Aluminum ingot yard intelligent operation configuration method

Abstract

The application discloses an intelligent operation configuration method for an aluminum ingot yard, which is applied to a casting workshop and an aluminum ingot yard. The casting workshop comprises an offline area and a forklift charging area. The aluminum ingot yard comprises a buffer area, a delivery area, a loading area and a stacking area. The intelligent operation control of the forklift in the offline area, the forklift charging area, the buffer area, the delivery area, the loading area and the stacking area realizes the whole process of the aluminum ingot from the production line of the aluminum ingot casting machine in the casting workshop to the stacking in the aluminum ingot yard and the loading and outward transportation of the stacked aluminum ingot. The offline, transfer, stacking and loading operations of the aluminum ingot all adopt the unmanned AGV forklift, so that the operation cost is reduced without the need of a driver and only with part of control and inspection personnel. The 24-hour continuous operation can be realized, the operation efficiency of the aluminum ingot yard is improved, and the forklift is more environmentally friendly and energy-saving than the traditional fuel forklift.

Description

Technical Field

[0001] This invention relates to the field of aluminum ingot handling, storage, and loading operations, specifically to an intelligent operation configuration method for aluminum ingot storage yards, enabling the transportation of aluminum ingots from the foundry to the aluminum ingot storage yard in an electrolytic aluminum plant for handling, storage, and loading operations. Background Technology

[0002] Casting is the final step in electrolytic aluminum production, producing products such as ordinary aluminum ingots, alloy rods, and large flat ingots, but ordinary aluminum ingots are the main product. Before being sold and shipped, aluminum ingots need to be temporarily stored within the factory area; this storage area is called the aluminum ingot storage yard. The aluminum ingot storage yard is used to store bundled aluminum ingots and for loading them onto trucks for transport. Therefore, the aluminum ingot storage yard has three basic functions: aluminum ingot transportation, storage, and loading.

[0003] Aluminum ingot storage yards are generally hardened sites located near the foundry. There are usually three layout options: the most common is to place them on one side of the aluminum tapping end of the foundry; the second option is to place them on both sides of the foundry; and the third option is to place them far away from the foundry due to land restrictions or railway transportation reasons.

[0004] For a long time, the transportation of aluminum ingots from the foundry to the aluminum ingot yard and the unloading of aluminum ingots within the yard have been carried out using manned forklifts. The loading equipment for transporting aluminum ingots out of the yard usually includes forklifts, truck cranes, gantry cranes, and container front cranes.

[0005] In traditional aluminum ingot yards, the forklifts used for transporting aluminum ingots and the loading and unloading equipment are all operated by people. The operation is relatively flexible, and there are no special requirements for the storage and loading of aluminum ingots. However, this also results in a large number of personnel required, low operating efficiency, high energy consumption, and high carbon emissions. Summary of the Invention

[0006] In view of the above-mentioned shortcomings and deficiencies, the present invention provides an intelligent operation configuration method for aluminum ingot storage yards.

[0007] To achieve the above objectives, the main technical solution adopted by this invention is: application in foundries and aluminum ingot storage yards.

[0008] The foundry workshop includes: an off-line area and a forklift charging area;

[0009] The aluminum ingot storage yard includes: a buffer area, a shipping area, a loading area, and a storage area;

[0010] Intelligent operation control of forklifts in the off-line area, forklift charging area, buffer area, shipping area, loading area and storage area realizes the entire process of aluminum ingots from the aluminum ingot casting machine production line in the foundry to the aluminum ingot storage yard, and then loading the stored aluminum ingots onto trucks for transportation.

[0011] The foundry workshop is equipped with a charging area for forklifts, which also serves as a storage area for the forklifts. The off-line area is located at the aluminum output end of the aluminum ingot casting machine production line within the foundry workshop. The buffer area is adjacent to the foundry workshop and is equipped with a rain shelter. On the side of the buffer area away from the foundry workshop, a shipping area and a loading area are arranged in sequence. The loading area is located near the edge of the aluminum ingot storage yard.

