Die plate heating / changing system and method for changing plate in pelletizer

Abstract

To provide a die plate changing system.SOLUTION: A die plate changing system holds first and second die plates and selectively transitions the first and second die plates into and out of communication with a material source. The die plate changing system has a frame having a main body defining a first recess that receives the first die plate and a second recess that receives the second die plate, wherein the frame heats the first and second die plates when the first and second die plates are disposed in the first and second recesses, respectively. The die plate changing system also includes a movement assembly that is operably coupled to the frame and selectively moves the frame between a first position where the first die plate receives a material from the material source, and a second position where the second die plate receives the material from the material source.SELECTED DRAWING: Figure 1A

Description

[Technical field]

[0001] The present disclosure relates generally to a die plate exchange system, and more particularly to a die plate exchange system configured to hold and heat two die plates in a pelletizing system.

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 856,271, filed June 3, 2019, the entire disclosure of which is incorporated herein by reference. [Background technology]

[0003] Conventionally, pelletizing systems can be utilized to produce pellets of material from a stream of molten material, which can be an adhesive. In such pelletizing systems, a diverter valve and a die plate are operatively connected to a pelletizer. In such an arrangement, the die plate has a number of holes in the die plate and is mounted between the diverter valve and the pelletizer, particularly at the inlet to the pelletizer. The pelletizer then includes a rotating cutting head having a cutting blade positioned adjacent to a surface of the die plate through which the stream of molten material flows. The rotating cutting head cuts the stream of material into pellets of various sizes depending on the extrusion flow rate through the holes in the die plate and the rotational speed of the cutting head. The pellets can be received by a flow of water, which serves to cool the pellets and carry them out of the pelletizing assembly.

[0004] During operation of a pelletizing system, it may become necessary to replace a die plate. This may be necessary to produce different size pellets, perform routine maintenance, resolve issues affecting operations, etc. However, replacing a die plate can be a burden to the pelletizing operation because pellet production must be stopped, the pelletizing system must be at least partially disassembled, the currently used die plate must be removed, and a new die plate must be installed. Furthermore, the new die plate must be heated after installation before pelletizing operations can begin again. This further increases the downtime between pelletizing operations and increases the production costs of pellets.

[0005] Therefore, a need exists for a die plate exchange system capable of holding and heating two die plates in a pelletizing system. Summary of the Invention

[0006] One embodiment of the present disclosure is a die plate exchange system configured to hold a first die plate and a second die plate and selectively transition the first die plate and the second die plate into and out of communication with a material source. The die plate exchange system includes a frame having a body defining a first recess configured to receive the first die plate and a second recess configured to receive the second die plate, the first die plate and the second die plate being disposed in the first recess and the second recess, respectively, and heated. The die plate exchange system also includes a translation assembly operably coupled to the frame and configured to selectively move the frame between a first position, in which the first die plate is configured to receive material from the material source, and a second position, in which the second die plate is configured to receive material from the material source.

[0007] Another embodiment of the present disclosure is a method of replacing a die plate in a pelletizing system. The method includes heating a first die plate and providing material to the first die plate when a frame is in a first position. The method also includes heating a second die plate and moving the frame from the first position to a second position and providing material to the second die plate.

[0008] The present application is better understood when read in conjunction with the accompanying drawings. For the purpose of illustrating the present subject matter, there are shown in the drawings example embodiments of the present subject matter. However, the presently disclosed subject matter is not limited to the particular methods, apparatus, and systems disclosed. [Brief description of the drawings]

[0009] [Figure 1A] FIG. 1 is a perspective view of a pelletizing system according to one embodiment of the present disclosure. [Figure 1B] FIG. 1B is an alternative perspective view of the pelletizing system shown in FIG. 1A. [Diagram 2] FIG. 2 is a cross-sectional view of the pelletizing system shown in FIG. 1A taken along line 2-2 of FIG. 1B. [Diagram 3] FIG. 1B is a front view of a die plate exchange system of the pelletizing system shown in FIG. 1A. [Figure 4] 4 is a cross-sectional view of a portion of the die plate exchange system shown in FIG. 3 taken along line 4-4 shown in FIG. 2. [Diagram 5] 5 is a partial cross-sectional view of the die plate exchange system shown in FIG. 3 taken along line 5-5 shown in FIG. 2. [Figure 6A] FIG. 2 is a perspective view of a pelletizing system according to another embodiment of the present disclosure. [Figure 6B] FIG. 6B is an alternative perspective view of the pelletizing system shown in FIG. 6A. [Figure 7] FIG. 7 is a cross-sectional view of the pelletizing system shown in FIG. 6A taken along line 7-7 shown in FIG. 6B. [Figure 8]8 is a cross-sectional view of the die plate exchange system of the pelletizing system shown in FIG. 6A taken along line 8-8 shown in FIG. 7. [Figure 9] FIG. 1 is a process flow diagram of a method for replacing a die plate in a pelletizing system according to one embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Described herein is a pelletizing system 10 configured to produce pellets P from a flow of liquid material L. The pelletizing system 10 includes a die plate exchange system 70, 370 configured to hold and heat a first die plate 25, 325 and a second die plate 50, 350. Certain terminology is used in the following description to describe the pelletizing system 10 for convenience only and is not intended to be limiting. The terms "right", "left", "lower", and "upper" refer to directions within the drawings to which reference is made. The words "inner" and "outer" refer to directions toward and away from the geometric center of the description, respectively, to describe the pelletizing system 10 and its associated components. The terminology includes the terms listed above, their derivatives, and terms of similar import.

[0011] Unless otherwise specified herein, the terms "longitudinal," "transverse," and "vertical" are used to describe the orthogonal directional components of the various components of the pelletizing system 10, as indicated by the longitudinal direction 2, the transverse direction 4, and the vertical direction 6. Although the longitudinal direction 2 and the transverse direction 4 are shown as extending along a horizontal plane and the vertical direction 6 is illustrated as extending along a vertical plane, it should be understood that the planes encompassing the various directions may vary during use.

