Claims:WE CLAIM:

1. A compacting apparatus (100) for compressing metallic chips entrained with fluid to form briquettes and extract said fluid therefrom, comprising:
• a powerpack assembly (101) supplying power to the compacting apparatus (100);
• a vertical pressing cylinder (102) coupled with variable volume piston;
• a gate cylinder (103) slidably connected a cylindrical die;
• a geared motor (104) connected to vertical cylinder (102);
• a shredder assembly (105) having an opening for retaining a plurality of metal chips;
• a vibrator feeder (106) positioned beneath the shredder assembly (106);
• a base structure assembly (107) providing structural support to the compacting apparatus (100);
• a control panel (108) regulating the functioning of the compacting apparatus (100);and
• a proximity sensor (109) coupled to vibrator feed (106),
wherein,
i. a cylindrical die connected with the vibrator feed (106);
ii. the apparatus is facilitated beneath a computer numerical control (CNC) machine; and
iii. the proximity sensor (109) configured to provide uniform volumetric dosing into the vibrator feeder (106).

2. The compacting apparatus (100) as claimed in claim 1, wherein a cylindrical die is embraced with a plurality of grooves to provide passage for fluid.

3. The compacting apparatus (100) as claimed in claim 1, wherein a plurality of stopper seals is connected to the cylindrical die.

4. The compacting apparatus (100) as claimed in claim 1, wherein the apparatus is up stroking type.

5. The compacting apparatus (100) as claimed in claim 1, wherein the CNC machine conveyor is integrated with the apparatus (100) to regulate its sequential cycle .

6. A method for compressing metallic chips entrained with fluid to form briquettes and extract said fluid therefrom via the apparatus claimed in claim 1, comprising the following steps:
i. pressing a start button to initiate 1st sequence of compacting apparatus (100);
ii. setting timer on the vibrator feeder (106);
iii. introducing the plurality of chips into the shredder assembly (105);
iv. passing the plurality of chips through an open inlet of the vibrator feeder (106);
v. switching off the vibrator feeder (106);
vi. detecting the pre-determined volume of shredded chips into the vibrator feeder (106) through proximity sensor (109);
vii. transferring the signal from proximity sensor (109) to control panel (108);
viii. transmitting the plurality of chips to the cylindrical die;
ix. sliding the cylindrical die into the compaction chamber;
x. actuating the variable volume piston into the cylindrical die;
xi. converting the shredded metallic chips into briquettes;
xii. extracting fluid into the plurality of stopper seals; and
xiii. repeating the sequence i to xii to initiate another cycle.

7. The method as claimed in claim 6, wherein the control panel (108) on receiving the signal from the proximity sensor (109) closes inlet of the vibrator feeder (106) to provide uniform volumetric dosing of the metal chips.

8. The method as claimed in claim 6, wherein a geared motor (104) drives the variable volume piston in longitudinal motion.

9. The method as claimed in claim 6, wherein the plurality of stopper seals extracts maximum fluid from the cylindrical die to remove toxication from another sequence.
, Description:FIELD OF INVENTION

[001] The present invention relates to an apparatus that facilitates compacting various metal wastes into high density briquettes. Particularly, the present invention relates to an apparatus and method providing high density briquettes processed through maximum extraction of the coolant.

BACKGROUND OF THE INVENTION

[002] Metal chips/Scrap metal/Loose Material are gathered during the machining of metal workpieces. A chip compactor machine compresses loose metal chips to form strong briquettes. Through chip compaction, loose metal chips can be made easy to handle and profitable. Measures have been taken to provide efficient waste management system for discarding metal chips formed during machining processes with minimum utilization of space and energy. Further, machining processes usually utilize a cutting fluid to lubricate and cool the workpiece during the operation, the machining processes unavoidably generate metal chips infused with cutting fluid.

[003] Usage of a compactor is economically desirable to separate the cutting fluid from the metal chips to facilitate a re-use of the cutting fluid during subsequent machining processes. Compaction of the metal chips into dense briquettes thus facilitates an improved handling and transportation of the metal chips during the recycling process.

[004] US6349638B1 a prior art document discloses a briquetting machine for compacting metal chips into briquettes with a movable die that provides plural die cavities. After metal chips are loaded into a loading chamber from a hopper, a chip compacting ram pushes the chips at a high speed and low pressure into one of several bores, disposed within a sliding die gate, and against an endplate. The bore and endplate together constitute a die and define at least two die cavities. After the ram reaches a predetermined low pressure, the ram then proceeds at a relatively low speed and relatively high pressure to compress the chips within the die into a briquette. Upon reaching a predetermined compaction pressure, the ram retracts from the bore. After such time, the die gate is moved to a location where one bore lies before an ejector cylinder. The ejector cylinder then extends into the bore, expelling the briquette from the bore.

