Maintenance of the furnace of a recovery furnace without intervention by an operator

Abstract

The invention relates to a method for clearing accumulated material deposits inside a hearth, comprising: initiating a pre-programmed sequence to position a robot proximate an opening on a recovery furnace wall; positioning an end effector of the robot at a designated angle for accessing the opening; operating the robot to cause the end effector to penetrate the accumulated material deposits; and retracting the end effector.

Description

Technical Field

[0001] This application claims priority and benefit to U.S. Provisional Patent Application No. 63 / 600,906, filed November 20, 2023, the disclosure of which is incorporated herein by reference in its entirety. Background Technology

[0002] Unless otherwise stated herein, the materials described in this section are not prior art to the claims of this application, nor are they admitted as prior art by virtue of their inclusion in this section.

[0003] In the sulfate pulping process, a recovery boiler is used to recover and regenerate chemicals for white liquor from black liquor. The black liquor is burned in the furnace of the recovery boiler. The concentrated black liquor contains sodium sulfate from the cooking chemicals added in the digester, as well as dissolved organic wood residue. The heat generated from the combustion of the organic portion of the chemicals in the recovery boiler furnace is used to produce high-pressure steam, which can be used to generate electricity for the plant. As a result of the combustion process, partially burned residue accumulates at the bottom of the recovery boiler furnace, and the reduced chemicals are continuously extracted as a liquid melt.

[0004] During normal operation, molten material accumulates at the bottom of the recovery boiler furnace, and excess molten material overflows through one or more openings in the recovery boiler furnace wall. This excess molten material flows down to one or more chutes attached to the recovery boiler furnace wall. Figure 1A This is a diagram showing the opening 110 in the furnace wall 120 of the recovery boiler. Figure 1B This is an illustration of a chute 130 attached to the furnace wall 120 of the recovery boiler to allow the extraction of molten material. During normal operation of the recovery boiler furnace, the molten material flows through an opening 110 in the furnace wall 120 and down the chute 130 into a melting tank (not shown). Figure 1C This is an exploded perspective view of the chute 130, the opening 110 in the furnace wall 120, and the blocking component 140 located adjacent to the opening 110.

[0005] Dynamic furnace disturbances (such as unexpected furnace shutdowns in reclaimed boilers) can sometimes lead to the accumulation of solid material (frozen molten material, salt cake, and / or other agglomerates) near openings in the furnace walls, preventing the normal flow of molten material from the furnace and down the chute. Conventional practice requires manual removal of this solid material from the furnace, either through mechanical cleaning (i.e., manually breaking up or clearing the accumulated material from the furnace openings with metal rods) or by locally heating the material with a handheld torch to melt it and allow it to flow out. Both methods are manual, difficult, dangerous, and time-consuming. Summary of the Invention

[0006] A system and method are provided for using robots to remove and recycle solid materials accumulated inside a boiler furnace.

[0007] According to various aspects, a system for removing accumulated deposits inside a furnace is provided. In some aspects, the system may include: a robot having an end effector configured to remove accumulated deposits inside the furnace; and a control system configured to execute one or more pre-programmed sequences of operations for controlling the robot to operate the end effector.

[0008] According to various aspects, a robot for removing accumulated deposits inside a furnace is provided. In some aspects, the robot may include: an end effector configured to remove accumulated deposits inside the furnace; a robotic arm coupled to the end effector and configured to control the position of the end effector; a tool bit coupled to the end effector; and a plurality of sensors configured to sense the position of the end effector and torque or force applied to the end effector. The end effector and the tool bit are configured to penetrate the accumulated deposits inside the furnace.

[0009] According to various aspects, a method for removing accumulated deposits inside a furnace is provided. In some aspects, the method may include initiating a pre-programmed sequence to: position a robot close to an opening in the furnace wall; position the robot's end effector at a specified angle for approaching the opening; operate the robot to allow the end effector to clear the accumulated deposits; and retract the end effector.

[0010] According to various aspects, a system is provided for inserting a plugging element into an opening in the wall of a recycling furnace. In some aspects, the system may include: a robot having an end effector configured to mount a plugging element sized to plug the opening; and a control system configured to execute one or more pre-programmed sequences of operations for controlling the robot to operate the end effector.

