SYSTEMS AND METHODS FOR AUTOMATION OF A DEVICE FOR LOADING SCRAP

Abstract

A molten metal processing system for processing molten material, such as molten metal, includes a scrap submergence device, one or more sensors, and a controller. The scrap submergence device may mix the molten material in a containment structure, and the one or more sensors may obtain information about one or more processing parameters of the molten metal processing system. The controller is communicatively coupled with the one or more sensors and may receive data from the one or more sensors. The controller may determine a position or other parameter of the scrap submergence device within the containment structure and / or may determine a control response for the scrap submergence device.

Description

Patent Application Attorney Docket #: 108050-1460177 SYSTEMS AND METHODS FOR AUTOMATING SCRAP SUBMERGENCE DEVICE REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 597,430, filed on November 9, 2023, and entitled SYSTEMS AND METHODS FOR AUTOMATING SCRAP SUBMERGENCE DEVICE, the content of which is hereby incorporated by reference in its entirety. FIELD OF THE INVENTION

[0002] This application relates to the metallurgy generally and more specifically to devices, systems, and methods for furnaces, molten metal containment structures, and scrap submergence devices for mixing, conveying, treating, and / or holding molten metals. BACKGROUND

[0003] Metals, such as aluminum and aluminum alloys, are frequently melted in metal melting furnaces. For example, aluminum and copper scrap materials, as well as pure metals, are usually melted in reverberatory furnaces for eventual use or re-use by metal fabricators. To produce a high quality product suitable for subsequent casting or other processing, it may be desirable to cause the molten material to flow within the furnace. In particular, stirring, circulating, and / or otherwise causing movement of the molten metal may distribute the material within the furnace, help homogenize the temperature of the material, and / or provide improved melting of solid material. Flux addition may further remove contaminants and oxides from the metal, thereby resulting in improved metal quality and metal recovery. SUMMARY

[0004] Embodiments covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various embodiments and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. ThePatent Application Attorney Docket #: 108050-1460177 subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings, and each claim.

[0005] According to certain embodiments, a molten metal processing system includes a scrap submergence device for mixing molten metal in a furnace and a scrap submergence control system. The scrap submergence control system includes one or more sensors for obtaining position information about the scrap submergence device. The scrap submergence control system additionally includes a controller, which may receive data from the one or more sensors and determine a position of the scrap submergence device within the furnace based on the data from the one or more sensors.

[0006] According to some embodiments, a molten metal processing system includes a scrap submergence device for mixing molten metal in a furnace and a scrap submergence control system having one or more sensors for obtaining information about at least one processing parameter of the molten metal processing system. The scrap submergence control system includes a controller communicatively coupled with the one or more sensors, and the controller may receive data from the one or more sensors and determine a control response for the scrap submergence device based on the data from the one or more sensors.

[0007] According to various embodiments, a scrap submergence control system includes at least one camera having a field of view of at least a portion of a furnace and a scrap submergence device, and a controller communicatively coupled to the at least one camera. In various embodiments, the controller may receive visual data from the at least one camera and identify at least one of a characteristic of the scrap submergence device or a characteristic of molten metal within a vicinity of the scrap submergence device. The controller may compare the identified characteristic of the scrap submergence device or the characteristic of the molten metal with a desired characteristic and implement a control response with the scrap submergence device responsive to a difference between the identified characteristic of the scrap submergence device or the characteristic of the molten metal and the desired characteristic.

[0008] According to certain embodiments, a method of controlling a scrap submergence device of a molten metal processing system for molten metal includes receiving information from one or more sensors about at least one processing parameter of the molten metal processing system and determining a control response for the scrap submergence device based on the received information from the one or more sensors. The method includes controlling the scrap submergence device pursuant to the determined control response.Patent Application Attorney Docket #: 108050-1460177

[0009] Various implementations described herein can include additional systems, methods, features, and advantages, which cannot necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The specification makes reference to the following appended figures, in which use of like reference numerals in different figures is intended to illustrate like or analogous components.

[0011] FIG. 1 is a representation of a molten metal processing system with a scrap submergence control system according to embodiments.

[0012] FIG. 2 illustrates the molten metal processing system of FIG. 1 according to embodiments.

[0013] FIG.3 illustrates a portion of the molten metal processing system of FIG.2.

[0014] FIG.4 illustrates a portion of the molten metal processing system of FIG.2.

[0015] FIG. 5 illustrates a scrap submergence device of the molten metal processing system of FIG.2.

[0016] FIG.6 illustrates a process for controlling a scrap submergence device using the scrap submergence system of FIG.1 according to embodiments. DETAILED DESCRIPTION

[0017] Described herein are systems and methods for controlling a scrap submergence device for a molten metal processing system. In certain embodiments, the systems and methods described herein utilize a scrap submergence control system, which may include one or more sensors and a controller communicatively coupled with the one or more sensors. In various embodiments, the one or more sensors may obtain information about at least one processing parameter of the molten metal processing system, and the controller may determine a control response for the scrap submergence device based on the data from the one or more sensors. Additionally, or alternatively, other control responses may include controlling other equipmentPatent Application Attorney Docket #: 108050-1460177 and / or components of the molten metal processing system and / or generating an alert and / or an alarm. The at least one processing parameter may be various characteristics and / or parameters of the molten metal processing system, including but not limited to a characteristic of metal being processed by the molten metal processing system and / or a characteristic of the scrap submergence device. As non-limiting examples, the at least one processing parameter may be an incoming feed rate of metal into a metal containment structure of the metal processing system, a type of material supplied to the metal containment structure, a level of molten metal within the metal containment structure, a temperature of molten metal, a size of a vortex in the molten metal, a size and / or characteristic of dross balls in the molten metal, a vertical position of the scrap submergence device, a horizontal position of the scrap submergence device, a tilt angle of the scrap submergence device, a rotational speed of the scrap submergence device, torque on the scrap submergence device (measured directly or indirectly), a depth of the scrap submergence device within molten metal, combinations thereof, and / or any other processing parameter as desired. The processing parameters described herein may be directly measured or may be indirectly determined as desired. As an example, a vertical position of the scrap submergence device may be directly measured or may be determined based on encoding of an actuator and / or using various reference points as desired. As another non-limiting example, the torque on the scrap submergence device may be directly measured and / or may be determined indirectly based on the power, current, amperage of the motor, and / or as otherwise desired. In various embodiments, the control response may include maintaining a current operational state of the scrap submergence device and / or may include controlling, adjusting, and / or modifying one or more characteristics of the scrap submergence device. As non-limiting examples, the control response may include adjusting and / or controlling a rotational speed of the scrap submergence device, a tilt angle of the scrap submergence device, a vertical position of the scrap submergence device, a horizontal position of the scrap submergence device, a duration of vertical movement, a duration of horizontal movement, and / or a duration of rotation of the scrap submergence device.