[005] Prior art briquetting machine have cylindrical die and when the chips are being compressed the fluid would get entrapped in the briquette which result in less compact density and more fluid retention. Therefore, the existing briquetting machines have low compact density, are slow in operation, are bulky and occupies more floor space and fail to provide a compaction process that provides maximum extraction of coolant. Further the system also does not disclose any process related to reduction in pollution caused due to processing of residual coolant at the time of recycling the metal chips. Furthermore, the existing compact machine has many design flaws including feeding mechanism for the chips and also takes more floor space and is difficult to maintain and service .

[006] In view of the above problems there is a need for a method and apparatus for compacting metal chips efficiently while also reducing the pollution caused due to processing of residual coolant.

OBJECTIVE OF THE INVENTION

[007] The primary objective of the present invention is to provide an apparatus and method that facilitates maximum extraction of the coolant.

[008] Yet another objective of the present invention is to reduce overall shape of the machine so that it has low footprint and less height to fit under the conveyor of CNC machine and also reduce weight.

[009] Another objective of the present invention is to provide a machine to generate uniform briquettes from the scrap metal to provide better compact density.

[0010] Yet another objective of the present is to redesign the die to make passage for the fluid to be released to achieve more extraction and better compact density of the scrap metal/metal chips.

[0011] Another objective of the present invention is to provide a robust fabricated structure to harness the whole machine to avoid any vibration on the machine.

[0012] Yet another objective of the present invention is to provide an apparatus that reduces power consumption.

[0013] Other objectives and advantages of the present invention will become apparent from the following description taken in connection with the accompanying drawings, wherein, by way of illustration and example, the aspects of the present invention are disclosed.

BRIEF DESCRIPTION OF DRAWINGS
[0014] The present invention will be better understood after reading the following detailed description of the presently preferred aspects thereof with reference to the appended drawings, in which the features, other aspects and advantages of certain exemplary embodiments of the invention will be more apparent from the accompanying drawing in which:
[0015] Figure 1 illustrates different types of metal chips processed in the apparatus of the present invention.

[0016] Figure 2 illustrates extraction of cutting fluid.

[0017] Figure 3 illustrates reduction in volume of broken chips and spiral chips.

[0018] Figure 4 and 5 illustrates perspective view of a compacting apparatus.

[0019] Figure 6 illustrates the accident-free working environment of the industry/shop utilizing the present invention.

[0020] Figure 7 illustrates the hygienic chip storage area and shop floor area of industry/shop utilizing the present invention.

[0021] Figure 8 illustrates the safe transportation of briquettes as compared to the loose material.
[0022] Figure 9 of the present invention illustrates the approximate specification of the components of the compacting apparatus.

SUMMARY OF THE INVENTION
[0023] The present invention relates to a method and apparatus which compacts various machining wastes into briquettes, while providing maximum extraction of the coolant. In a preferred embodiment the present invention relates to a chip compactor machine that compresses loose metal chips wherein the chips may be both ferrous or non-ferrous to form strong briquettes. The compaction of the chips provides easy and profitable handling of the loose chips.

DETAILED DESCRIPTION OF INVENTION
[0024] The following detailed description and embodiments set forth herein below are merely exemplary out of the wide variety and arrangement of instructions which can be employed with the present invention. The present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. All the features disclosed in this specification may be replaced by similar other or alternative features performing similar or same or equivalent purposes. Thus, unless expressly stated otherwise, they all are within the scope of the present invention.

[0025] Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope of the invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.

[0026] The terms and words used in the following description and claims are not limited to the bibliographical meanings but are merely used to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustration purpose only and not for the purpose of limiting the invention.

[0027] It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

[0028] It should be emphasized that the term “comprises/comprising” when used in this specification is taken to specify the presence of stated features, integers, steps, or components but does not preclude the presence or addition of one or more other features, integers, steps, components, or groups thereof.

[0029] The present invention provides an up stroking type apparatus, vertical orientation high density generating briquettes from metal wastes( such as loose material from cast iron, aluminum, steel and alloy steel, brass, bronze, silver, titanium etc. ) formed during machining processes and providing maximum coolant extraction to reduce pollution. The chip compactors of the present invention can process both ferrous and non- ferrous chips. During metal removal process, use of cutting fluid is universal. These loose chips with cutting fluid can be processed in machine of the present invention to make briquettes as illustrated in Figure 1 and as byproduct up to 90% of cutting fluid can be extracted as illustrated in Figure 2.

[0030] In an exemplary embodiment the machine provides 20 kg briquette output per hour. Further get the apparatus provides better compact density of steel briquettes i.e. 5.4 gm per cm3.