[0011] According to various aspects, a maintenance system for a recycling furnace without operator intervention is provided. The system may include: a robot having a robotic arm and one of a plurality of end effectors, each of which is configured to perform maintenance operations selected from the group consisting of: clearing an opening in the furnace wall that is at least partially blocked by solid melt; collecting a sample of solid melt from the opening; plugging the opening with a plug; and removing the plug from the opening; and a control system configured to execute one or more pre-programmed sequences of operations for controlling the robot to operate two of the end effectors to complete at least two of the maintenance operations. Attached Figure Description

[0012] Some aspects and features of the various embodiments will become more apparent from the examples in the accompanying drawings, in which: Figure 1A It is a perspective view showing the openings in the furnace wall of the recycling boiler; Figure 1B This is a perspective view showing a chute attached to the furnace wall of the recovery boiler in Figure 1 to allow for the extraction of molten material; Figure 1C yes Figure 1B An exploded 3D view of the chute shown. Figure 2 This is a schematic diagram illustrating an example of a recycled boiler furnace with an accumulation of solid material; Figure 3 This is an illustration of an example of a robot used to remove solid materials accumulated inside a boiler furnace, according to some aspects of this disclosure; Figure 4 An example of a tool drill bit that can be attached to the end effector of a robot for cleaning up solid molten material accumulated inside a boiler furnace, according to some aspects of this disclosure; Figure 5 This is an illustration showing an example of a robotic arm and end effector of a robot according to some aspects of this disclosure being positioned for removing solid material accumulated inside a boiler furnace; Figure 6 This is a schematic diagram illustrating an example of a control system that can be used with a robot for removing solid materials accumulated inside a boiler furnace, according to some aspects of this disclosure; Figure 7 This is a flowchart illustrating an example of a method for controlling a robot to clear blockages inside a reclaimed boiler furnace, according to some aspects of this disclosure; Figure 8A Is with Figure 3 A 3D diagram of a chute blocking bar used by robots. Figure 8B yes Figure 8A The chute blocking rod shown is being blocked Figure 3 The image shown is a 3D view of a robotic arm inserted into an opening in the furnace wall of a recycling boiler. Figure 8C This is a magnified perspective view showing the insertion of the plug; Figure 9 This is a schematic diagram illustrating a maintenance system for a recycling furnace that requires no operator intervention. Detailed Implementation

[0013] Although certain embodiments have been described, these embodiments are presented by way of example only and are not intended to limit the scope of protection. The devices, methods, and systems described herein can be implemented in a variety of other forms. Furthermore, various omissions, substitutions, and changes can be made to the form of the described exemplary methods and systems without departing from the scope of protection.

[0014] Unless otherwise stated, the same reference numerals are used throughout several views to denote corresponding parts. Although the drawings represent various features and components according to various embodiments of the present disclosure, the drawings are not necessarily drawn to scale, and some features may be exaggerated in order to better illustrate embodiments of the present disclosure, and such exemplary illustrations should not be construed as limiting the scope of the present disclosure.

[0015] Unless otherwise expressly stated herein, the following rules of interpretation apply to this specification: (a) All words used herein shall be interpreted as the form of gender or number (singular or plural) as required; (b) as used in the specification and appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context explicitly specifies otherwise; (c) the antecedent “about” applied to the range or value indicates an approximation of a deviation from a range or value known or anticipated in the art; (d) the words “this,” “here,” “thus,” “below,” and “in the following,” and words with similar meanings refer to the entire specification and not any particular paragraph, claim, or other subsection, unless otherwise specified; (e) descriptive headings are for convenience only and shall not control or affect the meaning or interpretation of any part of this specification; and (f) “or” and “any” are not exclusive, and “including” and “contains” are not restrictive. Furthermore, the terms “including,” “having,” “comprising,” and “containing” shall be interpreted as open-ended terms (i.e., meaning “including but not limited to”).