[0018] In some embodiments, the systems and methods described herein determine a position of the scrap submergence device in a horizontal direction and in a vertical direction. In certain embodiments, the systems and methods described herein may automatically position the scrap submergence device based on data from the one or more sensors to provide a desired melting, mixing, conveying, treating, and / or holding of metal within the metal containment structure. The systems and methods described herein may provide improved circulation of molten metal,Patent Application Attorney Docket #: 108050-1460177 improved homogenization of the molten material, allow for reduced power consumption, allow for reduced salt consumption, increase the life cycle of the scrap submergence device, and / or reduce consumption of gas during processing among other benefits. Various other benefits and advantages may be realized with the systems and methods described herein, and the aforementioned benefits and advantages should not be considered limiting.

[0019] FIGS.1-5 illustrate an example of a system 100 for processing molten metal according to embodiments. The system 100 may process various metals and / or other molten material as desired, including but not limited to aluminum, aluminum alloys, steel, or other metals as desired. In some examples, the molten metal may be an aluminum or an aluminum alloy in the 1xxx series, 2xxx series, 3xxx series, 4xxx series, 5xxx series, 6xxx series, 7xxx series, 8xxx series and / or any other aluminum or aluminum alloy as desired.

[0020] As illustrated in FIGS. 1-5, the system 100 generally includes a metal containment structure 102, a scrap submergence device 104, and a scrap submergence control system 116.

[0021] The metal containment structure 102 may be various structures suitable for containing molten metal and / or for treating and / or processing molten metal. As a non-limiting example, the metal containment structure 102 may be a furnace 106, such as but not limited to a melting or holding furnace, and include one or more heating elements for directing heat into the furnace 106. As illustrated in FIGS.1 and 2, in certain embodiments, the metal containment structure 102 includes a plurality of chambers for receiving molten material, such as a main chamber 108 and a side well chamber 110. In this embodiment, a volume of the side well chamber 110 may be less than a volume of the main chamber 108, although it need not be in other embodiments. In various embodiments, the side well chamber 110 may be utilized for receiving the scrap submergence device 104 and thus a location where flow or circulation is generated as discussed in detail below. Additionally, or alternatively, the side well chamber 110 may be a location for introducing additional material such as scrap metal (e.g., used beverage cans or other), salt flux, alloying elements, and / or other material for treatment and processing into the molten metal. In other embodiments, the metal containment structure 102 may have any number of chambers for receiving the molten metal as desired, including a single chamber, two chambers, three chambers, etc. In embodiments with a plurality of chambers such as illustrated in FIGS. 1 and 2, ports 111, 113 may allow for a flow of the molten material between the chambers.Patent Application Attorney Docket #: 108050-1460177

[0022] As illustrated in FIG.5, the scrap submergence device 104 generally includes a shaft 122 and an impeller 124 with one or more blades 126. In certain embodiments, the scrap submergence device 104 optionally includes a plate 128. In some embodiments, the scrap submergence device 104 may be similar to the scrap submergence device described in U.S. Patent Application No. 17 / 904,909, filed on April 29, 2021, and entitled SCRAP SUBMERGENCE DEVICE AND RELATED PROCESSES, the content of which is hereby incorporated by reference in its entirety. The scrap submergence device 104 may be used with the metal containment structure 102 for mixing, circulating, and / or otherwise causing movement of the molten metal within the metal containment structure 102 from a first location (e.g., the side well chamber 110) to a second location (e.g., the main chamber 108). Additionally, or alternatively, the scrap submergence device 104 may be provided for mixing and / or submerging scrap material (e.g., used beverage cans, metal chips, etc.), salt flux, alloying elements, and / or other elements for treatment and processing. In various embodiments, the scrap submergence device 104 generates a downward vortex circulating material from an upper region to a lower region, thereby mixing and submerging material within the metal containment structure 102.

[0023] In various embodiments, a support structure 112 may support the scrap submergence device 104 relative to the metal containment structure 102. In certain embodiments, an actuator 114 is provided for controlling a position and / or other operating characteristic of the scrap submergence device 104 and / or the support structure 112. In some embodiments, the scrap submergence device 104 and / or the support structure 112 are freely movable and / or adjustable. In other embodiments, the scrap submergence device 104 and / or the support structure 112 may have one or more restrictions on movement. As a non-limiting example, the scrap submergence device 104 and / or the support structure 112 may have a range of movement in an X-Y plane by utilizing rails, stoppers, and / or other features as desired. As another non-limiting example, the scrap submergence device 104 and / or the support structure 112 may include a pivot point (e.g., allowing tilting or pivoting of the scrap submergence device 104) with a defined range of pivoting movement. As a further non-limiting example, the scrap submergence device 104 and / or the support structure 112 may include a horizontal extension structure and / or a vertical extension structure, each movable between a stowed position and a deployed position. Various other features may be utilized to control movement of the scrap submergence device 104 and / or the support structure 112 as desired. As discussed in detail below, in various embodiments, thePatent Application Attorney Docket #: 108050-1460177 scrap submergence device 104 and / or associated components may be selectively controlled by the scrap submergence control system 116.

