Automatic guide vehicle for ingot casting

Abstract

An automatic guided vehicle (AGV) for an automatic casting facility includes a frame, a ground contact element connected to the frame to support the AGV, and a heat shield. The AGV can grab, move and release a mold used for producing cast ingots. A method of operating a casting facility is also described involving an AGV moving a mold between workstations.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is related to and is a non-provisional application, which claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 63 / 428,005, filed on November 25, 2022, entitled “Automated Guided Vehicle for Ingot Casting,” and U.S. Provisional Patent Application No. 63 / 447,448, filed on February 22, 2023, entitled “Automated Guided Vehicle for Ingot Casting,” the specifications of which are incorporated herein by reference in their entirety. Background Art (a) Technical field

[0002] The disclosed subject matter generally relates to automated guided vehicles (AGVs) having improved functionality suitable for use in ingot casting production processes.

[0003] The disclosed subject matter generally relates to improvements in systems, environments, supporting components, and methods for the production of aluminum ingots, including improvements to AGVs and AGV operations used in production. (b) Related prior art

[0004] Aluminum smelters and recycling facilities produce solidified aluminum products in a variety of forms and alloys for safe transportation to other locations destined for various applications. Products that have not yet reached their final form and are designed to require complete remelting to achieve their final shape are called "remelted products." The shape itself offers little added value to the re-liquified product beyond ease of transportation and handling, so solidifying the metal as cost-effectively as possible is paramount.

[0005] A common method for manufacturing remelted products is to cast ingots: large blocks of metal, usually weighing at least 100 kg, with weights ranging from 400 kg to 900 kg being common, whose special shape facilitates solidification, demoulding, forklift handling and easy stacking. Modern automatic ingot casting machine versions usually include a set of round or oval carriages that move the molds along rails, moving the molds from one workstation to another. All molds are supported by supporting trolleys that are connected to each other to form a chain, so the movement of individual molds cannot be controlled. In addition, removing and replacing the molds (as part of the consumables) usually requires stopping production and human intervention.

[0006] The main difference between sow casting and the smaller "pig" ingot casting is the size of the aluminum ingot produced. Ingot casting refers to metal products weighing between 5kg and 25kg, with the most common types being alloy ingots of 5kg to 15kg and virgin P1020 ingots of 20kg to 25kg.

[0007] Ingot casting refers to the production of solidified aluminum products weighing significantly more than 100 kg (typically 400-800 kg). This can be for alloy or P1020 aluminum, but is most commonly used to produce virgin P1020 aluminum ingots. Unlike ingots, ingots are not typically designed to interlock to form larger bundles. Due to their large size and low profile, ingots are typically stacked directly on top of each other without the need for bundling. The ingot shape is designed to accommodate this stacking method by integrating a forklift pickup position into each ingot's shape.

[0008] Ingot casting can generally be divided into three types: 1. Manual ingot casting 2. Water-cooled ingot casting machine 3. Air-cooled ingot casting machine 1. Manual ingot casting

[0009] Figure 2 shows a typical manual pouring system.

[0010] The mold is placed in a fixed position, and molten aluminum is manually poured into the mold using a crucible, sprue, or other auxiliary pouring equipment. After pouring, the pouring equipment is moved to another empty ingot mold, or the ingot mold is removed and replaced with another empty one. The mold filled with molten aluminum is then transferred to a cooling position or held in its current position until it solidifies and is ready for removal.

[0011] This is a highly manual process. It's typically used sparingly, typically only to dispose of excess molten aluminum. Due to its reliance on operator input, the final product can vary greatly depending on the operator. The operator's close proximity to critical, hazardous operations also creates safety risks. 2. Water-cooled ingot casting machine

[0012] Figure 3 shows a typical water-cooled ingot casting machine.

[0013] Ingot casting is automated or semi-automated using a circular carriage mounted with a series of molds. This carriage, typically resembling a rigid disk, rotates, guiding the mold from one position to the next after each operation. Metal is poured at a specific location, or "station," within the disk. The disk and mold are then gradually moved to the next position, where additional operations can occur or cooling can occur. The ingot mold is demolded and preheated before the entire mold returns to its starting position.

[0014] The system allows for a degree of automation and therefore does not rely on operator input to start and stop pouring in each mold. Due to the use of water cooling technology, this system is compact, although the space inside the disc is often not used efficiently.

