| WO2012055233A1 | 2012-05-03 | |||
| WO1987007187A1 | 1987-12-03 | |||
| WO1994020229A1 | 1994-09-15 |
| US20170072435A1 | 2017-03-16 | |||
| KR100905624B1 | 2009-06-30 | |||
| EP0861124B1 | 2001-08-16 |
| We claim : 1. An Impact-hopper comprises: two vertical, parallel walls namely front-wall (80) and back-wall (81) a vertical, upper left-side-wall (85) an inclined, removable, lower left-side- wall (36) a vertical, upper right-side-wall (82), an inclined, removable, lower right-side-wall (31), a hit- bar (24), a pre-feeder unit, a distributor unit, a streamliner (42), a mini-expander unit and a skirt-board (113). 2. The Impact-hopper as claimed in claim 1 , wherein said front-wall (80) has a stick-out flange type inspection door (22) fixed using bolts and nuts (23) inserting a rubber gasket. 3. The impact-hopper as claimed in claim 2, wherein said front-wall (80) is shorter than said back wall (8.1). 4. The Impact-hopper as claimed in claim 1 , wherein said front-wall (80) and said back-wall (81) narrow down at the lower portion upto skirt-box (113). 5. The Impact-hopper as claimed in claim 1 , wherein the flange (144) fixed by welding at the upper portion of the Impact-hopper (1), is connected to the main supporting structure (78) using bolts and nuts (183); at the middle level the bracket (69) welded to said front-wall (80) and the bracket (32) welded to said back-wall (81) are attached to said main supporting structure (78) by bolts and nuts (35). 6. The Impact-hopper as claimed in claim 1 , wherein said inclined, removable, lower left-side-wall (36) and said inclined, removable, lower right-side-wall (31) flanges (84) are attached to flanges (34) with bolts and nuts (33) in an inclined manner and are removable and also smoothly aligned with said vertical, upper left-side-wall (85) and said vertical, upper right-side-wall (82). 7. The Impact-hopper as claimed in claim 1 , wherein a replaceable wear-plate known as side-wall wear-plate (138) is fixed in between said inclined, removable, lower left-side-wall (36) and flanges (34)÷ and another said side-wall wear-plate (138) is fixed between said inclined, removable, lower right-side-wall (31 ) and flanges (34) wherein rubber or other suitable material gaskets are introduced in between each of the flanges so that only the wear-plate (138) surface comes in contact with the falling bulk material. 8. The Impact-hopper as claime in claim 1 , wherein said hit-bar (24) is located at said back-wall (81) just above said inclined, removable, lower left-side-wall (36) and said inclined, removable, lower right-side-wall (31). 9. The Impact-hopper as claimed in claim 8, wherein said hit-bar (24) has a step (145) inward as to fit perfectly with the inner surface of said back-wall (81). 10. The Impact-hopper as claimed in claim 8, wherein said hit-bar (24) fixed in position by plurality of U-clamps (25), the legs of which are welded to said back-wall (81) and plurality of bolts (26) 7 by plurality of fixed nuts (179) which are welded to the U-clamps and plurality of lock nuts (180). 11. The Impact-hopper as claimed in claim 8, wherein said hit-bar (24) is quickly replaceable and is made of steel or other alloys or metal or elastomeric material. 12. The Impact-hopper as claimed in claim 1 , wherein said pre-feeder unit has a rectangular plate known as feed-plate (19) positioned in an inclined manner, in the bulk material flow direction, fixed to the brackets (169) welded to the inner sides of vertical, upper left-side-wall (85) and vertical, upper right-side-wall (82), with plurality of nuts and bolts (21). 13. The Impact-hopper as claimed in claim 12, wherein said pre-feeder unit has two guide-rails (20) fixed by welding and positioned wider in the receiving end and narrower in the delivery end in such a way that the received flattened bulk material is not squeezed further. 14. The Impact-hopper as claimed in claim 1 , wherein said distributor unit comprises a thick base plate known as distributor base-plate (141) welded to the inner side of said front-wall (80) and also welded to the inner side of said vertical, upper left-side-wall (85) and said vertical, upper right-side -wall (82), in an inclined position, for the free flow of bulk material, just below said pre-feeder, proceeding from said front wall (80) towards said back-wall (81) and ends just before touching said back-wall (81) giving a gap known as the hit-gap (87) which depends on the bulk material size range and speed at which the material slides down said distributor wear-plate (38) and is fixed. 15. The Impact-hopper as claimed in claim 14, wherein said distributor unit comprises a wear-plate known as distributor wear-plate (38) positioned over said base-plate (141) and bolted to threaded holes (143) in said distributor base-plate (141). 16. The Impact-hopper as claimed in claim 14, wherein said distributor unit comprises a convex strip known as pre-expander (40) at the bulk material receiving end, set on top of said distributor wear-plate (38) bolted to plurality of threaded holes (142) in said distributor base-plate (141). through aligned holes (41) in said distributor wear-plate (38) and in both ends of said pre-expander (40). 17. The Impact-hopper as claimed in claim 14, wherein two deflectors (88) are fixed at the two corners of the discharge end of said distributor wear-plate (38) and are bolted to plurality of threaded holes (156) in said distributor base-plate (141) through aligned holes (115) in said distributor wear-plate (38) and said two deflectors (88). 18. The Impact-hopper as claimed in claim 1 , wherein said feed-plate (19) ends just before said pre-expander (40) and focuses on the centre of said pre-expander (40) giving a gap known as feed-gap (222) which depends on the bulk material size range and speed at which the material slides down said feed-plate (19) and is fixed. 19. The Impact-hopper as claimed in claim 1 , wherein the inclination angle of said feed plate (19) and the inclination angle of said distributor base-plate (141) are fixed. 20. The-lmpact hopper as claimed in claim 1 , wherein said streamliner (42) is a concave trapezium plate with a barrier-blade (47) at its centre, fixed below the hit-gap, in an inclined position, touching said inclined, removable, lower left-side-wall (36) and said inclined, removable, lower right-side-wall ( 31), bolted to said back-wall (81) with the help of a bracket (167) welded to the back part of said streamliner (42) with the help of plurality of nuts (166) welded to said bracket (167) using plurality of bolts (27) through plurality of holes in said back-wall (81). 21. The Impact-hopper as claimed in claim 20, wherein said barrier-blade (47) edges are sharp. 22. The Impact-hopper as claimed in claim 1 , wherein said mini-expander unit comprises a mini-expander (43) bolted to mini-expander base (223), said mini-expander base (223) welded to bracket (44) means a hollow box type bracket; left arm (161 ) means a flat strip attached to left side of said mini-expander-base (223), right arm (162) means a flat strip attached to right side of said mini-expander base (223); an adapted linear motion potentiometer sensor (164) bolted to said bracket (44) and linear motion potentiometer sensor piston head (90) bolted to back side of said skirt-board (113); an adapted actuator unit known as mini-expander actuator unit means a motor (28) coupled to a self-locking gear-box (29) fixed on base (185) using bolts and nuts (184), coupled to a shaft (45) with threads (118), means said shaft (45) using journal bearing (119) fixed to back side of said skirt-board (113), said shaft with threads (118) fitting in to a nut (46), said nut (46) welded inside a hole in said bracket (44); two threaded holes in said left-arm (161) and two threaded holes in said right arm (162) are for fixing studs (48). 23. The Impact-hopper as claimed in claim 22, wherein equaliser-gap 248 means, the distance between said streamliner (42) discharge edge and said mini-expander (43) discharge edge. 24. The Impact-hopper as claimed in claim 1 , wherein said skirt-board (113) covered on left, right and back sides except on front side through which, layered bulk material flows forward. 25.The Impact-hopper as claimed in claim 24, wherein said skirt-board (113) which is fixed to said Impact-hopper (1) by its flange connected to Impact-hopper bottom-flange (34), stays just above the bottom conveyor (5) leaving a gap. 26. The Impact-hopper as claimed in claim 24, wherein said skirt-board (113) on the left side and on the right side a removable bracket (159) on each side is fixed to flanges (112) using bolts and nuts (111 ) through holes (157) in said removable bracket (159). 27.The Impact-hopper as claimed in claim 26, wherein top portions of said flanges (112) are connected to flange (34) by welding. 28. The Impact-hopper as claimed in claim 24, wherein two slots (158) are provided in each of said removable bracket (159), in which two movable studs (48) move, which are connected to threaded holes (165) in said left-arm (161) and said right-arm (162) in said mini-expander unit, with lock-nuts (203) at their ends. 29. A Three-way splitter comprises a top-box (224), first-duct (57), second-duct (58), third-duct (59). 30. The three-way splitter of claim 29, wherein said top-box (224) comprises first splitter-blade (50) having stiffeners (259), fixed to first splitter-blade base (108) by plurality of bolts and nuts (109); said first splitter-blade base (108) being connected to first splitter blade shaft (103) using bolts and nuts (246) ; said first-splitter-blade-shaft (103) being journaled to said top-box (224) on both sides and the actuator side being coupled to self locking gear-box (51); the opposite side being fixed with an angular sensor (62); second-splitter-blade (49) having stiffeners (260) fixed to second-splitter-blade-base (199) using plurality of bolts and nuts (200); said second-splitter-blade-base (199) being connected to second splitter-blade-shaft (201) using plurality of bolts and nuts (247); said second-splitter-blade-shaft (201) being journaled to said top-box (224) on both sides and the actuator side being coupled to self locking gear-box (65); the opposite side being fixed with an angular-sensor (61); a first-splitter-blade-actuator unit comprising a motor (52) coupled to a self-locking gear-box (51); a second-splitter-blade-actuator unit comprises a motor (67) coupled to a self-locking gear-box (65); a first-splitter-blade-actuator unit base (105) and second-splitter-blade-actuator unit base (196) fixed by welding, diagonally opposite to each other on the outer side of said top-box (224). 