[0024] As illustrated in FIG. 1, for example, the scrap submergence control system 116 generally includes one or more sensors 118 and a controller 120. In various embodiments, the one or more sensors 118 may monitor or detect one or more processing parameters of the system 100, and the controller 120 may determine one or more control responses for the scrap submergence device 104 based on information from the one or more sensors 118. Additionally, or alternatively, the controller 120 may determine one or more control responses for other equipment and / or for generating an alert and / or an alarm to a user. Optionally, the controller 120 may control the scrap submergence device 104 and / or other equipment pursuant to the determined control response.

[0025] While three sensors 118A-C are illustrated in FIG. 1, in other embodiments, any number of sensors 118 may be utilized as desired. As non-limiting examples, in other embodiments, the scrap submergence control system 116 may include one sensor 118, two sensors 118, three sensors 118, and / or more than three sensors 118. In embodiments with a plurality of sensors 118, the sensors 118 need not be a same type of sensor and / or need not detect a same processing parameter. As an example, and as discussed in greater detail below, the sensor 118A may be position sensor, the sensor 118B may be a temperature sensor, and the sensor 118C may be a flow rate sensor. The sensors 118 may be provided at various locations and / or on various structures of the system 100 as desired. In the example of FIG.1, the sensor 118A is on the scrap submergence device 104, the sensor 118B is at a first location remote from the scrap submergence device 104, and the sensor 118C is at a second location remote from the scrap submergence device 104. However, the particular locations illustrated should not be considered limiting.

[0026] The one or more processing parameters detected by the one or more sensors 118 may be various characteristics of the scrap submergence device 104, the metal being processed by the system 100, and / or other components of the system 100, and thus the one or more sensors 118 may be various types of sensors as desired. As non-limiting examples, the one or more processing parameters may be an operating characteristic of the scrap submergence device 104, such as but not limited to, a horizontal position (e.g., a position in the X direction and / or the Y direction) of the scrap submergence device 104, a vertical position (e.g., a position in the Z direction) of the scrap submergence device 104, a rotational speed of the scrap submergence device 104, a tilt angle of the scrap submergence device 104 (e.g., an angle relative to a verticalPatent Application Attorney Docket #: 108050-1460177 axis), a direction of rotation of the scrap submergence device 104, a depth of the scrap submergence device 104 within molten metal, torque or other forces on the scrap submergence device 104 (measured indirectly or directly), combinations thereof, and / or other characteristics as desired. As additional non-limiting examples, the one or more processing parameters may be characteristics of the metal being processed by the system 100, such as but not limited to, an incoming feed rate of metal into the system 100, a type of material being supplied to the system 100, a level or depth of molten metal within the metal containment structure 102, a temperature of the metal, a size of a vortex in the molten metal, a size of dross balls in the metal, a metal flow rate, combinations thereof, and / or other characteristics as desired. As further non-limiting examples, the one or more processing parameters may be a characteristic of other equipment of the system 100, such as but not limited to, a furnace temperature, a furnace condition (e.g., a burner status, an atmospheric composition within the metal containment structure 102, etc.), a current furnace operation, combinations thereof, and / or other characteristics as desired. As such, non-limiting examples of sensors 118 suitable for monitoring and / or detecting one or more processing parameters of the system 100 include position sensors, optical sensors, laser sensors, temperature sensors, flow sensors, force sensors, vibration sensors, combinations thereof, or other devices or systems as desired.

[0027] In some embodiments, the one or more sensors 118 includes at least a position sensor for detecting a position of the scrap submergence device 104. In various embodiments, the position sensor may detect and / or obtain information related to a position of the scrap submergence device 104 in the horizontal direction (e.g., X direction and / or Y direction) and / or in the vertical direction (e.g., Z direction). The position sensor may detect the position of the scrap submergence device 104 using various techniques as desired, such as but not limited to lasers, radar, ultrasound, radio frequency, images or visual data, GPS, Wi-Fi, LiFi, ultra- wideband, Bluetooth®, cellular, encoder feedback, combinations thereof, and / or other techniques as desired. In various embodiments, the position sensor may directly measure the position of the scrap submergence device 104, while in other embodiments, the information obtained by the position sensor may be used to determine the position of the scrap submergence device 104.

[0028] Additionally, or alternatively, the one or more sensors 118 includes an optical sensor, such as one or more cameras, suitable for capturing one or more images of the system 100. As non-limiting examples, the optical sensor may be visible light cameras such as grayscale, color, RGB, and / or other visible light cameras. In some embodiments, the optical sensor may bePatent Application Attorney Docket #: 108050-1460177 cameras capable of observing light outside the visible spectrum, such as infrared, near infrared, or ultraviolet cameras. In some embodiments, the optical sensor may include cameras that are capable of recording distance or ranging information, such as time-of-flight cameras or LIDAR sensors. Such one or more time-of-flight or LIDAR sensors or cameras can be used to provide accurate distance, size, shape, dimensions, and other important physical information about components in a field of view as discussed in detail below. In some embodiments, the optical sensor may include arrays of cameras, wide-angle, 360 degree cameras, or other such image capturing devices. The optical sensor may be video cameras, or may be cameras taking still images, or a combination thereof. In some embodiments, by including many cameras, aspects of the present disclosure can be resilient against individual camera failures by switching to use as input another camera that has not failed. In some embodiments, interpretative processing can be used to fill gaps in image data caused by transmission dropout, blind spots, or other occlusions to monitor aspects of the system 100 that are temporarily or permanently not visible to the optical sensor. Any number of optical sensors may be utilized, and when a plurality of optical sensors are utilized, they need not be the same type. As a non-limiting example, one optical sensor may be a visible light camera, another optical sensor may be an infrared camera, and yet another optical sensor may be a video camera.