[0012] 1A-3, a pelletizing system 10 according to one embodiment of the present disclosure is shown. The pelletizing system 10 can include a material source in fluid communication with an extruder (not shown), the material source configured to receive a flow of liquid material L from the extruder. In one embodiment, the material source can be a diverter valve 14, although embodiments of the present disclosure are not so limited. The diverter valve 14 can define a body extending from a first end 14a to a second end opposite the first end 14a along the longitudinal direction 2, as well as a passageway 18 extending through the diverter valve 14 from the first end 14a to the second end 14b. The passageway 18 can be configured to receive the flow of liquid material L from the extruder at the first end 14a such that the flow of liquid material L flows through the passageway 18 of the diverter valve 14 along the longitudinal direction 2. A bypass valve piston 20 can be attached to the diverter valve 14 and in fluid communication with the passageway 18. The bypass valve piston 20 can be configured to selectively divert the flow of liquid material L from the passage 18, such as to a dolly, for recycling or disposal of the liquid material L. This diversion may occur during interruptions in the pelletizing operation or when components of the pelletizing system 10 are being repaired or replaced.

[0013] The second die plate 50 can be positioned adjacent the second end 14b of the diverter valve 14 such that the second die plate 50 is configured to receive the flow of liquid material L exiting the passages 18 of the diverter valve 14. The second die plate 50 can be supported by a frame 75 of a die plate exchange system 70, the first die plate 25 and the second die plate 50, and the die plate exchange system 70 being discussed further below. The second die plate 50 can have a body 58 that defines a plurality of passages 61 extending therethrough. Each of the passages 61 can define a diameter that correlates to a diameter of the pellets P produced by the pelletizing system 10. In conjunction with other features of the pelletizing system 10, the diameter of each of the passages 61 can be significantly smaller than the diameter of the passages 18 of the diverter valve 14. The flow of liquid material L can be pressurized to an extent that it is forced through the passages 61 of the second die plate 50 to produce an elongated rod of liquid material L. The liquid material L is then forced out the output line 124, as described further below.

[0014] The pelletizing system 10 may further include a pelletizer 100. The pelletizer 100 may be positioned on a track 102 so that the pelletizer 100 may be moved away from other components of the pelletizing system 10, such as the die plate replacement system 70, during certain maintenance procedures, such as die plate replacement operations. The pelletizer 100 may include a motor 104 as well as a shaft 108 extending from the motor 104 to a cutting head 112. The cutting head 112 may be positioned within a cutting chamber 122 adjacent to the second die plate 50, specifically on the side of the second die plate 50 opposite the diverter valve 14. During operation, the motor 104 of the pelletizer 100 may be configured to rotate the cutting head 112 via the shaft 108. The cutting head 112 may include a plurality of blades such that the cutting head 112 is configured to cut the elongated rod of liquid material L exiting the second die plate 50 into separate pellets P of a particular length. The length of the pellets P produced by the cutting head 112 can be increased and decreased by adjusting the rotational speed of the cutting head 112 .

[0015] 1A-3, the pelletizing system 10 can include an input line 120 that defines a water input 116. The input line 120 can be configured to receive water W from a water source (not shown) through the water input 116, which can be configured to provide room temperature or cooler water W to the pelletizing system 10. The input line 120 is configured to direct the water W through the pelletizing system 10 to a cutting chamber 122. The cutting chamber 122 can be configured to receive the cutting head 112 and can be positioned adjacent an end of the second die plate 50 opposite the diverter valve 14. The cutting chamber 122 can be configured to receive both the flow of water W from the input line 120 and the pellets P cut by the cutting head 112. When the pellets P are placed in contact with the water W, the water W serves multiple purposes. First, because the water W may have a significantly lower temperature than the pellets P immediately after they exit the second die plate 50 and are cut by the cutting head 112, the water W may cool the pellets P such that the pellets P maintain the size and shape as they were cut. Second, the flow of water W may carry the pellets P away from the cutting head 112 through the pelletizing system 10. Specifically, the flow of water W and pellets P may flow upwardly from the cutting chamber 122 into an output line 124 along the vertical direction 6. The output line 124 may extend from the cutting chamber 122 to a slurry output 128. From the slurry output 128, the mixture of pellets P and water W may flow to a pellet dryer (not shown), which may function to separate the water W from the pellets P, providing an operator of the pelletizing system 10 with a supply of substantially dry pellets P.

[0016] The die plate exchange system 70 and the first and second die plates 25, 50 will now be described in more detail with reference to Figures 3-5. The first die plate 25 can include a body 28 and a number of passages 31 extending through the body 28 along the longitudinal direction 2. In the illustrated embodiment, the passages 31 are positioned in a substantially ring-like arrangement, however, in other embodiments, it is contemplated that the passages 31 can be alternatively positioned. The passages 31 can define substantially cylindrical elongated holes that can be designed with a diameter that corresponds to the intended diameter of the pellets P to be produced by the pelletizing system 10. As a result, the passages 31 can have alternative sizes and / or shapes to produce pellets P having other sizes. Additionally, while the first die plate 25 is illustrated as defining a particular number of passages 31, in other embodiments, the first die plate 25 can define any number of passages.

[0017] The first die plate 25 may further define a plurality of holes 34 extending through an upper end of the body 28 of the first die plate 25 along the longitudinal direction 2. Each of the holes 34 may be positioned along the periphery of the first die plate 25, although other locations for the holes 34 are contemplated. The holes 34 may each be configured to receive a fastener 35 to secure the first die plate 25 to a frame 75 of the die plate exchange system 70, which is further described below. The fasteners 35 may be bolts, screws, pins, or any conventional fastener capable of extending through the respective holes 34 to releasably couple the first die plate 25 to the frame 75. The first die plate 25 may define an input passage 43 positioned at a lower end of the body 28. The input passage 43 may extend from the channel 40 to an outer surface of the first die plate 25. The input passage 43 can be configured to receive heated liquid from the frame 75 and provide the heated liquid to the channel 40. Although shown positioned at the lower end of the body 28, the input passage 43 can be otherwise positioned at the first die plate 25 as desired. The channel 40 can be configured to receive heated liquid from the input passage 43 and distribute the heated liquid throughout the first die plate 25 to uniformly heat the first die plate 25. In pelletizing operations, it is important to heat the first die plate 25 and the second die plate 50 to substantially maintain the flow of the liquid material L as it is extruded through one of the first die plate 25 and the second die plate 50. Excessive cooling of the liquid material L in the first die plate 25 and the second die plate 50 can lead to clogging of the passages 31, 61, thus interrupting the overall operation of the pelletizing system 10.

