Automatic anode carbon block casting method using robot in combination with vision

Abstract

The invention discloses an automatic anode carbon block casting method using a robot in combination with vision, which belongs to the technical field of carbon block casting and comprises the following steps of: automatically receiving molten iron: driving a heat preservation steel ladle to move to a proper position through an RGV rail car, and automatically receiving the molten iron; the liquid level of the heat preservation steel ladle is detected, specifically, the liquid level of molten iron in the heat preservation steel ladle is monitored in real time through a first visual detection module; pouring molten iron: pouring the molten iron by matching a mechanical arm with a casting bowl; anode guide rod detection and visual detection: carrying out real-time monitoring on the casting condition of the guide rod and the carbon block through a visual detection module II, and detecting the cast carbon block through a visual detection module III; and completing irrigation. According to the automatic anode carbon block casting method using the robot in combination with vision, casting can be automatically carried out, meanwhile, the casting amount can be accurately controlled, and meanwhile in the casting process, the casting process can be monitored in real time.

Description

Technical Field

[0001] The invention belongs to the technical field of carbon block casting, and in particular relates to an automatic casting method of anode carbon blocks using a robot combined with vision. Background Art

[0002] At present, the carbon block anode assembly for electrolytic aluminum is connected by the guide rod and the anode carbon block after being cooled by molten ferrophosphorus water. The casting system consists of a parallel double-station casting station, and is equipped with a corresponding carbon block conveyor and two plate chains. Two independent casting stations can cast at the same time. The pre-baked anode carbon block enters the double-station casting station from the warehouse plate chain, and the supporting conveyor enters the assembly station, anode alignment assembly device, anode carbon block fast and slow conveying device, guide rod clamping device, guide rod straightening device and other equipment of each casting station respectively, completing the functions of anode alignment and mold closing, accumulation and waiting, casting, cooling, online, and waste block discharge.

[0003] There are four carbon bowls on the top of the anode carbon block that need to be connected to the guide rod steel claws. Since the guide rod steel claws are reused, the pouring amount of molten iron in each carbon bowl is different. The traditional pouring method is to manually observe and control the pouring amount. The existing technical operators need to observe at a high temperature site, the labor intensity is high, and the pouring quality cannot be guaranteed. Some automated equipment can only pour in a certain amount in advance, which is more likely to cause problems such as insufficient pouring or overflow of molten iron, which seriously affects the pouring quality or causes safety accidents. Summary of the invention

[0004] The purpose of the present invention is to provide an automatic casting method of anode carbon blocks using a robot combined with vision, so as to solve the problems raised in the above background technology that the operators of the prior art need to observe at a high temperature on-site, the labor intensity is high, the casting quality cannot be guaranteed, and some automated equipment can only cast a certain amount in advance, which is more likely to cause problems such as insufficient casting or overflow of ferrophosphorus water, which seriously affects the casting quality or causes safety accidents.

[0005] To achieve the above object, the present invention provides the following technical solution: an automatic casting method of anode carbon blocks using a robot combined with vision, comprising the following steps:

[0006] Step 1: Automatically receive molten iron: The RGV rail car drives the insulation ladle to move to the appropriate position and automatically receives molten iron;

[0007] Step 2: Insulated steel ladle liquid level detection: The liquid level of the molten iron in the insulated steel ladle is monitored in real time by a visual detection module;

[0008] Step 3, pouring molten iron: pouring molten iron through the robotic arm in conjunction with the casting bowl;

[0009] Step 4, anode guide rod inspection and visual inspection: the casting conditions of the guide rod and the carbon block are monitored in real time by the second visual inspection module, and the cast carbon block is inspected by the third visual inspection module;

[0010] Step 5: Complete watering.

[0011] In a further embodiment, a protective box is installed on the RGV rail car, and the insulated ladle is installed in the protective box. A tilting mechanism for flipping the insulated ladle is installed in the protective box to complete the automatic rotation of the insulated ladle and discharge the molten iron in the insulated ladle. On the premise of ensuring that the molten iron outlet always remains in the same position, the system converts the consumption and adjusts the staying position automatically under the premise of ensuring that the molten iron does not overflow. The surface of the insulated ladle is provided with a protective cover that can be opened and closed automatically.