[0029] The one or more optical sensors may be provided at various locations and / or at various orientations relative to the system 100 such that each of the one or more optical sensors has a field of view of at least a portion of the system 100. In this regard, the one or more optical sensors may observe and / or monitor the portions of the system 100 within the field of view. In some embodiments, the one or more optical sensors are arranged to have a field of view of a particular component, equipment, or machinery of the system 100. In the embodiments illustrated and described herein, at least one optical sensor is arranged to have a field of view of at least a portion of the scrap submergence device 104 and / or molten metal within the vicinity of the scrap submergence device 104. However, in other embodiments, the one or more optical sensors may be arranged to have fields of view that include other portions of the system 100 and / or a plurality of components, equipment, or machinery of the system 100 as desired.

[0030] As mentioned, other types of sensors 118 may be utilized, and the aforementioned examples should not be considered limiting.

[0031] In addition to the one or more sensors 118, as mentioned, in various embodiments the scrap submergence control system 116 includes the controller 120 communicatively coupledPatent Application Attorney Docket #: 108050-1460177 to one or more sensors 118. In certain embodiments, the controller 120 may selectively control the scrap submergence device 104 based on information from the one or more sensors 118.

[0032] The controller 120 may include one or more processing units and / or one or more memory devices. The processing unit may be various suitable processing devices or combinations of devices including but not limited to one or more application specific integrated circuits, digital signal processors, digital signal processing devices, programmable logic devices, field programmable gate arrays, processors, controllers, micro-controllers, microprocessors, other electronic units, and / or a combination thereof. The one or more memory devices may be any machine-readable medium that can be accessed by the processor, including but not limited to any type of long term, short term, volatile, nonvolatile, or other storage medium, and is not to be limited to any particular type of memory or number of memories, or type of media upon which memory is stored. Moreover, as disclosed herein, the term “storage medium,” “storage” or “memory” can represent one or more memories for storing data, including read only memory (ROM), random access memory (RAM), magnetic RAM, core memory, magnetic disk storage mediums, optical storage mediums, flash memory devices and / or other machine readable mediums for storing information. The term “machine-readable medium” includes, but is not limited to, portable or fixed storage devices, optical storage devices, wireless channels, and / or various other storage mediums capable of storing that contain or carry instruction(s) and / or data.

[0033] In certain embodiments, the controller 120 optionally includes an associated user interface, including but not limited to a graphical user interface or a human machine interface, such that the controller 120 may obtain information from a user and / or provide information to the user. In such embodiments, the user interface and / or human machine interface may be on the controller 120 itself or may be at a location remote from the controller 120.

[0034] In certain embodiments, the controller 120 may receive information from the one or more sensors 118 and may determine a control response for the scrap submergence device 104 based on the information from the one or more sensors 118. As mentioned, determining the control response may include maintaining current operational parameters or characteristics and / or controlling, modifying, and / or adjusting one or more operational parameters or characteristics. Optionally, the controller 120 may implement the control response. Non- limiting examples of control responses may include adjusting and / or controlling a rotational speed of the scrap submergence device, a tilt angle of the scrap submergence device, a horizontal position of the scrap submergence device, a duration of vertical movement, aPatent Application Attorney Docket #: 108050-1460177 duration of horizontal movement, a duration of rotation, and / or a vertical position of the scrap submergence device. Optionally, control responses may include controlling other equipment and / or generating an alert and / or an alarm. Feedback control of the scrap submergence device 104 by the controller 120 and based on the information from the one or more sensors 118 may allow for improved (e.g., real time) control of mixing, conveying, treating, and / or holding molten metals and / or may allow for additional control of processing by the system 100.

[0035] FIG.6 illustrates an example of a process for controlling the scrap submergence device 104 with the scrap submergence control system 116.

[0036] In a block 602, the method includes receiving, by the controller 120, data from the one or more sensors 118 about one or more processing parameters of the system 100. In certain embodiments, block 602 may include receiving information from the one or more sensors 118 about an operating characteristic of the scrap submergence device 104, such as but not limited to a horizontal position of the scrap submergence device 104, a vertical position of the scrap submergence device 104, a rotational speed of the scrap submergence device 104, a tilt angle of the scrap submergence device 104, torque or forces acting on the scrap submergence device 104, a depth of the scrap submergence device 104 in molten metal, combinations thereof, and / or other characteristics as desired. As mentioned, such operating characteristics of the scrap submergence device 104 may be directly measured and / or indirectly measured as desired. Additionally, or alternatively, block 602 may include receiving information about metal of this system 100, such as but not limited to a feed rate of metal into the system 100, a type of material being fed into the system 100, a metal level within the metal containment structure 102, a flow rate of molten metal, size of a vortex in the molten metal, a size of dross balls, a temperature of the molten metal, combinations thereof, and / or other characteristics as desired. Additionally, or alternatively, block 602 may include receiving information about other equipment devices of the system 100, such as but not limited to an operational stage of the process, a status of a burner, a temperature of the furnace, atmospheric conditions within the furnace, combinations thereof, and / or other characteristics as desired.

[0037] In some embodiments, the data received in block 602 may be the processing parameter data itself. As a non-limiting example, if the sensor 118 is a temperature sensor and the processing parameter is a temperature of molten metal, the data received in block 602 may be the temperature as measured by the temperature sensor. Additionally, or alternatively, the controller 120 may determine the processing parameter based on the data received in block 602.Patent Application Attorney Docket #: 108050-1460177

[0038] As a non-limiting example, the sensor 118 may be a camera, and the processing parameter may be a position of the scrap submergence device 104. In this example, in block 602, the data from the sensor 118 may be visual data, and based on the visual data, the controller 120 may determine the position of the scrap submergence device 104 using various techniques as desired. As examples, the controller 120 may determine the position of the scrap submergence device 104 based on a frame of reference (e.g., the furnace itself), real or virtual reference points on the scrap submergence device 104 and / or other structure, and / or other techniques or combinations of techniques as desired.