[0012] When the aluminum ingot storage yard is located on one side of the aluminum ingot exit end of the foundry, the storage area is set on one side of the buffer area, shipping area, and loading area; when the aluminum ingot storage yard is located on both sides of the foundry, the storage area is set on both sides of the buffer area, shipping area, and loading area.

[0013] The aluminum ingot storage area is equipped with internal roads in the production line area, forklift charging area, buffer area, shipping area, loading area and storage area; the loading area is equipped with multiple loading positions for vehicles transporting aluminum ingots.

[0014] All forklifts are laser-guided AGV unmanned transport forklifts, including off-line forklifts, loading forklifts, and unloading forklifts. Operating routes are set for the three types of forklifts to achieve 24-hour continuous operation.

[0015] The intelligent operation of the aluminum ingot yard includes the normal state without adverse weather and the abnormal state when there is adverse weather. The forklifts transport the bundled aluminum ingots from the aluminum output end of the aluminum ingot casting machine production line to the offline area.

[0016] When the aluminum ingot storage yard is in normal intelligent operation mode, the forklift operation process is as follows:

[0017] Phase 1: Forklifts transport aluminum ingots from the production line area to the storage area; loading forklifts travel between the shipping area and the loading area to perform loading operations. During this phase, the transport forklifts have no operational tasks.

[0018] Phase Two: Loading forklifts finish loading operations and return to the charging area to recharge; Transport forklifts prioritize transporting aluminum ingots from the storage area to the shipping area. Once the shipping area is full, the transport forklifts finish their operations and return to the charging area to recharge; Offline forklifts prioritize transporting aluminum ingots to the shipping area to ensure sufficient aluminum ingots for the shipping area and the continuous operation of aluminum ingot transportation; Once the shipping area is full, the offline forklifts transport the aluminum ingots to the storage area.

[0019] When the intelligent operation of the aluminum ingot storage yard is in an abnormal state, the forklift operation process is as follows: the forklifts stop operating outside the foundry, the off-line forklifts transport the aluminum ingots from the off-line area to the buffer area with a rain shelter for stacking; the transfer forklifts and loading forklifts stop operating.

[0020] After the bad weather ends, the forklift operation process is as follows:

[0021] Phase 1: Offline forklifts and reverse forklifts transport aluminum ingots from the offline area to the storage area, while loading forklifts travel between the shipping area and the loading area to perform loading operations.

[0022] Phase Two: After loading, the loading forklifts return to the charging area to recharge; the off-line forklifts transport aluminum ingots from the off-line area to the shipping area; the transfer forklifts transport aluminum ingots from the buffer area to the shipping area. When the shipping area is full, the off-line forklifts transport aluminum ingots from the off-line area to the storage area, and the transfer forklifts transport aluminum ingots from the buffer area to the storage area. Once the buffer area is empty, the transfer forklifts finish their operation and return to the charging area to recharge and wait.

[0023] The present invention has the following beneficial effects and advantages:

[0024] 1. By adopting the above-mentioned aluminum ingot yard operation configuration method and combining it with the control system, the unloading, transfer, storage and loading of aluminum ingots can all be carried out by unmanned AGV forklifts, which do not require drivers, only some control and inspection personnel. The number of operators in the aluminum ingot yard is reduced by about 60%, which reduces the company's operating costs.

[0025] 2. Because AGV unmanned forklifts can automatically charge and coordinate multiple vehicles, they can operate continuously for 24 hours, avoiding the work interruptions caused by traditional forklifts during worker rest and shift handover, thus improving the operating efficiency of aluminum ingot storage yards.

[0026] 3. AGV unmanned forklifts are powered by batteries, which are more environmentally friendly and energy-saving than traditional fuel forklifts. Energy costs can be reduced by about 80% compared to fuel vehicles, and carbon emissions can be reduced by about 30% compared to fuel vehicles. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the planar layout of the aluminum ingot storage area when it is located on both sides of the aluminum tapping end in this invention.

