Retrofitting Balers with Load-Cell Sensors for OCC Weight Measurement
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Solution Overview
Problem
Retailers lack the capability to produce bales of consistent size and weight for recyclable materials like old corrugated containers (OCC), leading to inefficiencies in transportation, economic losses, and potential regulatory issues due to under or overloading of shipping containers.
Innovation Solution
A system combining a baler, scale, identification system, and processors to compact and weigh OCC on-site, producing bales of consistent size and weight, and assigning identifiers for accurate inventory management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If retailers use simpler balers without weighing capability, then the device complexity is reduced and ease of operation is improved, but manufacturing precision of bale weight and measurement precision of waste weight deteriorate
Solution Approach 1:
The patent introduces an intermediary weighing system (scale and sensor) between the baler and the ground to measure the weight of compacted material without requiring the baler itself to have inherent weighing capability. This mediator enables precise measurement while keeping the baler design simple and easy to operate.
2Productivity
If retailers produce bales without precise weighing capability, then device complexity is reduced, but productivity is improved through simpler operations, however loss of substance occurs due to inefficient container loading
Solution Approach 1:
The patent implements a feedback mechanism where the weighing system continuously monitors the weight of compacted material and provides this information to the operator or control system. This feedback enables real-time adjustments to achieve optimal bale weights that maximize container utilization, preventing both underloading and overloading.
Solution Approach 2:
The patent replaces manual estimation and rough mechanical balancing methods with electronic sensing and digital weighing technology. Load cells or weight sensors provide precise electronic measurement, substituting for traditional mechanical balance systems and enabling more accurate control of bale weight.
3Measurement precision
If retailers install weighing systems on existing balers, then measurement precision is improved, but device complexity increases and ease of manufacture deteriorates
Solution Approach 1:
The patent incorporates weighing components (scale, load cells, sensors) into the baler design during the manufacturing stage rather than adding them as retrofits. This preliminary integration ensures proper structural support, electrical connections, and calibration are built-in from the start, making the system easier to manufacture as a complete unit rather than modifying existing equipment.
4Ease of operation
If retailers use unverified weight reporting from haulers, then device complexity is reduced and ease of operation is improved, but loss of information occurs regarding accurate weight data
Solution Approach 1:
The patent enables the retail facility to perform its own weight measurement and verification independently, without relying on external haulers to provide weight data. The on-site weighing system allows the retailer to self-monitor, self-record, and self-verify the weight of recyclable materials, eliminating information asymmetry and building trust in the transaction.
Data Source
AI summary
A recycling method is disclosed that includes the steps of compacting recyclable material into a fixed bale of recyclable material while concurrently weighing the OCC in the compactor and independently of the force that the compactor applies to the material or to the bale, assigning an individual identifier to the fixed bale in which the identifier includes at least the weight of the bale, and sending the fixed identified bale to a destination selected from the group consisting of shippers, mills, rebalers, or a customers for the baled recyclable material. Also, devices and methods are disclosed for upgrading existing or new balers to enable them to perform at least some portions of the improved recycling methods. Example devices include baler-mounted load-cell weight sensors and U-shaped anchor plates for securing them in place in a free-floating arrangement.