31. The three-way splitter of claim 29, wherein said motor (52) is coupled to said self-locking gear-box (51), fixed to said first-splitter-actuator unit base (105) by plurality of bolts and nuts (202). 32. The three-way splitter of claim 29, wherein said motor (67) coupled to said self-locking gear-box (65) and fixed to said second-splitter-actuator unit base (196) by plurality of bolts and nuts (195). 33. The three-way splitter of claim 29, wherein the flange (37) at the top edge of said top-box (224) is connected to the angles of the support structure by plurality of bolts and nuts (188). 34. The three-way splitter of claim 29, wherein the bottom portion of said top-box (224) below the said first splitter blade shaft (103) branches into first duct (57) and second duct (58). 35. The three-way splitter of claim 29, wherein the bottom portion of said top-box (224.) below the said second splitter blade shaft (201) branches into said second-duct (58) and third duct (59). 36. The three-way splitter of claim 29, wherein each splitter-duct has three segments namely top-segment, middle-segment and bottom-segments. 37. The three-way splitter of claim 36 wherein the top-segment of said first-duct (57) is the portion between said first-splitter-blade-shaft (103), first-duct back-wall (226) and first-duct middle pair of flanges (193). 38. The three-way splitter of claim 36 wherein the middle-segment of said first-duct (57) is the portion between said first-duct middle pair of flanges (193) and first-duct bottom pair of flanges (.147). 39. The three-way splitter of claim 36 wherein the bottom-segment of said first-duct (57) is-the portion below said first-duct bottom pair of flanges (147) up to the portion just below the clean-out-door (56). 40. The three-way splitter of claim 36 wherein the top-segment of said second-duct (58) and top segment of said third-duct (59) have a common middle pair of flanges (191). 41. The three-way splitter of claim 36, wherein the top-segment of said second-duct (58) is the portion between the two splitter-blades and the middle pair of flanges (191). 42. The three-way splitter of claim 36, wherein the middle segment of the said second-duct (58) is the portion between the middle pair of flanges (191 ) and bottom pair of flanges (146). 43. The three-way splitter of claim 36, the bottom-segment of said second-duct (58) is the portion below said second-duct bottom pair of flanges (146) up to the portion just below the clean out door (53). 44. The three-way splitter of claim 29, wherein brackets (189) are welded at the outer side of bottom-segments of said first-duct (57), said second-duct (58) and said thirdrduct (59) below the lower pairs of flanges and are fixed to holes in the angles of said frame (78 ) by bolts and nuts (194) using holes near the edges of said brackets (189). 45. The three-way splitter of claim 44, wherein the same level brackets (189) are welded between first-duct front-wall (225) and second-duct back-wall (230), between second-duct front-wall (229) and third-duct back-wall (234), which are connected by bolts and nuts. 46. The three-way splitter of claim 29, wherein just below the said first-splitter-blade-shaft (103 ), and inside the first-duct (57) post-feeder-1 , a feeder-plate (73) is connected to brackets (213) welded at an inclined position to the inner side of left-side-wall (228) and right-side-wall (227) by bolts and nuts through the holes (214) in said post feeder-1 feeder plate (73) and holes in said brackets (213). 47. The three-way splitter of claim 46, wherein the post-feeder- 1 feeder-plate (73) inclines from said front-wall (225) towards said back-wall (226) leaving a gap known as first-duct post-feeder gap (261). 48. The three-way splitter of claim 46, wherein below post-feeder-1 , a wear-plate-T(211) which is a rectangular plate covering area between middle pair of flanges (193) and bottom pair of flanges (147) is fixed to holes in said back-wall (226) by bolts and nuts. 49. The three-way splitter of claim 46, wherein post-expander-1 (72) is. fixed at the upper portion of said wear-plate-1 (211 ) through set holes (209) and set holes (208) in said wear-plate-1 (211) and set matching holes in said back- wall (226) by bolts and nuts. 50. The three-way splitter of claim 36, wherein said middle-segments are wider than said top-box (224) in order to handle the expanded bulk material. 51.The three-way splitter of claim 36, wherein, in the bottom-segments below the camera and light source, the ducts narrow down to fit a conveyor skirt box or a conveyor inlet duct or an elevator inlet-duct. 52. The three-way splitter of claim 46, wherein said bottom-segment of said first-duct (57) comprises: a light-source base (237) attached to the outer side of said back-wall (226) by welding; a rectangular slit provided at said back-wall (226) in front of said light-source (173) for the light to pass through; a camera- base (238) attached to the outer side of said front- wall (225) by welding; a hole te provided at said front-wall (225) in front of said camera (!76) for said camera (176) to receive light from said light-source (173). 53. The three-way splitter of claim 52 wherein the light-source (173) is fixed to said base {237) by bolts and nuts through holes in said base (237) and holes in said light source (173). 54.The three-way splitter of claim 52 wherein the camera (176) is fixed to said base (238) by bolts and nuts through holes in said base (238) and holes in said camera (176). 55. The three-way splitter as claimed in claim 52, wherein at said bottom- segment, the camera, its base and the corresponding hole on the wall-can be on either wall, back-wall or front-wall. 56. The three-way splitter as claimed in claims 52 and 55 wherein the light-source, its base and corresponding slit can be on either wall, back-wall or front-wall, based on the condition that both camera and light source must be on opposite walls to each other. 57. The three-way splitter as claimed in claims 55 and 56 wherein this condition applies to each of said ducts. 58. The three-way splitter as claimed in claim 29, wherein the middle-segment of said first-duct (57), comprises a clean-out door (55) fixed using plurality of bolts (192) through holes in said clean-out door (55) fitting in to nuts welded on the inner side of said right-side-wall (227) through preset holes in said right-side-wall (227). 59. The three-way splitter as claimed in claim 29, wherein the the bottom-segment of said first-duct (57) comprises a clean-out door (56) fixed using plurality of bolts (193) through holes in said clean out door (56) fitting in to nuts welded on the inner side- of said right-side wall (227) through preset holes in said right-side wall (227). 60. The three-way splitter as claimed in claim 29, wherein just below the said second-splitter-blade-shaft (201), inside said second-duct (58) a post-feeder-2 feeder-plate (74) is connected to brackets (221) welded at an inclined position to the inner side of left-side wall (232) and right-side wall (231) by means of bolts and nuts through the holes (217) in said post feeder-2 feeder plate (74) and preset holes (220) in said brackets (221). 61. The three-way splitter as claimed in claims 29 and 60 , wherein said post-feeder-2 feeder-plate (74) inclines from said back-wall (230) towards said front-wall (229) leaving a gap known as second-duct post-feeder-gap (262), 62. The three-way splitter as claimed in claims 29 and 60, wherein the middle-segment of said second-duct (58), comprises of a clean-out door (63) fixed using plurality of bolts (192) through holes in said clean-out door (63) fitting in to nuts welded on the inner side of said right-side wall (231) through preset holes in said right-side wall (231), 63. The three-way splitter as claimed in claims 29 and 60 wherein the said bottom-segment of said second duct (58) comprises a light-source base (239) attached to the outer side of said back- wall (230) by welding; a rectangular slit is provided at said back wall (230) in front of said light-source (174) for the light to pass through; a camera base (240) attached to the outer side of said front-wall (229) by welding; a hole is provided at said front wall (229) in front of said camera (!76) for said camera (177) to receive light from said light source (174). 64. The three-way splitter as claimed in claims 29 and 60 wherein the bottom-segment of said second-duct (58) comprises a clean-out door (53) fixed by plurality of bolts (193) through preset holes in said clean out door (53) fitting in to nuts welded on the inner side of said right-side wall (231 ) through preset holes in said right-side wall (231). 65. The three-way splitter as claimed in claims 29 and 63 wherein said light-source (174) is fixed to said base (239) using bolts and nuts through preset holes in said base (239) and holes in. said light- source (174). 66. The three-way splitter as claimed in claims 29 and 63 wherein said camera (177) is fixed to said base (240) by bolts and nuts through preset holes in said base (240) and holes in said camera (177). 67. The three-way splitter as claimed in claim 29, wherein said third-duct (59) is similar to said second-duct (58). 68. The three-way splitter as claimed in claim 29, wherein said dust-removal pipe (64) which branches into three bent pipes namely pipe - a (106), pipe - b (110) and pipe - c (127) and are inserted in to middle-segments of right-side walls of said first-duct (57), said second-duct (58) and said third-duct (59) respectively. 