Abstract: The present disclosure provides methods and systems for autonomous data collection and system control of a material recovery facility (MRF). A control system receives data from set of sensors that reflect a status of the MRF. The control system determines an operating status of various MRF components (e.g., material handling units (MHUs), sensors, and/or other elements) and/or a composition of a waste stream being processed by the MRF. The control system controls MHU(s) based on the data to optimize the recovery and/or purity of recoverable materials from the waste stream. The control system may rearranging MHUs within the MRF and/or re-tasking individual MHUs to perform different handling functions. Machine learning (ML) and/or artificial intelligence (AI) mechanisms can be used to optimize the operation of the MRF in an autonomous fashion. Other aspects are also disclosed.

Abstract: System and methods for manipulating and sorting of objects being moved along a conveyor are disclosed, whereby control of the object is achieved through the application of one or more of vacuum, impaling, or mechanical grasping. One embodiment is directed to a robotic arm and vision detection system operable for detecting a target object to be grasped from a stream of objects being moved on a conveyor, and moving a suction head into position over the target object that has been detected on the conveyor, the suction head having a flexible cup section disposed at a distal end thereof, the vacuum item pick-up system/method using high subsonic air flow (e.g., on the order of 60 scfm or more) through a suction cup having a flow opening area large enough that an airflow of 60 scfm does not result in an airspeed exceeding Mach 0.2 under standard conditions of temperature and pressure, and further having a flow opening area whose ratio to cup opening area falls between 0.36 and 1.

Abstract: Disclosed embodiments include an apparatus for reducing contamination or obstruction of a multi-directional flow filtration system. As one example, a scalper that is to be employed on a multi-directional flow filtration system comprises a body and a set of scalping walls forming a plurality of helical chambers, the set of scalping walls helically extending along at least a portion of an interior of the body in a longitudinal direction. In this way, the plurality of helical chambers may enable the multi-directional flow filtration system to passively scalp contaminants in a manner that improves overall operation of the multi-directional flow filtration system. Other embodiments may be described and/or claimed.

Abstract: Disclosed embodiments include methods and systems for autonomous data collection and system control of a material recovery or recycling facility. In some embodiments, a central control system receives inputs in the form of at least one data stream from each of one or more environmental sensors that reflect the status of a material recovery facility (MRF). The inputs are used to determine the operating status of one or more components of the MRF, and/or composition of a waste stream being processed by the MRF. At least one material handling unit is controlled in response to the inputs to optimize the recovery and/or purity of recyclable or recoverable materials from the waste stream. A service unit or mechanism may also be controlled in response to the inputs indicating that a component of the MRF requires servicing.

Abstract: System and methods for manipulating and sorting of objects being moved along a conveyor are disclosed, whereby control of the object is achieved through the application of one or more of vacuum, impaling, or mechanical grasping. One embodiment is directed to a robotic arm and vision detection system operable for detecting a target object to be grasped from a stream of objects being moved on a conveyor, and moving a suction head into position over the target object that has been detected on the conveyor, the suction head having a flexible cup section disposed at a distal end thereof, the vacuum item pick-up system/method using high subsonic air flow (e.g., on the order of 60 scfm or more) through a suction cup having a flow opening area large enough that an airflow of 60 scfm does not result in an airspeed exceeding Mach 0.2 under standard conditions of temperature and pressure, and further having a flow opening area whose ratio to cup opening area falls between 0.36 and 1.

Abstract: A disc assembly with a substantially rigid disc core includes a first section removably attached to a second section and mounted to a disc screen shaft. The disc core includes a transport surface extending between a left side of the disc core and a right side of the disc core, and a replaceable coating of textured wear material is deposited along the transport surface.

Abstract: A disc screen includes a shaft, a first disc mounted on the shaft, and a second disc mounted on the shaft. An interfacial opening (IFO) extends between the first disc and the second disc. A width of the IFO as measured between the first disc and the second disc varies according to a rotational position of the shaft.

Abstract: A disc screen includes a shaft, a first disc mounted on the shaft, and a second disc mounted on the shaft. An interfacial opening (IFO) extends between the first disc and the second disc. A width of the IFO as measured between the first disc and the second disc varies according to a rotational position of the shaft.

Abstract: A material separation system includes a separation screen and an air directing device positioned above the separation screen. The separation screen has at least one rotating shaft, wherein the separation screen transports the relatively rigid material and relatively flexible material to the rotating shaft. The air directing device directs air towards the separation screen such that the relatively flexible material is blown beneath the rotating shaft in a first material stream, wherein the relatively rigid material continues on the separation screen past the rotating shaft in a second material stream.

Abstract: A separation system includes an air separator that, in one embodiment, primarily receives Municipal Solid Waste (MSW) containing a mixture of relatively light MSW recyclable materials such as plastic, paper, cardboard, plastic containers, and/or metal containers and relatively heavy MSW such as textiles, food waste, yard debris, etc. The air separator blows the relatively light MSW recyclable materials up though a chamber and onto a first conveyor while the other relatively heavy MSW material drops down a chute onto a second conveyor. A separation screen receives the relatively light MSW recyclable materials from the air separator and separates the relatively flat fiber and plastic film materials from the other paper, plastic and metal containers. In another separation stage, an electrostatic emitter is positioned adjacent to a conveyor for applying an electrostatic charge to the fiber and plastic materials.