[0012] In a further embodiment, an installation sleeve is provided on the outside of the insulated ladle, a weight sensor is installed in the installation sleeve, and a visual detection module 1 is installed on the protective box. The weight sensor can monitor the weight of the molten iron in and inside the insulated ladle in real time to ensure that there is not too much molten iron and accidents. According to the real-time detection of the liquid level in the insulated ladle by the visual detection module and the dual real-time detection of the weight sensor under the insulated ladle, it is determined that the insulated ladle is replenished with water to the exact position, and the pouring safety is ensured, and real-time overflow and fool-proof monitoring is performed.

[0013] In a further embodiment, a support frame and a mounting plate for supporting the detection module 2 are installed on the outside, and a mounting frame for supporting the detection module 3 is installed on the outside.

[0014] Technical effects and advantages of the present invention:

[0015] The automatic casting method of anode carbon blocks using robots combined with vision can stably transport materials through the RGV rail car, reducing the risk of accidental injury caused by handling. At the same time, it can drive the installation sleeve and the insulation ladle to rotate automatically to export the molten iron in the insulation ladle. Under the premise of ensuring that the molten iron outlet is always kept in the same position, the system converts the consumption and automatically adjusts the stay position under the premise of ensuring that the molten iron does not overflow, so as to ensure that the robot arm always maintains a uniform consumption time for receiving the molten iron and ensure the casting accuracy.

[0016] The weight sensor can monitor the weight of the molten iron in and inside the insulation ladle in real time to ensure that there is not too much molten iron and accidents. At the same time, according to the production rhythm of the robot arm, when the casting bowl of the casting robot arm is replenished with molten iron, the visual detection module can detect the liquid level in the insulation ladle in real time and the weight sensor under the insulation ladle in real time to determine the exact position of the insulation ladle, ensure the safety of pouring, and conduct real-time monitoring to prevent overflow and foolproof.

[0017] Through the automatically opening and closing protective cover, when the molten iron reaches the set capacity, the protective cover is automatically closed to keep the molten iron in the insulation ladle warm;

[0018] The second visual inspection module performs the first inspection on the carbon bowl, judges the position information, and combines with the visual system to give corresponding signal instructions to the casting robot arm, so that the robot arm selects the appropriate carbon bowl for casting to ensure the casting effect. At the same time, after the casting is completed, the cast carbon block is inspected by the third visual inspection module to further ensure the casting effect and casting quality. The automatic casting method of anode carbon blocks using robots combined with vision can not only automatically cast, but also accurately control the casting amount. At the same time, during the casting process, the casting process can be monitored in real time. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the specific implementation methods of the present invention or the technical solutions in the prior art, the drawings required for use in the specific implementation methods or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some implementation methods of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0020] Figure 1 is a flow chart of the present invention;

[0021] Figure 2 It is a structural schematic diagram of the present invention;

[0022] Figure 3 It is a front view of the protection box of the present invention;

[0023] Figure 4 It is a cross-sectional view of the installation sleeve and the insulation ladle of the present invention;

[0024] Figure 5 For the present invention Figure 1 The enlarged view of point A in the middle;

[0025] Figure 6 It is a structural schematic diagram of the mechanical arm of the present invention;

[0026] Figure 7 It is a structural schematic diagram of the support frame and the mounting plate of the present invention;

[0027] Figure 8 A cross-sectional view of the connection between the support frame and the mounting plate of the present invention;

[0028] Fig. 9 It is a structural schematic diagram of the mounting frame of the present invention.

[0029] In the figure: 1. RGV rail car; 2. protection box; 3. fixing rod; 4. rotating shaft; 5. mounting sleeve; 6. weight sensor; 7. insulation ladle; 8. stepping motor; 9. adjusting shaft; 10. driving sprocket; 11. driven sprocket; 12. chain; 13. protective cover; 14. fixing frame; 15. rotating motor; 16. rotating shaft; 17. connecting block; 18. visual inspection module one; 19. sound and light alarm; 20. robotic arm; 21. casting bowl; 22. workbench; 23. carbon block; 24. guide rod; 25. support frame; 26. mounting plate; 27. positioning block; 28. positioning pin; 29. ​​fixing ring; 30. fixing spring; 31. visual inspection module two; 32. mounting frame; 33. supporting block; 34. visual inspection module three; 35. two-color alarm light. DETAILED DESCRIPTION

[0030] In the following description, a large number of specific details are provided to provide a more thorough understanding of the present invention. However, it is apparent to those skilled in the art that the present invention can be implemented without one or more of these details. In other examples, in order to avoid confusion with the present invention, some technical features well known in the art are not described.

