Shredder Base Plate Flap for Coarse Waste Discharge
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Solution Overview
Problem
Existing waste shredding devices face inefficiencies due to the need to interrupt the comminution process when a coarse part cannot be comminuted, leading to long downtimes and reduced efficiency.
Innovation Solution
The device incorporates an openable base plate with a pivotable flap for discharging coarse parts by gravity, along with a toggle lever system for efficient force transmission, and multiple feed slides for continuous operation, allowing for the automatic recognition and discharge of coarse parts without interrupting the shredding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a coarse part that cannot be comminuted blocks the cutting rotor, then the comminution process must be interrupted to remove the blockage, but this results in long downtimes that reduce efficiency
Solution Approach 1:
The base plate is segmented into a fixed portion and a movable flap portion that can be independently opened. This allows the flap to be opened specifically for discharge of coarse parts without interrupting the comminution process in the main chamber, enabling continuous operation while removing blockages
Solution Approach 2:
The movable flap extracts the discharge function from the base plate structure, creating a separate egress path for coarse parts. This allows coarse parts to be removed through the flap without requiring interruption of the main comminution process or manual access to the cutting rotor area
2Productivity
If a movable flap is added to the base plate for discharging coarse parts, then continuous operation is enabled, but the device complexity increases due to the toggle lever mechanism
Solution Approach 1:
The flap is designed as a movable component that transitions between closed and open states dynamically. The toggle lever mechanism provides dynamic force multiplication, requiring minimal actuation force to open the flap against the weight of waste material, while automatically returning to a latched closed position when actuation force is removed
Solution Approach 2:
The toggle lever mechanism automatically latches the flap in the closed position during normal operation without requiring continuous actuation force. The mechanical advantage of the toggle lever system causes the flap to self-latch when closed, eliminating the need for additional locking mechanisms or continuous power input to maintain the closed state
3Force
If the flap is held closed during operation with high forces acting on it, then waste is contained, but significant holding force is required to maintain the closed state
Solution Approach 1:
The toggle lever mechanism transforms the static holding force requirement into a dynamic mechanical advantage system. When the flap is closed, the toggle lever geometry creates a self-latching effect where the force required to keep the flap closed is minimal, as the system naturally settles into a stable closed position due to the mechanical advantage of the lever arms
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
This design enables continuous shredding operations without downtime, enhances throughput, and reduces wear on the cutting rotor by allowing coarse parts to be discharged while maintaining the comminution of crushable waste, thereby improving overall efficiency and reducing maintenance costs.
Implementation Method 1
The flap is expediently designed to be pivotable downwards. In this way, the coarse part can be discharged by gravity.
Implementation Method 2
A lower toggle lever is advantageously provided, which is connected at a first end to the at least one flap so that it can rotate about a first axis. Toggle levers have proven their worth in order to use a lever principle to carry out clamping processes that require high forces.
Implementation Method 3
a cutting rotor which can be driven by the motor and has at least one cutting edge
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The device (1) has a cutting rotor (3) driven by a motor and provided with a blade (4) and a base plate (6). A cutting profile of the cutting rotor cooperates with a counter part (7) i.e. counter blade. The counter part is formed by the cutting profile or fastened at the base plate or adapted to the cutting profile. The base plate comprises an openable flap (8) to deliver a rough part. A lower toggle lever is provided for opening the flap. The lower toggle lever is brought into a stable position, in which the lower toggle lever holds the flap in a form-fit manner. An independent claim is also included for a method for cutting wastes such as splinters.