[0028] Figure 2 This is a schematic diagram of the plan layout of the aluminum ingot storage yard when it is located on one side of the foundry in this invention;

[0029] Figure 3 This is a schematic diagram of the partition configuration of the method of the present invention.

[0030] In the diagram: 1. Foundry workshop, 2. Aluminum ingot storage yard, 3. Rain shelter, 4. Internal road of aluminum ingot storage yard, 5. External road of aluminum ingot storage yard, 6. Aluminum ingot casting machine, A. Offline area, B. Forklift charging area, C. Buffer area, D. Shipping area, E. Loading area, F. Storage area. Detailed Implementation

[0031] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings, but the scope of protection of the present invention is not limited to the embodiments.

[0032] The aluminum ingot storage yard 2 has two layout options compared to the foundry workshop 1: the aluminum ingot storage yard 2 is located on the side of the foundry workshop 1 where aluminum ingots are discharged (e.g., Figure 2 (As shown) or aluminum ingot storage yard 2 is arranged on both sides of foundry 1 (as shown) Figure 1 (as shown); applied to foundry 1 and aluminum ingot storage yard 2, this invention is an intelligent operation configuration method for aluminum ingot storage yard, applied to foundry 1 and aluminum ingot storage yard 2.

[0033] like Figure 3 As shown, in this embodiment, the aluminum ingot storage yard 2 is arranged on both sides of the casting workshop 1, wherein the casting workshop 1 includes: the unloading area A and the forklift charging area B;

[0034] Aluminum ingot storage yard 2 includes: buffer area C, shipping area D, loading area E, and storage area F;

[0035] Intelligent operation control of forklifts in the off-line area A, forklift charging area B, buffer area C, shipping area D, loading area E, and storage area F enables the entire process of aluminum ingots being transported from the aluminum ingot casting machine 6 production line in the foundry workshop 1 to the aluminum ingot storage yard 2 for storage, and then loading the stored aluminum ingots onto trucks for external transport.

[0036] The foundry workshop 1 is equipped with a charging area B for charging forklifts, which also serves as a storage station for forklifts. The off-line area A is located at the aluminum output end of the aluminum ingot casting machine 6 production line within the foundry workshop 1. The buffer area C is adjacent to the foundry workshop 1 and is equipped with a rain shelter 3. On the side of the buffer area C away from the foundry workshop 1, the shipping area D and the loading area E are arranged in sequence, with the loading area E located near the edge of the aluminum ingot storage yard.

[0037] In the arrangement of aluminum ingot storage yard 2 relative to casting workshop 1, when aluminum ingot storage yard 2 is located on one side of the aluminum ingot outlet end of casting workshop 1, the storage area F is located on one side of buffer area C, shipping area D and loading area E; in this embodiment, the arrangement of aluminum ingot storage yard 2 relative to casting workshop 1 is such that aluminum ingot storage yard 2 is arranged on both sides of casting workshop 1, and the storage area F is located on both sides of buffer area C, shipping area D and loading area E.

[0038] The aluminum ingot storage area is equipped with internal roads 4 between the offline area A, forklift charging area B, buffer area C, shipping area D, loading area E, and storage area F. When forklifts are operating, they travel on the internal roads 4 of the aluminum ingot storage area according to the set routes. The loading area E is equipped with multiple loading positions for vehicles transporting aluminum ingots. External vehicles enter the corresponding loading positions of the aluminum ingot storage area E through the external roads 5 of the aluminum ingot storage area.

[0039] All forklifts are laser-guided AGV unmanned transport forklifts, including off-line forklifts, loading forklifts, and unloading forklifts. There are one or more of each type of forklift. The forklifts are programmed with operating routes to achieve 24-hour continuous operation.

[0040] The intelligent operation of the aluminum ingot yard is divided into two types: normal state without adverse weather and abnormal state with adverse weather. In both states, the forklifts will transport the bundled aluminum ingots from the aluminum output end of the aluminum ingot casting machine 6 production line to the offline area A.