[0018] In the illustrated embodiment, the channel 40 is shown having a substantially ring-like shape extending radially around the entire circumference of the passage 31. However, the channel 40 may be otherwise configured to heat the first die plate 25. For example, it is contemplated that the channel 40 may define any combination of additional passages or channels or may define various other shapes. The first die plate 25 may further define a first output passage 37a extending from an outer surface of the first die plate 25, and a second output passage 37b spaced apart from the first output passage 37a also extending from an outer surface of the first die plate 25. Although shown positioned at an upper end of the first die plate 25, the first output passage 37a and the second output passage 37b may be otherwise positioned on the first die plate 25 as desired. The first output passage 37a and the second output passage 37b may be configured to receive the heated liquid from the channel 40 and direct the heated liquid to the frame 75. A first output passage 37a and a second output passage 37b can extend from an outer surface of the first die plate 25 to the channel 40. Additionally, although the first die plate 25 is shown as defining two output passages 37a, 37b and one input passage 43, in other embodiments the first die plate 25 can define more or less input and output passages.

[0019] Continuing with FIGS. 3-5, the pelletizing system 10 can include a second die plate 50. The second die plate 50 can include a body 58 and a number of passages 61 extending through the body 58 along the longitudinal direction 2. In the illustrated embodiment, the passages 61 are positioned in a substantially ring-like arrangement, however, in other embodiments, it is contemplated that the passages 61 can be alternatively positioned. The passages 61 can define substantially cylindrical elongated holes that can be designed with a diameter that corresponds to the intended diameter of the pellets P to be produced by the pelletizing system 10. As a result, the passages 61 can have alternative sizes and / or shapes to produce pellets P having other sizes. Additionally, while the second die plate 50 is shown as defining a particular number of passages 61, in other embodiments, the second die plate 50 can define any number of passages. In the illustrated embodiment, the passages 31, 61 of the first die plate 25 and the second die plate 50 are shown as having substantially identical designs and arrangements. However, it is contemplated that the first die plate 25 and the second die plate 50 may have passages 31, 61 that are differently sized and / or arranged, such as when the die plate exchange system 70 is utilized to alternate between two different pelletizing operations.

[0020] The second die plate 50 may further define a plurality of holes 64 extending through an upper end of the body 58 of the second die plate 50 along the longitudinal direction 2. Each of the holes 64 may be positioned along the periphery of the second die plate 50, although other locations for the holes 64 are contemplated. The holes 64 may each be configured to receive a fastener, such as the fastener 35 described above, to secure the second die plate 50 to a frame 75 in the die plate exchange system 70. The second die plate 50 may further define an input passage 69 positioned at a lower end of the body 58. The input passage 69 may extend from the channel 68 to an outer surface of the second die plate 50. The input passage 69 may be configured to receive heated liquid from the frame 75 and provide heated liquid to the channel 68. Although shown positioned at a lower end of the body 58, the input passage 69 may be otherwise positioned in the second die plate 50 as desired. The channels 68 can be configured to receive heated liquid from the input passages 69 and distribute the heated liquid throughout the second die plate 50 so as to uniformly heat the second die plate 50.

[0021] In the illustrated embodiment, the channel 68 is shown having a substantially ring-like shape extending radially around the entire passage 61. However, the channel 68 may be otherwise configured to heat the second die plate 50. For example, it is contemplated that the channel 68 may define any combination of additional passages or channels or may define various other shapes. The second die plate 50 may further define a first output passage 67a extending from an outer surface of the second die plate 50, and a second output passage 67b spaced apart from the first output passage 67a also extending from an outer surface of the second die plate 50. Although shown positioned at a top end of the second die plate 50, the first output passage 67a and the second output passage 67b may be otherwise positioned on the second die plate 50 as desired. The first output passage 67a and the second output passage 67b may be configured to receive the heated liquid from the channel 68 and direct the heated liquid to the frame 75. A first output passage 67a and a second output passage 67b may extend from an outer surface of the second die plate 50 to a channel 68 that extends through the second die plate 50. Additionally, although the second die plate 50 is shown as defining two output passages 67a, 67b and one input passage 69, in other embodiments, the second die plate 50 may define more or fewer input and output passages.

[0022] Continuing with FIG. 3-FIG. 5, the die plate exchange system 70 will be described in more detail. The die plate exchange system 70 can be configured to hold the first die plate 25 and the second die plate 50 and selectively transition between communication and non-communication between the first die plate 25 and the second die plate 50 and the diverter valve 14. The die plate exchange system 70 can include a frame 75, the frame 75 having a body 78. The body 78 can define a surface 78a and a back surface 78b opposite the surface 78a along the longitudinal direction 2. The body 78 can also define a top surface 78c and a bottom surface 78d opposite the top surface 78c along the vertical direction 6. Furthermore, the body 78 can define a first side surface 78e and a second side surface 78f opposite the first side surface 78e along the lateral direction 4. In this manner, the body 78 of the frame 75 can be shaped substantially as a rectangular prism. However, other shapes and designs are contemplated for the frame 75. In the pelletizing system 10, a front surface 78a of the frame 75 can be adjacent the diverter valve 14 and a back surface 78b can be adjacent the cutting head 112 of the pelletizer 100.

[0023] The frame 75 may define a first recess 82a extending from the front surface 78a into the body 78, and a second recess 82b extending from the front surface 78a into the body 78. The first recess 82a is configured to receive the first die plate 25, and the second recess 82b is configured to receive the second die plate 50. A portion of the first recess 82a and the second recess 82b may extend completely through the body 78 from the front surface 78a to the back surface 78b, such that a flow of liquid material L may flow through the passages 31, 61 of one of the first die plate 25 and the second die plate 50 when the first die plate 25 and the second die plate 50 are disposed within the first recess 82a and the second recess 82b. The frame 75 can include a plurality of holes 95a that can align with the holes 34 of the first die plate 25 when the first die plate 25 is received in the first recess 82a to receive fasteners 35 that are configured to pass through the plurality of holes to secure the first die plate 25 to the frame 75. The frame 75 can also include a plurality of holes 95b that can align with the holes 64 of the second die plate 50 when the second die plate 50 is received in the second recess 82b to receive fasteners 35 that are configured to pass through the plurality of holes to secure the second die plate 25 to the frame 75. The number, arrangement, and shape of the holes 95a, 95b generally correspond to the number, arrangement, and shape of the holes 34, 64 that are configured to align with the holes and the fasteners 35 that are configured to receive the holes. However, in other embodiments, like holes 34, 64, holes 95a, 95b may be shaped and / or positioned differently than shown.

