Overhead Leveler with Shafted Screw for Open-Top Container Filling

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Solution Overview

Problem

Existing overhead material handling systems face challenges in evenly distributing hazardous materials without exposing personnel, controlling odor buildup, and protecting contents from outdoor elements during the filling process of open-topped containers.

Innovation Solution

An overhead material handling system featuring a leveler with a cover, shafted screw, and bottomless trough, supported by a pivoting cover and mechanical hoist, which allows for automated and efficient distribution of materials into open-top containers, incorporating odor filtration and pest control mechanisms.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If personnel manually distribute hazardous materials into containers, then even distribution can be achieved, but personnel exposure to hazardous materials increases

Engineering Contradiction:

Improvematerial distribution evennessVSAvoidpersonnel exposure to hazardous materials

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent introduces an automated leveler system with a cover and screw mechanism as an intermediary device between the material source and container. This mechanical intermediary performs the distribution function that would otherwise require manual personnel intervention, thereby eliminating personnel exposure to hazardous materials while maintaining even distribution through the automated screw conveying mechanism.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces manual mechanical distribution with an automated mechanical leveler system. The automated screw conveyor and cover mechanism substitute for manual shoveling and spreading operations, achieving even material distribution without requiring personnel direct contact with hazardous materials.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If the container remains open-topped for easy loading, then material distribution is simplified, but odor buildup and pest attraction increase

Engineering Contradiction:

Improvematerial loading simplicityVSAvoidodor buildup and pest attraction

Core Design Contradiction:

Ease of operationVSObject-generated harmful factors

Solution Approach 1:

The patent segments the container opening into two functional zones: a covered area where material is deposited and a remaining open area for continued loading. The cover acts as a selective barrier that segments the container interior from the external environment during the critical loading phase, preventing odor escape and pest entry while maintaining loading accessibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies preliminary protective action by positioning the cover over the container opening before the loading process begins. This preliminary coverage prevents odor buildup and pest attraction from the outset, while the automated leveler system ensures material can still be successfully loaded through the covered opening.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If the leveler is manually handled for removal, then flexibility is improved, but labor requirements and safety risks increase

Engineering Contradiction:

Improveleveler removal flexibilityVSAvoidleveler handling safety and labor

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The patent implements self-service by equipping the leveler with an integrated handle attached to its cover. This allows the leveler to be easily grasped, lifted, and repositioned by the automated system itself or with minimal mechanical assistance, eliminating the need for manual handling by personnel and thereby reducing safety risks and labor requirements while maintaining operational flexibility.

Inventive Principle:

Principle #25Self-service

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

Ensures even distribution and high fill efficiency of materials within containers, reduces personnel exposure, minimizes odor buildup, and protects contents from environmental elements, enhancing safety and operational efficiency.

Implementation Method 1

receiving material through an inlet of a conduit within a cover of a leveling system, such as a rotating a shafted screw within the conduit to direct the received material around the screw and along the container

Methodology Applied

Scientific EffectScrew mechanism: Screw

Implementation Method 2

the at least one hydraulic piston functions to pivot the pivotable cover about an axis

Methodology Applied

Scientific EffectHydraulic pressure: Hydraulic Press

Implementation Method 3

the at least one mechanical hoist aids in supporting the pivotable cover

Methodology Applied

Scientific EffectMechanical advantage: Mechanical Advantage

Data Source

PatentUS10046927B2Apparatus for loading and leveling material into a container

Publication Date: 2018.08.14 JDV EQUIPMENT CORP

AI summary

A material handling system is provided that allows for the even distribution and increased fill percent of a container without the need for personnel to manually even out the distribution of the material, and contains and protects material from the environment. The system deposits and levels material into an open-top container, and may include a leveler comprising a cover, a screw coupled to the cover, and a trough. The screw may be a shafted screw and the trough may be a bottomless trough. A hydraulic piston may be coupled to the cover and a support structure may both support and move the cover of the leveler.