Vertical Refuse Baler With Encoder-Based Cycle Control
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Solution Overview
Problem
Existing compactor devices lack control over the duration and actuation of compaction cycles, require manual weight measurement of refuse bales, and do not provide operating and safety indications to operators.
Innovation Solution
Incorporation of an electrical linear drive system with an encoder and processor to control platen travel, a weighing system with load cells for automatic weight measurement, and a laser projection system for safety indicators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual weight measurement is used for refuse bales, then device complexity is reduced, but productivity decreases due to decreased efficiency
Solution Approach 1:
The baler performs weight measurement automatically during the compaction cycle without requiring separate manual intervention. The load cells continuously monitor platen position and bale weight, and the processor automatically determines when compaction is complete based on this data, making the system self-sufficient and eliminating manual weighing steps
Solution Approach 2:
The patent replaces manual mechanical weighing operations with an automated electronic measurement system using load cells and a processor. The electronic system detects weight and position data automatically, substituting the need for manual measurement tools and operations
2Productivity
If no control system is used for compaction cycle, then device complexity is reduced, but productivity decreases due to lack of control over duration and actuation
Solution Approach 1:
The processor receives continuous feedback from load cells regarding platen position and bale weight during compaction. Based on this feedback data, the processor automatically determines when the compaction cycle should end and triggers ejection, creating a closed-loop control system that optimizes cycle duration without manual intervention
Solution Approach 2:
The control system operates autonomously using the baler's own operational data. The processor monitors the compaction process in real-time and self-determines cycle completion based on pre-established criteria from weight and position measurements, eliminating the need for external control mechanisms
3Reliability
If no safety indication system is provided, then device complexity is reduced, but reliability decreases due to lack of operating and safety indications to operators
Solution Approach 1:
The laser projection system uses visual indicators (light projections) to communicate safety information and operational status to operators. The system projects visible laser patterns or colors onto surfaces to indicate safe zones, operational states, or warnings, providing intuitive visual feedback without complex displays
Solution Approach 2:
The laser projection system acts as an intermediary communication channel between the baler's control system and the operator. It translates internal operational data into external visual signals that operators can perceive and respond to, enhancing safety through improved information transmission
4Measurement precision
If manual monitoring of platen position is used, then device complexity is reduced, but measurement precision decreases due to inability to accurately determine compaction completion
Solution Approach 1:
The patent replaces manual visual monitoring of platen position with an automated electronic measurement system. The encoder provides precise digital position data, and the processor automatically analyzes this data along with weight information to determine compaction completion, achieving high measurement precision without manual intervention
Solution Approach 2:
The encoder provides continuous feedback on platen position to the processor, enabling real-time monitoring and precise determination of compaction status. This feedback loop allows the system to accurately detect when the platen reaches its final position and when bale ejection should occur
Data Source
AI summary
A vertical baler includes a frame defining a compaction chamber, a platen configured for vertical travel within the compaction chamber to compact refuse contained within the compaction chamber, a linear actuator coupled to the platen and configured to raise and lower the platen within the compaction chamber, an electric motor coupled to the linear actuator and configured to control extension and retraction of the linear actuator, an encoder coupled to the electric motor and configured to measure rotation of the motor, and one or more processors.