[0015] This type of ingot caster presents safety issues due to the presence of water where large quantities of molten aluminum are poured. Water may be present in the bottom of the mold before pouring, or it may seep through the mold if there is an unreported mold malfunction. Water trapped by the molten aluminum is a significant safety hazard to both operators and nearby equipment.

[0016] In addition, the dies are placed around the edge of the disc, so a large disc is required for a high-capacity machine, which increases the difficulty of operation and creates more wasted space in the center of the disc where there is no die. 3. Air-cooled ingot casting machine

[0017] Figure 4 shows a typical air-cooled ingot caster.

[0018] Air-cooled ingot casters have become commonplace for ingot casters with capacities exceeding approximately 10 tons per hour. They utilize air cooling through forced air cooling, radiant heat transfer, and natural convection. Each mold is placed on its own movable carriage. These carriages are interconnected and can move simultaneously along a track. Similar to water-cooled systems, specific operations are performed at fixed locations around the track, known as workstations. Mold preheating occurs before the pouring position. After the ingot mold is poured, the liquid ingot is skimmed at a downstream location before the mold moves along the track, solidifying and cooling. Cooling can be achieved through forced air cooling or natural heat transfer. The solidified ingot is removed from the mold for further processing before returning to the preheating position.

[0019] Compared to water-cooled ingot casters, air-cooled types offer improved safety features because there is no water present in the casting area. The equipment can be fully automated to ensure consistent product production. It also reduces labor requirements by removing them from hazardous areas.

[0020] Air-cooled machines typically have higher capacity (production capacity) than water-cooled machines because the primary limiting factor is cooling capacity, which can be increased during the design phase. Higher-capacity machines require shorter cycle times, necessitating a larger number of positions between pouring and demolding. Consequently, air-cooled ingot casters typically have more molds and carriages, resulting in a larger equipment footprint. Consequently, machine capacity is limited by available space and, if the required tasks cannot be completed within the allotted time, capacity is also limited.

[0021] These air-cooled ingot casters safely and reliably produce ingots of consistent size, with high capacity and automation. They offer a simple and cost-effective solution for handling and forming liquid aluminum into transportable ingot shapes.

[0022] However, this existing technology has limitations. Cooling is limited to the time the entire mold spends on track between the pouring and demoulding positions. Therefore, the cooling process is distributed over a large area.

[0023] The tracks support interconnected carts, which are typically rectangular with large radius corners to allow them to be pulled around. This configuration leaves a large unused area in the center of the track.

[0024] The mold trolleys are interconnected so that all trolleys are guided uniformly as each subsequent mold is poured. Consequently, the mold accelerates and decelerates with each cycle, disturbing the surface of the unsolidified ingot and affecting its quality. This movement also creates the risk of the trolley chain derailing.

[0025] Because all equipment is interconnected, capacity (production capacity) is determined by the key function—the operation at the point in the cycle that takes the longest. Typically, the pouring or cooling point determines the capacity of the entire machine. Capacity changes are extremely limited and costly, as they require modifying the entire machine to accommodate the new characteristics.

[0026] The mold trolley is mobile. Therefore, each supporting structure of the mold needs to be manufactured with high precision to form an interconnected chain.

[0027] If there is a problem in any part of the machine, it affects all molds and carriages. If there is a problem in a specific location, the entire machine is either shut down or all molds bypass that location until it is remedied.

[0028] Since each mold and trolley moves along a continuous path between each functional station, the function must include a trolley and track system in its design. Therefore, these stations (i.e., workstations or stations) must allow the trolley and mold to enter and exit the area of ​​​​the workstation, thereby reducing the cost and function of the workstation itself.

[0029] Existing ingot casting machines of this type perform well but often waste space and are difficult to modify later. They are designed to cast at a specific capacity and become less efficient when a lower capacity is required. Furthermore, the molds are interconnected, so downtime or problems can affect the entire production line. Summary of the Invention

[0030] This patent application describes a process where an automated guided vehicle (AGV) is fully integrated as part of a machine to move ingot molds from one location to the next. This replaces the circular chain and trolley system of a traditional ingot casting machine.

[0031] This process significantly reduces floor space, offers unlimited adaptability to layout, shortens installation time, allows for future retrofitting as capacity changes, provides greater flexibility in production speeds, and reduces cold start times. Furthermore, the process avoids some of the costs associated with currently available systems.