[0016] Statements of numerical ranges herein are intended solely as a shorthand for each individual value falling within the range and any subranges thereof, unless otherwise expressly stated herein. Each individual value within the range is incorporated into the specification or claims as if each individual value were stated separately herein. Where a particular numerical range is provided, it should be understood that every intermediate value between the upper and lower limits of the range, to one-tenth or less of the lower limit unit, and any other stated or intermediate value within the range or subranges, is included herein unless the context expressly provides otherwise. All subranges are also included. The upper and lower limits of these smaller ranges are also included, but are subject to any specific and expressly excluded limitations within the range.

[0017] Combustion of black liquor in the furnace of a recovery boiler results in the accumulation of partially burned reducing chemicals as a liquid melt at the bottom of the furnace. During normal operation, the melt is continuously extracted from the furnace via one or more chutes, which allow it to flow into a dissolution tank for further processing. Dynamic furnace disturbances can cause an accumulation of solid material near openings in the furnace wall, preventing the normal outflow of melt from the furnace. This accumulated solid material may include solidified melt as well as other materials, such as, but not limited to, salt cake and / or other agglomerates.

[0018] Figure 2 This is a schematic diagram illustrating an example of a recycled boiler furnace with an accumulation of solid material. (See diagram for example.) Figure 2 As shown, solid material accumulation 210 caused by furnace disturbance conditions can form inside the furnace 220 of the recovery boiler. Solid material accumulation 210 may block the opening 255 in the wall 250 of the recovery boiler furnace 220 and may prevent the molten material 230 from reaching the chute 130 extending through the wall 250 of the recovery boiler furnace 220, thereby preventing the extraction of the molten material 230 from the recovery boiler furnace 220.

[0019] Traditionally, robots are used to perform scheduled maintenance, such as removing solid molten material deposits from chutes outside a recovery boiler furnace. Appropriate end effectors mounted at the end of the robotic arm can be used to remove molten material deposits from the chutes without contact. However, currently only manual methods (e.g., mechanical cleaning bars and / or heating via handheld torches) are used to break up solid material accumulations inside the recovery boiler furnace that block the flow of molten material into the chutes. Some aspects of this disclosure can provide systems and methods for utilizing robots to remove solid material accumulated inside the recovery boiler furnace.

[0020] Figure 3 This is an illustration of an example of a robot used to remove and recycle solid materials accumulated inside a boiler furnace, according to some aspects of this disclosure. Figure 3As shown, the robot 300 can be suspended from a support structure such as a gantry or platform 350 or from other support structures, so that the robot arm 310 and the end effector 320 can be suspended relative to the opening 110 (see Figure 1) and chute 130 (e.g.) in the furnace wall 120 of the recycling boiler. Figure 1A , Figure 1B , Figure 2 and Figure 3 (As shown) Correct positioning. In some embodiments, robot 300 can be mounted on a platform positioned below robot 300.

[0021] When used for unplanned removal of solid material accumulated inside the furnace of a reclaimed boiler, the end effector 320 for removing molten deposits from the chute can be replaced with an end effector configured to clear blockages inside the furnace of the reclaimed boiler. In some embodiments, the end effector 320 may be equipped with a rotary tool (not shown), such as, but not limited to, a drill, which has sufficient power and tool bits (e.g., see...). Figure 4 The tool drill bit is configured to drill one or more holes in accumulated molten material deposits inside the furnace of a recovery boiler. In some embodiments, the end effector 320 may be equipped with a pneumatic hammer. In some embodiments, the end effector 320 for removing molten material deposits may also be used to clear blockages inside the furnace of a recovery boiler. The robot 300 may be programmed to have the robotic arm 310 apply pressure to advance the tool drill bit through the solid material deposits.

[0022] In some embodiments, a tool drill bit 360 is configured to drill one or more holes in the accumulated solid deposits inside the boiler furnace (e.g., see...). Figure 4 An end effector 320 can be attached to robot 300. Robot 300 can be programmed to provide oscillating motion of robot arm 310 while applying pressure to propel tool drill bit through molten deposit.

