Vibrating Chute and Air Jet System for Scrap Metal Sorting
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Solution Overview
Problem
Existing methods for separating bulk materials, such as crushed scrap, struggle to effectively separate mixtures that are difficult or impossible to distinguish, particularly when it comes to recyclable materials like copper cables, copper strands, plastics, printed circuit boards, iron, stainless steel, stones, glass, and non-ferrous metals.
Innovation Solution
A method involving a distribution trough with a vibration drive, a separating chute at an angle with a vibration drive, and air nozzles for pre-sorting and separation, where bulk materials are fed via a hopper or conveyor belt, with a rake for initial separation and air flows to enhance the separation process, allowing for the effective separation of recyclable materials from non-recyclable ones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional separation methods are used, then simple bulk materials can be separated, but complex mixtures of difficult-to-distinguish materials remain unseparated
Solution Approach 1:
The separation process is divided into multiple stages: pre-separation using a rake, primary separation using a distribution chute with air jets, and secondary separation using a separating chute. This multi-stage segmentation allows progressively finer separation of complex material mixtures, transforming a single inadequate separation step into a coordinated sequence of specialized separation actions.
Solution Approach 2:
The invention employs dynamic vibration drives on both the distribution chute and separating chute, allowing the separation surfaces to oscillate and actively engage with the bulk material. This dynamic action enhances the separation effectiveness for difficult-to-distinguish materials by creating varying contact forces and motion patterns that amplify subtle differences in material properties.
2Manufacturing precision
If a single separation method is used, then the device structure remains simple, but the ability to separate difficult mixtures is insufficient
Solution Approach 1:
The device is segmented into functionally distinct components: a rake for pre-separation, a distribution chute with integrated air jets for primary separation, and a separating chute for secondary separation. Each component addresses a specific separation challenge, and their coordinated arrangement creates a comprehensive separation system without requiring excessive complexity in any single element.
Solution Approach 2:
The vibration drives serve multiple functions: they advance material through the chutes, enhance separation efficiency, and control material flow distribution. The air jets simultaneously provide lifting forces for separation and facilitate material distribution. This multi-functionality reduces the need for additional dedicated components, managing device complexity while achieving high separation precision.
3Productivity
If no pre-sorting is applied, then the separation process is simpler, but the overall separation efficiency is reduced
Solution Approach 1:
A rake is positioned at the discharge edge of the distribution chute to perform pre-sorting of the bulk material before it enters the main separation zones. This preliminary action removes easily separable materials and prepares the remaining mixture for more sophisticated separation techniques, increasing the overall efficiency of the separation process by handling different material types in appropriate stages.
Solution Approach 2:
The separation process is divided into distinct stages with the rake performing initial pre-separation, followed by air jet-assisted primary separation, and finally vibration-based secondary separation. This segmentation of the separation task into manageable stages allows each component to specialize in separating specific material types, thereby increasing overall productivity without requiring any single component to be overly complex.
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 method enables the successful separation of previously unseparable materials, optimizing the recovery of recyclable materials like copper cables, plastics, and printed circuit boards by utilizing vibration and air flow to promote separation and pre-sorting, achieving effective separation results with optimal inclination and vibration parameters.
Implementation Method 1
a distribution trough (1) with a vibration drive (2) for the areal distribution of the bulk material on its surface
Implementation Method 2
Since the parts to be separated preferably have an increased air resistance in relation to their weight, this air flow already carries out a pre-separation
Implementation Method 3
a separating chute (4), which is arranged at an angle and also with a vibration drive (5) for separation of the bulk material into two types of bulk material
Data Source
Figure 1
Figure 2
AI summary
The process is used for separating and/or sorting bulk materials, in particular shredded scrap metal for the recovery of recyclable materials. First, the bulk material is fed onto a distribution trough (1) via a hopper, screw conveyor, conveyor belt, or similar device. The distribution trough (1) is equipped with a vibratory drive (2) for distributing the bulk material evenly. This causes the bulk material to move to the edge of the distribution trough (1) and from there fall onto a separation trough (4) located below. The separation trough is inclined and also equipped with a vibratory drive (5). This separates the bulk material into two types: one that moves upwards in the separation trough (4) and one that moves downwards. These two types can be collected separately at the upper and lower edges of the separation trough (4), respectively.