Scrap Sorting with Size Classification and Object Singulation

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Solution Overview

Problem

The existing recycling methods for scrap materials, particularly aluminum, involve manual sorting and long-distance transport, which are labor-intensive, environmentally costly, and subject to export/import restrictions, necessitating a more efficient and cost-effective local recycling process.

Innovation Solution

A method involving shredding scrap into objects with maximum pass-through dimensions of 50-200 mm, followed by classification and sorting while maintaining interspace between objects, using a shredder, classifier, and sorter to facilitate automated selection and reduce manual handling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If scrap material is shredded into small pieces and buffered for transport, then volume is reduced and transport efficiency is improved, but manual sorting labor and long-distance transport requirements increase

Engineering Contradiction:

Improvescrap volumeVSAvoidmanual sorting labor

Core Design Contradiction:

Volume of moving objectVSEase of operation

Solution Approach 1:

The scrap processing is segmented into distinct size fractions using classifiers with different screen openings. The method separates scrap into multiple size ranges (e.g., first fraction with larger objects, second fraction with smaller objects), allowing automated processing of different fractions through appropriate equipment rather than manual sorting of uniformly small pieces.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention introduces size classification as an additional dimension to the processing workflow. By classifying scrap into different size fractions before further processing, the system adds a classification stage that enables automated handling and reduces manual labor requirements while managing volume efficiently.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Loss of energy

If scrap is shredded to small sizes for compact bulk transport, then transport cost and energy consumption are reduced, but the need for manual selection and processing increases

Engineering Contradiction:

Improvetransport energyVSAvoidautomated sorting

Core Design Contradiction:

Loss of energyVSExtent of automation

Solution Approach 1:

The scrap stream is segmented into different size fractions using classifiers. Each fraction can be directed to appropriate automated processing equipment or recycling streams, enabling automation rather than manual selection while managing transport efficiency through size-based separation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the size parameter of scrap objects through controlled shredding and classification. By creating specific size distributions with defined maximum dimensions for different fractions, the system optimizes both transport efficiency and automated processing capability.

Inventive Principle:

Principle #35Parameter changes

3Measurement precision

If manual sorting is used to select specific scrap objects, then sorting precision is improved, but productivity decreases and labor costs increase

Engineering Contradiction:

Improvesorting precisionVSAvoidsorting throughput

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The sorting process is segmented into automated classification stages based on size fractions. Classifiers with different screen openings automatically separate scrap into predefined size ranges, providing sufficient precision for recycling purposes while dramatically increasing throughput compared to manual sorting.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Manual mechanical sorting is replaced with automated classification systems. The invention uses mechanical classifiers and automated handling equipment to perform sorting functions that previously required human labor, maintaining adequate precision while vastly improving productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Adaptability or versatility

If long-distance transport is used to move scrap to recycling locations, then local recycling capacity is improved, but export/import restrictions and environmental impact increase

Engineering Contradiction:

Improverecycling capacityVSAvoidenvironmental impact

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The invention performs preliminary size classification and fractionation at or near the scrap source before transport. By pre-processing scrap into standardized size fractions with defined maximum dimensions, the system enables local recycling operations to handle the material efficiently without requiring long-distance transport of bulk scrap, reducing environmental impact and avoiding trade restrictions.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12551929B2Recycling of scrap

Publication Date: 2026.02.17 REUKEMA PARTICIPATIONS BV

AI summary

A method of recycling scrap is disclosed, comprising the steps of shredding the scrap with a shredder into shredded scrap objects, classifying the shredded scrap objects into fractions of scrap objects having different size ranges with a classifier, and sorting scrap objects while substantially maintaining interspace between the objects. Further, a singulating arrangement for singulating scrap objects is disclosed, comprising a substantially horizontally disposed feeder that extends from a receiving area for receiving scrap objects to a feed gate positioned at a top portion of a chute, as well as an ejector arrangement, comprising a conveyor with a substantially flat conveying plane and an ejector device disposed along the conveyor.