[0023] As the end effector 320 extends into the recovery boiler furnace, a linear position sensor (not shown) on the robot 300 determines the extent of extension of the end effector 320, and a torque and / or force sensor (not shown) senses when the end effector 320 has completely penetrated the solid deposit. In some cases, the accumulated deposit inside the recovery boiler furnace may be so thick that it cannot be drilled through before the end effector 320 reaches its maximum extension as sensed by the linear position sensor. In this situation, the end effector 320 can retract its position; for example, the angle at which it enters the opening of the recovery boiler furnace can be adjusted, and drilling into the molten deposit can resume.

[0024] Figure 4An example of a tool drill 360, which can be attached to the end effector of a robot used for removing accumulated solid molten material inside a boiler furnace, is shown, according to some aspects of this disclosure. Figure 4 As shown, the tool bit 360 can be a push-button type drill bit used in the mining industry. In some embodiments, the tool bit 360 can be a tip or edge cutting drill bit, or a drill bit consumed in the process of removing accumulated deposits.

[0025] Figure 5 This is an illustration showing an example of a robotic arm and end effector of a robot positioned for cleaning and recycling solid materials accumulated inside a boiler furnace, according to some aspects of this disclosure. Figure 5 In this context, robot 500, robot arm 510, and end effector 520 can be combined with... Figure 3 The robot 300, robot arm 310, and end effector 320 described are identical. (See reference...) Figure 5 The robot 500 can be suspended from the support structure 550. The support structure 550 allows the robot 500 to be positioned relative to one or more openings in the wall of the recovery boiler furnace 530 for chutes 535a, 535b. In some embodiments, the base of the robot 500 can be mounted on a platform located below the robot 500. The robot 500 can be positioned and operated by a control system.

[0026] Figures 8A-8C This is a view showing a blocking device 810 for an opening 110 in the furnace wall 120, utilizing a robot 800 (which may be identical to and similarly mounted to robots 300 and 500). The blocking device 810 includes an end effector 820 that tapers at its distal end. A robotic arm 810 is attached to the end effector 820. A blocking element 840 is detachably mounted on the end effector 820.

[0027] like Figure 8B and 8C As shown, the robotic arm 810 can be positioned (via a gantry, etc.) such that the end effector 820 with the installed plug 840 is located near the opening 255 in the wall 250 of the boiler furnace 220 inside the chute 130. The robotic arm 810 is used to insert the plug 840 into the opening 255 and then retract it while leaving the plug 840 in the opening 255.

[0028] It is also conceivable that different end effectors (not shown) could be used together with the robotic arm 810 to remove the blockage 840 at the appropriate time.

[0029] Figure 6This is a schematic diagram illustrating an example of a control system for controlling a robot configured to remove solid material accumulated inside a boiler furnace, according to some aspects of this disclosure. The control system 600 may include a controller 610, a memory 615, a user interface (UI) 620, robot position control 630, arm control 640, an arm position sensor 650, and a linear position and / or torque / force sensor 660.

[0030] The controller 610 may be a programmable logic controller (PLC), a general-purpose processor, a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), or other programmable logic devices. The controller 610 can electrically communicate with the memory 615, the robot position control 630, the arm control 640, the arm position sensor 650, and the linear position / torque / force sensor 660. The controller 610 can control the overall operation of the robot 500. The controller 610 can receive signals generated by various sensors, including but not limited to the arm position sensor 650 and the linear position / torque / force sensor 660, and can perform operations or processing on these signals. The controller 610 can transmit various commands to the robot 500, such as, but not limited to, robot position, arm control, or other commands.

[0031] The robot can be used for both chute cleaning and cleaning of solid materials accumulated inside the furnace of a recycling boiler. The drill bit configured to clean solid materials accumulated inside the furnace can be different from the drill bit configured to clean chutes; therefore, the drill bit can be switched when the robot is used for different purposes. The controller 610 can execute operator-selectable pre-programmed sequences for cleaning solid materials accumulated inside the furnace of the recycling boiler; these sequences are unplanned and can be initiated by user input; and pre-programmed chute cleaning sequences are executed automatically according to a preset schedule during normal operation of the recycling boiler.