[0024] The frame 75 can be configured to couple to the diverter valve 14 during the pelletizing operation. Specifically, the frame 75 can include a plurality of holes 95a positioned radially around the first recess 82a, each configured to receive a respective fastener 98 to couple the frame 75 to the diverter valve 14 when the first die plate 25 is in fluid communication with the diverter valve 14 and the pelletizer 100. The frame 75 can also include a plurality of holes 95b positioned radially around the second recess 82b, each configured to receive a respective fastener 98 to couple the frame 75 to the diverter valve 14 when the second die plate 50 is in fluid communication with the diverter valve 14 and the pelletizer 100. Although a particular number and arrangement of holes 95a, 95b are shown, more or fewer holes 95a, 95b, as well as holes 95a, 95b having different designs, may be included in the frame 75. It is contemplated that the fasteners 98 may be bolts or any other type of conventional fastener capable of releasably coupling the frame 75 to the diverter valve 14.

[0025] During operation, only one of the first die plate 25 and the second die plate 50 is in fluid communication with the diverter valve 14 and the pelletizer 100. In previous pelletizing systems, the system would have to be disassembled to repair and / or replace the die plate. In the pelletizing system 10, the die plate exchange system 70 can easily transition between positionings of the first die plate 25 and the second die plate 50 in fluid communication with other aspects of the pelletizing system 10. To do this, the die plate exchange system 70 can include a moving assembly 204 operably coupled to the frame 75 and configured to selectively move the frame 75 between a plurality of positions. For example, the moving assembly 204 can be configured to move the frame 75 between a first position, in which the first die plate 25 is configured to receive liquid material from the diverter valve 14, and a second position, in which the second die plate 50 is configured to receive material from the diverter valve 14. The second position is explicitly shown in FIGS. 1A-2.

[0026] In the embodiment shown in FIGS. 1-5, the moving assembly 204 is configured to move the frame 75 linearly between a first position and a second position along the lateral direction 4. To do so, the moving assembly 204 can include a linear track 208. The die plate exchange system 70 can further include a support structure 200, to which the linear track 208 is coupled. The support structure 200 shown can have an arch-shaped body comprising a metal beam, although other shapes for the support structure 200 are contemplated. The pelletizing system 10 can further include a first support 216a and a second support 216b, each of which is configured to extend from the frame 75 to the linear track 208 and couple the frame 75 to the linear track 208. Specifically, the frame 75 can be suspended from the linear track 208 via the first support 216a and the second support 216b. As such, the frame 75 is configured to selectively move between a first position and a second position along the linear track 208. To move the frame 75, the die plate exchange system 70 may include a motor 212 operably coupled to the frame 75. Specifically, the motor 212 may be coupled to the support structure 200, the linear track 208, and / or the first support 216a and the second support 216b. The motor 212 may be configured to automatically move the frame 75 between the first direction and the second direction along the linear track 208 in response to either receiving a command by the controller or an instruction by an operator of the pelletizing system 10. Alternatively, the frame 75 may be manually transitioned by an operator between the first position and the second position. To do so, the operator may manually apply a lateral force to the frame 75 and / or the first support 216a and the second support 216b to move the frame 75 to the desired first or second position along the linear track 208.

[0027] In addition to moving between the first and second positions to selectively place one of the first and second die plates 25 and 50 in fluid communication with the diverter valve 14 and the pelletizer 100, the die plate exchange system 70 can be further configured to heat the first and second die plates 25 and 50. In other words, the die plate exchange system 70 can heat both one of the first and second die plates 25 and 50 that is in fluid communication with the diverter valve 14 and the pelletizer 100, and the other of the first and second die plates 25 and 50 that is not in fluid communication with the diverter valve 14 or the pelletizer 100. In pelletizing systems, the die plates must be heated before use so that the liquid material passing therethrough remains heated and maintains optimal flow characteristics. As a result, when a die plate must be replaced, additional downtime is conventionally required to allow the temperature of the newly installed die plate to become high enough to allow pelletizing operations to take place. This additional downtime further increases the costs associated with performing a die plate replacement operation.

[0028] In contrast, the die plate exchange system 70, and in particular the frame 75, is configured to heat both the first die plate 25 and the second die plate 50 when they are disposed in the first recess 82a and the second recess 82b, respectively. As a result, one of the die plates 25, 50 can be brought to temperature before installation in order to replace the other of the die plates 25, 50 in fluid communication with the diverter valve 14 and the pelletizer 100, thus eliminating a time-consuming step in die plate replacement that was previously required. To perform this function, the die plate exchange system 70 can include multiple passages and valves for controlling the flow of heated liquid through the die plate exchange system 70. The heated liquid can be heated oil or heated water, although other liquids are contemplated.

[0029] To supply heated liquid to the first die plate 25, the die plate exchange system 70 can include a first input passage 140 defined by the frame 75 and extending from a first input valve 148 to the first input 86a. The first input passage 140 can be configured to receive heated liquid from a heated liquid source (not shown) and direct the heated liquid to the first input 86a of the plate. When the first input valve 148 is in fluid communication with the first input 86a, the first input valve 148 can be configured to control the flow of heated liquid to the first input passage 140 and the first input 86a. For example, the first input valve 148 can be configured to allow heated liquid to flow to the first input 86a during a die plate heating operation and selectively block heated liquid from flowing to the first input 86a during a liquid draining operation, as will be further described below.

