Shredder Hammer Replacement With Integrated Remote Lifting Control
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Solution Overview
Problem
Current methods for changing hammers in shredders are complex, demanding significant operator involvement and pose safety risks due to the need for manual control of cranes and limited visibility, requiring multiple systems and personnel.
Innovation Solution
A system and method for changing hammers that integrates a single control unit to manage both the lifting system and shredder operations, utilizing hydraulic or robotic arms with remote control, and includes an electronic safety control to enhance safety and automation, reducing the need for on-site operators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a fixed service crane with manual controls is used for hammer change, then the crane can handle heavy hammers (90-150 kg), but the operator has limited visibility and must be present on site, increasing safety risks and operational complexity
Solution Approach 1:
The patent replaces manual mechanical crane controls with an automated robotic arm system equipped with sensors and programmable control. The robotic arm can be controlled remotely or autonomously, eliminating the need for an operator to be physically present near the crane controls, thereby improving visibility and reducing safety risks while maintaining the ability to handle heavy hammers
Solution Approach 2:
The patent introduces a remote control station as an intermediary between the operator and the crane/robotic arm. This allows the operator to control the heavy hammer handling equipment from a safe distance with full visibility, eliminating the visibility limitations and safety hazards of on-site manual control
2Adaptability or versatility
If separate control systems are used for the shredder and lifting system, then each system can be controlled independently, but the maintenance process becomes very complex and requires multiple operators
Solution Approach 1:
The patent merges the control systems of the shredder and lifting equipment into a single integrated control unit. This unified system can coordinate both the shredder operations and the hammer change process, reducing operational complexity and enabling a single operator to manage both functions simultaneously, whether through automated or manual control modes
3Device complexity
If manual control methods are used for crane operations during maintenance, then the system remains simple, but the process is time-consuming and requires significant operator involvement
Solution Approach 1:
The patent implements a dynamic control system that can operate in multiple modes: fully automated robotic arm control for high-productivity operations, or manual control for simpler tasks. This dynamic adaptability allows the system to optimize between automation and manual operation based on the specific maintenance needs, improving efficiency without requiring overly complex automated systems for all operations
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
Simplifies the hammer-changing process, enhances safety by minimizing operator presence, and reduces costs through centralized control and automation, while ensuring efficient and collision-free operations.
Implementation Method 1
a first control system to control said first lifting devices... (a1) a housing defining a shredding chamber and which is equipped with one or more covers which can be lifted and lowered by means of relative lifting devices, in particular hydraulic lifting devices
Implementation Method 2
a lifting system, preferably hydraulically operated, suitable to move said hammers by means of a second control system
Data Source
AI summary
The invention relates to a system for changing the hammers of a shredder including a shredder with one or more covers and a rotating drum equipped with a plurality of hammers; a lifting system suitable to move said hammers and a control unit which controls both the opening of the shredder and the movements of the lifting system and preferably also the unlocking/locking of the hammers from/on the drum to allow their replacement. The system can be managed hydraulically with a single hydraulic supply. It is included to be able to control the system remotely or to include its automation according to a maintenance plan. A relative method for changing the hammers of a shredder is also disclosed.