" Technical Field ζ 5 The present invention relates to a method and

* apparatus for removing banding material which holds a bale of generally loose material together. More particularly, the invention relates to a method and apparatus for severing the banding material holding a 10 bale of used paper products together, removing and coiling the material, and depositing it into a collection bin.

Background Art

15 The recycling of used paper products, and other materials derived from wood pulp, has been steadily increasing in volume, creating a need for new equipment and methods of handling such products. While recycling used paper products is not a new idea, the benefits and

20 attitudes toward recycling have dramatically changed in recent years. There has been, and continues to be, an increasing amount of used paper products being recycled. In order to reduce the costs and increase the efficiency of recycling this expanding amount of used paper, new

25 machines and methods for collecting, transporting, and processing are being developed where few existed before. Certain types of re-pulping machinery require that the banding material holding a bale of used paper products together be removed before processing begins.

30 When bales of such products are brought to a recycling facility which uses such machinery, the banding material (usually metal wire or bands) containing the bale must be cut and removed from the bales before the paper product can enter the re-pulper. Because the re-pulping

35 machinery is sensitive to the introduction of such banding material, it will generally break down or become contaminated if any non-wood fiber material is introduced

therein.

Removal of banding material holding a bale of used paper product or other compressible material together presents a special challenge. Such material, once cut, often becomes unmanageable because the waste paper tends to expand quickly, thereby making it difficult to retrieve the banding material. Removal of metal wire or bands presents a significant safety risk to persons in the vicinity of the debanding process. Since the bands are usually highly stressed when they are applied, a sudden release of stress causes the banding material to violently separate thereby making it hazardous for a person to manually cut the band with wire cutters. Remotely operated devices have been proposed, but because of the difficulty associated with the removal of the banding material as described above, efficacy of such prior devices has not been as great as desired.

Yet another challenge associated with debanding a bale is how to handle and reduce the storage space of the banding material once it has been removed. New banding material is usually taken from a spool and fed into a machine that bands a bale of used paper product or the like. However, after being removed from a bale, it becomes unwieldy and cumbersome. Ideally when removed, the banding material should be converted into a manageable form and delivered to a receiving destination.

Accordingly, there is a need for a method and apparatus which can be used to safely break and remove the banding material from bales while insuring that all of the bands are removed from the bale and that substantially all of the banding material is stored in a convenient manner. It is also desirable to have the bales debanded on a conveyor thereby allowing the bales to freely expand as they are introduced to the processing equipment.

Disclosure of the Invention

The present invention comprises a band breaking assembly and a band removing assembly. The apparatus has a frame with vertical and horizontal support members. The vertical support member is principally associated with the band removing assembly. The band removing assembly comprises the vertical support member which supports a vertically positionable, rotatable mandrel for removing banding materials. The mandrel has an axially extending hollow inner portion and an exterior surface. There is at least one band catch opening extending from the hollow portion substantially radially outwardly to the exterior surface. An extendable band catch having a retracted position and an extended position is mounted for reciprocating motion in a generally radial direction through the opening. In the retracted position, the band catch is contained within the mandrel with no portion of the band catch extending outwardly of the exterior surface of the mandrel. In the extended position, the band catch has a band engaging portion which extends outwardly from the exterior surface of the mandrel. The band catch has an inner rack portion which reciprocates generally within the hollow portion of the mandrel. Contained within the hollow portion of the mandrel is an independently rotatable shaft and pinion gear which is in meshing contact with the rack portion of the band catch. A rotary actuator causes the shaft and pinion gear to rotate in one direction or another, thereby causing the band catches to extend or retract. The horizontal support member is primarily associated with the band breaking assembly. The band breaking assembly comprises the horizontal support member which supports a table on which bales are placed and transported. The table has a recess through which a rotatable, band breaking blade passes. Adjacent to the band breaking blade and intermediate the blade and the recess are anvil inserts for providing a hardened support

surface for the banding material when 'subject to a shearing force imparted by the band breaking blade.