[0032] In certain aspects, the description of the present application relates to a method for producing ingots from liquid metal poured into a mold, the method comprising: having at least three workstations for performing different tasks during the process of producing the ingots, and each workstation has a dedicated position and operates at a dedicated rate of number of ingots per unit time, wherein during the production of the ingots, the tasks associated with producing the ingots are performed in a preset order; having a plurality of molds that can be moved between dedicated positions of the workstations; and having a plurality of automatic guided vehicles (AGVs) capable of moving independently between the workstations, the AGV being capable of moving any mold from any dedicated position of the workstation to any other dedicated position of the workstation.

[0033] In some aspects, the present description relates to a method in which an AGV can get hold of a mold located at a first dedicated location, move the get hold of the mold to a second dedicated location, and release the get hold of the mold at the second dedicated location.

[0034] In some aspects, the description of the present application relates to a method that also includes: having a first number of molds located at a first workstation at a certain moment, a second number of molds located at a second workstation, and a third number of molds located at a third workstation, wherein at least one of the first number, the second number, and the third number is at least 2.

[0035] In some aspects, the description herein relates to a method further comprising: the number of AGVs is less than the number of molds.

[0036] In some aspects, the description herein relates to a method further comprising: having a buffer station, wherein a first mold is moved into the buffer station after a second mold, and the first mold exits the buffer station before the second mold.

[0037] In some aspects, the description of the present application relates to a method, further comprising: causing a first AGV to move a first mold to a first workstation and release the first mold at the first workstation, and causing a second AGV to grab the first mold at the first workstation and move the first mold away from the first workstation.

[0038] In some aspects, the present description relates to a method in which an AGV includes a lifting top, and the AGV is able to grasp and release molds by raising and lowering the top.

[0039] In some aspects, the description herein relates to a method in which an AGV includes at least two ground-contacting drive wheels and at least four additional ground-contacting wheels.

[0040] In some aspects, the description herein relates to a method in which the ground-contacting drive wheels of an AGV are independently motor-driven.

[0041] In some aspects, the description herein relates to a method in which ground-contacting drive wheels of an AGV can be backdriven.

[0042] In some aspects, the description herein relates to a method in which one of the workstations includes a stationary robot.

[0043] In some aspects, the description of the present application relates to a method further comprising: a support structure, wherein a captured mold can be placed alone on the support structure, the support structure including upwardly extending forks for preventing the captured mold from moving in a horizontal direction.

[0044] In some aspects, the description herein relates to a method in which an AGV can grasp a grasped mold by lifting one of the support structures supporting the grasped mold.

[0045] In some aspects, the description herein relates to a method wherein a support structure includes legs configured to provide space underneath for any one AGV to travel thereunder.

[0046] In some aspects, the description of the present application relates to a method in which an AGV can grasp a grasped mold by lifting one of its support structures so that the legs lose contact with the ground.

[0047] In some aspects, the description herein relates to a method in which the first support structure spaces a first grasped mold in the first support structure from the first AGV while the first support structure is held by the first AGV.

[0048] In some aspects, the description herein relates to a method in which an AGV and a workstation are operated automatically.

[0049] In some aspects, the description of the present application relates to a method wherein one workstation is a preheating station including a closable heated interior compartment, wherein the interior compartment is closed between two tasks of preheating first and second molds, thereby conserving energy.

[0050] In some aspects, the description herein relates to a method in which workstations are located in an environment having a layout that includes station-free areas connecting the workstations and is used by AGVs to move between the workstations.

[0051] In some aspects, the description herein relates to a method further comprising: placing a first AGV in a charging state, and cooling the first AGV while in the charging state. The features and advantages of the present subject matter will become more apparent from the following detailed description of selected embodiments, as illustrated in the accompanying drawings. It will be appreciated that the disclosed and claimed subject matter is capable of modifications in various respects, all without departing from the scope of the claims. The drawings and description are, therefore, to be regarded as illustrative in nature and not restrictive, and the full scope of the subject matter is set forth in the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] Further features and advantages of the present application will become apparent from the following detailed description taken in conjunction with the accompanying drawings, in which:

[0053] Figure 1A is a plan view of the overall layout of an ingot casting system according to one embodiment;