[0031] Further as illustrated in Figure 3 the present invention provides volume reduction up to 4 times for broken chips and up to 15 times for spiral chips.

[0032] Further the present invention facilitates reduction in size of the machine so that it has low foot-print and less height to fit under the conveyor of CNC machine. In an exemplary embodiment the height of the machine is reduced by 20% and weight is reduced by 200 kg.

[0033] Figure 4 and Figure 5 of the present invention illustrates the various components of the machine including:
• a powerpack assembly (101): The powerpack assembly includes horse power unit (HPU) consisting of 40Ltr reservoir fabricated out of MS steel material using ISO VGA68 Oil. The top of the reservoir houses variable volume piston pump with housing motor 5Hp utilized for saving energy by using lesser power and generating lesser heat upto 98%. Further, manifold mounted directional valves are utilized to control hydraulic cylinder actuator wherein the velocity is controlled by throttle valves and pressure is sensed through pressure switches.
• a vertical pressing cylinder (102): The vertical pressing cylinder includes at least diameter 150 to generate 30Ton force for compaction. The acquitted pressure required to generate this force is given by this piston pump and sensed through the pressure switches.
• a gate cylinder (103): The gate hydraulic of at least diameter 40 is utilized for the movement of the briquette and for pushing out the briquette. The chips from the vibrator feeder is filled in the block and then it is sent to the die with the help of the gate cylinder.
• a geared motor (104): The geared motor is utilized only for shedding long chips generated during the working of the machine specially from materials like ductile steel and aluminium shredding.
• a shredder assembly (105): The shredder assembly is configured to be driven by the geared motor (104) utilized for shredding long chips generated during the working of the machine specially from materials like ductile steel and aluminium shredding.
• a vibrator feeder (106): The vibrator feed moves the scarp material into the measuring conveyor accurately to the same filling up the distance.
• a base structure assembly (107): The base structure provides support to the base for the whole assembly as a supporting stand.
• a control panel (108): The control panel includes programmable logic controller (PLC) and relays to implement the working of the machine step by step in a uniform manner. The PLC which gives command to the sensors at every steps.
• a proximity sensor (109): The proximity sensor is utilized to sense the shredded material movement and provides signals to the panel. Further, programming for the sensor is implemented in the control panel.
• a compaction chamber: The compaction chamber provides implementation of compacting the shredded material into a briquette of size at least diameter 40.
• a cylindrical die: The gate cylinder provides filing the material in the die and then due to high pressure on the cylinder the material is converted into the briquette in the compaction chamber;and
• stopper seals: The plurality of stopper seals are included in the cylindrical die to isolate fluid passage and retain the fuel for future use. The plurality of stopper seals are configured to extract maximum fluid from the cylindrical die to remove toxication from another sequence for compressing metallic chips.

[0034] In accordance with Figure 4 and 5 illustrates the components of the apparatus of the present invention. The apparatus comprises a powerpack assembly (101) having a start button. It receives power from the external power source for supplying power to the various components of the machine. Further, a shredder assembly (105) is connected to vibrator feeder (106). All the loose chips in a chips hopper are introduced into the shredder assembly (105). The loose chips after shredding proceed downwards towards the vibrator feeder (106). Furthermore, the vibrator feeder (106) is connected with a proximity sensor (109) for facilitating uniform volumetric dosing. When the proximity sensor (109) detects a predetermined uniform volume of chips received by the vibrator feeder (106), it closes the inlet of the feeder (106) in accordance with the directions received by the proximity sensor (109). The proximity sensor (109) is connected with a control panel (108). The control panel regulates the opening and closing of the vibrator feeder (106) along with the driving of the shredder assembly (105). Further, the vibrator feeder (106) is connected with cylindrical die . The vibrator feeder (106) feeds the shredded chips into a die that is slidably connected to the gate cylinder (103). The die is controlled by a gate cylinder (103) that provides a substantial linear motion to the die and slides it to the compaction chamber to convert the chips into briquettes through actuation of the vertical cylinder (102). A geared motor (104) is connected to the vertical cylinder (102) so as to impart a vertical reciprocal motion to drive the vertical pressing cylinder (102). Further, grooves are included to the die to make passage for fluids. The die allows the fluid entrapped in the briquettes to be released, which results in more extraction and a higher compact density of the fluid. Further , additional stopper seals are also included in the die to isolate fluid passage and retain the fuel for future use.

[0035] In the present invention as the apparatus works under heavy loads and vibrates excessively during compaction and shredding operations, so as to reduce the vibrations and improve stability, the machine is provided with the base structure assembly (107). The base structure assembly (107) is provided in the present invention that interconnects with other components and provides a strong base to the machine.

