Automated Cutting Machine for Plastic Composite IBC Recycling
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Solution Overview
Problem
Manual cutting of industrial tanks containing viscous liquids is inefficient, hazardous, and fails to optimize plastic volume for cleaning, leading to substandard recycling quality and increased costs.
Innovation Solution
A cutting machine with horizontal and vertical electric saws, assisted by a gripper, cuts industrial tanks into planar portions, optimizing the cutting process for safety and efficiency by rotating the tank to separate and clean each part before grinding, ensuring the plastic composite IBCs are processed hygienically and efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual cutting is used by experienced operators, then cutting precision is improved, but operator safety deteriorates and process cost increases
Solution Approach 1:
The patent replaces manual mechanical cutting operations with an automated cutting machine equipped with electric saws. The machine includes a control unit that automatically controls the cutting process, substituting human operators with automated mechanical systems to eliminate safety risks while maintaining cutting precision through programmed control
Solution Approach 2:
The cutting machine is designed to perform cutting operations autonomously without human intervention during the actual cutting process. The machine self-regulates the cutting speed, depth, and path through its control system, achieving both precision and safety through automated self-controlled operations
2Manufacturing precision
If manual cutting is used, then cutting precision can be maintained, but cutting speed deteriorates
Solution Approach 1:
The automated cutting machine with electric saws replaces manual cutting tools, enabling higher cutting speeds through powered mechanical systems while maintaining precision through automated control. The machine can operate continuously at optimized speeds without fatigue or speed limitations of manual operations
Solution Approach 2:
The cutting machine incorporates adjustable cutting parameters and dynamic control capabilities, allowing optimization of cutting speed based on material properties and desired precision. The system can dynamically adjust cutting depth, speed, and path to achieve both high speed and precision simultaneously
3Productivity
If IBC is cut into planar portions, then cleaning efficiency is improved, but device complexity increases
Solution Approach 1:
The cutting machine automatically segments the IBC into planar portions corresponding to its six faces through programmed cutting paths. This segmentation enables each face to be cleaned separately and efficiently, improving cleaning productivity while the automation reduces the operational complexity for operators
Solution Approach 2:
The cutting machine is designed with multi-functional capabilities to handle different IBC sizes and shapes through programmable control. The same machine can perform various cutting patterns and accommodate different cleaning requirements, reducing the need for multiple specialized devices
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 automated cutting machine significantly enhances operator safety, increases cutting speed, and improves the quality of recycled plastic by allowing precise separation and cleaning of residual liquids, reducing water and detergent usage, and enhancing the overall recycling efficiency.
Implementation Method 1
at least one electric saw internal to the insulating cabin and arranged to cut the plastic composite IBC
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A process for recovering industrial tanks (100) comprises a step of prearranging a tank (100) to recover, said tank (100) comprising a plastic composite IBC (110) arranged, in use, to contain liquid (10), a pallet (120) arranged to support the plastic composite IBC (110), a cage (130) arranged to wrap the plastic composite IBC (110). The plastic composite IBC (110) has a parallelepiped shape and comprises a bottom face (110a), a top face (110b) and four side walls (110c). The process also comprises the steps of removing the cage (130) and the pallet (120), cutting the plastic composite IBC (110) obtaining planar portions (115), cleaning the planar portions (115) from possible residuals of the liquid (10), grinding the planar portions (115) obtaining a plurality of residual scales of plastic composite. In particular, the cutting phase of the plastic composite IBC (110) is carried out by a cutting machine (200), said cutting machine (200) comprising at least one electric saw (220) arranged to cut the plastic composite IBC (110). In particular, the cutting step comprises the steps of arranging the plastic composite IBC (110) in the cutting machine (200), horizontal cutting along a curve γ1 joining the bottom face (110a) with the side walls (110c), vertical cutting along curves λ joining the side walls (110c), horizontal cutting along a curve Y2 joining the top face (110b) with the side walls (110c).