[0054] Figure 1B is an isometric perspective view of the general layout of an ingot casting system according to one embodiment;

[0055] FIG2 is a depiction of a prior art manual pouring system for pouring ingots; and

[0056] FIG3 is a depiction of a typical water-cooled ingot casting machine of the prior art;

[0057] FIG4 is a depiction of a typical air-cooled ingot casting machine of the prior art;

[0058] Figure 5A and 5B is an isometric view of the components involved in the pouring operation, where Figure 5A Depicts the mold before any pouring, Figure 5B Depicts the pouring in progress;

[0059] Figure 6 is a depiction of the components involved in the skimming operation;

[0060] Figure 7 is a depiction of a cooling station layout according to one embodiment;

[0061] Figure 8A and 8B is a depiction of the general layout of a demoulding station according to one embodiment, wherein Figure 8A Depicts the demoulding of the ingot, Figure 8B depicts weighing the ingot;

[0062] Figure 9 is a depiction of an exemplary general layout of an area where stacking, weighing, and labeling operations are performed;

[0063] Figure 10is an exemplary general layout diagram of a preheating station;

[0064] Figure 11 is a plan view of an exemplary multi-cast metal processing station according to one embodiment;

[0065] Figure 12 is an isometric view of an exemplary multi-pour metal processing station according to one embodiment;

[0066] Figure 13 is a depiction of an exemplary reduction unit to a mold according to a first concept variation;

[0067] Figure 14 is a depiction of a mobile extraction device including a robot according to a first conceptual variation;

[0068] Figure 15 is a plan view of an ingot casting machine based on an electrolytic cell building according to a first conceptual variant;

[0069] Figure 16 is a depiction of a mobile extraction device according to a first conceptual variant, the device comprising a robot equipped with a tool;

[0070] Figure 17 is a depiction of an exemplary reduction unit to a mold according to a second concept variation;

[0071] Figure 18 is a depiction of a siphon device in an open position according to a second conceptual variant; and

[0072] Figure 19 It is a variation of the second concept Figure 18 depiction of a siphon device in a closed position;

[0073] Figure 20 is a perspective view of an alternative layout of a system according to one embodiment;

[0074] Figure 21 is an oblique perspective view of an automated guided vehicle (AGV) holding a mold on a support structure according to one embodiment;

[0075] Figure 22 is a side oblique perspective view of an AGV support structure mold holding the mold on the support structure according to one embodiment;

[0076] Figure 23 is a bottom oblique perspective view of an AGV support structure mold holding the mold on the support structure according to one embodiment;

[0077] Figure 24 is a perspective cross-sectional view of a mold having liquid metal according to one embodiment;

[0078] Figure 25 is a cross-sectional view of a portion of an anti-spill ring according to one embodiment;

[0079] Figure 26 is a UML sequence diagram of AGV operations in a system according to one embodiment;

[0080] Figure 27 is a flow chart of a method of operating a system according to one embodiment;

[0081] Figure 28A and 28B is an isometric view of an alternative subsystem for supplying liquid metal to a mold according to one embodiment;

[0082] Figure 29 yes Figures 28A-28B An isometric view of a subsystem according to one embodiment wherein the mobile extraction device is mounted on an AGV and the molten metal pump is tilted;

[0083] Figure 30 is an isometric view of a mold on a support table and an AGV according to one embodiment; and

[0084] Figure 31 is a front view of the mold on the support table, with the AGV moving underneath it in a lowered position and a raised position, lifting the support table off the ground.

[0085] It should be noted that throughout the Figures, like features are provided with like reference numerals. DETAILED DESCRIPTION

[0086] Embodiments will now be described more fully with reference to the accompanying drawings, in which embodiments are shown. However, the above may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.

[0087] For purposes of this specification, references to singular items should be understood to include the plural items, and vice versa, unless expressly stated otherwise or the context clearly indicates otherwise. Grammatical conjunctions are intended to express any and all disjunctive and conjunctive combinations of clauses, sentences, words, etc., unless otherwise stated or the context clearly indicates otherwise. Thus, the term "or" should generally be understood as "and / or," etc.