69. The three-way splitter as claimed in claim 68, wherein pipe - a (106) is biggest, said pipe - b (110) smaller and said pipe - c (127) the smallest and pipe-ending (198) at said third duct (59) is blinded; the flange (197) is connected to the suction pipe of a dust-removal blower and the discharge pipe (79) of said blower branches out into plurality of small bent pipes (243) which are fixed in to the upper portion of top-hopper (2) using U-clamps (86). 70. The three-way splitter as claimed in claim 68, wherein the dust-removal pipe (64) is fixed using clamps (66) and bolts and nuts (121). 71. The three-way splitter as claimed in claim 68, wherein said dust-removal pipe (64) is fixed to said right-side walls or said left-side walls of said middle-segments of said first, second and third ducts on condition, said clean-out doors will be on the opposite side walls. 72. The Impact-hopper as claimed in claim 1 , wherein said walls, said wear-plates (138), said pre-feeder unit, said distributor unit, said streamliner (42), said mini-expander (43), mini-expander base (223), bracket (44), shaft (45), said skirt-board are made of non-magnetic steal or iron. 73. The three-way splitter as claimed in claim 29, wherein said top-box (224), all three ducts with post-feeders, said wear-plates, said post-expanders and said clean out doors are made of non-maqnetic steal or iron. 74. The three-way splitter of claim 29 and 62, wherein below post-feeder-2, a wear-plate-2 (102) which is a rectangular plate covering area between middle pair of flanges (191) and bottom pair of flanges (146) is fixed to holes in said front-wall (229) by bolts and huts. 75. The three-way splitter of claim 29 and 62, wherein post-expander-2 (71) is fixed at the upper portion of said wear-plate-2 (102) through set holes (114) and set holes (99) in said wear-plate-2 (102) and set matching hojes in said front-wall (229) using bolts and nuts. 76. A 4-way splitter comprises four splitter-ducts, three splitter blades with three splitter-blade angular sensors and three splitter-blade actuator units controlled by said PCU (6) and three particle-size-analyser units controlled by said PCU (6) is used in place of said 3-way splitter (4). 77. A 2-way splitter comprises two splitter-ducts, a single splitter-blade with a single splitter-blade angular sensor and with a single splitter-biade actuator unit controlled by said PCU (6) and a single particle analyser unit controlled by said PCU (6) is used in place of said 3-way splitter (4). 78. The 2-way splitter as claimed in claim 77 comprises 2 splitter ducts, a single splitter- blade with a single splitter-blade angular sensor and a single splitter-blade actuator unit, splitting on percentage of fines in incoming load basis controlled by said PCU (6). 79 An Impact-screen comprises . a top-hopper (2), a top-conveyor (3), an Impact-hopper (1), bottom conveyor (5), a 3-way splitter (4), a dust-handling unit, a process-control unit (PCU) (6) and a casing (130). 80. The Impact-screen as claimed in claim 79, wherein said top hopper (2) . comprises a high-level sensor (15) and a low-level sensor (16). 81. The Impact-screen as cla'imed in claim 79, wherein said top-hopper (2) comprises a vibrator (17) at the outside-wall for smooth flow of incoming bulk material. 82. The Impact-screen as claimed in claim 79, wherein said top-hopper (2) comprises an adjustable regulator-gate (97) to set the bulk material outflow. 83. The Impact-screen as claimed in claim 79, wherein said top-hopper (2) comprises a dust-header (79) with plurality of branches (243) at the upper portion to receive dust from said splitter ducts. 84. The Impact-screen as claimed in claim 79, wherein said top-conveyor (3) is a flat belt conveyor which runs towards said impact-hopper (1) with guide rails (12) and is powered by a variable-speed-drive unit (7) controlled by said PCU (6). i ' ' . ' . 85. The Impact-screen as claimed in claim 79, wherein a bulk material flow sensor unit (18) is fixed above said top-conveyor (3) just after said top-hopper (2) which sends rate of flow of bulk material information to said PCU (6). 86. The Impact-screen as claimed in claim 79, wherein said Impact-hopper (1) comprises a pre-feeder unit which receives bulk material from said top-conveyor(3). 87. The Impact-screen as claimed in claim 86, wherein said Impact-hopper (1) comprises a distributor unit which receives and spreads said bulk material to a thin layer using said pre-expander (40) de.wering it to said hit bar (24), and said deflectors (88) prevent straying bulk material from hitting back wall corners. 88. The Impact-screen as claimed in claim 86, the hit-bar (24) gets hit by bulk material from said distributor.unit that the smallest particles of bulk material fall close to said back-wall (81) and the bigger particles fall away from said back-wall (81 ), part of the bulk material falling on said lower-left-side wall (36) and said lower-right-side wall (31 ). 89. The Impact-screen as claimed in claim 86, wherein the Impact-hopper (1) comprises a streamliner (42) which is concave, receives falling material in a way major portion of said material flows to the centre towards said barrier-plate (47) and delivers into said mini-expander unit. 90. The Impact-screen as claimed in claim 86, wherein the Impact-hopper (1 ) comprises said mini-expander (43) which is convex, receives the bulk material from said streamliner (42) and neutralises the convex portion of bulk material at the centre, making it flat ί 91. An Impact-screen as claimed in . claim 86, wherein the Impact-hopper (1) comprises said mini-expander (43) which is moved forward or backward by an actuator unit controlled by said PCU (6) which is monitored by said linear-motion potentiometer-sensor (164) which sends a feed back to said PCU (6). 92. The Impact-screen as claimed in claim 86, wherein said bottom-conveyor (5) is a flat belt conveyor running towards said 3-way splitter (4), with guide rails and is powered by a variable. speed drive unit (8) controlled by said PCU (6). · 93. The Impact-screen as claimed in claim 92, wherein the bottom-conveyor (5) receives bulk material falling from said Impact-hopper (1) in a flattened, layered manner that small particles are at the bottom and gradually bigger particles at the top, delivering it to said 3-way splitter (4). 94. The Impact-screen as claimed in claim 79, wherein said 3-way splitter (4) comprises said first splitter-blade (50) which receives said flattened & layered material and splits into fines and medium oarticles sending fines to said first-duct (57) and medium sized particles to said second-duct (58). 95. The Impact-screen as claimed in claim 94, wherein the 3-way splitter (4) comprises said second-splitter-blade (49) which receives remaining material and splits into medium particles and big particles sending medium particles to said second-duct (58) and big particles to said third duct (59). 96. The Impact-screen as claimed in claim 94, wherein said 3-way splitter comprises said first-duct (57) receives said fines which pass through said post-feeder-1 (73) and post-expander-1 (72) and spread out as a thin layer on said wear-plate and fall through the particle-size-analyser comprising said camera (176) and said light source (173), to the respective conveyor or elevator. 97. The Impact-screen as claimed in claim 94, wherein said 3-way splitter comprises said second-duct (58) receives said medium sized particles which pass through said post-feeder-2 (74) and post-expander-2 (71) and spread out as a thin layer on said wear-plate and fall through particle-size-analyser comprising said camera (177) and said light-source (174), to the respective conveyor or elevator. 98. The Impact-screen as claimed in claim 94, wherein said 3-way splitter comprises said third-duct (59) receives said big particles which pass through said post-feeder-3 (75) and post expander-3 (70) and spread out as a thin layer on said wear-plate and fall through particle-size-analyser comprising said camera (178) and said light-source (175), to the respective conveyor or elevator. 99. The Impact-screen as claimed in claim 79, wherein a dust-pan (91 ) is fixed between said bottom-conveyor (5) discharge frame and inner side of said back- wall (226) of said first-duct (57), where fine dust gets collected and slides into said first-duct (57). 100. The Impact-screen as claimed in claim 94, wherein the 3-way splitter comprises two splitter-blades which are tilted forward or backward by two actuator units, which are controlled by said PCU (6) according to the feedback from particle-size-analyser units, and the two angular-sensors, fixed to said splitter-blade shafts send splitter-blades position detail to said PCU (6). 101. The Impact-screen as claimed in claim 79, wherein a dust-handling unit comprises a dust-header (64) branching in to each of the splitter ducts; bigger branch pipe in said first-duct (57), smaller n said second-duct (58) and even smaller in said third-duct (59), in the middle-segments to remove dust, which is connected to a blower and its discharge-header (79) branches into plurality of small pipes (243) into said top-hopper (2) upper portion to deliver the collected dust. 102. The Impact-screen as claimed in claim 101 , wherein said dust-handling unit protects the camera & light-source from dust and for clear visibility of falling particles. 103. The impact-screen as claimed in claim 79, wherein said dust-handling unit comprises a dust-header (64) branching into plurality of pipes with adequate support into each of splitter ducts; more number of pipes inside said first-duct (57), lesser number of pipes inside said second duct (58) and even lesser number of pipes inside said third duct (59), in the middle-segments. 