[0032] Memory 615 may be a storage device such as a solid-state storage device or other storage device, and may be a combination of volatile and non-volatile memory. In some embodiments, a portion of the memory may be included in the controller 610 to form a combination of internal and external memory. Memory 615 may be configured to store instructions executable by the controller 610 to control the operation of robot 500, as well as other applications executable by the controller 610. Memory 615 may store pre-programmed sequences for clearing accumulated solid molten material inside the boiler furnace and pre-programmed chute clearing sequences.

[0033] The user interface (UI) 620 may be a touch panel or other device configured to accept manual input from a user for operating the robot 500. The user interface (UI) 620 may be located away from the robot 500, for example, behind a safety barrier (not shown).

[0034] When clearing blockages inside the recovery boiler furnace, the operator can initiate a pre-programmed sequence of operations via UI 620 to move robot 500 to the appropriate chutes 535a, 535b to approach openings in the recovery boiler furnace wall. Alternatively, operator commands can be entered for individual robot control operations. Robot 500 can use positioning sensors (not shown) (e.g., but not limited to laser positioning sensors or other positioning sensors) to identify the positions of chutes 535a, 535b. Signals from the positioning sensors can be provided to controller 610, and controller 610 can transmit commands to robot position control 630 to provide coarse positioning at specific chutes 535a, 535b.

[0035] The trajectory of end effectors (e.g., end effectors 320, 520) used to remove accumulated solid molten material inside the recovery boiler furnace can be controlled by a pre-programmed sequence selectable by the operator. The robot can precisely control the position and orientation of the end effectors, ensuring they are not guided by contact with the chute. This non-contact guidance prevents damage to the recovery boiler furnace.

[0036] The arm controller 640 can receive commands from the controller 610 and can position the end effector at a predetermined angle (e.g., 10° or other angles relative to the horizontal) to enter an opening (e.g., opening 110 shown in Figure 1) in the recovery boiler furnace. The arm position sensor 650 can provide the controller 610 with robot arm position information. The robot arm (e.g., robot arms 310, 510) can advance the end effector through the opening at a predetermined angle into the recovery boiler furnace to clear blockages inside the furnace. The linear position / torque / force sensor 660 can provide the controller 610 with information about the end effector position and the position and / or torque and / or force applied to the end effector. The controller 610 can determine the insertion depth of the end effector within the recovery boiler furnace and can determine whether the end effector has penetrated the blockage based on the torque and / or force information received from the linear position / torque / force sensor 660. For example, based on a signal provided by the linear position / torque / force sensor 660 indicating that the end effector has not yet reached its maximum extension but the torque and / or force applied to the end effector has decreased, the controller 610 can determine that the end effector has penetrated the blockage.

[0037] When controller 610 determines that the linear position information received from linear position / torque / force sensor 660 indicates the maximum insertion depth (e.g., 3 feet or other insertion depth) of the end effector through the furnace wall of the recovery boiler, and the torque information received from linear position / torque / force sensor 660 indicates that the end effector has not yet penetrated the blockage, a pre-programmed sequence allows controller 610 to command arm control 640 to retract the end effector.

[0038] Operator-selectable pre-programmed sequences or operator-guided operating sequences can cause controller 610 to transmit commands to arm control 640 to change the entry angle of the end effector into the recovery boiler furnace opening, for example, from 10° to 15° with respect to the horizontal, and cause arm control 640 to advance the end effector into the recovery boiler furnace at the new angle. If the blockage is not cleared (e.g., if no molten material begins to flow in the chute), the sequence can be repeated until controller 610 determines that the end effector has penetrated the blockage inside the recovery boiler furnace, for example, as indicated by a decrease in torque sensed by linear position / torque / force sensor 660. In this way, multiple holes can be drilled at different angles in the accumulated material deposits inside the recovery boiler furnace until the blockage is cleared. The molten material flow can also be visually determined, for example, but not limited to operator observation of the chute, video camera, etc.

[0039] In some implementations, each time the end effector retracts without penetrating the blockage, the operator can select a different operator-selectable pre-programmed sequence to change the entry angle and drill additional holes. In some implementations, the sequence of setting the initial entry angle of the end effector, drilling holes in the blockage, retracting the end effector, changing the entry angle, and drilling additional holes in the blockage can be executed automatically as part of the currently executing pre-programmed sequence. In some implementations, the insertion depth and / or torque and / or force settings instructing the end effector to clear the blockage can be set by the operator.