[0030] As mentioned above, the frame 75 may include a first input 86a configured to receive heated liquid from the first input passage 140. The frame 75 may further include a first input passage 90a extending from the first input 86a to the first recess 82a. When the first input valve 148 is opened, the first input passage 90a is configured to receive heated liquid from the first input 86a and provide heated liquid to the first die plate 25. Specifically, the first input passage 90a may be in fluid communication with the input passage 43 of the first die plate 25, which directs heated liquid to the channel 40 of the first die plate 25 and then to the first output passage 37a and the second output passage 37b of the first die plate 25. The frame may also define a first output passage 92a and a second output passage 92b, each of which extends from the first recess 82a to a first output 94a and a second output 94b, respectively. The first output passage 92a and the second output passage 92b may be configured to receive heated liquid from the first die plate 25, specifically from the first output passage 37a and the second output passage 37b of the first die plate 25, and direct the heated liquid to the first output 94a and the second output 94b, respectively. The die plate exchange system 70 may further include a first output passage 172 extending from the first output 94a and the second output 94b to a first output valve 176. Specifically, the first output passage 172 may include a first branch 172a extending from the first output 94a and a second branch 172b extending from the second output 94b. When the first output valve 176 is in fluid communication with the first output 94a and the second output 94b, the first output valve 176 may be configured to selectively control the flow of heated liquid from the frame 75 through the first output valve 176 to either supply heated liquid or return the heated liquid to an area (not shown) that collects used heated liquid.For example, the first output valve 176 can be configured to allow heated liquid to flow through the first output valve 176 during a die plate heating operation, as well as to selectively prevent heated liquid from flowing through the first output valve 176 during a liquid drainage operation, as described further below.

[0031] The die plate exchange system 70 may include additional components that may be utilized for the discharge operation of the first die plate 25. This may be done when the first die plate 25 is no longer in operation and the operator of the pelletizing system 10 needs to remove the first die plate 25 from the frame 75, such as to install a new die plate or perform maintenance on the first die plate 25. The die plate exchange system 70 may include a first discharge passage 144 extending from the first input passage 140 to the first discharge valve 152, and a first ventilation passage 180 extending from the first output passage 172. When the first input valve 148 and the first output valve 176 are closed and the first discharge valve 152 is opened, heated liquid may flow from within the frame 75 and the first die plate 25 through the first discharge passage 144 and out of the die plate exchange system 70. The first ventilation passage 180 can allow air to flow through the frame 75 and the first die plate 25 to replace the heated liquid exiting the frame 75 and the first die plate 25 through the first exhaust passage 144.

[0032] Continuing with FIGS. 3-5, to supply heated liquid to the second die plate 50, the die plate exchange system 70 can include a second input passage 156 defined by the frame 75 and extending from the second input valve 164 to the second input 86b. The second input passage 156 can be configured to receive heated liquid from a heated liquid source (not shown) and direct the heated liquid to the second input 86b of the frame 75. When the second input valve 164 is in fluid communication with the second input 86b, the second input valve 164 can be configured to control the flow of heated liquid to the second input passage 156 and the second input 86b. For example, the second input valve 164 can be configured to allow heated liquid to flow to the second input 86b during a die plate heating operation, as well as selectively block heated liquid from flowing to the second input 86b during a liquid draining operation, as will be further described below.

[0033] As mentioned above, the frame 75 may include a second input 86b configured to receive heated liquid from the second input passage 156. The frame 75 may further include a second input passage 90b extending from the second input 86b to the second recess 82b. When the second input valve 164 is opened, the second input passage 90b is configured to receive heated liquid from the second input 86b and provide heated liquid to the second die plate 50. Specifically, the second input passage 90b may be in fluid communication with the input passage 69 of the second die plate 50, which directs heated liquid to the channel 68 of the second die plate 50 and then to the first output passage 67a and the second output passage 67b of the second die plate 50. The frame 75 may also define a third output passage 92c and a fourth output passage 92d, each of which extends from the second recess 82b to the third output passage 94c and the fourth output passage 94d, respectively. The third output passage 92c and the fourth output passage 92d may be configured to receive heated liquid from the second die plate 50, specifically from the first output passage 67a and the second output passage 67b of the second die plate 50, and direct the heated liquid to the third output 94c and the fourth output 94d, respectively. The die plate exchange system 70 may further include a second output passage 184 extending from the third output 94c and the fourth output 94d to a second output valve 188. Specifically, the second output passage 184 may include a first branch 184a extending from the third output 94c and a second branch 184b extending from the fourth output 94d. When the second output valve 188 is in fluid communication with the third output 94c and the fourth output 94d, the second output valve 188 may be configured to selectively control the flow of heated liquid from the frame 75 through the second output valve 188 to either supply the heated liquid or return it to a used heated liquid collection area (not shown).For example, the second output valve 188 can be configured to allow heated liquid to flow through the second output valve 188 during a die plate heating operation, as well as to selectively prevent heated liquid from flowing through the second output valve 188 during a liquid drainage operation, as described further below.

[0034] The die plate exchange system 70 may include additional components that may be utilized for the discharge operation of the second die plate 50. This may be done when the second die plate 50 is no longer in operation and the operator of the pelletizing system 10 needs to remove the second die plate 50 from the frame 75, such as to install a new die plate or perform maintenance on the second die plate 50. The die plate exchange system 70 may include a second discharge passage 160 extending from the second input passage 156 to the second discharge valve 168, and a second ventilation passage 192 extending from the second output passage 184. When the second input valve 164 and the second output valve 188 are closed and the second discharge valve 168 is opened, heated liquid may flow from within the frame 75 and the second die plate 50, through the second discharge passage 160, and out of the die plate exchange system 70. The second ventilation passage 192 can allow air to flow through the frame 75 and the second die plate 50 to replace the heated liquid exiting the frame 75 and the second die plate 50 through the second exhaust passage 160.

[0035] As explained above, the die plate exchange system 70 can include a system of two fluidly isolated passages for heating the first and second die plates 25 and 50 and the frame 75 using heated liquid. This allows the first and second die plates 25 and 50 to be heated or to drain and remove heated liquid from the frame 75 independently of each other, thus allowing the die plates to be pre-installed and brought up to temperature for use in future operations before removing from operation the die plates currently in fluid communication with the diverter valve 14 and pelletizer 100. As a result, the time required to perform a die plate exchange operation is significantly reduced, which in turn reduces the associated pelletizing operation costs.