[0039] As another non-limiting example, the sensor 118 may be a camera, and the processing parameter may be a size of a vortex in the molten metal. In this example, in block 602, the data from the sensor 118 may be visual data, optionally a thermal image, and the controller 120 may identify dross balls (based on a different temperature than metal) to identify and determine a size of the vortex.

[0040] As an additional non-limiting example, the sensor 118 may be an encoder measuring linear or rotary motion of the scrap submergence device 104, and the processing parameter may be a vertical position of the scrap submergence device 104. In this example, in block 602, the data from the sensor 118 may be encoder feedback (e.g., an analog or digital signal), and based on the encoder feedback, the controller 120 may determine the vertical position of the scrap submergence device 104.

[0041] As another non-limiting example, the sensor 118 may be an optical sensor and / or a temperature sensor, and the processing parameter may be a melt rate of metal. In such an example, the controller 120 may determine a size of a vortex (as discussed previously) based on visual data from the optical sensor and estimate a melt rate based on the vortex. Additionally, or alternatively, in such an example, the controller 120 may determine a temperature gradient based on temperature data from the temperature sensor and estimate a melt rate based on the temperature gradient.

[0042] Block 602 may include various other determinations by the controller 120 to receive and / or obtain a particular processing parameter as desired.

[0043] In a block 604, the method includes determining whether a control response of controlling the scrap submergence device 104 is needed based on the processing parameter received and / or determined in block 602. In various embodiments, block 604 may include comparing the processing parameter received and / or determined in block 602 to a desired valuePatent Application Attorney Docket #: 108050-1460177 for the one or more processing parameters of the system 100. As non-limiting examples, block 602 may include comparing a determined melt rate with a desired melt rate, a determined position of the scrap submergence device 104 with a desired position of the scrap submergence device 104, a determined vortex size with a desired vortex size, a determined metal depth and determined speed of the scrap submergence device 104 with a desired rotational speed at the metal depth, combinations thereof, and / or as otherwise desired. Such desired values may be threshold or desired values, qualities, etc., and may be input by the user, determined by the controller 120, and / or otherwise determined as desired.

[0044] If no control response is needed (e.g., the controller 120 determines that the current operational status should be maintained based on the received processing parameter being within thresholds or tolerances of the desired value), the process may return to block 602.

[0045] If a control response is needed (e.g., based on the received processing parameter being outside of thresholds or tolerances), in a block 606, the method includes determining a control response for the scrap submergence device 104. In certain embodiments, block 606 includes determining a control, adjustment, and / or modification of one or more of a rotational speed of the scrap submergence device, a tilt angle of the scrap submergence device, a vertical position of the scrap submergence device, a horizontal position of the scrap submergence device, a duration of vertical movement, a duration of horizontal movement, and / or a duration of rotation of the scrap submergence device. As a non-limiting example, based on a determined position of the scrap submergence device 104 compared to a desired position within the metal containment structure 102 for achieving a desired melt rate, block 606 may include determining a change in the horizontal and / or vertical position of the scrap submergence device 104.

[0046] In a block 608, the method may further include controlling the scrap submergence device 104 to implement the control response determined in block 606.

[0047] In a block 610, the method includes determining whether the system 100 is still being utilized to determine whether the method should continue or end.

[0048] Additional examples of control are discussed below, but these examples should not be considered limiting. Various other control responses for the scrap submergence device 104 may utilize the scrap submergence control system 116 based on the measured and / or determined processing parameter(s). Moreover, various other processes may utilize the measured processing parameter(s) as desired.Patent Application Attorney Docket #: 108050-1460177

[0049] In some embodiments, one or more operating characteristics of the scrap submergence device 104 (e.g., horizontal position, vertical position, speed, tilt angle, etc.) may be automatically controlled by the controller 120 based on one or more characteristics (e.g., feed rate, material type, etc.) of incoming material being provided into the system.

[0050] In various embodiments, one or more operating characteristics of the scrap submergence device 104 may be automatically controlled by the controller 120 based on a changing metal level.

[0051] In certain embodiments, one or more operating characteristics of the scrap submergence device 104 may be automatically controlled by the controller 120 based on a changing furnace temperature and / or a changing furnace condition.

[0052] In some embodiments, one or more operating characteristics of the scrap submergence device 104 may be automatically controlled by the controller 120 based on a current furnace operation and such that the scrap submergence device 104 is positioned at an ideal location within the furnace.

[0053] In certain embodiments, one or more operating characteristics of the scrap submergence device 104 may be automatically controlled by the controller 120 based on a measured torque and / or current of the scrap submergence device 104 to improve the useful life of the scrap submergence device 104. Additionally, or alternatively, the measured torque and / or current may be monitored to detect or estimate events such as failing motors, damage to equipment, and / or as otherwise desired.

[0054] In various embodiments, one or more operating characteristics of the scrap submergence device 104 may be automatically controlled by the controller 120 based on measured temperature readings. As non-limiting examples, based on temperature readings from a plurality of locations (e.g., at port 111, port 113, and main chamber 108), the position of the scrap submergence device 104 within the side well chamber 110 may be controlled. As an example, the scrap submergence device 104 may successively move a predetermined distance towards a predetermined location and remain at the predetermined location for a set period of time until a temperature gradient is controlled (e.g., a difference in temperatures at the locations is 10 degrees or less).