104. The Impact-screen as claimed in claim 79, wherein a casing (130) is provided, to protect falling bulk material from said top-conveyor (3) discharge and bottom-conveyor (5) discharge, from wind. 105. The Impact-screen as claimed in claim 79, wherein a contour-sensor (30) is optionally fixed immediately after said mini-expander (43) on said bottom-conveyor (5), which senses whether said layered, flattened bulk material is flat or convex or concave and sends information to said PCU (6) which adjusts said mini-expander (43) so that said layered, flattened bulk material is flat. 106. A method of operating an Impact-screen, said Impact-screen comprising receiving bulk material to be screened in ine top-hopper (2), which regulates the flow of said bulk material on the top-conveyor (3) and then delivers said bulk material into said impact-hopper (1 ); layering said bulk material by the Impact-hopper on the bottom-conveyor (5) which then delivers said layered bulk material into said 3-way splitter (4); splitting said bulk material into three different sizes by said 3-way splitter and delivering separately; controlling the screening process by a process-control-unit (PCU) (6); removing the dust evolved inside splitter-ducts by a dust-removal unit and the flowing bulk material is protected from wind by a casing (130) 107. The method of operating an Impact-screen as claimed in claim 106, wherein said bulk material to be screened is received by said top-hopper (2), on said top conveyor (3); moisture level of said bulk material not exceeding 0.5 to1.5% by weight depending on the type of bulk material used. 108. The method of operating an Impact-screen as claimed in claim 106, wherein said bulk material flows through the top-hopper (2) adjustable regulator-gate (97) which is fixed at an optimum position by adjustable bolts with nuts (96), regulates and flattens said bulk material as it flows. 109. The method of operating an Impact-screen as claimed in claim 106, wherein said bulk material flows through a bulk-material-flow-sensor (18) which senses the rate of flow of said bulk material and sends the information to said PCU (6). 110. The method of operating an Impact-screen as claimed in claim 106, wherein said bulk material then falls in to said impact hopper (1) on said pre-feeder plate (19) and slides and falls on said pre-expander (40). 111. The method of operating an Impact-screen as claimed in claim 106, wherein said bulk material is spread into a thin layer by said pre-expander (40) on said distributor-plate (38) in a way said bulk material flows in between said deflectors (88). 112. The method of operating an Impact-screen as claimed in claim 106, wherein the thin layer of said|bulk material then hits said hit-bar (24) and gets i - reflected in such a way that the fine. particles fall close to said back-wall (81 ) and bigger particles fall awayfrom said back-wall (81). Part of said reflected fine particles and bigger particles fall on said lower, inclined left side wall (36) and said lower, inclined-right-side wall (31 ). 113. The method of operating an Impact-screen as claimed in claim 106, wherein the reflected fine particles and bigger particles flow through said streamliner (42) most of said particles rushing towards the centre towards said barrier-blade (47) since said streamliner 42) is concave in shape. 114. The method of operating an Impact- screen as claimed in claim 106, wherein said particles grouped near said barrier blade (47) fall on said mini-expander (43) which is convex in shape, spreads said particles so that the total particles output falling On said bottom-conveyor (5) would be flat. 115. The method of operating an Impact-screen as claimed in claim 106, wherein said mini-expander (43) is moved forward or backward by said mini-expander actuator-unit which is cont, oiled by said PCU (6), as per rate of flow of said bulk material; said mini-expander movement is sensed by said linear-motion-potentiometer-sensor (164) which sends the information to said PCU (6). 116. The method of operating an Impact-screen as claimed in claim 106, wherein the output from said Impact-hopper (1 ) falling on said bottom-conveyor (5) is layered and flattened bulk material ir. a way that finer particles are at the bottom, over that the medium sized and on top bigger particles, all in a gradual manner. 117. The method of claim of operating an Impact-screen as claimed in claim 106, wherein said layered and flattened bulk material is delivered by said bottom-conveyor (5) into said 3-way splitter. 118. The method of claim of operating an Impact-screen as claimed in claim 106, wherein said layered and flattened bulk material falls on said first-splitter-blade (50) and the separated fine particles fall into said first-duct (57) and medium sized particles in to said second-duct (58). 119. The method of claim of operating an Impact-screen as claimed in claim 106, wherein the rest of said layered, flattened bulk material falls on said second-splitter-blade (49) and the separated medium sized particles fall into said second duct (58) and the separated bigger particles fall in to said third-duct (59). 120. The method of claim of operating an Impact-screen as claimed in claim 106, wherein said fine particles fall. on post-feeder-1 (73). 121. The method of claim of operating a Impact-screen as claimed in claim 106, wherein said fine particles slide and fall on said post-expander- 1 (72) and spread into a thin layer on said wear-plate-1 (21 1 ) and fall. 122. The method of claim of operating an Impact-screen as claimed in claim 106, wherein said thin layer of fine particles fall through the space between said camera (176) and said light-source (173), which are part of first-duct particle-size-analyser unit and fall into the inlet of a screen output conveyor or elevator. 123. The method of claim of operating an Impact-screen as claimed in claim 106, wherein said separated medium sized particles in said second-duct (58) and separated bigger particles in said third-duct (59) go through similar processes as said fine particles go through said first-duct (57). 124. The method of claim of operating an Impact-screen as claimed in claim 106, wherein said particle-size-analyser in each of said ducts, senses the size of said fine, medium and bigger size particles and sends the information to said PCU (6). 125. The method of claim of operating an Impact-screen as claimed in claim 106, wherein said PCU (6) actuates said fi st splitter blade (50) or said second splitter blade (49) or both, by respective splitter-blade actuator-units and getting feedback from particle-size-analysers and respective angular sensors, as said PCU (6) is programmed to allow particular range of particle sizes in to respective ducts. 126. The method of claim of operating an Impact-screen as claimed in claim 106, wherein as said bulk material inflow increases and hits high level mark said high level sensor (15) gets actuated and sends information to said PCU (6). 127. The method of claim of operating an Impact-screen as claimed in claim 106, wherein said PCU (6) increases the speed of said top-conveyor (3) giving command to said variable speed drive-unit (7) and getting feedback from top-conveyor speed-sensor (11) to maintc.n said bulk material level in said top-hopper (2) at an optimum preset level. 128. The method of claim of operating an Impact-screen as claimed in claim 106, wherein said PCU (6) receives increased said bulk material rate of flow information from said bulk-material flow-sensor (18) and accordingly decreases the speed of said bottom-conveyor (5) with necessary time- delay, giving command to said variable-drive-unit (8) and getting feedback from bottom-conveyor speed-sensor (14) to off ;et the forward shift in discharge flow of said layered, flattened bulk material from said bottom-conveyor (5), due to increase in said bulk material rate of flow. 129. The method of claim of operating an Impact-screen as claimed in claim 106, wherein said PCU (6) moves forward said mini-expander (43) using said actuator-unit, corresponding to increased bulk material rate of flow information from said bulk-material flow-sensor (18) and getting feed back from said linear-motion-potentiometer-sensor (164). 130. The method of claim of operating an Impact-screen as claimed in .claim 106, wherein as said bulk material flow decreases and hit the low level mark, said low-level sensor (16) gets actuated and sends information to said PCU (6). 131. The method of claim of operating an Impact-screen as claimed in claim 106, wherein said PCU (6) decrease· ; the speed of said top-conveyor (3) giving command to said variable-speed drive-unit (7) and getting feedback from top-conveyor speed-sensor (1 1) to maintain said bulk material level in said top-hopper (2) at an optimum preset level. 132. The method of claim of operating an Impact-screen as claimed in claim 106, wherein said PCU (6) receives decreased said bulk material rate of flow information from said bulk-material flow-sensor (18) and accordingly increases the speed of said bottom-copveyor (5) with necessary time-delay, giving command to said variable drive unit, (8) and getting feedback from bottom- conveyor speed sensor (14) to offset the backward shift in discharge flow of said layered, flattened bulk material from said bottom-conveyor (5), due to decrease in said bulk material rate of flow. 133.The method of claim of operating an Impact-screen as claimed in claim 106, wherein said PCU (6) moves backward said mini-expander (43) using said actuator-unit, corresponding to decreased bulk material rate of flow information from said bulk material flow-sensor (18) and getting feed back from said linear motion potentiometer sensor (164). 134. The method of claim of operating an Impact-screen as claimed in claim j’ 106, wherein dust inside said splitter-ductc is removed using a dust-handling unit comprises a dust-header (64) branching in to each of the splitter-ducts; bigger branch pipe in said first duct, smaller in said second duct and even smaller in said third duct; in the middle-segments to remove dust, which is connected to a blower and its discharge header (79) branches into plurality of small pipes into said top hopper (2) upper portion to deliver the collected dust. This is to protect camera & light-source from dust and for clear visibility of falling particles. |
FIELD OF THE INVENTION
This invention is about screening of bulk materials like Urea, NPK, sand, iron ore ..etc. without using screening-meshes.