The band breaking blade has at least one notch or removed material section to cause the banding material to engage the blade when it is brought in contact therewith. Once engaged, the banding material is brought to bear on the anvil whereupon each side of the anvil supports the banding material and the band breaking blade causes a point load substantially in the middle and perpendicular to the material. Because the band breaking blade is rotating, the force exerted by it on the banding material continues until it exceeds the banding material's sheer point, at which time the banding material breaks.

A feature of the present invention provides for a flexible pressure flap assembly to aid in the wrapping of removed banding material. This assembly is positioned so that banding material encircling the mandrel will be urged to remain thereon.

Another feature of the present invention provides for a pivoted protective hood to substantially enclose the band removing assembly. This assembly is positioned in a similar manner as the pressure flap assembly. During removal of the banding material, the protective hood substantially encloses the upper portion of the mandrel, thereby preventing the removed and rotating banding material from extending much beyond the area of the mandrel. As will be shown below, the protective hood can be pivoted away from the mandrel to permit removal of the coiled banding material. Another feature of the present invention provides for a movable cleaning assembly to remove banding material coiled on the mandrel. Attached to the vertical support member is a cleaning plate support member that is mounted in substantially the same plane as defined by the mandrel and vertical support. Located on the cleaning support member is an axially movable cleaning plate having a lower portion constructed so as to closely fit

the upper arc portion of the mandrel. ^' When the mandrel is positioned adjacent to the cleaning plate, the band catches are retracted, the protective hood is positioned away from the mandrel, and the cleaning plate is moved to the free end of the mandrel thereby clearing the mandrel of the coiled banding material.

Still another feature of the present invention relates to the band breaking blade. One or more banding material engaging notches may be formed in the band breaking blade to more effectively engage the banding material. In an embodiment, the internal edge surfaces of the notches are sharpened to aid in the breaking action of the banding material. Depending upon design consideration, both the band breaking blade and the anvil may be constructed of hardened steel so as to resist the destructive forces encountered when breaking high tensile strength banding material such as wire.

A method for using the debanding apparatus comprises the steps of positioning a bale of material having bands to be removed onto a bale receiving table; extending band catches outwardly from an exterior surface of a mandrel, rotating the mandrel, and moving the mandrel towards the bale such that while the band catches begin engaging the banding material, a band breaking blade breaks the banding material; wrapping the removed banding material around the mandrel; repeating the above described steps until it is desired to remove the banding material from the mandrel by retracting the band catches and exposing the mandrel to a reciprocating cleaning plate that removes the coiled banding material.

Brief Description of the Drawings

In the drawings, unless otherwise noted, like reference numerals designate like parts throughout the several views, and:

Fig. 1 is a partial plan view showing an upper

portion of a debanding apparatus including a frame and a mandrel (cleaning plate assembly and protective hood omitted for clarity);

Fig. 2 is an elevation view of the debanding apparatus with portions thereof shown in phantom (protective hood omitted for clarity);

Fig. 2a is an enlarged, cross-section view of a portion of Fig. 2 showing in more detail a band breaking assembly. Fig. 3 is a partial end view showing the mandrel with a pair of band catches extended and the top portion of a piston rod for providing vertical movement, and a cleaning plate for removing coiled banding material (flexible pressure flaps and a protective hood omitted for clarity);

Fig. 4 is an enlarged sectional view taken substantially along line 4-4 of Fig. 2, showing a pair of band catches in an extended position with one catch shown in a retracted position in phantom; Fig. 5 is an elevation view of the band breaking blade detailing band retaining notches;

Fig. 6 is a side elevation of a preferred embodiment of the debanding apparatus during the removal of banding material; Fig. 7 is the same view as in Fig. 6 except that the apparatus is shown removing coiled banding material from the mandrel;