[0036] Another embodiment of the pelletizing system 310 will now be described with reference to Figures 6A-8. The pelletizing system 310 may include a diverter valve 314 in fluid communication with an extruder (not shown), the diverter valve 314 configured to receive a flow of liquid material L from the extruder. The diverter valve 314 may define a body extending from a first end 314a to a second end opposite the first end 314a along the longitudinal direction 2, as well as a passageway 318 extending through the diverter valve 314 from the first end 314a to the second end 314b. The passageway 318 may be configured to receive a flow of liquid material L from the extruder at the first end 314a such that the flow of liquid material L flows through the passageway 318 of the diverter valve 314 along the longitudinal direction 2. A bypass valve 320 may be attached to the diverter valve 314 and in fluid communication with the passageway 318. The bypass valve 320 can be configured to selectively divert the flow of liquid material L from the passage 318 to an apparatus for recycling or disposal, such as during interruptions in the pelletizing operation or when components of the pelletizing system 310 are being repaired or replaced.

[0037] The first die plate 325 can be positioned adjacent the second end 314b of the diverter valve 314 such that the first die plate 325 is configured to receive the flow of liquid material L exiting the passages 318 of the diverter valve 314. The first die plate 325 can be supported by a frame 375 of a die plate exchange system 370, the first die plate 325 and the second die plate 350, and the die plate exchange system 370 being discussed further below. The first die plate 325 can have a body 328 defining a plurality of passages 331 extending therethrough. Each of the passages 331 can define a diameter that correlates to a diameter of the pellets P produced by the pelletizing system 310. In conjunction with other features of the pelletizing system 310, the diameter of each of the passages 331 can be significantly smaller than the diameter of the passages 318 of the diverter valve 314. The stream of liquid material L can be pressurized to an extent that it is forced through passages 331 in the first die plate 325 to produce elongated rods of liquid material L. The liquid material L is then extruded to an output line 424, as described further below.

[0038] The pelletizing system 310 may further include a pelletizer 400. The pelletizer 400 may include a motor 404 and a shaft 408 extending from the motor 404 to a cutting head 412. The cutting head 412 may be positioned adjacent to the first die plate 325 in the cutting chamber 422 on a side of the first die plate 325 opposite the diverter valve 314. During operation, the motor 404 of the pelletizer 400 may be configured to rotate the cutting head 412 via the shaft 408. The cutting head 412 may include multiple blades such that the cutting head 412 is configured to cut the elongated rod of liquid material L exiting the first die plate 325 into separate pellets P of a particular length. The length of the pellets P created by the cutting head 412 may be increased and decreased by adjusting the rotational speed of the cutting head 412.

[0039] Continuing with FIGS. 6A-8, the pelletizing system 310 can include an input line 420 that defines a water input 416. The input line 420 can be configured to receive water W from a water source (not shown) through the water input 416, which can be configured to provide room temperature or cooler water W to the pelletizing system 310. The input line 420 is configured to direct the water W through the pelletizing system 310 to a cutting chamber 422. The cutting chamber 422 can be configured to receive the cutting head 412 and can be positioned adjacent an end of the first die plate 325 opposite the diverter valve 314. The cutting chamber 422 can be configured to receive both the flow of water W from the input line 420 and the pellets P cut by the cutting head 412. When the pellets P are placed in contact with the water W, the water W serves multiple purposes. First, because the water W may have a significantly lower temperature than the pellets P immediately after they exit the first die plate 325 and are cut by the cutting head 412, the water W may cool the pellets P such that the pellets P maintain the size and shape as they were cut. Second, the flow of water W may carry the pellets P away from the cutting head 412 through the pelletizing system 310. Specifically, the flow of water W and pellets P may flow upwardly from the cutting chamber 422 into an output line 424 along the vertical direction 6. The output line 424 may extend from the cutting chamber 422 to a slurry output 428. From the slurry output 428, the mixture of pellets P and water W may flow to a pellet dryer (not shown), which may function to separate the water W from the pellets P, providing a supply of substantially dry pellets P to an operator of the pelletizing system 310.

[0040] As noted above, the first die plate 325 can include a body 328 and a number of passages 331 extending through the body 328 along the longitudinal direction 2. In the illustrated embodiment, the passages 331 are positioned in a substantially ring-like arrangement, although it is contemplated that in other embodiments, the passages 331 can be alternatively positioned. The passages 331 can define substantially cylindrical elongated holes that can be designed with a diameter that corresponds to the intended diameter of the pellets P to be produced by the pelletizing system 310. As a result, the passages 331 can have alternative sizes and / or shapes to produce pellets P having other sizes. Additionally, while the first die plate 325 is illustrated as defining a particular number of passages 331, in other embodiments, the first die plate 325 can define any number of passages.

[0041] The first die plate 325 may further define a plurality of holes 334 extending radially through an outer surface of the body 328 of the first die plate 325. Each of the holes 334 may be spaced about the circumference of the first die plate 325, although other locations for the holes 334 are contemplated. The holes 334 may each be configured to receive a fastener 335 to secure the first die plate 325 to a frame 375 of the die plate exchange system 370, which is further described below. The fasteners 335 may be bolts, screws, pins, or any conventional fastener capable of extending through the respective holes 334 to releasably couple the first die plate 325 to the frame 375. In contrast to the first and second die plates 25, 50, which are configured to heat through receiving a flow of heated oil, the first die plate 325 can define a plurality of cartridge passages 337 extending radially through an outer surface of the body 328, each cartridge passage 337 configured to receive a respective heating cartridge 388. The heating cartridges 388 can be various types of electric heating cartridges. When energized, the heating cartridges 388 can be configured to heat the first die plate 325 before and after it is placed in fluid communication with the diverter valve 314 and the pelletizer 400. As shown, the outer periphery of the body 328 defines an alternating arrangement of holes 334 and cartridge passages 337. However, it is contemplated that other arrangements and numbers of holes 334 and cartridge passages 337 can be utilized.