DESCRIPTION OF THE PRIOR ART
When it comes to bulk material screening, vibrating screens are being used for many decades now. But due to operational and maintenance difficulties due to meshes, alternate types of screening are evolving. One such type regarding bulk material screening without using meshes, is cyclone type bulk material screening. One such cyclone type screening machine is shown in
US Pat. no. 6186334 B.
But in this prior art, output is only fines and coarse material and handling large volumes needs a lot of energy and space. In this present invention of
Impact-screen, bulk material is segregated into multiple grades, handling large volumes with lesser energy and space.
SUMMARY OF THE INVENTION
The bulk material to be screened is received into the top-hopper. It has a low-level sensor and a high-level sensor. A manually adjustable regulator-gate at the skirt-board controls the output rate of the material flow at the
top-conveyor. A flow sensor sends the rate of flow information to the Process Control Unit (PCU). The top-conveyor is a variable-speed flat-belt conveyor.
The flattened bulk material is delivered by the top-hopper into the
Impact-hopper, on the pre-exp>ander through the pre-feeder unit. Here the bulk material gets dispersed uniformly sliding through the distributor-plate.
The thin layer of spread out bulk material hits the hit-bar at the back-wall which is vertical and gets reflected in a way, the fines fall close to the back-wall and gradually the bigger particles fall further away from the back-wall. Then the falling material passes through the streamliner which is concave and through the mini-expander which is movable and convex. The mini-expander is moved forward or backward by an actuator-unit which is controlled by the PCU. A linear-sensor monitors the mini-expander movement and sends the feed back to the PCU.The bulk material output after the mini-expander is flat and layered in a way that the fines are at the bottom and bigger particles are on top gradually, as it falls on the bottom-conveyor.
The bottom-conveyor runs at an optimum speed and delivers the layered, flattened bulk material into the 3-way splitter. The two splitter-blades split the layered, flat bulk material into fines, medium and bigger particles and they fall into the first-duct, second-duct and third-duct respectively.
Each of the splitter blades are tilted using separate actuator-units controlled by the PCU. Tilting angles of the splitter-blades are monitored by separate angular-sensors which send feedbacks to the PCU. Each splitter-duct has a post-feeder unit followed by a wear-plate with a post-expander and a particle analyser-unit which has a camera and a light-source.
The separated material falls through the feeder and then dispersed by the post-expander, pass through the particle-size-analyser. If the falling particles are not within the set size range, the particle-size-analyser sends feedback to PCU and the PCU adjusts the splitter-blade accordingly, getting feedbacks from angular-sensors. When the top-hopper input is not constant and the level increases, the high-level alarm is activated, the PCU increases the speed of the top-conveyor and slows the speed of the bottom-conveyor.
When the top-hopper input decreases, the low-level alarm is activated, the PCU decreases the speed of the top-conveyor and increases the speed of the bottom-conveyor. When the rate of bulk material flow increases, PCU moves the mini-expander forward and when the rate of bulk material flow decreases PCU moves the mini-expander backward so that the output from the
Impact-hopper is flat.
The foregoing abstract is not to be taken as limiting the invention described herein, and in order to understand the full nature and extent of the technical disclosure herein, reference should be made to the accompanying drawings and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be more fully understood, some embodiments will now be described with reference to the figures in which: FIG. 1 is a perspective right-side view of an impact-screen ;
FIG. 2 is a perspective angular view of the top-hopper and the top-conveyor ; FIG. 2a is a perspective view of the top-hopper regulator ;
FIG. 3 & 4 are perspective views of impact-hopper’s front and back portions ; FIG. 5 is an angular right-side perspective view of impact-hopper ;
FIG. 6 is the vertical cut-view of impact-hopper with the back-wall removed ; FIG. 7 is the vertical cross-section view of impact-hopper with the right-side walls removed ;
FIG. 8 is the horizontal cross-section view of the impact-hopper showing the streamliner and the mini-expander ;
FIG.9 is impact-hopper skirt-board left side view showing left-side
movable-studs of mini-expander unit ;
FIG. 10 is a perspective view of distributor wear-plate with
pre-expander ;
FIG. 11 is a perspective bottom view of impact-hoppershowing mini-expander unit inside Impact-hopper ;
FIG. 12 is a perspective view of the distributor base-plate ;
FIG. 13 is a perspective view of the mini-expander movable stud ;
FIG. 14 is a perspective view of inclined, removable, lower left-side or right-side wall ;
FIG. 15 is a perspective view of side-wall wear-plate ;
FIG. 16 is a perspective view of hit-bar ;
FIG. 17 is a perspective view of the removable bracket for mini-expander movable studs ;
FIG. 18 is a perspective view of mini-expander unit ;
FIG. 19 is a perspective back-side view of streamliner with the bracket ;
FIG. 20 & 21 are perspective views of pre-feeder fixing brackets and
pre-feeder respectively ;
FIG. 22 is a perspective view of a U-clamp with bolt & nuts which hold the hit-bar ;
FIG. 23 is a perspective view of the dust-pan ;
FIG. 24 & 25 are perspective right-side and left-side views respectively of a 3-way splitter ; FIG. 26 & 27 are transparent view of a 3-way splitter from Its right side ;
FIG. 28 is a perspective plan view of a 3-way splitter ;
FIG. 29 is a perspective plan view of top-hopper ;
FIG. 30 is a perspective angular view of an Impact-screen with outer casing ;
FIG. 31 is perspective angular views of first splitter-blade and second
splitter-blade ;
FIG. 32 is a perspective view of the dust-header with branch-pipes ;
FIG. 33 is a schematic block-diagram showing the inputs outputs of PCU ;
FIG. 34 is a schematic block-diagram of splitter-unit dust-handling system ;
FIG. 35 & 36 are perspective views of first- duct wear-plate and second-duct wear- plate respectively ;
FIG. 37 & 38 are perspective views of post-feeder-1 unit fixing brackets and post-feeder-1 unit respectively ;
FIG. 39 & 40 are perspective views of post-feeder-2 unit and post-feeder-2 unit fixing brackets respectively ;
FIG. 41 is a perspective view of a 4-way splitter ;
FIG. 42 is a perspective view of a 2-way splitter ;
FIG. 43 is a perspective view of a simple 2-way splitter.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In describing different embodiments of the present invention common reference numerals are used to describe like features.