[0055] In some embodiments, one or more operating characteristics of the scrap submergence device 104 may be automatically controlled by the controller 120 based on a measured metal depth. As a non-limiting example, based on the measured metal depth, the speed of the scrapPatent Application Attorney Docket #: 108050-1460177 submergence device may be controlled by the controller 120 to be from about 40 RPM to about 100 RPM, such as from about 40 RPM to about 70 RPM, such as from about 40 RPM to about 65 RPM, such as from about 40 RPM to about 50 RPM. As non-limiting examples, the speed may be about 40 RPM, about 41 RPM, about 42 RPM, about 43 RPM, about 44 RPM, about 45 RPM, about 46 RPM, about 47 RPM, about 48 RPM, about 49 RPM, about 50 RPM, about 51 RPM, about 52 RPM, about 53 RPM, about 54 RPM, about 55 RPM, about 56 RPM, about 57 RPM, about 58 RPM, about 59 RPM, about 60 RPM, about 61 RPM, about 62 RPM, about 63 RPM, about 64 RPM, about 65 RPM, about 66 RPM, about 67 RPM, about 68 RPM, about 69 RPM, about 70 RPM, about 71 RPM, about 72 RPM, about 73 RPM, about 74 RPM, about 75 RPM, about 76 RPM, about 77 RPM, about 78 RPM, about 79 RPM, about 80 RPM, about 81 RPM, about 82 RPM, about 83 RPM, about 84 RPM, about 85 RPM, about 86 RPM, about 87 RPM, about 88 RPM, about 89 RPM, about 90 RPM, about 91 RPM, about 92 RPM, about 93 RPM, about 94 RPM, about 95 RPM, about 96 RPM, about 97 RPM, about 98 RPM, about 99 RPM, and / or about 100 RPM. In some embodiments, the speed of scrap submergence device 104 may be controlled to gradually increase as the metal depth increases and / or a maximum speed is reached.

[0056] In certain embodiments, the scrap submergence device 104 may be controlled by the controller 120 to perform various other operations within the system 100. As a non-limiting example, the scrap submergence device 104 may be controlled to perform a refractory wear check and / or detection. In this example, the scrap submergence device 104 may be extended vertically (e.g., lowered, optionally from a known position and / or a start position) until a torque limit is reached in the vertical direction (determined directly or indirectly), thereby implying that a bottom surface of the side well chamber 110 has been reached. The vertical distance traveled by the scrap submergence device 104 to reach the torque limit may thus be utilized to determine the current height of the refractory material and / or wear on the refractory material. As an example, a baseline height for the refractory material may be provided by a user by correlating the baseline height to a baseline travel distance. In this example, the measured travel distance may be compared to the baseline travel distance to determine the change in height of refractor material. As another non-limiting example, the baseline height may be determined directly or indirectly by the scrap submergence control system 116 (e.g., during extension of the scrap submergence device 104 initial installation and / or before being used, based on input data, etc.), and the determined height of the refractory material may be compared to the baseline height. In some embodiments, the scrap submergence control system 116 may perform thePatent Application Attorney Docket #: 108050-1460177 refractory wear check and / or detection at a plurality of locations (e.g., by changing the horizontal position of the scrap submergence device 104) and optionally may generate a mapping or identification of the profile of the wear or change in height in the refractory material. Various other processes may be utilized to determine the current height and / or wear on the refractory material.

[0057] As mentioned, various other control responses for the scrap submergence device 104 may utilize the scrap submergence control system 116 based on the measured and / or determined processing parameter.

[0058] A collection of exemplary embodiments is provided below, including at least some explicitly enumerated as an “Illustration” providing additional description of a variety of example embodiments in accordance with the concepts described herein. These illustrations are not meant to be mutually exclusive, exhaustive, or restrictive; and the disclosure not limited to these example illustrations but rather encompasses all possible modifications and variations within the scope of the issued claims and their equivalents.

[0059] Illustration 1. A molten metal processing system comprising: a scrap submergence device for mixing molten metal in a furnace; and a scrap submergence control system comprising: one or more sensors configured to obtain position information about the scrap submergence device; and a controller communicatively coupled with the one or more sensors, wherein the controller is configured to receive data from the one or more sensors and determine a position of the scrap submergence device within the furnace based on the data from the one or more sensors.

[0060] Illustration 2. The molten metal processing system of any preceding or subsequent illustration or combination of illustrations, wherein the one or more sensors is on the scrap submergence device.

[0061] Illustration 3. The molten metal processing system of any preceding or subsequent illustration or combination of illustrations, wherein the one or more sensors is at a location remote from the scrap submergence device.

[0062] Illustration 4. The molten metal processing system of any preceding or subsequent illustration or combination of illustrations, wherein the one or more sensors is an optical sensor.

[0063] Illustration 5. The molten metal processing system of any preceding or subsequent illustration or combination of illustrations, wherein the controller is configured to determine the position of the scrap submergence device in at least two directions.Patent Application Attorney Docket #: 108050-1460177

[0064] Illustration 6. The molten metal processing system of any preceding or subsequent illustration or combination of illustrations, wherein the controller is configured to determine the position of the scrap submergence device at least in a vertical direction.

[0065] Illustration 7. The molten metal processing system of any preceding or subsequent illustration or combination of illustrations, wherein the controller is further configured to compare the determined position with a desired position and to control the position of the scrap submergence device based on a difference between the determined position and the desired position.

[0066] Illustration 8. A molten metal processing system comprising: a scrap submergence device for mixing molten metal in a furnace; and a scrap submergence control system comprising: one or more sensors configured to obtain information about at least one processing parameter of the molten metal processing system; and a controller communicatively coupled with the one or more sensors, wherein the controller is configured to receive data from the one or more sensors and determine a control response for the scrap submergence device based on the data from the one or more sensors.

[0067] Illustration 9. The molten metal processing system of any preceding or subsequent illustration or combination of illustrations, wherein the at least one processing parameter is at least one characteristic of metal being processed by the furnace.

[0068] Illustration 10. The molten metal processing system of any preceding or subsequent illustration or combination of illustrations, wherein the at least one characteristic of the molten metal comprises at least one of an incoming feed rate of metal into the furnace, a type of material supplied to the furnace, a level of molten metal within the furnace, a temperature of molten metal, a size of a vortex in the molten metal, or a size of dross balls in the molten metal.