[0031] Unless otherwise defined, the up, down, left, right, front, back, inside and outside directions involved in this document are based on the up, down, left, right, front, back, inside and outside directions in the figures shown in the present invention, and are explained here together.

[0032] See also Figure 1-9 The present invention provides an automatic casting method of anode carbon blocks using a robot combined with vision, comprising the following steps:

[0033] Step 1: Automatically receive molten iron: The RGV rail car drives the insulation ladle to move to the appropriate position and automatically receives molten iron;

[0034] Step 2: Insulated steel ladle liquid level detection: The liquid level of the molten iron in the insulated steel ladle is monitored in real time by a visual detection module;

[0035] Step 3, pouring molten iron: pouring molten iron through the robotic arm in conjunction with the casting bowl;

[0036] Step 4, anode guide rod inspection and visual inspection: the casting conditions of the guide rod and the carbon block are monitored in real time by the second visual inspection module, and the cast carbon block is inspected by the third visual inspection module;

[0037] Step 5: Complete watering.

[0038] The casting method is implemented by the following equipment: including an RGV rail car 1 and a protective box 2 installed on the surface of the RGV rail car 1. The RGV rail car 1 is a prior art and can be customized according to actual use requirements. Its structure will not be described in detail here. The factory is provided with an RGV track for the RGV rail car 1 to travel. Two fixed rods 3 are symmetrically welded in the protective box 2. A rotating shaft 4 is rotatably connected to the fixed rod 3 through a welded bearing. A mounting sleeve 5 is welded between the two rotating shafts 4. A weight sensor 6 is installed on the bottom wall of the inner cavity of the mounting sleeve 5, and an insulating ladle 7 is installed on the surface of the weight sensor 6. A protective cover 13 is movably connected to the surface of the insulating ladle 7. A molten iron outlet is opened on one side of the outer wall of the insulating ladle 7.

[0039] A stepper motor 8 is installed on the outer wall of one side of the protection box 2 by bolts, and an adjusting shaft 9 is fixed to the output end of the stepper motor 8 by a coupling. One end of the adjusting shaft 9 is rotatably connected to the inner wall of the protection box 2 by a welded bearing to ensure the stability of the adjusting shaft 9 during rotation. Two active sprockets 10 are welded on the outer wall of the adjusting shaft 9, and driven sprockets 11 are welded on the outer walls of the two rotating shafts 4. The outer sleeves of the active sprocket 10 and the driven sprocket 11 are connected with chains 12. The RGV rail car 1 can stably transport materials, reducing the risk of accidental injury that may be caused by transportation. At the same time, the stepper motor 8 drives the adjusting shaft 9 and the active sprocket 10 to rotate, and the active sprocket 10 drives the driven sprocket 11 and the rotating shaft 4 to rotate through the chain 12, thereby driving the installation sleeve 5 and the insulation ladle 7 to rotate automatically, and the molten iron in the insulation ladle 7 is discharged. On the premise of ensuring that the molten iron outlet is always kept in the same position, the system converts the consumption to ensure that the molten iron does not overflow, and adjusts the dwelling position automatically to ensure the accuracy of casting;

[0040] Two fixing frames 14 are symmetrically welded on the outer wall of one side of the insulation ladle 7, and a rotating motor 15 is installed on the outer wall of one side of the fixing frame 14 by bolts. A rotating shaft 16 is fixed to the output end of the rotating motor 15 by a coupling. The rotating shaft 16 is rotatably connected to the fixing frame 14 by a welded bearing, and a connecting block 17 welded and fixed to the protective cover 13 is welded on the outer wall of the rotating shaft 16. A visual detection module 18 and an audible and visual alarm 19 are respectively installed on the surface of the protective box 2 by bolts. The weight sensor 6 can monitor the weight of the molten iron in and inside the insulation ladle 7 in real time to ensure that the molten iron will not be excessive and accidents will not occur. According to the production rhythm, when the casting bowl 21 of the casting robot arm 20 is replenished with molten iron, the visual detection module 18 performs real-time detection of the liquid level in the insulation ladle 7 and the weight sensor 6 below the insulation ladle 7 to determine that the insulation ladle 7 is replenished to the correct position, and ensure the safety of pouring, and perform real-time monitoring to prevent overflow and foolproof. The rotating motor 15 drives the rotating shaft 16 and the connecting block 17 to rotate, thereby driving the protective cover 13 to rotate on the surface of the insulation ladle 7, realizing the automatic opening and closing of the protective cover 13. When the molten iron reaches the set capacity, the protective cover 13 is automatically covered to keep the molten iron in the insulation ladle 7 warm.