[0088] The description of numerical ranges and numerical values ​​herein or in the accompanying drawings is not intended to be limiting, but refers solely to any and all numerical values ​​falling within the range, unless otherwise specified herein, and each individual numerical value within such a range is incorporated into the specification as if it were individually listed herein. Words such as "about" and "approximately" when accompanying numerical values ​​should be interpreted as indicating a deviation, and those of ordinary skill in the art will understand that this deviation can satisfactorily achieve the intended purpose. The values ​​and / or ranges of numerical values ​​provided herein are merely examples and do not constitute a limitation on the scope of the implementation. The use of any and all examples or exemplary language ("for example", "such as", etc.) provided herein is only intended to better illustrate the exemplary implementation and does not limit the scope of implementation. Any language in the specification should not be interpreted as indicating that any unclaimed element is essential to the practice of implementation.

[0089] In the following description, it will be understood that terms such as "first," "second," "top," "bottom," "above," "below," etc. are used for convenience and should not be construed as limiting terms.

[0090] The terms "top", "upward", "upper", "bottom", "lower", "downward", "vertical", "horizontal", "inside" and "outside" are intended to be interpreted according to their normal meanings according to normal operating modes.

[0091] Referring now to the drawings and more particularly to Figure 1A and 1B , shows a first exemplary overall layout according to one embodiment, in which different parts participate in the innovation.

[0092] Figure 20 A second exemplary overall layout is further provided using a single axis, station-free zone configuration, highlighting the range of available variations between acceptable layouts.

[0093] In addition, not shown in the figure, there are preferably various workstations that support the AGV 1 and general operations, such as: an AGV charging station; a safety fence with automatic entrances and exits for the AGV 1; mold temperature monitoring; and a power unit.

[0094] The process of casting aluminum into ingots4 requires different operations: - Preheating the mold 3 to remove moisture from the mold 3 and obtain a suitable pouring temperature; - pouring liquid metal into the ingot 4; - skimming the poured liquid aluminum in the ingot mold 3; - Cooling the liquid metal in the mold 3 to form a solidified ingot 4; - removing the ingot 4 from the mold 3; and - Handling the ingots 4, including weighing each ingot 4; determining the ingot mass; marking the ingots 4; stacking the ingots 4; and displaying the ingot stack for removal.

[0095] The innovation concerns at least the operations related to the handling of the mould 3 and the ingot 4 contained therein. According to one aspect, the handling of the ingot 4 after it has been removed from its mould 3 is of limited concern, however, these other steps are significantly affected by the innovation.

[0096] The mold 3 is designed to be placed on and supported solely by the support table 2. The support table 2 is designed to support the volume of one mold 3 and allow the AGV 1 to lift the support table 2 from below and carry the support table 2, mold 3 and ingot 4 in the same movement.

[0097] Alternatively, the mold 3 can be lifted and moved directly by the AGV 1, so that there is no need for an intermediate support table 2. In this arrangement, the mold support structure is located at the destination so that the mold 3 can be unloaded and the AGV 1 can continue to move to manipulate other molds 3.

[0098] The individual movement of a specific mold 3, ingot 4, and optionally the support table 2 and ingot 4, provides a great deal of control and flexibility over how the ingot 4 is transported within the area, especially compared to the prior art. Thus, the prior art practice of guiding the mold 3 around the circuit in a large, single movement is replaced with smaller, individual movements of the mold 3 as needed for the specific ingot 4.

[0099] The AGV 1 of the present invention can avoid columns and pillars. It can also bypass walls or fences. Therefore, unlike other ingot casting machines of the prior art, the present invention does not require a specifically shaped building. It is versatile and fully utilizes valuable available space in smelters or recycling facilities. The AGV's independent mobility and versatility enable the use of a compact cooling mechanism for the ingot 4 without tracks, eliminating the need for redundant space in the center of the track and thus optimizing valuable space.

[0100] Therefore, the embodiments of the present invention differ from the known prior art in at least one or more of the following features: - Use AGV 1 to transport the liquid in the open mold 3; - independent handling of the mould 3 , for example managing the mould 3 through the various steps (preheating, pouring, skimming, cooling, demoulding, etc.); - Modularize tasks so that individual functions are performed at different independent workstations; - Provide flexibility in processing steps, including flexibility in mold movement and processing tasks, thereby avoiding unnecessary tasks; -Easy replacement of dies between and during operations3; -The production capacity of existing equipment can be increased by adding more components; - Dedicated areas for high-density cooling stations; and - During the solidification and cooling of the material in the mould, the mould 3 is essentially at rest. pouring station

[0101] Now refer to Figure 1A -B and Figure 5A -B, shows the general layout of the pouring station operating with AGV 1 and its related components.