Referring to FIG.1 there is shown 2 the top hopper which receives the bulk material with moisture level of bulk material not exceeding 0.5 to1.5% by weight depending on the type of bulk material used. The top hopper 2 has a high level sensor 15 and a low level sensor 16 which send signal to the computer 6 in FIG. 1 known as Process-Contrpl-Unit, PCU in short. The top hopper 2 has a vibrator 17 as shown in FIG.2 attached to it, which works at equal intervals to avoid deposits and for free flow of bulk material received.
Referring to FIG. 2a, there is shown the regulator-gate 97, fixed at the
skirt-board of Top hopper 2. The regulator-gate 97 can be moved up or down and fixed in position by bolts and nuts 96 which move in rectangular slots (not shown). The top half portion of the skirt-board behind the regulator-gate 97 is partially closed by a welded plate to avoid spilling over of bulk material when the regulator-gate 97 is lowered. There are position markings 129 as shown in FIG. 2a, to know the position and alignment of regulator-gate 97. The received bulk material gets flattened as it flows through the regulator-gate 97.
Underneath the top hopper 2 is the top conveyor 3 as shown in FIG. 1. It is a flat-belt conveyor. It is powered by a variable speed drive-unit 7 with the speed-sensor 11 as shown in FIG. l and 2. A local switch-panel 10 is provided to start or stop the top-conveyor locally. It has got guide-plates 12 on both sides of the flat conveyor belt. A rubber-strip 13 is bolted to the guide-plate 12 to avoid bulk material from straying away. After the regulator-gate 78 a bulk-material flow-sensor unit 18 is fixed as shown in FIG. 2. The bulk material flow-sensor unit 18 senses the rate of flow of passing bulk material and sends information to the PCU 6. After top conveyor 3 the impact-hopper 1 is located as shown in FIG. 1. impact-hopper 1 is an important part of this invention, since most part of the separation happens here. The flange 144 fixed by welding, at the upper portion of the impact-hopper 1 , is connected to the main supporting structure 78 using bolts and nuts 183. At the middle level the bracket 69 welded to the front-wall 80, and the bracket 32 welded to the back-wall 81 , are attached to the main supporting structure 78 by bolts and nuts 35.
The impact-hopper 1 has two parallel vertical walls known as front-wall 80 and back-wall 81 as shown in FIG. 3 and FIG. 4. On the left side, it has vertical upper left side wall 85 and inclined, removable lower left side wall 36. On the right side, it has vertical upper right side wall 82 and inclined, removable lower right side wall 31 as shown in FIG. 4 & 5. As shown in FIG.14, removable lower right side wall 31 has flanges 84, with fixing holes 139. The removable lower left side wall 36 is similar to the removable lower right side wall 31. The removable lower left side wall 36 and the removable right side wall 31 are fixed to respective flanges by plurality of bolts and nuts 33. The front-wall 80 has an inspection door 22 fixed by plurality of bolts and nuts 23 as shown in FIG. 3.
The brackets in the front-wall 80 and back-wall 81 are fixed to the structure 78 by bolts and nuts 35. The upper flange 144 is fixed to the structure 78 by bolts and nuts 183. The impact-hopper 1 has replaceable wear-plate known as side wall
wear-plate 138 with fixing plurality of preset holes 140 as shown in FIG.15 is fixed in between inclined, removable, lower left side wall 36 and flanges 34; and another said side wall wear-plate 138 is fixed between inclined, removable, lower right side wall 31 and flanges 34 wherein rubber or other suitable material gaskets are introduced in-between each of the flanges so that only the wear- plate 138 surface comes in contact with the falling bulk material. .
The flattened bulk material is received by the pre-feeder unit inside the impact hopper 1 , which has the feeder-plate 19 with guide-plates 20 as shown in FIG.
3. and FIG. 21. The feeder-plate fixing brackets 169 are welded to the vertical upper left side wall 85 and vertical upper right side wall 82 at an optimum inclined angle, according to the characteristics of the bulk material handled. The feeder-plate 19 is fixed to the fixing brackets 169 as shown in FIG. 20, through plurality of holes 168 in the fixing brackets 169 and plurality of holes 120 in the feeder-plate 19 using plurality of bolts and nuts 21.
The bulk material from the pre-feeder unit is received by the distributor unit.The distributor unit comprises a thick base-plate known as distributor base-plate 141 welded to the inner side of front wall 80 and also . welded to the inner side of said vertical, upper left side wall 85 and vertical, upper right side wall 82, in an inclined position, for the free flow of bulk material, just below the pre-feeder, proceeding from the front wall 80 towards the back wall 81 and ends just before touching the back wall 81 giving a gap known as the hit gap 87, which depends on the bulk material size range and speed at which the material slides down the distributor wear-plate 38 and. is fixed.
Referring to FIG. 6,10 & 12, the distributor unit comprises a wear-plate known as the distributor wear-plate 38 positioned over the base-plate 141 and bolted to threaded holes 143 in the distributor base-plate 141 , through the preset holes 187 in the distributor wear-plate by plurality of bolts and nuts 39. The distributor unit comprises a convex strip known as pre-expander 40 at the bulk material receiving end, set on top of the distributor wear-plate 38, bolted to plurality of threaded holes 142 in the distributor base-plate 141 , through aligned holes 41 in the distributor wear-plate 38 and in both ends of the pre-expander 40. The distributor unit comprises two deflectors 88 fixed at the two corners of the discharge end of the distributor wear-plate 38 and are bolted to plurality of threaded holes 156 in the distributor base-plate 141 through aligned holes 115 in the distributor wear-plate 38 and the two deflectors 88.
The feed plate 19 ends just before said pre-expander 40 and focuses on the centre of the pre-expander 40 giving a gap known as feed-gap 222 which depends on the bulk material size range and speed at which the material slides down the feed-plate 19 and is fixed. The inclination angle of the feed plate 19. and the inclination angle of the distributor base-plate 141 are fixed.
Referring to FIG. 6 & 7 the bulk material falling on the pre-expander 40 is spread as a thin layer on the distributor wear-plate 38, slides on the distributor wear-plate 38 and hits the hit-bar 24 passing through the hit-gap 87. Even at maximum load the bulk material gets spread in between the deflectors 88 before hitting the hit-bar 24. The straying bulk material particles are diverted by the deflectors 88 to hit the hit-bar 24.
The hit-bar 24 is located at the back-wall 81 just above the inclined,
removable, lower left side wall 36 and the inclined, removable, lower right side wall 31. As shown in FIG.16, the hit-bar 24 has a step 145 inward as to fit perfectly with the inner surface of the back wall 81. As shown in FIG.4, 5 and 22, the hit-bar 24 is fixed in position by plurality of U-clamps 25, the legs of which are welded to said back wall 81 and plurality of bolts 26 , by plurality of fixed nuts 179 which are welded to the U-clamps and plurality of lock nuts 180. The hit-bar 24 is quickly replaceable and is made of steel or other alloys or metal or elastomeric material.
The thin layer of bulk material hits the hit-bar 24 and gets reflected according to Newton’s 3rd law of motion and hence the fine particles fall close to the back-wall 81 and gradually bigger particles fall away from the back-wall 81, Part of the reflected particles fall forward and part of the reflected particles falls on. the inclined, removable, lower left side wall 36 and the rest on the inclined, removable, lower right side wall 31. Collectively all the reflected material falls on streamliner 42.
The streamliner 42 is a concave trapezium plate with a barrier blade 47 at its centre as shown in FIG. 7 & 8, fixed below the hit-gap 87, in an inclined position, touching the inclined, removable, lower left side wall 36 and the inclined, removable, lower right side wall 31. bolted to the back-wall 81 with a bracket 167 welded to the back part of the streamliner 42 by plurality of nuts 166 welded to the bracket 167 as shown in FIG.19, by plurality of bolts 27 through plurality of holes in the back wall 81. The barrier blade 47 edges are sharp.
The streamliner 42 receives the falling material in a manner the finer particles are at the bottom and gradually the bigger particles are on top. The streamliner output material is convex at the centre and flat on the sides since the
streamliner 42 is concave. After passing through the streamliner 42, the layered bulk material falls on the mini-expander 43.