Fig. 8 is an enlarged sectional end view taken substantially along line 8-8 of Fig. 2, showing a portion of the mandrel, and a support carriage with a pressure flap assembly and a protective hood (hydraulic hoses have been omitted for clarity);

Fig. 9 is a cross-section view taken substantially along line 9-9 of Fig. 8 showing the mandrel support member and an end portion of the mandrel (the pressure flap assembly and protective hood have been omitted for clarity);

Fig. 10 is an enlarged cross section taken substantially along line 10-10 of Fig. 2, showing the location of a hydraulic rotary actuator within a mandrel mounting flange; Fig. 11 is an enlarged partial sectional view showing a band catch hub with band catches, and the hydraulic rotary actuator attached thereto;

Fig. 12 is a perspective view of the band breaking blade about to engage a banding wire resting on anvil inserts;

Fig. 13 is similar to Fig. 12 but shows the band breaking blade engaging the banding wire; and

Fig. 14 is a partial cross section view of Fig. 13 detailing the interaction of the band breaking blade and the anvil inserts acting on the banding wire.

Best Mode for Carrying Out the Invention

Referring now to the drawings, and first to Figs. 1 and 2, a debanding device 12 is shown to have frame 14 with vertical support member 22 and horizontal support member 24. Horizontal support member 24 supports bale receiving table 26 through which band breaking blade 42 passes. Vertical support member 22 provides support for mandrel support member 32 and cleaning plate support member 34.

As is better shown in Fig. 9, mandrel 16 is rotatably located in mandrel collar 77 and supported therein by bearings 76 which are preferably high load type bearings. Mandrel collar 77 is fixedly attached to mandrel support member 32 which is in turn slidably mounted to vertical support member 22 so as to permit vertical movement thereon by means of hydraulic cylinder 38 and piston rod 50. Mandrel 16 is caused to rotate by hydraulic motor 20 and drive chain 21 rotating sprocket 78.

Returning again to Figs. 1 and 2, cleaning plate support member 34 is attached to vertical frame 22 at a

location above mandrel support member 32. To reduce the torque moment acting on the attachment point, cleaning plate support member 34 is further supported by brace 33. Cleaning plate 36 is mounted for reciprocating axial motion along cleaning plate support member 34. Cleaning plate 36 is driven by motor 35 and chain 40. In preferred form, cleaning plate 36 includes sliding collar 37 which is in sliding engagement with cleaning plate support member 34. Those persons skilled in the art will recognize that numerous possibilities exist for providing a bearing-type sliding engagement between sliding collar 37 and cleaning plate support member 34. As shown in Fig. 3, cleaning plate 36 is preferably constructed to have two portions: a first portion 52 is an ultra-high molecular weight plastic while a second portion 53 is a mild steel plate that is attached to collar 37.

As shown in Fig. 2, pressure flap assembly 39 includes a pair of flexible pressure flaps 41 and frame member 45 which is attached to mandrel support member 32. Flexible pressure flaps 41, preferably constructed of thick reinforced rubber, contact mandrel 16 in such a manner so as to aid in holding banding material 30 in place on rotating mandrel 16. Frame member 45 is adjustable such that the pressure applied by flexible pressure flaps 41 against mandrel 16 can be varied by repositioning frame member 45. Typical flexible pressure flap 41 engagement with mandrel 16 is shown in Fig. 8.

Also attached to frame member 45, as shown in Fig. 8, is protective hood 47 which is pivotally attached thereto by hinge 51. Protective hood 47 fits closely over mandrel 16, aiding in the wrapping or winding of banding material 30 around mandrel 16. In addition, plastic end plates (not shown) may be added to the ends of protective hood 47 to further aid the winding process of banding material 30 and increase safety for persons near debanding device 12. Protective hood 47 pivots on frame member 45 in order to swing out of the way of

cleaning plate 36 during the banding material removal process.