[0069] Illustration 11. The molten metal processing system of any preceding or subsequent illustration or combination of illustrations, wherein the at least one processing parameter is at least one characteristic of the scrap submergence device.

[0070] Illustration 12. The molten metal processing system of any preceding or subsequent illustration or combination of illustrations, wherein the at least one characteristic of the scrap submergence device comprises at least one of a vertical position of the scrap submergence device, a horizontal position of the scrap submergence device, a tilt angle of the scrap submergence device, a rotational speed of the scrap submergence device, torque on the scrap submergence device, or a depth of the scrap submergence device within molten metal.Patent Application Attorney Docket #: 108050-1460177

[0071] Illustration 13. The molten metal processing system of any preceding or subsequent illustration or combination of illustrations, wherein the controller is configured to determine the control response by determining an adjustment or modification of at least one of a rotational speed of the scrap submergence device, a tilt angle of the scrap submergence device, a vertical position of the scrap submergence device, a horizontal position of the scrap submergence device, a duration of vertical movement, a duration of horizontal movement, or a duration of rotation.

[0072] Illustration 14. The molten metal processing system of any preceding or subsequent illustration or combination of illustrations, wherein the controller is configured to perform a refractory wear check of a refractory material of the furnace by controlling a vertical position of the scrap submergence device until a torque limit is reached.

[0073] Illustration 15. A scrap submergence control system comprising: at least one camera having a field of view of at least a portion of a furnace and a scrap submergence device; a controller communicatively coupled to the at least one camera, the controller configured to: receive visual data from the at least one camera; identify at least one of a characteristic of the scrap submergence device or a characteristic of molten metal within a vicinity of the scrap submergence device; compare the identified characteristic of the scrap submergence device or the characteristic of the molten metal with a desired characteristic; and implement a control response with the scrap submergence device responsive to a difference between the identified characteristic of the scrap submergence device or the characteristic of the molten metal and the desired characteristic.

[0074] Illustration 16. The scrap submergence control system of any preceding or subsequent illustration or combination of illustrations, wherein the control response comprises a control of a rotational speed of the scrap submergence device, a tilt angle of the scrap submergence device, a vertical position of the scrap submergence device, a horizontal position of the scrap submergence device, a duration of vertical movement, a duration of horizontal movement, or a duration of rotation.

[0075] Illustration 17. The scrap submergence control system of any preceding or subsequent illustration or combination of illustrations, wherein the control response comprises an activation of an alarm.

[0076] Illustration 18. A method of controlling a scrap submergence device of a molten metal processing system for molten metal, the method comprising: receiving, by a controller,Patent Application Attorney Docket #: 108050-1460177 information from one or more sensors about at least one processing parameter of the molten metal processing system; determining, by the controller, a control response for the scrap submergence device based on the received information from the one or more sensors; and controlling the scrap submergence device pursuant to the determined control response.

[0077] Illustration 19. The method of any preceding or subsequent illustration or combination of illustrations, wherein the at least one processing parameter is at least one characteristic of metal being processed by the molten metal processing system, and wherein the at least one characteristic of the molten metal comprises at least one of an incoming feed rate of metal into a furnace, a type of material supplied to the furnace, a level of molten metal within the furnace, a temperature of molten metal, a size of a vortex in the molten metal, or a size of dross balls in the molten metal.

[0078] Illustration 20. The method of any preceding or subsequent illustration or combination of illustrations, wherein the at least one processing parameter is at least one characteristic of the scrap submergence device, and wherein the at least one characteristic of the scrap submergence device comprises at least one of a vertical position of the scrap submergence device, a horizontal position of the scrap submergence device, a tilt angle of the scrap submergence device, a rotational speed of the scrap submergence device, torque on the scrap submergence device, or a depth of the scrap submergence device within molten metal.

[0079] Illustration 21. The method of any preceding or subsequent illustration or combination of illustrations, wherein controlling the scrap submergence device comprises controlling at least one of a control of a rotational speed of the scrap submergence device, a tilt angle of the scrap submergence device, a vertical position of the scrap submergence device, or a horizontal position of the scrap submergence device.

[0080] Illustration 22. A method of controlling a scrap submergence device of a molten metal processing system, the method comprising: lowering a scrap submergence device from a start position until a torque limit is reached; determining a vertical distance travelled by the scrap submergence device from the start position until the torque limit is reached; and determining a current height of refractor material of the molten metal processing system based on the determined vertical distance travelled.

[0081] Illustration 23. The method of any preceding or subsequent illustration or combination of illustrations, wherein the torque limit is directly measured or indirectly measured.Patent Application Attorney Docket #: 108050-1460177

[0082] As used herein, the terms “invention,” “the invention,” “this invention,” and “the present invention” are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.

[0083] In this description, reference is made to alloys identified by AA numbers and other related designations, such as “series” or “5xxx.” For an understanding of the number designation system most commonly used in naming and identifying aluminum and its alloys, see “International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys” or “Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot,” both published by The Aluminum Association.

[0084] All ranges disclosed herein are to be understood to encompass any and all subranges subsumed therein. For example, a stated range of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more, e.g., 1 to 6.1, and ending with a maximum value of 10 or less, e.g., 5.5 to 10.

[0085] As used herein, the meaning of “a,” “an,” and “the” includes singular and plural references unless the context clearly dictates otherwise.

[0086] The elements included in the illustrations herein may not be drawn to scale. For example, figures depicting scrap submergence devices and / or furnaces may include exaggerated features for illustrative purposes.