[0041] In this embodiment, the operation of the aluminum ingot storage yard is set to be divided into three shifts per day, with each shift lasting 8 hours; by default, the storage area F will not be filled in this embodiment.

[0042] When the aluminum ingot storage yard is in normal intelligent operation mode, the forklift operation process is as follows:

[0043] First shift: Forklifts transport aluminum ingots from the production line area A to the storage area F; loading forklifts travel between the shipping area D and the loading area E to perform loading operations. Forklifts used for transporting goods have no work tasks during this shift.

[0044] Second shift operation: Loading forklifts finish loading and return to charging area B to charge; Transport forklifts prioritize transporting aluminum ingots from storage area F to shipping area D. When shipping area D is full, the transport forklifts finish their operation and return to charging area B to charge; Offline forklifts prioritize transporting aluminum ingots to shipping area D. In order to ensure that shipping area D has sufficient aluminum ingots to guarantee the offline transport operation of aluminum ingots the next day, when shipping area D is full, the offline forklifts transport aluminum ingots to storage area F.

[0045] The third shift's assignment follows the same procedure as the second shift's assignment.

[0046] The three shifts of homework are completed within 24 hours, which constitutes one homework cycle. After the third shift of homework is completed, the first shift of homework will start again.

[0047] When the intelligent operation of the aluminum ingot yard is in an abnormal state, the forklift operation process is as follows: all forklifts stop operating outside the foundry, and the off-line forklifts transport aluminum ingots from off-line area A to buffer area C with rain shelter 3 for stacking; at this time, the transport forklifts and loading forklifts stop operating.

[0048] When the inclement weather ends and forklift operations return to normal, the specific process is as follows:

[0049] First shift operation: The off-line forklift and the reverse forklift transport aluminum ingots from the off-line area A to the storage area D, and the loading forklift travels between the shipping area D and the loading area E to perform loading operations.

[0050] Second shift operation: The loading forklift finishes loading and returns to charging area B to charge; the off-line forklift transports aluminum ingots from off-line area A to shipping area D; the transfer forklift transports aluminum ingots from buffer area C to shipping area D. When shipping area D is full, the off-line forklift transports aluminum ingots from off-line area A to storage area F. The transfer forklift transports aluminum ingots from buffer area C to storage area F. When there are no aluminum ingots in buffer area C, the transfer forklift operation ends and returns to charging area B to charge and wait.

[0051] Second shift assignment: Same as the second shift assignment process.

[0052] The three shifts of homework are completed within 24 hours, which constitutes one homework cycle. After the third shift of homework is completed, the first shift of homework will start again.

[0053] This intelligent operation method for aluminum ingot storage yards completes the entire process from the aluminum ingots coming off the production line to their storage in storage yard 2, and then loading and transporting them. The processes of unloading, transferring, storing, and loading aluminum ingots are all performed using unmanned AGV forklifts, eliminating the need for drivers and requiring only a few control and inspection personnel. This reduces the number of operators in the aluminum ingot storage yard by approximately 60%, lowering the company's operating costs. Because the AGV unmanned forklifts can automatically charge and operate in multi-vehicle coordination, they can operate continuously for 24 hours, avoiding the operational interruptions caused by traditional forklifts during worker rest and shift changes. This improves the operational efficiency of the aluminum ingot storage yard and is more environmentally friendly and energy-efficient than traditional fuel-powered forklifts.