Referring to FIG. 8,11 & 18, the mini-expander unit comprises a mini-expander 43 bolted to mini-expander base 223 by plurality of bolts and nuts 163, the mini-expander-base 223 welded to bracket 44 means a hollow box type bracket; left arm 161 means a flat strip attached to left side of the mini-expander base 223; the right arm 162 means a flat strip attached to right side of the mini-expander base 223; an adapted linear motion potentiometer sensor 164 bolted to the bracket 44 using bolts 155 and linear-motion potentiometer-sensor -piston 89 with the piston-head 90 bolted to back side of the skirt-board 113 by plurality of bolts and nuts 116; an adapted actuator unit known as
mini-expander actuator-unit, means a motor 28 coupled to a self-locking (worm- gear) gear-box 29 fixed on base 185 using bolts and nuts 184, coupled to a shaft 45 with threads 118, means the shaft 45 using journal bearing 119 fixed to back side of the skirt-board 113, the shaft with threads 118 fitting in to a nut 46, the nut 46 welded inside a hole-in the bracket 44; two threaded holes in said left arm 161 and two threaded holes in the right arm 162 are for fixing studs 48. The skirt-board 113 is covered on left, right and back sides except on front side through which, layered bulk material flows forward. The skirt-board 113 is fixed to the Impact-hopper by its flange connected to the Impact-hopper bottom flange 34, stays just above the bottom conveyor 5 leaving a gap. As shown in FIG. 9, the skirt-board 113 on the left side and on the right side a removable bracket 159 on each side is fixed to flanges 112 by bolts and nuts 111 through the holes 157 in the removable bracket 159.
The top portions of said flanges 112 are connected to flange 34 by welding. As shown in FIG.17, the two slots 158 are provided in each of the removable bracket 159,. in which two movable studs 48 move, which are connected through holes 157, into threaded holes 165 in the left arm 161 and the right arm 162 in the mini-expander unit, with lock nuts 203 at their ends! The stud 48 as shown in FIG.13 has a bush area 160, which is the sliding portion. The
equaliser-gap 248 means, the distance between the streamliner 42 discharge edge and the mini-expander 43 discharge edge. The PCU 6 using the
mini-expander actuator unit, increases the equaliser-gap 248 when the bulk material flow after the regulator 78 increases and decreases the equaliser-gap 248 when the bulk material flow after the regulator 78 decreases. Thus the convex portion of layered bulk material coming out of the Impact-hopper 1 is neutralised. The overall output material coming out of impact-hopper 1 is a layered, flat bulk material as it falls on the bottom-conveyor 5. The bottom conveyor 5 has a variable speed drive-unit 8 with speed-sensor 14 as shown in FIG.1. Also a local switch panel 9 is provided to start or stop manually the bottom conveyor 5 and to control splitter blades position manually.
Referring to FIG. 24 upto FIG. 28 and FIG.31 , the layered, flat bulk material is carried by the bottom conveyor 5 and delivered in to the 3-way splitter. The bottom conveyor runs at an optimum speed, that the layered, flat bulk material is thrown in to the 3-way splitter 4, where according to Newton’s second law of motion, the fine particles fall closer, where bigger particles fall away which are captured and separated by the first splitter- blade 50 and second
splitter-blade 49.
The three-way splitter has the top-box 224, which is fixed to the structure 78 by the flange 37 fixed by plurality of bolts and nuts 188, comprises the
first-splitter-blade 50 having stiffeners 259, fixed to first splitter-blade base 108 using plurality of bolts and nuts 109; the first splitter-blade base 108 being connected to first splitter blade shaft 103 using bolts and nuts 246 ; the first splitter shaft 103 being journaled to the top-box 224 on both sides and the .
actuator side being coupled to self locking gear-box 51 ; the opposite side being fixed with an angular sensor 62; a second splitter-blade 49 having stiffeners 260, fixed to second splitter-blade base 199 using plurality of bolts and nuts 200; the second splitter-blade base 199 being connected to second splitter-blade shaft 201 using plurality of bolts and nuts 247; the second splitter-blade shaft 201 being journaled to the top-box 224 on both sides and the actuator side being coupled to self locking gear-box 65; the opposite side being fixed with an angular sensor 61 ; a first-splitter blade actuator unit comprises a motor 52 coupled to a self locking gear-box 51 ; a second-splitter blade actuator comprising a motor 67 coupled to a self locking gear-box 65; a first
splitter-blade actuator-unit base 105 and a second splitter-blade actuator-unit base 196 fixed by welding, diagonally opposite to each other on the outer side of the top-box 224. The motor 52 is coupled to the self locking gear-box 51 , fixed to the first splitter actuator-unit base 105 by plurality of bolts and nuts 202. The motor 67 is coupled to the self locking gear-box 65 and fixed to the second-splitter- actuator-unit base 196 by plurality of bolts and nuts 195. The flange 37 at the top edge of the top^box 224 is connected to the angles of the support structure by plurality of bolts and nuts 188.
The bottom portion of the top-box 224 below the first splitter blade shaft 103 branches into first duct 57 and second duct 58. The bottom portion of the top-box 224 below the second splitter blade shaft 201 branches into the second duct 58 and third-duct 59.
Each splitter duct has three segments namely top segment, middle segment and bottom segments. The top segment of the first duct 57 is the portion between the first splitter blade shaft 103, first duct back wall 226 and first duct middle pair of flanges 193. The middle segment of the first duct 57 is the portion between the first duct middle pair of flanges 193 and first duct bottom pair bf flanges 147. the bottom segment of the first duct 57 is the portion below the first duct bottom pair of flanges 147 upto the portion just below the clean-out door 56The middle pair of flanges are connected by bolts and nuts 190 as shown in FIG. 24.
The top segment of the second-duct 58 and top segment of the third duct 59 have a common middle pair of flanges 191. The top segment of second duct 58 is the portion between the two splitter-blades and the middle pair of flanges 191. The middle segment of the second duct 58 is the portion between the middle pair of flanges 191 and bottom pair of flanges 146. The bottom segment of the second duct 58 is the portion between the bottom pair of flanges 146 upto the portion below the clean out door 53. The top segment of third-duct 59 is the portion between the second splitter-blade 49, and the middle pair of flanges 191. The middle-segment of the third-duct 59 is the portion between the middle pair of flanges 191 and bottom pair of flanges 131. The bottom segment of the third-duct 59 is the portion between the bottom pair of flanges 131 upto the portion below the clean out door 54. The brackets 189 are welded at the outer side of the bottom segments of first duct 57, second duct 58 and third duct 59 below the bottom pairs of flanges and are fixed to holes in the angles of the frame 78 by bolts and nuts 194 using holes near the edges of the brackets 189. The same level brackets 189 are welded at first duct front wall 225 and second duct back wall 230, which are connected by bolts and nuts. The brackets 189 are welded at the second . duct front wall . 229 and third duct back wall 234, which are connected by bolts and nuts.
Just below the the first splitter blade shaft 103, and inside the first duct 57 post-feeder-1 , a feeder-plate 73 is connected to brackets 213 welded at ah inclined position to the inner side of left side wall 227 and right side wall 228 by bolts and nuts through the holes 214 in the post-feeder-1 feeder plate 73 and holes in the brackets 212.The post-feeder-1 feeder-plate 73 inclines from the front-wall 225 towards the back-wall 226 leaving a gap known as the first-duct post-feeder-gap 261 and has guide strips 215.
Referring to FIG.35 upto FIG.40, below post-feeder-1 , wear-plate-1 (211) which is a rectangular plate covering area between middle pair of flanges 193 and bottom pair of flanges 147 isifixed to holes in the back-wall 226 by bolts and nuts 249. The post-expander- 1 (72) is fixed at the upper portion of the .
wear-plate-1 (211) through set holes 209 and through set holes 208 in the wear-plate-1 (211) and set matching holes in the back-wall 226 using bolts and nuts as shown in FIG. 24, 26 & 35.
The middle segments are wider than the top-box 224 in order to handle the expanded bulk material.The bottom segments below the camera and light source, the ducts narrow down to fit a conveyor skirt box or a conveyor inlet duct or an elevator inlet duct.
The bottom segment of the first duct 57 comprises a light-source base 237 attached to the outer side of the back wall 226 by welding; a rectangular slit provided at the back wall 226 in front of the light source 173 for the light to pass through; a camera base 238 attached to the outer side of the front wall 225 by welding; a hole is provided at the front wall 225 in front of the camera 176 for the camera 176 to receive light from the light source 173. The light source 173 is fixed to the base 237 using bolts and nuts through holes in the base 237 and holes in said light source 173. The camera 176 is fixed to said base 238 using bolts and nuts through holes in the base 238 and holes in the camera 176.