Band breaking blade 42 is mounted for rotatable motion on horizontal frame 24 using a pair of bearing blocks 43 (see Fig. 2a). As shown in Fig. 2a, band breaking blade 42 is positioned to rotate through anvil 49 which is made of a hardened steel, e.g., ASTRALOY ^* ' which aids in the breaking of banding material 30, as is further described below. Referring now to Figs. 3 and 4, the structure and operation of mandrel 16 will be discussed in more detail. Mandrel 16 includes hollow portion 44 wherein pinion shaft 56 and pinion gear 46 are located. Pinion shaft 56 drives pinion gear 46 which in turn drives band catches 18 to retract or extend by engaging a rack portion 48 of band catches 18 (as shown in Fig. 4).

Referring specifically now to Fig. 4, mandrel 16 is shown in cross-section while band catches 18 are shown in elevation. Each band catch 18 includes protruding portion 54 and rack portion 48. Rack portion 48 of each band catch 18 is in meshing engagement with pinion gear 46. Pinion gear 46 is driven by axially aligned pinion shaft 56 through key member 58. Each band catch 18 extends through a machined opening 60. Openings 60 extend generally radially to mandrel 16, however these openings are spaced sufficiently off-center to allow pinion gear 46 to be placed between the pair of rack portions 48. In preferred form, band catches 18 and pinion gear 46 are carried by band catch disk 61, as shown in Fig. 11. Each band catch 18 includes rack end 62 and outer end 64. Mandrel 16 includes cavity 66 for receiving rack end 62 of band catch 18 when it is in its retracted position. Cover plate 67 covers cavity 66. Band catch disk 61 described above is preferably machined from a solid disk of steel. As best shown in Fig. 11, band catch disk 61 performs two functions. First, it provides a way to join the two segments of

mandrel 16 together. Second, and more ^' importantly, band catch disk 61 houses band catches 18 by having openings 60 through which band catches 18 reciprocate. Hydraulic rotary actuator 72 is mounted to band catch disk 61 so that pinion shaft 56 extends therein. When subject to a hydraulic pressure, hydraulic rotary actuator 72 causes pinion shaft 56 and pinion gear 46 to rotate, thereby causing band catches 18 to extend or retract.

Referring now to Fig. 5, band breaking blade 42 is shown. Band breaking blade 42 is preferably constructed from a 22.7 cm ASTRALOY ^* blade that has been machined and heat treated to approximately 815° C and air cooled. To aid in the engagement and breaking of banding material 30, band breaking blade 42 has uniform notches 68 removed from it. Each notch has an internal diameter of approximately 3.5 cm. Internal edge 70 is preferably sharpened to aid in breaking banding material 30. In addition, the circumferential edge of band breaking blade 42 is tapered as indicated in Fig. 6 at A to 30 degrees from sectional center before being heat-treated.

Anvil inserts 49 aid band breaking blade 42 in breaking banding material 30 by providing side supports to limit banding material 30 from distributing the force created by band breaking blade 42 beyond a narrow length of material bounded by each edge of anvil inserts 49. The sequential action of band breaking blade 42 on a length of banding material 30 is best shown in Figs. 12- 14. The combination of notches 68 in conjunction with anvil inserts 49 provide a most efficient use of energy for breaking banding material 30. Moreover, use of anvil inserts 49 localizes the point of breakage, thereby ensuring that band catches 18 will engage a sufficient length of banding material 30 so that it may be effectively removed from bale 28.

Operation of the Invention:

In order to more fully understand the invention, the

following is a description of the method for using an embodiment of the apparatus. For convenience, reference may be had to Figs. 6 and 7.