Claims

1. An aluminum ingot yard intelligent operation configuration method, characterized in that: Be applied to foundry workshop (1) and aluminum ingot yard (2), Wherein, the foundry workshop (1) includes: the offline area (A) and the forklift charging area (B); The aluminum ingot yard (2) includes: the buffer area (C), the delivery area (D), the loading area (E) and the stacking area (F); Through the intelligent operation control of the forklift in the offline area (A), the forklift charging area (B), the buffer area (C), the delivery area (D), the loading area (E) and the stacking area (F), the aluminum ingot is produced from the aluminum ingot casting machine (6) production line offline in the foundry workshop (1) to the aluminum ingot yard (2) for stacking, and the whole process of loading and transporting the stacked aluminum ingot is realized; The forklift is a laser navigation AGV unmanned forklift, the forklift includes offline forklift, loading forklift, and reverse forklift, the three forklifts are set with operation route to realize 24-hour continuous operation; The aluminum ingot yard intelligent operation includes normal state without bad weather and abnormal state with bad weather, the offline forklift transports the baled aluminum ingot from the aluminum ingot casting machine (6) production line to the offline area (A); When the aluminum ingot yard intelligent operation is in normal state, the forklift operation process is as follows: First stage: the offline forklift transports the aluminum ingot from the offline area (A) to the stacking area (F); the loading forklift goes back and forth between the delivery area (D) and the loading area (E) for loading operation, and the reverse forklift has no operation task in this stage; Second stage: the loading forklift finishes the loading operation and returns to the charging area (B) for charging; the reverse forklift preferentially transports the aluminum ingot in the stacking area (F) to the delivery area (D), and when the delivery area (D) is full, the operation of the reverse forklift ends and returns to the charging area (B) for charging; the offline forklift preferentially transports the aluminum ingot to the delivery area (D) to ensure that the aluminum ingot transportation operation can continue to run normally; when the delivery area (D) is full, the offline forklift transports the aluminum ingot to the stacking area (F); When the aluminum ingot yard intelligent operation is in abnormal state, the forklift operation process is as follows: the forklift stops operation outside the foundry workshop, the offline forklift transports the aluminum ingot from the offline area (A) to the buffer area (C) under the rainproof shed (3) for stacking; the reverse forklift and the loading forklift stop operation; When the bad weather ends, the forklift operation process is as follows: First stage: the offline forklift and the reverse forklift respectively transport the aluminum ingot from the offline area (A) to the stacking area (F) for storage, and the loading forklift goes back and forth between the delivery area (D) and the loading area (E) for loading operation; Second stage: the loading forklift finishes the loading operation and returns to the charging area (B) for charging; the offline forklift transports the aluminum ingot from the offline area (A) to the delivery area (D); the reverse forklift transports the aluminum ingot in the buffer area (C) to the delivery area (D), and when the delivery area (D) is full, the offline forklift transports the aluminum ingot from the offline area (A) to the stacking area (F), the reverse forklift transports the aluminum ingot in the buffer area (C) to the stacking area (F), and when the buffer area (C) has no aluminum ingot, the operation of the reverse forklift ends and returns to the charging area (B) for charging.

2. The aluminum ingot yard intelligent job configuration method according to claim 1, characterized in that: The casting workshop (1) is provided with a charging area (B) for charging the forklift, and the charging area (B) is also a storage site of the forklift; the offline area (A) is located at an aluminum ingot casting machine (6) production line outlet of the casting workshop (1); the buffer area (C) is adjacent to the casting workshop (1), the buffer area (C) is provided with a rainproof shed (3), and the buffer area (C) is sequentially provided with a delivery area (D) and a loading area (E) away from the casting workshop (1), and the loading area (E) is arranged at a position close to an edge of the aluminum ingot yard.

3. The aluminum ingot yard intelligent job configuration method according to claim 1, characterized in that: Compared with the arrangement mode of the casting workshop (1), when the aluminum ingot yard (2) is arranged on one side of the aluminum ingot casting machine (6) production line outlet of the casting workshop (1), the storage area (F) is arranged on one side of the buffer area (C), the delivery area (D) and the loading area (E); compared with the arrangement mode of the casting workshop (1), when the aluminum ingot yard (2) is arranged on both sides of the casting workshop (1), the storage area (F) is arranged on both sides of the buffer area (C), the delivery area (D) and the loading area (E).

4. The aluminum ingot yard intelligent job configuration method according to claim 1, characterized in that: The aluminum ingot yard is provided with an internal road (4) between the offline area (A), the forklift charging area (B), the buffer area (C), the delivery area (D), the loading area (E) and the storage area (F); and the loading area (E) is provided with a plurality of loading positions for loading the aluminum ingot vehicles.

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