[0040] Figure 7 This is a flowchart illustrating an example of a method for controlling a robot to clear blockages inside a recycling boiler furnace, according to some aspects of this disclosure. (Refer to...) Figure 7 At box 710, the robot can move to a position close to an opening in the furnace wall of the recycling boiler. An operator can initiate a pre-programmed sequence of operations via a user interface to move the robot to the appropriate chute location to approach the opening in the furnace wall. In some embodiments, operator commands can be input for individual control operations of the robot. The robot can use positioning sensors (e.g., but not limited to laser positioning sensors or other positioning sensors) to identify the location of the chute. Signals from the positioning sensors can be provided to the controller to provide coarse positioning at a specific chute location.

[0041] At box 715, a robot can be operated to position an end effector at an opening in the furnace wall of a recycling boiler. The trajectory of the end effector, used to remove accumulated solid material from the interior of the recycling boiler furnace, can be controlled by a pre-programmed sequence. The robot can precisely control the position and orientation of the end effector so that it is not guided by contact with a chute. The robot (e.g., an arm controller) can receive commands from a controller and can position the end effector at a predetermined angle (e.g., 10° or other angles to the horizontal) to enter the opening in the recycling boiler furnace.

[0042] At box 720, it can be determined whether the end effector is a rotary tool or a pneumatic hammer. In some embodiments, the end effector may be equipped with a rotary tool, such as, but not limited to, a drill rig, having sufficient power and a tool bit. In some embodiments, the tool bit may be attached to the end effector, and the robotic arm may provide oscillating motion while applying pressure to propel the tool bit through the molten deposit. In some embodiments, the end effector may be a pneumatic hammer.

[0043] In response to determining that the end effector is a rotary tool or a pneumatic hammer (720-Yes), at block 725, the driver for the rotary tool or the pneumatic hammer can be engaged to initiate the operation of the rotary tool or the pneumatic hammer, and the process continues at block 730.

[0044] In response to determining that the end effector is not a rotary tool or pneumatic hammer (720-No), the process continues at box 730.

[0045] At box 730, the robot can be operated to perform a pre-programmed sequence of operations selectable by the operator to clear blockages inside the recovery boiler furnace. Alternatively, operator commands can be input for individual control operations of the robot. An arm position sensor can provide the controller with robot arm position information. The robot arm can advance its end effector at a predetermined angle through the opening into the recovery boiler furnace to clear blockages inside the furnace.

[0046] At box 735, it can be determined whether the maximum insertion depth of the end effector has been reached. The controller can determine whether the linear position information received from the linear position sensor indicates that the maximum insertion depth of the end effector has been reached.

[0047] In response to determining that the maximum insertion depth of the end effector (735 - Yes) has been reached, at box 740, the controller can cause the robot to retract the end effector from the opening in the furnace wall of the recovery boiler.

[0048] At box 745, the position of the end effector can be changed. In some embodiments, the operator can select different operator-selectable pre-programmed sequences to change the entry angle of the end effector and proceed to box 730. In some embodiments, the currently executed pre-programmed sequence can automatically change the entry angle of the end effector, and the process can proceed to box 730.

[0049] In response to determining that the maximum insertion depth of the end effector has not been reached (735-No), at box 750, it can be determined whether the blockage inside the recovery boiler furnace has been cleared. The controller can determine that the end effector has penetrated the blockage inside the recovery boiler furnace, for example, as indicated by a decrease in torque and / or force sensed by a torque / force sensor when the end effector penetrates the blockage.

[0050] In response to the determination that the blockage inside the boiler furnace has been cleared (450 - Yes), the end effector can be retracted at frame 755, and the process ends.

[0051] In response to the determination that the blockage inside the boiler furnace has not been cleared (750-No), the process continues at box 730.