[0087] The subject matter of embodiments of the present disclosure is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. Directional references such as “up,” “down,” “top,” “bottom,” “left,” “right,” “vertical,” “horizontal,” “lateral,” “longitudinal,” “front,” and “back,” among others, are intended to refer to the orientation as illustrated and described in the figure (or figures) to which the components and directions are referencing.Patent Application Attorney Docket #: 108050-1460177

[0088] The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the invention, and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

[0089] The above-described aspects are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Many variations and modifications can be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure. Moreover, although specific terms are employed herein, as well as in the claims that follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described embodiments, nor the claims that follow.

Claims

1. A system for handling molten metal, comprising: a scrap loading device for stirring molten metal in a furnace; and a scrap loading control system, comprising: one or more sensors configured to receive information about the position of the scrap loading device; and a controller connected in communication with the one or more sensors, wherein the controller is configured to receive data from the one or more sensors and to determine the position of the scrap loading device in the furnace based on the data from the one or more sensors.

2. The molten metal processing system of claim 1, wherein one or more sensors are located on the scrap loading device.

3. The molten metal handling system of claim 1, wherein one or more sensors are located at a location remote from the scrap loading device.

4. The molten metal processing system of claim 1, wherein one or more sensors are an optical sensor.

5. The molten metal processing system of claim 1, wherein the controller is configured to determine the position of the scrap loading device in at least two directions.

6. The molten metal processing system of claim 1, wherein the controller is configured to determine the position of the scrap loading device in at least a vertical direction.

7. The molten metal processing system of claim 1, wherein the controller is further configured to compare the set position with the desired position, and to control the position of the scrap loading device based on the difference between the set position and the desired position.

8. A molten metal handling system comprising: a scrap loading device for stirring molten metal in a furnace; and a scrap loading control system comprising: one or more sensors configured to receive information about at least one processing parameter of the molten metal handling system; and a controller communicatively connected to the one or more sensors, wherein the controller is configured to receive data from the one or more sensors and to determine a control action on the scrap loading device based on information received from the one or more sensors.

9. The molten metal processing system of claim 8, wherein at least one processing parameter represents at least one characteristic of a metal being processed by the molten metal processing system.

10. The molten metal processing system of claim 9, wherein the at least one characteristic of the molten metal comprises at least one of a feed rate of metal into the furnace, a type of material fed into the furnace, a level of molten metal within the furnace, a temperature of the molten metal, a swirl size in the molten metal, or a size of slag inclusions in the molten metal.

11. The molten metal processing system of claim 8, wherein at least one processing parameter is at least one characteristic of the scrap loading device.

12. The molten metal processing system of claim 11, wherein at least one characteristic of the scrap loading device includes at least one of a vertical position of the scrap loading device, a horizontal position of the scrap loading device, an angle of the scrap loading device, a rotational speed of the scrap loading device, a torque on the scrap loading device, or an immersion depth of the scrap loading device in the molten metal.

13. The molten metal processing system of claim 8, wherein the controller is configured to determine a control action by determining an adjustment or change in at least one of the rotational speed of the scrap loading device, the angle of the scrap loading device, the vertical position of the scrap loading device, the horizontal position of the scrap loading device, the duration of the vertical movement, the duration of the horizontal movement, or the duration of rotation.

14. The molten metal processing system of claim 8, wherein the controller is configured to perform a wear test on the furnace refractory material by controlling the vertical position of the scrap loading device until the maximum torque is reached.

15. A scrap loading control system comprising: at least one camera having a field of view that covers at least a portion of a furnace and a scrap loading device; a controller communicatively coupled to the at least one camera, wherein the controller is configured to: receive visual data from the at least one camera; determine at least one of a characteristic of the scrap loading device or a characteristic of molten metal near the scrap loading device; compare the determined characteristic of the scrap loading device or the characteristic of the molten metal with a desired characteristic; and implement a control action using the scrap loading device in response to a difference between the determined characteristic of the scrap loading device or the characteristic of the molten metal and the desired characteristic.

16. A scrap immersion control system according to claim 15, wherein the control action includes controlling the speed of rotation of the scrap immersion device, the angle of inclination of the scrap immersion device, the vertical position of the scrap immersion device, the horizontal position of the scrap immersion device, the duration of the vertical movement of the scrap immersion device, the duration of the horizontal movement of the scrap immersion device, or the duration of rotation of the scrap immersion device.

17. A method for controlling a scrap loading device of a molten metal processing system, comprising: receiving, using a controller, information from one or more sensors about at least one processing parameter of the molten metal processing system; determining, using the controller, a control action on the scrap loading device based on the received information from the one or more sensors; and controlling the scrap loading device in accordance with the determined control action.

18. The method of claim 17, wherein the at least one processing parameter is at least one characteristic of a metal being processed by the molten metal processing system, wherein the at least one characteristic of the molten metal includes at least one of a feed rate of metal into the furnace, a type of material fed into the furnace, a level of molten metal within the furnace, a temperature of the molten metal, a swirl size in the molten metal, or a size of slag inclusions in the molten metal.

19. The method of claim 17, wherein at least one processing parameter is at least one characteristic of the scrap loading device, and the at least one characteristic of the scrap loading device includes at least one of a vertical position of the scrap loading device, a horizontal position of the scrap loading device, an angle of inclination of the scrap loading device, a rotational speed of the scrap loading device, a torque on the scrap loading device, or a depth of immersion of the scrap loading device in the molten metal.

20. The method according to claim 17, wherein controlling the scrap loading device includes controlling at least one of the speed of rotation of the scrap loading device, the angle of inclination of the scrap loading device, the vertical position of the scrap loading device, or the horizontal position of the scrap loading device.

21. A method for controlling a scrap loading device of a molten metal handling system, comprising: lowering the scrap loading device from an initial position until a maximum torque is reached; determining a vertical distance traveled by the scrap loading device from the initial position until the maximum torque is reached; and determining the current height of the refractory material of the molten metal handling system based on the determined vertical distance traveled.

22. The method according to claim 21, wherein the ultimate torque is measured directly or indirectly.