Hopper Ram Bulk Material Loader for Container Space Utilization
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Solution Overview
Problem
Current methods for loading bulk materials like scrap metal into freight containers are inefficient, as they often result in underutilization of space, damage to containers, and require costly and complex equipment with many moving parts, especially when dealing with irregularly shaped materials like Heavy Melting Scrap (HMS).
Innovation Solution
A bulk material loader apparatus comprising a hopper with a ram and a reciprocating conveyor floor system, where the hopper is sized to fit within the container and equipped with a hydraulic driver to efficiently push material into the container, reducing the need for complex mechanisms and minimizing container damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conveyer belt is used to load bulk material into the container, then the material can be transported into the container, but the irregular shaped bulk material cannot be properly transported and requires further shredding or size reduction
Solution Approach 1:
The loading apparatus divides the loading process into two distinct phases: a loading phase where the hopper receives and stores bulk material, and a discharge phase where the material is released into the container. This segmentation allows the system to handle irregular shaped material effectively by first collecting it in the hopper and then discharging it in a controlled manner, eliminating the need for pre-shredding.
Solution Approach 2:
The apparatus employs a movable partition wall that dynamically adjusts the hopper's configuration. The partition wall can move between positions to control material flow and discharge timing, enabling the system to adapt to different material types and container configurations while maintaining ease of operation.
2Productivity
If a conveyer belt is used for loading, then material can be loaded into the container, but there is not enough clearance in the container to permit stacking bulk material beyond a certain height
Solution Approach 1:
The hopper is pre-positioned within the container before loading begins. This preliminary placement allows the material to be discharged directly into the container's available space, maximizing volume utilization from the start and eliminating the need for subsequent stacking operations that would be limited by clearance constraints.
Solution Approach 2:
The apparatus transitions from a horizontal conveying approach to a vertical discharge approach. By discharging material vertically from the hopper into the container rather than horizontally along a conveyer belt, the system充分利用 the container's vertical space and eliminates clearance limitations that would otherwise restrict stacking height.
3Productivity
If bulk material is loaded using conventional methods, then the material can be loaded into the container, but irregularly shaped pieces of material impact with the sidewalls of the container causing severe damage
Solution Approach 1:
The hopper acts as an intermediary device between the material source and the container. It receives irregularly shaped material and controls its discharge into the container, preventing direct impact with the sidewalls. The partition wall serves as an additional intermediary that guides material flow and prevents harmful impacts during the loading process.
Solution Approach 2:
The apparatus applies preliminary control measures by positioning the hopper and partition wall to guide material flow before it enters the container. This preliminary action prevents irregularly shaped pieces from impacting the sidewalls by controlling their trajectory and discharge timing, thereby preventing damage before it occurs.
4Ease of operation
If a skid loader is used to load bulk material, then the material can be carried into the container and dumped in place, but errors in operation can lead to physical injuries to workmen and damage to the sidewalls and ceiling of the container
Solution Approach 1:
The loading apparatus is designed to perform the loading operation autonomously without requiring manual intervention or complex operational controls. The hopper automatically receives and discharges material, and the partition wall dynamically adjusts to control flow, eliminating the safety risks associated with manual skid loader operation while maintaining ease of use.
Solution Approach 2:
The apparatus replaces the manual mechanical operation of a skid loader with an automated hopper system. This substitution eliminates the need for operators to manually carry and dump material, thereby removing the safety risks associated with manual handling while maintaining the capability to load bulk material efficiently.
5Ease of operation
If a skid loader is used for loading, then material can be loaded into the container, but only small skid loaders can be used because of the relatively small size of the containers, requiring operators to make numerous trips
Solution Approach 1:
The hopper is nested within the container, allowing the loading apparatus to operate inside the container's boundaries. This nesting enables the system to load material directly into the container without requiring external skid loaders to make multiple trips, thereby reducing time loss while maintaining operational ease.
Solution Approach 2:
The movable partition wall dynamically adjusts the hopper's internal configuration to optimize material discharge. This dynamic adjustment allows the hopper to efficiently load large quantities of material in fewer operations, reducing the number of trips required compared to fixed-skid-loader methods.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution allows for efficient loading of bulk materials, maximizing container space utilization while minimizing equipment wear and reducing the risk of container damage, with fewer moving parts and lower operational costs compared to existing methods.
Implementation Method 1
The driver is configured and capable of moving the plate between the first end and the open end to load the material into the shipping container. Optionally, the driver comprises a hydraulic cylinder.
Data Source
AI summary
Disclosed are apparatuses and methods for use thereof for loading bulk material into freight containers. One apparatus comprises a hopper configured to receive bulk material that is sized and shaped to be at least partially enclosable by a container to occupy a substantial volume of the container and a ram. The ram comprises a plate and a driver configured to move the plate from a back end of the hopper to an open end of the hopper to expel material into a container. Another apparatus comprises a hopper configured to receive bulk material that is sized and shaped to be at least partially enclosable by a container to occupy a substantial volume of the container and a reciprocating conveyor floor system. Optionally, the apparatuses further include a stand and/or collapsible legs to further support the hopper.