[0042] The pelletizing system 310 may also include a second die plate 350. The second die plate 350 may comprise a body 358 and a number of passages 361 extending through the body 358 along the longitudinal direction 2. In the illustrated embodiment, the passages 361 are positioned in a substantially ring-like arrangement, although it is contemplated that in other embodiments, the passages 361 may be alternatively positioned. The passages 361 may define substantially cylindrical elongated holes that may be designed with a diameter corresponding to the intended diameter of the pellets P to be produced by the pelletizing system 310. As a result, the passages 361 may have alternative sizes and / or shapes to produce pellets P having other sizes. Additionally, while the second die plate 350 is illustrated as defining a particular number of passages 361, in other embodiments, the second die plate 350 may define any number of passages.

[0043] The second die plate 350 may further define a plurality of holes 364 extending radially through an outer surface of the body 358 of the second die plate 350. Each of the holes 364 may be spaced about the circumference of the second die plate 350, although other locations for the holes 364 are contemplated. The holes 364 may each be configured to receive a fastener 335 to secure the second die plate 350 to a frame 375 of the die plate exchange system 370. Like the first die plate 325, the second die plate 350 may define a plurality of cartridge passages 367 extending radially through an outer surface of the body 358, each cartridge passage 367 configured to receive a respective heating cartridge 388. When energized, the heating cartridges 388 may be configured to heat the second die plate 350 before and after it is placed in fluid communication with the diverter valve 314 and the pelletizer 400. As shown, the periphery of the body 358 defines an alternating arrangement of holes 364 and cartridge passages 367. However, it is contemplated that other arrangements and numbers of holes 364 and cartridge passages 367 may be utilized.

[0044] Continuing with Figures 6A-8, the die plate exchange system 370 will be described in more detail. The die plate exchange system 370 can be configured to hold the first die plate 325 and the second die plate 350 and selectively transition the first die plate 325 and the second die plate 350 into and out of communication with the diverter valve 314. The die plate exchange system 370 can include a frame 375, which includes a body 378. The body 378 can define a first recess 382a and a second recess 382b extending into the body 378. The first recess 382a is configured to receive the first die plate 325 and the second recess 382b is configured to receive the second die plate 350. A portion of the first recess 382a and the second recess 382b can extend completely through the body 378, such that when the first die plate 325 and the second die plate 350 are disposed within the first recess 382a and the second recess 382b, a flow of the liquid material L can flow through the passages 331, 361 of one of the first die plate 325 and the second die plate 350. Further, each of the heating cartridges 388 can extend at least partially through the frame 375 and into one of the first die plate 325 and the second die plate 350, such that the plurality of heating cartridges 388 are configured to heat the frame 375 and the first die plate 325 and the second die plate 350.

[0045] One of the first and second die plates 325 and 350, which are in fluid communication with the diverter valve 314 and the pelletizer 400 during the pelletizing operation, can be configured to couple the frame 375 and the first and second die plates 325 and 350 to the diverter valve 314. Specifically, the first die plate 325 can define a number of holes 396a, each configured to receive a fastener 398 to couple the frame 375 and the first die plate 325 to the diverter valve 314. Similarly, the second die plate 350 can define a number of holes 396b, each configured to receive a fastener 398 to couple the frame 375 and the second die plate 350 to the diverter valve 314. The fastener 398 can be a bolt or any other type of conventional fastener capable of releasably coupling the first and second die plates 325 and 350 to the diverter valve 314. Additionally, although a particular number and configuration of holes 396a, 396b are shown, the holes 396a, 396b can have other designs and / or arrangements as desired.

[0046] As with pelletizing system 10, during operation of pelletizing system 310, only one of first die plate 325 and second die plate 350 is in fluid communication with diverter valve 314 and pelletizer 400. In previous pelletizing systems, the system would have to be disassembled to repair and / or replace a die plate. In pelletizing system 310, die plate exchange system 370 can easily transition between positioning of first die plate 325 and second die plate 350 in fluid communication with other aspects of pelletizing system 310. To do this, die plate exchange system 370 can include a movement assembly 430 operably coupled to frame 375 and configured to selectively move frame 375 between a plurality of positions. For example, the translation assembly 430 can be configured to move the frame 375 between a first position in which the first die plate 325 is configured to receive the liquid material from the diverter valve 314 and a second position in which the second die plate 350 is configured to receive the material from the diverter valve 314. The first position is explicitly shown in Figures 6A-8.

[0047] The moving assembly 430 of the pelletizing system 310 is configured to rotate the frame 375 between a first position and a second position. To do so, the moving assembly 430 can include a support structure 438 and a pivot 434 coupled to the frame 375 and the support structure 438. The support structure 438 is depicted as a metal beam, although other types of support structures 438 are contemplated. The pivot 434 can be configured to extend through a pivot hole 399 defined by the frame 375 to selectively rotate the frame between the first position and the second position. The pivot 434 can be configured to rotate the frame 375 about an axis that is substantially parallel to the longitudinal direction 2, although other orientations for this axis are contemplated. In one embodiment, the frame 375 is configured to be manually transitioned between the first position and the second position. However, it is also contemplated that the die plate exchange system 370 can include automated means, such as a motor, for transitioning the frame 375 between the first position and the second position.

[0048] A method of replacing a die plate 25, 50, 325, 350 in a pelletizing system 10, 310 will now be described with reference to FIG. 9. The method 900 begins at step 904 and includes heating a first die plate 25, 325 in a frame 75, 375. Heating the first die plate 25 at step 904 can include providing a heated liquid to the first die plate 25. Alternatively, heating the first die plate 325 at step 904 can include powering the heating cartridge 388. After step 904, at step 908, material is provided to the first die plate 25, 325 from the diverter valve 14, 314 when the frame 75, 375 is in a first position. Then, at step 912, a second die plate 50, 350 is heated in the frame 75, 375. After step 912, step 916 includes moving the frame 75, 375 from a first position to a second position. In one embodiment, moving the frame 75 includes translating the frame linearly from the first position to the second position. Moving the frame 75, 375 in step 916 can be performed manually. Alternatively, moving the frame 75 in step 916 can be performed automatically using the motor 212. Furthermore, moving the frame 375 can include rotating the frame 375 from the first position to the second position. Then, step 920 is performed, which includes providing material to the second die plate 50, 350. Step 920 can include providing a heated liquid to the second die plate 50. Alternatively, step 920 can include powering a plurality of heating cartridges 388.

