11) senses a minimum refuse input. If this input is maintained sufficiently long to allow Z6 to receive three pulses (between 2.13 and 3.20 seconds) the twelve bit counter will be reset. If the cycle command does not remain long enough, counter Z6 resets to zero and remains there until the next cycle command is received.
The outputs of both the twelve bit counter (Z4, Z5 and Z7) and two bit counters Z6 are then applied to set flip-flop Z8A and Z9A which turns on relay K1. Contact K1A turns on the reversing contactor (RVS) 57, which causes the motor to drive in reverse, thereby retracting the ram. The ram continues to retract until it reaches a limit switch S7 (maximum pull-back limit switch), shown in FIG. 11. When switch S7 closes, the Z8A - Z9A flip-flop is reset, turning off K1 and the reversing contactor 57.
Contact K1B turns on the chemical dispenser, which sprays deodorant, insecticide or any other suitable chemical, as selected. Contact K1C turns on neon indicator DS 3 indicating the machine is compacting. Switch S6 is for manual start of the compactor.
Closing of S7 also sets a second flip-flop (Z8B and Z9B), shown in FIG. 10, lower left. This activates relay K2, which causes the ram to compress the refuse in the hopper. Referring to FIG. 11, as the ram compresses the refuse, it moves past a second limit switch S9 (minimum position limits switch). This position represents the minimum acceptable ram stroke. The ram continues past S9 until either one of two possibilities occurs. One possibility is that the ram reaches limit switch S8 (maximum position limit switch). Switch S8 is located at the point of maximum downward ram travel. It resets flip-flop Z8B and Z9B, turning off relay K2. The other possibility is that the ram encounters sufficient physical resistance from the refuse to cause the motor current to rise beyond the setting of the Instantaneous Trip Current Relay K4. This also resets flip-flop Z8B and Z9B, turning off relay K2.
In the event that an object in the ram chamber 13 cannot be cut by the shearing blades, the Instantaneous Trip Current Relay K4 will be activated before the ram reaches S9. If this condition occurs, the machine cycle is reinitiated by inverter Z1D and gate Z8C, which sets flip-flop Z8A and Z9A. Gate Z8D also monitors this condition and feeds an input pulse to the clock input (CP) of two stage binary counter Z10, causing it to advance. If Z10 reaches the count of three, signifying that K4 has been actuated three times in succession without S9 closing, Z11A actuates K3, which interrupts the control power and turns on Jam Indicator DS2. Thus, the drive system will make three strokes to shear the object or move it through the ram chamber 13. If it cannot handle the object in this manner, the machine is stopped and a jam is indicated.
Four system interlocks are provided, any one or more of which interrupts control power shutting down the machine when the switch is open. The interlocks are: Access Door No. 1, S2; Access Door No. 2, S3; Shutoff Door, S4; and Bag End Switch (released when no bag is available to receive refuse), S5. Z1 is a hexode inverter; Z8 is a quad two input gate; and Z9 and Z11 are dual buffers.