A bale 28, which may be of any practical dimension, is placed on a conveyor to be transported to a position on support table 26. Support table 26 is slidable on plastic strips or any other low friction surface so that bale 28 can be moved progressively under mandrel 16 by a drive system. Upon activation of the apparatus, mandrel 16 is rotated by drive motor 20 and drive chain 21, at a preferred rate of 18 rpm and band catches 18 are moved to their extended position by pressurizing hydraulic rotary actuator 72. Hydraulic rotary actuator 72 cause pinion shaft 56 to rotate until the applied hydraulic pressure is stopped, at which point pinion shaft 56 is locked in place, holding it stationary relative to mandrel 16. When pressure is applied to rotate pinion shaft 56 in the reverse direction, the shaft counter-rotates thereby retracting band catches 18. Supplying hydraulic rotary actuator 72 with fluid are two hydraulic hoses which pass through rotating union 80 at the driven end of mandrel 16. After band catches 18 have attained their extended position, mandrel 16 is lowered by hydraulic cylinder 38 and piston rod 50 to a position adjacent bale 28.

Also upon activation of the apparatus, band breaking blade 42 is rotated by a hydraulic motor and chain (not shown) at a rate below 100 rpm and preferably at 4 to 10 rpm. The direction of rotation is preferably toward the approaching bale so as to pull down on banding material when engaged by a notch 68. After this engagement, banding material 30 is caused to contact both portions of anvil inserts 49 as best illustrated in Fig. 13. The resulting force from the inherent torque of band breaking blade 42 in a direction perpendicular to table 26 in combination with sharp edge 70 cause banding material 30 to break (See Fig. 14).

As banding material 30 breaks, it ^" engages one of the band catches 18. Consequently, banding material 30 begins to wrap around mandrel 16 since it is engaged with band catch 18 and held thereto by flexible pressure flap 41 and protective hood 47. Mandrel 16 is preferably rotated so that band catch 18 makes a climbing cut, i.e., rotated toward and downwardly into the approaching bale 28.

Bale 28 continues to move through the apparatus until all banding materials 30 are removed from one surface of bale 28. Depending upon the type of bale 28 and number of bands 30 broken, it may be desired to remove the accumulating bands from mandrel 16. If this is desired, protective hood 47 is caused to pivot away from mandrel 16, thereby exposing the top portion of mandrel 16 to facilitate the removal of banding material 30.

Referring to Fig. 7, mandrel 16 is preferably extended to a position above the bale by hydraulic cylinder 38 and piston rod 50 so that cleaning blade 36 is adjacent mandrel 16. Hydraulic pressure to hydraulic rotary actuator 72 is reversed so that the closed centered valves reverse the direction of rotation of pinion shaft 56 which in turn rotates pinion gear 46, thereby retracting band catches 18 into hollow portion 44 of mandrel 16. After band catches 18 have been retracted, cleaning plate 36 is drawn toward the free end of mandrel 16 to remove the coiled banding material 30 into receiver 90 which may then deliver the banding material 30 to chopper 92 via conveyor 94. Mandrel 16 may continue to rotate during this step or may be stopped. Cleaning plate 36 is then returned to its initial position and the process is repeated.

In order to remove banding material 30 from other surfaces of bale 28, the bale may either be repositioned and moved through the debanding apparatus as described above, or a second debanding apparatus may be used

wherein the mandrel 16 and the band breaking blade 42 are each mounted to a linear actuator capable of moving mandrel 16 and band breaking blade 42 over a different surface of bale 28, until all of the bands 30 have been removed from bale 28. Depending upon the application, bale 28 may be positioned such that the direction of movement across table 26 is diagonal to plane of rotation of band breaking blade 42. In this fashion, only one pass through the apparatus may be needed for a bale having any number of perpendicularly intersecting bands. From the foregoing, there is further modifications, component arrangements, and modes of utilization of the invention which will be apparent to those skilled in the art to which the invention is addressed. The scope of protection is not to be limited by the details of the embodiments which have been illustrated and described. Rather, the scope of protection is to be determined by the appended claims, interpreted in accordance with the established rules of patent claim interpretation, including the document equivalents.

Industrial Applicability

The present invention will find applicability and industrial utility in industries that handle and process baled materials. More particularly, the invention can be used in the wood fiber recycling industry where removal of banding material from bales is desired.