[0049] Although various inventive aspects, concepts, and features of the invention may be described and illustrated herein as embodied in combination in exemplary embodiments, these various aspects, concepts, and features may be used in many alternative embodiments, either individually or in their various combinations and subcombinations. All such combinations and subcombinations are intended to be within the scope of the invention, unless expressly excluded herein. Furthermore, although various alternative embodiments of the various aspects, concepts, and features of the invention may be described herein, such as alternative materials, structures, configurations, methods, circuits, devices and components, software, hardware, control logic, form, fit, and function alternatives, and the like, such descriptions are not intended to be a complete or comprehensive list of available alternative embodiments, whether currently known or later developed. In addition, although some features, concepts, or aspects of the invention may be described herein as being preferred arrangements or methods, such descriptions are not intended to imply that such features are required or necessary, unless expressly so stated. Furthermore, while example or representative values ​​and ranges may be included to aid in understanding the present disclosure, such values ​​and ranges should not be construed in a limiting sense, and are intended to be definitive values ​​or ranges only if so explicitly stated. Furthermore, although various aspects, features, and concepts may be expressly identified herein as being inventive or forming part of the present invention, such identification is not intended to be exclusive; rather, there may be aspects, concepts, and features of the invention fully described herein without being expressly identified as such a particular invention or part thereof, and instead the invention is described in the appended claims or in the claims of related or continuing applications. The description of an exemplary method or process is not limited to including all steps as required in all cases, nor is the order in which the steps are depicted construed as required or necessary unless expressly stated as such.Although the invention is described herein with respect to a limited number of embodiments, these specific embodiments are not intended to limit the scope of the invention as otherwise described and claimed herein. The exact arrangement of the various elements and order of steps of the articles and methods described herein should not be considered limiting.

Claims

1. 1. A die plate exchange system configured to hold a first die plate and a second die plate and selectively transition the first die plate and the second die plate into and out of communication with a material source, the die plate exchange system comprising: a frame having a body defining a first recess configured to receive the first die plate and a second recess configured to receive the second die plate, the first die plate and the second die plate being disposed in the first recess and the second recess, respectively, and being heated; a movement assembly operably coupled to the frame and configured to selectively move the frame between a first position, where the first die plate is configured to receive material from the material source, and a second position, where the second die plate is configured to receive the material from the material source.

2. 2. The die plate exchange system of claim 1, wherein the frame is configured to heat the first die plate and the second die plate when the first die plate and the second die plate are disposed in the first recess and the second recess, respectively.

3. the frame includes a first input, a first input passage extending from the first input to the first recess, a second input, and a second input passage extending from the second input to the second recess; 3. The die plate exchange system of claim 2, wherein the first input passage is configured to receive heated liquid from the first input and supply the heated liquid to the first die plate, and the second input passage is configured to receive heated liquid from the second input and supply the heated liquid to the second die plate.

4. the frame includes a first output, a first output passage extending from the first recess to the first output, a second output, and a second output passage extending from the second recess to the second output; 4. The die plate exchange system of claim 3, wherein the first output passage is configured to receive the heated liquid from the first die plate and direct the heated liquid to the first output, and the second output passage is configured to receive the heated liquid from the second die plate and direct the heated liquid to the second output.

5. a first valve in fluid communication with the first input and configured to selectively prevent the heated liquid from flowing to the first input; 5. The die plate exchange system of claim 4, further comprising: a second valve in fluid communication with the second input and configured to selectively block the heated liquid from flowing to the second input.

6. a third valve in fluid communication with the first output and configured to selectively prevent the heated liquid from flowing through the third valve; 6. The die plate exchange system of claim 5, further comprising: a fourth valve in fluid communication with the second output and configured to selectively prevent the heated liquid from flowing through the fourth valve.

7. Further comprising a support structure, 2. The die plate exchange system of claim 1, wherein the translation assembly comprises a linear track coupled to the support structure, and the frame is configured to selectively translate the linear track between the first position and the second position.

8. The die plate exchange system of claim 7 , wherein the frame is configured to be manually transitioned between the first position and the second position.

9. 8. The die plate exchange system of claim 7, further comprising a motor operably connected to the frame and configured to move the frame along the linear track between the first position and the second position.

10. 10. The die plate exchange system of claim 1, wherein the frame defines a plurality of holes configured to receive a plurality of fasteners configured to secure the first die plate and the second die plate to the frame.

11. The die plate exchange system of claim 1 , wherein the frame defines a plurality of holes configured to receive a plurality of fasteners configured to secure the frame to the source of material.

12. Further comprising a support structure, 2. The die plate exchange system of claim 1, wherein the translation assembly comprises a pivot coupled to the support structure, the pivot configured to selectively rotate the frame between the first position and the second position.

13. The die plate exchange system of claim 12 , wherein the frame is configured to be manually transitioned between the first position and the second position.

14. 2. The die plate exchange system of claim 1, further comprising a plurality of heating cartridges configured to extend at least partially through the frame and into one of the first die plate and the second die plate such that the plurality of heating cartridges heat the frame and the first die plate and the second die plate.

15. 1. A method for replacing a die plate in a pelletizing system, comprising: Heating the first die plate; providing material to the first die plate when the frame is in a first position; heating the second die plate; moving the frame from the first position to a second position; providing said material to said second die plate.

16. 16. The method of claim 15, wherein heating the first die plate comprises heating the first die plate within a frame, and heating the second die plate comprises heating the second die plate within the frame.

17. heating the first die plate includes providing a heated liquid to the first die plate; The method of claim 14 , wherein heating the second die plate comprises providing the heated liquid to the second die plate.

18. The method of claim 15 , wherein moving the frame comprises linearly translating the frame from the first position to the second position.

19. The method of claim 15 , wherein moving the frame comprises manually moving the frame.

20. The method of claim 15 , wherein moving the frame comprises automatically moving the frame using a motor.

21. heating the first die plate includes powering a plurality of heating cartridges; The method of claim 15 , wherein heating the second die plate comprises powering the plurality of heating cartridges.

22. The method of claim 15 , wherein moving the frame includes rotating the frame from the first position to the second position.

Images