[0036] In an exemplary embodiment the apparatus of the present system is a compact system and provides floor place which is reduced by 20% and is modular structure with integration of sub-assemblies facilitating easy maintenance and serviceability. In the present invention dovetail interlocking is utilized to eliminate bolts thereby reducing the base print. The system's overall height is reduced by the vertical compaction/bottom construction, which eliminates the need for daylight for feeding. Hence, overall reduction in volume and space.

[0037] In an embodiment the control panel (108) is employed for controlling the functioning of the apparatus by ensuring the minimal cycle operation of the machine. The control panel (108) helps in increasing the efficiency of the machine by managing the cycle of the machine, i.e., from introducing the metal chipset into the shredder assembly (105) till the extraction of briquettes, in sequence. As after completion of the first sequence, the control panel (108) facilitates the working of next sequential cycle accordingly.

[0038] The vertical pressing cylinder (102) incorporated in the apparatus of the present invention comprises a variable volume piston that enables smooth transitions during compaction. The variable volume piston is positioned at one end of the compaction chamber and applies longitudinal pressure to the chips in order to convert them into briquettes. By varying the volume of chips encompassing in the compaction chamber, the piston maintains constant pressure while matching the system output demand.

[0039] In an embodiment the apparatus of the present invention facilitates connection with Computer Numerical Control (CNC) by placing the compacting apparatus beneath the conveyor of the CNC. The CNC assists in integrating the apparatus’s cycle with it in order to run the machine without human interference. As a result, by automating the control of the machine’s components during its sequential cycle, the machine’s efficiency is increased.

[0040] The apparatus of the present invention facilitates connection between the components of the apparatus thereby eliminating the usage of bolts. Further, grooves have been incorporated to facilitate more extraction of oil and given suitable draft at top to help better compact density as well as extract more oil which also generate more compact density.

[0041] In an embodiment a method for compressing metallic chips entrained with fluid to form briquettes and extract said fluid therefrom via the compacting apparatus (100) comprises the following steps:
i. pressing a start button to initiate 1st sequence of compacting apparatus (100);
ii. setting timer on the vibrator feeder (106);
iii. introducing the plurality of chips into the shredder assembly (105);
iv. passing the plurality of chips through an open inlet of the vibrator feeder (106);
v. switching off the vibrator feeder (106);
vi. detecting the pre-determined volume of shredded chips into the vibrator feeder (106) through proximity sensor (109);
vii. transferring the signal from proximity sensor (109) to control panel (108);
viii. transmitting the plurality of chips to the cylindrical die;
ix. sliding the cylindrical die into the compaction chamber;
x. actuating the variable volume piston into the cylindrical die;
xi. converting the shredded metallic chips into briquettes;
xii. extracting fluid into the plurality of stopper seals; and
xiii. repeating the sequence i to xii to initiate another cycle.

[0042] Figure 6 of the present invention illustrates that the machine of the present invention provides no spillage of loose chips or cutting fluid and facilitates accident free working environment.

[0043] Figure 7 of the present illustrates that it promotes hygienic chip storage area and shop floor area and there is no chips/cutting fluid spillage.

[0044] Figure 8 of the present invention illustrates that there is up to 80 % reduction in chip handling time and logistics cost as the spillage of loose chip is reduced due to conversion in briquette.

[0045] In an exemplary embodiment Figure 9 of the present invention illustrates the approximate specification of the components of the compacting apparatus (100).

[0046] In an embodiment the advantages of the present invention are enlisted herein:
• maximum extraction of coolant with special die design;
• an up stroking type machine and smallest in size suitable for at least 30 ton capacity;
• generating high density briquettes better than any other machine of similar capacity as a consequence of more fluid extraction;
• redesigned the die to make passage for the fluid to be released and thereby achieving more extraction and better compact density of the scrap metal/metal chips. Further, total distance travelled by the cylinder is reduced by half resulting in less distance travelled thereby conservating power and also piston pump by its characteristics during compaction reduces power. Further, a regeneration system is included to double the velocity of cylinder using same power;
• Robust fabricated structure to harness the whole machine is provided to avoid any vibration on the machine;
• Reduces power consumption by utilizing a control panel with minimal use of repetitive cycle operation.

[0047] The salient features of the present invention in comparison to the existing compacting apparatus are included in the Table 1 illustrated below:
Particulars Existing Apparatus Present Invention
Type compact compact
Orientation horizontal vertical
Possible max output 20kg /hr 30 /kg hr
Power 3.5 KW 3.5 KW
Tonnage 30 tons 30 tons could go up to 40 tons with same power
Cast iron density 5.2 gms /cc 5.7gm/cc
Metal chips 4.2 gms/cc 4.7/cc
Coolant extraction by wt Max 16% Upto 45%
Controls PLC No PLC
LBH 1000/533/695 700/600/721
Die Plain With grooves to enhance extraction

[0048] While this invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.