Automated Spark Plug Tip Extraction System
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Solution Overview
Problem
Current methods for recycling spark plugs are time-consuming and labor-intensive due to the lack of automated systems for mechanically separating valuable metal tips from the rest of the spark plug body, making the process economically unviable.
Innovation Solution
An automated system comprising a vibratory feeder, camera, controller, rejection system, robot arm, and cutting tool that aligns and separates spark plug tips from the main body, allowing for efficient extraction and processing of platinum group metals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual methods using abrasive cut off wheels are used to remove spark plug electrodes, then the electrodes can be separated from the spark plug body, but the process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent replaces manual mechanical operations with an automated robotic system. A robot arm equipped with a gripper automatically positions and holds spark plugs, while a cutting tool mechanically separates the electrodes from the spark plug bodies. This automation eliminates manual labor and significantly increases processing throughput while maintaining separation effectiveness.
2Productivity
If automated systems are introduced to increase recycling throughput, then productivity improves, but system complexity increases
Solution Approach 1:
The automated system is divided into distinct functional modules: a vibratory feeder for presenting spark plugs, a robot arm with gripper for positioning and holding, a cutting tool for separation, and a collection system for electrodes and bodies. This segmentation allows each component to perform its specific function efficiently while simplifying the overall system design and maintenance.
3Productivity
If spark plugs are processed in high throughput, then economic viability improves, but separation precision may be compromised
Solution Approach 1:
The vibratory feeder pre-positions spark plugs in a consistent orientation and location before they reach the cutting station. The robot arm then reliably grasps and positions each spark plug at the correct location. These preliminary positioning actions ensure that the cutting tool can accurately separate electrodes from all spark plugs processed at high speed, maintaining separation precision throughout high-volume operation.
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 system enables high-throughput, efficient separation and concentration of valuable metals, increasing the economic viability of spark plug recycling by significantly improving the recovery of platinum group metals.
Implementation Method 1
a vibratory feeder configured to receive spark plugs and to generate a feeder output stream of spark plugs as a single file of spark plugs with their long axes substantially aligned
Implementation Method 2
a camera configured to capture images of the feeder output stream of spark plugs
Implementation Method 3
a cutting tool configured to cut through each spark plug to separate its electrode tip from the remainder of the spark plug
Data Source
AI summary
An automated, high throughput system that mechanically separates electrode tips from spark plugs to facilitate recovery of platinum group metals in the electrodes. Spark plugs may be fed into the system in bulk and an automated mechanism under computer control executes a sequence of operations to feed plugs in a fixed orientation and at a controlled rate to a robot arm. The robot arm has a gripper that securely holds a set of spark plugs and passes them across a cutting tool to separate tips from the bodies. The gripper has independently actuated finger assemblies that accommodate plugs of varying shapes. A visual inspection system ensures that spark plugs are oriented with the tips facing in the same direction to simplify operation of the robot and the cutting tool. The tips may be processed to extract the contained valuable metals; the remaining bodies may be recycled as iron scrap.