Abstract: Multiple shafts are aligned along a frame and configured to rotate in a direction causing paper products to move along a separation screen. The shafts are configured with a shape and spacing so that substantially rigid pieces of the paper products move along the screen while non-rigid pieces of the paper products slide down between adjacent shafts. In one embodiment, the screen includes at least one vacuum shaft that has a first set of air input holes configured to suck air and retain the non-rigid paper products. A second set of air output holes are configured to blow out air to dislodge the paper products retained by the input holes.

Abstract: A material separation screen includes multiple shafts mounted on a frame. Multi-diameter disc assemblies are mounted on the shafts and are configured to rotate and separate out different types of materials from a material stream. The multi-diameter disc assemblies include spacer discs that separately interlock together around the shafts. Compound discs are separately attached to the shafts next to the spacer discs. The spacer discs are made from a harder material than the compound discs to reduce spacer disc wear and to reduce the amount of material needed for fabricating the multi-diameter disc assembly.

Abstract: A separation system includes an air separator that, in one embodiment, primarily receives Municipal Solid Waste (MSW) containing a mixture of relatively light MSW recyclable materials such as plastic, paper, cardboard, plastic containers, and/or metal containers and relatively heavy MSW such as textiles, food waste, yard debris, etc. The air separator blows the relatively light MSW recyclable materials up though a chamber and onto a first conveyor while the other relatively heavy MSW material drops down a chute onto a second conveyor. A separation screen receives the relatively light MSW recyclable materials from the air separator and separates the relatively flat fiber and plastic film materials from the other paper, plastic and metal containers. In another separation stage, an electrostatic emitter is positioned adjacent to a conveyor for applying an electrostatic charge to faciliate separation of the MSW recyclable materials.

Abstract: A cross-flow air separation system comprises a conveyor configured to project material out over an end of the conveyor generally along a trajectory path into a far receiving bin. An optical sensing system is configured to identify particular objects in the projected material. A first air ejection system is configured to generate a first airstream that ejects the identified objects from the trajectory path into a second near receiving bin. A second cross air current system is configured to generate a second airstream that reduces air resistance for the materials projected along the trajectory path. The second airstream reduces certain aeronautic phenomena that would cause some of the projected materials to unintentionally fall into the wrong receiving bin, thus creating a higher purity/less contaminated materiel stream into the near bin.

Abstract: A material separation screen includes multiple shafts mounted on a frame. Multi-diameter disc assemblies are mounted on the shafts and are configured to rotate and separate out different types of materials from a material stream. The multi-diameter disc assemblies include spacer discs that separately interlock together around the shafts. Compound discs are separately attached to the shafts next to the spacer discs. The spacer discs are made from a harder material than the compound discs to reduce spacer disc wear and to reduce the amount of material needed for fabricating the multi-diameter disc assembly.

Abstract: A material separation system includes a separation screen and an air directing device positioned above the separation screen. The separation screen has at least one rotating shaft, wherein the separation screen transports the relatively rigid material and relatively flexible material to the rotating shaft. The air directing device directs air towards the separation screen such that the relatively flexible material is blown beneath the rotating shaft in a first material stream, wherein the relatively rigid material continues on the separation screen past the rotating shaft in a second material stream.

Abstract: A separation system includes an air separator that, in one embodiment, primarily receives Municipal Solid Waste (MSW) containing a mixture of relatively light MSW recyclable materials such as plastic, paper, cardboard, plastic containers, and/or metal containers and relatively heavy MSW such as textiles, food waste, yard debris, etc. The air separator blows the relatively light MSW recyclable materials up though a chamber and onto a first conveyor while the other relatively heavy MSW material drops down a chute onto a second conveyor. A separation screen receives the relatively light MSW recyclable materials from the air separator and separates the relatively flat fiber and plastic film materials from the other paper, plastic and metal containers. In another separation stage, an electrostatic emitter is positioned adjacent to a conveyor for applying an electrostatic charge to faciliate separation of the MSW recyclable materials.

Abstract: A separation system includes an air separator that in one embodiment primarily receives Municipal Solid Waste (MSW) containing relatively light MSW recyclable materials such as paper, cardboard, plastic containers, and/or metal containers. The air separator blows the relatively light MSW recyclable materials up though a chamber and onto a first conveyer while the other relatively heavy MSW material drops down a chute onto a second conveyer. A separation screen receives the relatively light MSW recyclable materials from the air separator and separates the relatively flat paper and cardboard from the plastic and metal containers.

Abstract: Multiple shafts are aligned along a frame and configured to rotate in a direction causing paper products to move along a separation screen. The shafts are configured with a shape and spacing so that substantially rigid pieces of the paper products move along the screen while non-rigid pieces of the paper products slide down between adjacent shafts. In one embodiment, the screen includes at least one vacuum shaft that has a first set of air input holes configured to suck air and retain the non-rigid paper products. A second set of air output holes are configured to blow out air to dislodge the paper products retained by the input holes.

Abstract: A cross-flow air separation system comprises a conveyor configured to project material out over an end of the conveyor generally along a trajectory path into a far receiving bin. An optical sensing system is configured to identify particular objects in the projected material. A first air ejection system is configured to generate a first airstream that ejects the identified objects from the trajectory path into a second near receiving bin. A second cross air current system is configured to generate a second airstream that reduces air resistance for the materials projected along the trajectory path. The second airstream reduces certain aeronautic phenomena that would cause some of the projected materials to unintentionally fall into the wrong receiving bin, thus creating a higher purity/less contaminated materiel stream into the near bin.