[0102] The pouring station is where the liquid metal is transferred from the holding device to the mold 3.

[0103] There are several methods available for this task, such as pouring directly from the crucible using the crucible tilting device shown, pouring through a furnace and launder system, manual pouring, or pouring using a pre-weighed temporary holding method. The crucible tilting device is a common method, as most aluminum smelters use crucibles, and it can be automated, is cost-effective, and reliable. This capability is achieved by finely controlling the tilting mechanism.

[0104] The method and related system of the present invention can utilize similar pouring methods, but it is more advantageous to use AGV 1. The pouring device is usually fixed, and the AGV transports the mold 3 to the pouring station 5 for filling. During the pouring process, the AGV 1 can wait (for example, in idle mode) until the mold 3 is filled, or perform different functions until the filled ingot 4 is ready to be removed. Another AGV 1 can take over. When the mold 3 is filled with a specified amount of liquid metal, the AGV 1 will pick up the filled mold 3 separately and take it to the skimming station.

[0105] The mold 3 is moved to the pouring station individually on the AGV 1, rather than on a track that must pass under the pouring point (as in the prior art). Therefore, unlike the prior art, where the sides of the pouring station 5 need to be kept clear for entry and exit, the mold 3 transported by the AGV 1 can exit the station from the same direction as it entered. As a result, the present invention simplifies the pouring structure and layout, providing better support from more sides.

[0106] Furthermore, the individual mobility of the ingots allows the pouring station 5 to be located away from other dedicated operations, provided the slag skimming process is completed within an appropriate delay. This provides flexibility in the layout of the smelter or recycling facility and allows movement between different parts of the smelter or facility when sufficient AGVs 1 are used.

[0107] With prior art automated machines, the pouring station is located at a single location, leaving room for the slag skimming operation, which must be performed immediately afterwards. However, if only a single crucible tilting device is installed, additional downtime is required for crucible changes. Each change requires lowering the empty crucible tilting device, removing the clamps, removing the empty crucible, aligning the new full crucible and lowering it onto the tilting device, engaging the clamps, and then raising the tilting device to prepare for pouring. This process takes time, often many minutes. For smaller crucibles, these changes occur much more frequently. Therefore, even with well-functioning prior art machines, significant downtime can occur. A known prior art method for reducing or eliminating this changeover downtime is to add a second crucible tilting device that pours from the other side of the track into the same pouring station 5. Adding a second crucible tilting device requires advance facility planning, requires appropriate foundation and space, and is easy to integrate. Furthermore, crucible tilting devices are expensive. Therefore, the trade-off between reducing / eliminating changeover time and adding a crucible tilting device may not be worthwhile, as it is unlikely to double production output. In many cases, the investment is not recovered through this increase in production capacity.

[0108] Through the innovation of this application, each crucible tilting device operates at its own pouring station 5. Installing a new crucible tilting device requires less planning and can be more easily implemented later. A new crucible tilting device can be added to the second pouring station 5. Since two pouring stations are used in parallel, either can be used to pour empty molds regardless of the status of the other, essentially doubling the pouring capacity. This provides additional options for the placement of multiple crucible tilting devices. Their placement can be customized to specific building conditions, such as side by side or, in some cases, spaced far apart.

[0109] It is also worth mentioning that for prior art machines equipped with rails, if two crucible tilting devices are used to pour into a single pouring position, a common arrangement is to place one tilting device on the outside of the circular trolley track and the other on the inside of the trolley track. Therefore, each crucible change with the internal crucible tilting device requires the crucible to pass through the trolley track and the top of the machine, which poses logistical and safety issues that must be addressed.

[0110] With the system of the present invention, each crucible tilting device has a separate pouring station 5, allowing the crucibles to be moved from the same direction to the respective tilting devices, thereby eliminating the need to transfer the crucibles from the casting mold 3 and the top of the apparatus.