[0041] Two robotic arms 20 are provided on one side of the protection box 2. The robotic arms 20 are prior art and their structure will not be described in detail here. A casting bowl 21 is installed at the driving end of the robotic arm 20. A workbench 22 is provided on one side of the robotic arm 20. A plurality of carbon blocks 23 are placed on the surface of the workbench 22. A plurality of carbon bowls are fixed on the surface of the carbon blocks 23, and a guide rod 24 is provided above the carbon bowl. The robotic arm 20 controls the casting bowl 21 to move to one side of the insulation ladle 7. The insulation ladle 7 rotates automatically to discharge the molten iron in the insulation ladle 7, and the molten iron is received through the casting bowl 21. The casting work is then controlled by the robotic arm 20 to control the casting bowl 21 and the casting time of the robotic arm 20, so that the casting amount can be accurately controlled to ensure the casting accuracy and casting quality.

[0042] Two support frames 25 are provided on one side of the workbench 22, and a mounting plate 26 is movably connected to the outer wall of one side of the support frame 25, and a plurality of visual inspection modules 31 are installed on the mounting plate 26. A cavity is provided in the support frame 25, and a positioning block 27 extending into the cavity of the support frame 25 is fixed to the outer wall of one side of the mounting plate 26. A through hole is provided on the surface of the support frame 25, and a positioning pin 28 is movably connected in the through hole on the surface of the support frame 25. A fixing ring 29 is fixed to the outer wall of the positioning pin 28, and the outer sleeve of the positioning pin 28 is used for fixing The fixing spring 30 supported by the fixing ring 29 has a positioning hole matching the positioning pin 28 on the surface of the positioning block 27. The fixing spring 30 supports the fixing ring 29 so that the positioning pin 28 is inserted into the positioning hole of the positioning block 27, and the positions of the mounting plate 26 and the second visual inspection module 31 can be fixed. The mounting plate 26 is quickly installed. The positioning pin 28 is pulled upward to separate the positioning pin 28 from the positioning block 27, and the mounting plate 26 can be removed from the support frame 25, which is convenient for disassembly and maintenance of the second visual inspection module 31.

[0043] A mounting frame 32 is provided on one side of the support frame 25, and a support block 33 is fixed to the outer wall of one side of the mounting frame 32. A visual inspection module three 34 is bolted to the outer wall of one side of the support block 33. The visual inspection module one 18, the visual inspection module two 31 and the visual inspection module three 34 are all prior arts, and the structure will not be described in detail here. A two-color alarm light 35 is bolted to the surface of the support block 33. The visual inspection module two 31 performs the first inspection on the charcoal bowl, judges the position information, and combines with the visual system to give corresponding signal instructions to the casting robot arm 20, so that the robot arm 20 selects a suitable charcoal bowl for casting to ensure the casting effect. At the same time, after the casting is completed, the cast carbon block is inspected by the visual inspection module three 34 to further ensure the casting effect and casting quality.

[0044] The standard parts used in the present invention can all be purchased from the market, and special-shaped parts can be customized according to the description in the specification and the drawings. The specific connection methods of each part adopt conventional means such as mature bolts, rivets, welding, etc. in the prior art. Machinery, parts and equipment all adopt conventional models in the prior art, and the circuit connection adopts the conventional connection method in the prior art, which will not be described in detail here. The control method of the present invention is controlled by a controller, and the control circuit of the controller can be realized by simple programming by technicians in this field. The contents not described in detail in this specification belong to the prior art known to professional and technical personnel in this field.