[0052] Figure 7 The specific operations illustrated provide a particular method for controlling a robot to clear blockages inside a recycling boiler furnace according to embodiments of this disclosure. According to alternative embodiments, other sequences of operations may also be performed. For example, alternative embodiments of this disclosure may perform the above operations in a different order. Furthermore, Figure 7 Each operation shown can include multiple sub-operations, which can be executed in various appropriate orders depending on the individual operation. Furthermore, additional operations can be added or removed depending on the specific application.

[0053] Method 700 may be embodied on a non-transitory computer-readable medium, such as, but not limited to, memory 615 or other non-transitory computer-readable media known to those skilled in the art, wherein a program is stored including computer-executable instructions for causing a controller, processor, computer or other programmable device to perform the operations of the method.

[0054] Now refer to Figure 9The document illustrates a maintenance system for a recycling furnace that requires no operator intervention and is generally designated 900. System 900 includes a robotic arm 905 and multiple end effectors (one of which is shown herein as 910). Each end effector 910 is configured to perform maintenance operations selected from the group consisting of: clearing an opening in the furnace wall that is at least partially blocked by solid melt; collecting a sample of solid melt from the opening; plugging the opening with a plug; and removing the plug from the opening. Each of these maintenance operations can be performed in the manner described above, with the appropriate end effector 910 attached to the robotic arm 905. Furthermore, the system includes a control system 920 configured to execute one or more pre-programmed operation sequences for controlling the robotic arm 905 to operate two of the end effectors 910 to complete at least two of the maintenance operations. For example, in the illustrated embodiment, programmed sequences for clearing the opening, collecting a sample of solid melt from the opening, plugging the opening, and removing the plug from the opening are included. Figure 9 These are labeled 930, 940, 950, and 960, respectively. However, in some embodiments, only two or three of these maintenance operations may be included, or additional maintenance operations may be included in other embodiments. The structure and operation of the control system 920 and the programming sequences 930, 940, 950, and 960 can be as described above and need not be described in detail here.

[0055] The system 900 described above can provide a recycling furnace with operator-free maintenance of the chute and surrounding area; that is, maintenance operations that pose a certain physical risk to the operator can be performed by the system 900, thereby avoiding the need for human intervention during these operations. As a result, the safety level associated with recycling furnace maintenance can be significantly improved.

[0056] Those skilled in the art will also recognize that other features and functionalities can be included in a system that does not require operator intervention. For example, the system may include a module capable of sensing unwanted movement / presence (e.g., a person) near the chute and robot. This module may rely on a static or video camera, one or more motion detectors, a light detector, or other presence sensing devices. The module may also include an alarm operable to the presence sensing device to alert a monitor to the presence of an unwanted visitor. The system may also include switches, etc., that stop any further operations (e.g., cleaning, sampling, etc.) if an unwanted presence is detected at or near the chute.

[0057] The presence sensing modules described above can take many forms. Exemplary modules include those available from Intenseye (the Intenseye platform), Rockwell (Allen Bradley presence sensing devices), and the like.

[0058] The examples and embodiments described herein are for illustrative purposes only. Various modifications or alterations to these examples and embodiments will be apparent to those skilled in the art. Such modifications or alterations will be included within the spirit and scope of this application and the appended claims.

Claims

1. A system for removing accumulated material deposits inside a furnace, the system comprising: A robot having an end effector configured to remove accumulated material deposits inside a furnace; as well as A control system configured to execute one or more pre-programmed operation sequences for controlling the robot to operate the end effector.

2. The system according to claim 1, wherein, The end effector includes a tool drill bit that is coupled to the end effector and configured to penetrate accumulated material deposits inside the furnace.

3. The system according to claim 2, wherein, The robot is controlled to cause oscillating motions in the end effector and the drill bit.

4. The system according to claim 1, wherein, The end effector includes a rotary tool.

5. The system of claim 4 further includes a tool drill bit coupled to the rotary tool and configured to penetrate accumulated material deposits inside the furnace.

6. The system according to claim 5, wherein, The rotary tool provides rotational motion to the tool drill bit to drill through the accumulated material deposits inside the furnace.

7. The system according to claim 1, wherein, The control system includes: A controller, configured to transmit commands to the robot, and Multiple sensors are arranged on the robot. The sensor is configured to sense the position of the end effector and the torque or force applied to the end effector.