[0111] Furthermore, with the system of the present invention, the mold 3 is positioned by the AGV 1 throughout the entire process, so that the position at which the liquid material is filled in the mold 3 can be changed, thereby changing the initial flow position of the molten aluminum and thus avoiding premature wear of the mold 3. This can distribute the wear caused by the inevitable thermal shock over time to the entire bottom of the mold, making the mold 3 thinner and lighter (potentially cheaper) while maintaining or extending the life of the mold 3.

[0112] With the system of the present invention, the molds 3 at the pouring station 5 are no longer part of a chain physically connected to one another (waiting for pouring in an unmodifiable queue). This provides flexibility in movement. The molds 3 can be moved and raised to the ideal position for the crucible tilting device or pouring spout. Thus, the crucible tilting device can be placed on the factory floor without the need for expensive excavation in the foundation or the need for mold chain support structures to lift the entire machine. This flexibility of the present invention again allows the addition of pouring stations 5 without requiring significant construction work on the foundation.

[0113] It is worth noting that the pouring into the mold 3 according to the present invention can be done in a variety of ways.

[0114] Using the AGV 1 to move the mold 3 allows, but is not limited to, pouring from a tilted crucible, pouring from a suspended crucible, pouring from a furnace outlet, pouring in a launder, pouring from a tiltable gate, pouring from an intermediate pouring container, pouring by mechanical or robotic ladle, and pressurizing or siphoning from a holding container.

[0115] Additional references Figure 28A 、 28B The crucible can be set in a specific position and positioned using a mechanical buffer stop 29. A usable embodiment includes a lifting and rotating structure 37, a molten metal pump 35 and a molten metal level sensor (not shown), which are then moved into position and lowered so that the inlet of the molten metal pump 35 is immersed in the molten metal in the crucible.

[0116] Such an embodiment also includes a preheater 36 for the molten metal pump inlet pipe, which is stored when not in use and preheated before use.

[0117] The molten metal pump 35 is started as needed to pump liquid metal into a large number of ingots.

[0118] Variations in pumping speed are achieved by changing the pump motor speed using a variable speed drive.

[0119] When the specified amount of metal has been delivered to the corresponding number of ingots, the emptying cycle stops.

[0120] The amount of metal delivered is measured by measuring the weight of the metal added to the mold 3 using a load cell or by measuring the height of the metal in the mold 3 using a laser.

[0121] Thus, one or another of the embodiments differs from the known prior art by at least one of the following features: - Crucible tilting device can be easily added when needed; - Each crucible tilting device has an associated pouring station. Thus, multiple pouring positions can be provided for one machine and operated simultaneously; - Lift the mold 3 individually to the pouring position; - Expensive foundation works are avoided due to the individually liftable moulds 3; - Simplifies the layout of facilities with crucible tilting devices (or other pouring methods) by avoiding the need for rails to pass under the pouring point; - Allows the placement of the mold 3 to be changed during the pouring process. By using AGV to change the position of the mold, the thermal shock generated by pouring is distributed to a larger area; -Pumping the metal, thus providing a safer environment than lifting the crucible; -The ability to fill multiple molds simultaneously from the same crucible, enabling faster pouring without adding a second, expensive crucible station; - Reduced complexity and thus lower costs compared to using a crucible tilting device; - Reduce the risk of unplanned downtime due to failure of large numbers of molten metal pumps; - Increased the speed of emptying the crucible. skimming station

[0122] See also Figure 1A -B and Figure 6 , depicting the components involved in pouring and skimming operations.

[0123] After a prescribed amount of liquid metal has been poured (deposited) into the mold 3, it is typically skimmed. Skimming involves scraping the top surface of the liquid metal with a skimmer 8 to remove solid material floating on top of the pool of liquid metal. The top surface of the metal is then removed and placed in a nearby silo where the scum can be processed and the remaining aluminum recovered.

[0124] This process removes aluminum dross or other floating materials, providing a smooth surface on the top of the ingot (i.e., the open surface of the mold). As a result, the proportion of usable metal is improved and the top surface is smoother, which is beneficial both for marketing appearance and for functionality when demolding using a vacuum lifter, as the smoother, flatter surface improves the achievement of a vacuum seal.