The bottom-segment, the camera, its base and the corresponding hole on the wall can be on either wall (back wall or front wall). The light source, its base and corresponding slit can be on either wall ( back wall or front wall), based on the condition that both (camera and light source) must be on opposite walls to each other. This condition applies to each of said ducts.
The middle-segment of the first duct 57, comprises of a clean-out door 55 fixed using plurality of bolts 192 through holes in the clean out door 55 fitting in to nuts welded on the inner side. of said right side wall 228 through preset holes in the right side wall 228. The bottom segment of the first duct 57 comprises of a clean out door 56 fixed using plurality of bolts 193 through holes in the clean-out-door 56 fitting in to nuts welded on the inner side of the right side wall
228 through preset holes in the right side wall 228.
Just below the the first splitter-blade shaft 103, inside the second duct 58 the post-feeder-2 feeder-plate 74 is connected to brackets 221 welded at an inclined position to the. inner side of left side wall 231 and right side wall 232 by means of bolts and nuts through preset holes 217 in the post feeder-2 feeder plate 74 and preset holes 220 in the brackets 221. The post-feeder-2 feeder- plate 74 inclines from the back-wall 230 towards the front-wall 229 leaving a gap known as the second-duct post-feeder-gap 262 and has guide strips 219.
Below posf-feeder-2, wear-plate-2 (102) which is a rectangular plate covering area between middle pair of flanges 191 and bottom pair of flanges 146 is fixed to holes in the front-wall 229 by bolts and nuts (249). The post-expander-2 (71) is fixed at the upper portion of the wear-plate-2 (102) through set holes 114 and set holes 99 in the wear-plate-2 (102) and set matching holes in the front-wall
229 using bolts and nuts as shown in FIG. 24, 26 & 36. The middle segment of the second duct 58, comprises of a clean-out door 63 fixed using plurality of bolts 192 through holes in the clean out door 63 fitting in to nuts welded on the inner side of the right side wall 232 through preset holes in the right side wall 232. The bottom segment of the second duct 58 comprises a light-source base 239 attached to the outer side of the back wall 230 by welding; a rectangular slit is provided at the back wall 230 in front of the light source 174 for the light to pass through; a camera base 240 attached to the outer side of the front wall 229 by welding; a hole is provided at the front wall 229 in front of the camera 177 for the camera 177 to receive light from the light-source 174.The bottom segment of the second duct 58 comprises of a clean out door 53 fixed using plurality of bolts 193 through preset holes in the clean out door 53 fitting in to nuts welded on the inner side of the right side wall 232 through preset holes in the right side wall 232. The light source 174 is fixed to the base 239 using bolts and nuts through preset holes in the base 239 and holes in the light source 174. The camera 177 is fixed to the base 240 using bolts and nuts through preset holes in the base 240 and holes in the camera 177.
Just below the the second splitter-blade shaft 201 , inside the third duct 59 the post-feeder-3 feeder-plate 75 is connected to brackets (not shown) welded at an inclined position to the inner side of left side wall 235 and right side wall 236 by means of bolts and nuts through preset holes in the post feeder-3 feeder plate 75 and preset holes in the brackets. The post-feeder-3 feeder-plate 75 inclines from the back-wall 234 towards the front-wall 233 leaving a gap known as the third-duct post-feeder-gap 263. The post-feeder -3 feeder-plate 75 as shown FIG. 28 is fixed by bolts and nuts 77 and has guide strips 76.
Below post-feeder-3, wear-plate-3 (270) which is a rectangular plate covering area between middle pair of flanges.191 and bottom pair of flanges 131 is fixed to holes in the front-wall 233 by bolts and nuts 249. The post-expander-3 70 is fixed at the upper portion of the wear-plate-3 (270) through set holes in the ' wear-plate-3 (270) and set matching holes in the front-wall 233 using bolts and nuts as shown in FIG. 24 & 26.
The middle-segment of the third duct 59, comprises of a clean out door 68 fixed using plurality of bolts 192 through holes in the clean out door 68 fitting in to nuts welded on the inner side of the right side wall 236 through preset holes in the right side wall 236. The bottom-segment of the third-duct 59 comprises a light-source base 241 attached to the outer side of the back wall 234 by welding; a rectangular slit is provided at the back wall 234 in front of the light-source 175 for the light to pass through; a camera base 242 attached to the outer side of the front wall 233 by welding; a hole is provided at the front wall 233 in front of the camera 178 for the camera 178 to receive light from the light source 175.
The bottom-segment of the third-duct 59 comprises of a clean out door 54 fixed using plurality of bolts 193 through preset holes in the clean out door 54 fitting into nuts welded on the inner side of the right side wall 235 through preset holes in the right side wall 236. The light source 175 is fixed to the base 241 using bolts and nuts through preset holes in the base 241 and holes in the light source 175. The camera 178 is fixed to the base 242 using bolts and nuts through preset holes in the base 242 and holes in the camera 178.
As shown in FIG. l and 23, a dust pan 91 , which has guide rails 92, fixed to the bottom conveyor 5 discharge frame by bolting its upper flange 94 and fixed to the inner side of back wall 226 of the first duct 57 by its bottom flange 95, where fine dust gets collected and slides into the first duct 57.
Referring to FIG. 33, there is shown the various inputs and outputs of PCU 6.
The Impact-screen as shown in FIG. 30, a casing 130 is provided, to protect falling bulk material from the top conveyor 3 discharge and bottom-conveyor 5 discharge, from wind. It has doors 125 on left, right and front sides. It has a dust pick up point 126 on top.
The embodiment shown in FIG. 2, 25, 29, 32 & 34, the dust removal pipe 64 which branches into three bent pipes namely pipe - a 106, pipe - b 110 and pipe - c 127 and are inserted in to middle segments of right side walls of the first duct 57, the second duct 58 and the third duct 59 respectively. The pipe - a 106 is biggest, the pipe - b 110 smaller and the pipe - c 127 the smallest and pipeending 198 at the third duct 59 is a blind end. The flange 197 is connected to the suction pipe of a dust removal blower and the discharge pipe 79 of the blower branches out into plurality of small bent pipes 243 which are fixed in to the upper portion of top hopper 2 by U-clamps 86 using bolts and nuts 83. The dust-removal-pipe 64 is fixed using clamps 66 and bolts and nuts 121. The dust-removal pipe 64 is fixed to the right side walls or the left side walls of the middle segments of the first, second and third ducts on condition, the clean-out doors will be on the opposite side walls.
In the embodiment shown in FIG.1 , a contour-sensor 30 is fixed immediately after the mini-expander 43, on the bottom-conveyor 5, which senses whether the layered, flattened bulk material is flat or convex or concave and sends
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information to the PCU 6, and PCU 6 adjusts said mini-expander 43 so that the layered, flattened bulk material is flat.
In the embodiment shown in FIG. 4i , a 4-way splitter comprises four
splitter-ducts, three splitter blades with three splitter-blade angular sensors and three splitter-blade actuator-units controlled by said PCU 6 and three
particle-size-analyser units controlled by said PCU 6 is used in place of a said 3-way splitter 4. It has. the fourth splitter-duct 128, third splitter-blade actuator unit 252 and the third splitter-blade 251.
In the embodiment shown in FIG. 42, a 2-way splitter comprises two
splitter-ducts, a single splitter-blade 253 with a single splitter-blade angular sensor and with a single splitter-blade actuator unit 254 controlled by said PCU 6 and a single particle-analyser-unit controlled by said PCU .6 is used in place of said 3-way splitter 4. It has a local switch-panel 255.
In the embodiment shown in FIG. 43, a 2-way splitter duct comprises two splitter ducts, a single splitter-blade 256 with a single splitter-blade angular sensor and a single splitter-blade-actuator-unit 257, splitting on percentage of fines in incoming load basis, controlled by said PCU 6. It has a local
switch-panel 258.
The Impact-screening machine is mounted on wheels or tracks in mobile screening. units other than using in fixed positions.
Although the present invention has been described in connection with preferred embodiments thereof, it will be appreciated by those skilled. in the art that additions, deletions, modifications, and substitutions not specifically
described may be made without department from the spirit and scope of the invention as defined in the appended claims
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