8. The system according to claim 7, wherein, The controller is configured to execute a sequence of instructions initiated by the operator to control the robot to remove accumulated material deposits inside the furnace.

9. The system according to claim 7, wherein, The controller is configured to control the robot based on signals received from the plurality of sensors, such that the end effector does not contact the chute or furnace wall.

10. The system according to claim 7, wherein, The control system also includes a memory. The memory is configured to store multiple operator-selectable pre-programmed sequences for clearing accumulated material deposits inside the furnace. The operator-selectable pre-programmed sequence specifies different end-actuator angles for approaching openings on the furnace wall.

11. A robot for removing accumulated material deposits inside a furnace, the robot comprising: An end effector configured to remove accumulated material deposits inside the furnace; A robotic arm, which is coupled to the end effector and configured to control the position of the end effector; A tool drill bit, which is coupled to the end effector; as well as Multiple sensors are configured to sense the position of the end effector and the torque or force applied to the end effector. The end effector and the tool drill bit are configured to penetrate the accumulated material deposits inside the furnace.

12. The robot according to claim 11, wherein, The robotic arm is controlled to cause oscillating motions in the end effector and the tool drill bit.

13. The robot according to claim 11, wherein, The end effector includes a rotary tool coupled to the robotic arm.

14. The robot of claim 13, further comprising a tool drill bit coupled to the rotary tool and configured to penetrate accumulated material deposits inside the furnace.

15. The robot according to claim 14, wherein, The rotary tool provides rotational motion to the tool drill bit to drill through the accumulated material deposits inside the furnace.

16. The robot according to claim 11, wherein, The plurality of sensors are configured to generate end effector position signals for maintaining non-contact operation of the end effector relative to the chute and furnace wall.

17. A method for removing accumulated material deposits inside a furnace, the method comprising initiating a pre-programmed sequence to: Position the robot close to the opening on the furnace wall; Position the robot's end effector at a specified angle for approaching the opening; The robot is operated so that the end effector can clear the accumulated material deposits; as well as The end effector is retracted.

18. The method of claim 17, further comprising: It is determined that the end effector has reached its maximum insertion depth in the furnace; In response to determining that the end effector has reached its maximum insertion depth in the furnace: Retract the end effector; Different pre-programmed sequences can be selected to change the angle at which the end effector enters the opening on the furnace wall; as well as The robot is operated at a changed angle so that the end effector can clear the accumulated material deposits.

19. The method of claim 17, further comprising: Determine that the drill bit is connected to the end effector; as well as In response to determining that the tool drill bit is coupled to the end effector, the robot is controlled to induce oscillating motions in the end effector and the tool drill bit.

20. The method of claim 17, further comprising: Determine that the rotary tool is connected to the end effector; as well as In response to determining that the rotary tool is coupled to the end effector, the driver of the rotary tool is engaged to provide rotational motion to the tool drill bit coupled to the rotary tool.

21. A system for inserting a plug into an opening in a recycling furnace wall, the system comprising: A robot having an end effector configured to mount a plug sized to block the opening; as well as A control system configured to execute one or more pre-programmed operation sequences for controlling the robot to operate the end effector.

22. A maintenance system for a recycling furnace that requires no operator intervention, the system comprising: The robot has a robotic arm and one of a plurality of end effectors, each of which is configured to perform maintenance operations selected from the following group: Remove at least some of the openings on the walls of the recycling furnace that are blocked by solid molten material; Collect solid melt samples from the opening; Block the opening with a plugging component; as well as Remove the plug from the opening; as well as A control system configured to execute one or more pre-programmed operation sequences for controlling the robot to operate two of the end effectors to complete at least two of the maintenance operations.

23. The system according to claim 22, wherein, The controller is configured to execute one or more pre-programmed operation sequences for controlling the robot to perform at least three of the maintenance operations.

24. The system according to claim 22, wherein, The at least two maintenance operations are performed without human intervention at the furnace wall.

25. The system of claim 22, further comprising a presence sensing module operably connected to the controller, the controller being configured to detect the presence of an unwanted visitor near the opening in the recycling furnace wall.

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