[0045] In the description of the present invention, it is necessary to understand that the indicated orientation or positional relationship is based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0046] Working principle:

[0047] The method for automatically casting anode carbon blocks using a robot combined with vision, when in use, starts the rotating motor 15, the rotating motor 15 drives the rotating shaft 16 and the connecting block 17 to rotate, thereby driving the protective cover 13 to rotate on the surface of the insulating ladle 7, realizing the automatic opening of the protective cover 13, injecting molten iron into the insulating ladle 7, and determining that the insulating ladle 7 is replenished with water to the accurate position according to the real-time detection of the liquid level in the insulating ladle 7 by the visual detection module 18 and the double real-time detection of the weight sensor 6 under the insulating ladle 7, and ensuring the safety of pouring, when the insulating ladle 7 is injected with a proper amount of molten iron, the rotating motor 15 rotates in the opposite direction, and the protective cover 13 is closed;

[0048] The mechanical arm 20 drives the casting bowl 21 to move to the bottom of the molten iron outlet of the insulation ladle 7, starts the stepper motor 8, drives the adjustment shaft 9 and the driving sprocket 10 to rotate, and the driving sprocket 10 drives the driven sprocket 11 and the rotating shaft 4 to rotate through the chain 12, thereby driving the installation sleeve 5 and the insulation ladle 7 to rotate automatically, and the molten iron in the insulation ladle 7 is led into the casting bowl 21. Under the premise of ensuring that the molten iron outlet is always kept in the same position, the system converts the consumption to ensure that the molten iron does not overflow, and adjusts the stay position automatically to ensure the casting accuracy;

[0049] The visual inspection module 2 31 performs the first inspection on the charcoal bowl, determines the position information, and combines with the visual system to give corresponding signal instructions to the casting robot arm 20, so that the robot arm 20 selects a suitable charcoal bowl for casting to ensure the casting effect. At the same time, after the casting is completed, the cast carbon block is inspected through the visual inspection module 3 34 to further ensure the casting effect and casting quality.

[0050] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. An automatic casting method of anode carbon blocks using a robot combined with vision, characterized in that: The steps include: Step 1: Automatically receive molten iron: The RGV rail car drives the insulation ladle to move to the appropriate position and automatically receives molten iron; Step 2: Insulated steel ladle liquid level detection: The liquid level of the molten iron in the insulated steel ladle is monitored in real time by a visual detection module; Step 3, pouring molten iron: pouring molten iron through the robotic arm in conjunction with the casting bowl; Step 4, anode guide rod inspection and visual inspection: the casting conditions of the guide rod and the carbon block are monitored in real time by the second visual inspection module, and the cast carbon block is inspected by the third visual inspection module; Step 5: Complete watering.

2. The method for automatic casting of anode carbon blocks using a robot combined with vision according to claim 1, characterized in that: A protective box is installed on the RGV rail car, and the insulated ladle is installed in the protective box. A tipping mechanism for flipping the insulated ladle is installed in the protective box to complete the automatic rotation of the insulated ladle and discharge the molten iron in the insulated ladle. Under the premise of ensuring that the molten iron outlet always remains in the same position, the system converts the consumption and adjusts the staying position automatically under the premise of ensuring that the molten iron does not overflow. The surface of the insulated ladle is provided with a protective cover that can be opened and closed automatically.

3. The method for automatic casting of anode carbon blocks using a robot combined with vision according to claim 2, characterized in that: An installation sleeve is provided on the outside of the insulated ladle, and a weight sensor is installed in the installation sleeve. A visual inspection module 1 is installed on the protective box. The weight sensor can monitor the weight of the molten iron in and inside the insulated ladle in real time to ensure that there is not too much molten iron and accidents. According to the real-time detection of the liquid level in the insulated ladle by the visual inspection module and the dual real-time detection of the weight sensor under the insulated ladle, it is determined that the water is replenished to the exact position of the insulated ladle, and the safety of pouring is ensured, and real-time overflow and fool-proof monitoring is carried out.

4. The method for automatic casting of anode carbon blocks using a robot combined with vision according to claim 1, characterized in that: A support frame and a mounting plate for supporting the detection module 2 are installed outside the detection module 2, and a mounting frame for supporting the detection module 3 is installed outside the detection module 3.

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