[0125] The skimming can be performed manually by an operator using an appropriate skimming tool, by an overhead mechanism (such as a tool suspended from a gantry crane), or by a robot with a skimming tool attached to its wrist. The action is usually performed with a paddle that passes across the top surface, pushing the scum aside, and then tilting the tool so that it picks up the scum. Alternatively, the action can be performed using opposing tools that are held together like pliers, such as Figure 6 As shown, when two opposing tools meet, dross can be picked up. Metal is removed in a single pass or in multiple passes to ensure that more coverage of the top surface of the ingot 4 is skimmed and more dross is removed. It is beneficial for the skimmer to avoid extending too far below the surface to avoid disturbing the liquid metal or removing unnecessary amounts of material.

[0126] Deslagging needs to be done while the top surface is still liquid, so it is usually done immediately after pouring using state-of-the-art machines. If deslagging is not done at this point, the top surface will be rougher, and the likelihood of successful demoulding will be reduced. The ingot may also be rejected and deemed unacceptable for sale.

[0127] With prior art ingot casting machines, the trolleys are interconnected by trolley chains and if a problem occurs anywhere in the machine, the chain guidance is prevented, with the risk that the top surface of the ingot 4 solidifies before slagging occurs.

[0128] The system of the present invention has advantages over slag skimming. The mold 3 is supported by its frame and transported by the AGV 1. The mold 3 that has just been poured is transported by the AGV 1 directly from the pouring station 5 to the slag skimming station 6.

[0129] In the skimming station of the prior art machines, the skimming robot is placed to the side of the mould and can only skim one ingot at a time from one position along the track.

[0130] The system of the present invention allows for slag skimming to be performed anywhere within the robot's reach, enabling multiple skimming locations (also known as points) to be positioned around a single robot. It does not require a location with a movable track underneath, thus offering greater design flexibility, particularly by enabling the use of a drip tray to collect aluminum dripping from the skimming tool. Mold 3 can be approached and exited along the same path. Mold 3 can be reached from any direction; thus, the same robot can skim more ingots simultaneously, making better use of existing equipment.

[0131] The location of the scum skimming robot and station 6 is flexible. For functionality, they are preferably located near the pouring station 5, but do not need to be located on a fixed path. The scum box 7 that receives the scum needs to be replaced regularly, which can be done when the scum skimming robot is idle, but other processes can be carried out independently. Emptying the scum box 7 is typically performed by an operator on a forklift, requiring interaction with operators and equipment outside the safety fence. This flexibility allows for finding a more ideal location for the scum skimming station 6, such as one that is easily accessible by a forklift.

[0132] The flexibility of the skimming robot's location offers the advantage that the system doesn't need to be located in close proximity to a crucible tilting device or pouring spout, where operating space is limited. This reduces the risk of collision with nearby equipment and makes the design simpler. It also reduces the heat experienced by the skimming robot and / or skimmer, as the number of nearby ingots holding hot metal can be flexibly limited to one being skimmed, another awaiting skimming, or already skimmed. This also minimizes the time they spend idle.

[0133] Multiple skimming locations associated with a single robot result in the ingot's motion no longer affecting the skimming process. The skimmer robot can transition directly from skimming one mold to the next without waiting for guidance from the trolleys of conventional cart-based systems. This allows for fine-tuning of the process. For example, the skimming rate can be reduced or the number of passes increased without reducing the overall productivity of the system.

[0134] Because each mold moves independently, skimming can occur as long as the skimmer is operational and a backup position is available. Therefore, throughout the process, regardless of any interruptions elsewhere downstream, the poured mold 3 can advance to the skimmer and be skimmed. This reduces the risk of the ingot 4 not being skimmed within an acceptable delay.

[0135] The skimming function is not typically a critical path in production with existing technology machines. If it is found to be hindering production, a second skimming robot is often added and installed in the system.

[0136] With the system of the present invention, a second skimmer can be used for redundancy.

[0137] The system and method of the present invention for moving the filled ingot to the slag skimming station via the AGV 1 is universal and can be used with various slag skimming methods, such as robotic skimming, gantry skimming, and mobile robot skimming. Manual skimming is also suitable, provided proper safety procedures are implemented to ensure the operator is in a safe and protected position. The skimming tool 8 used can vary and can be adapted for a single paddle / blade method, a dual blade method, or a manual tool.

[0138] Thus, the described embodiment differs from prior art machines by at least one of the following features: - The newly poured ingot 4 is moved by the AGV 1 to the slag skimming station 6; - skimming multiple ingots 4 using a single skimming robot, provided they are within the robot's operating range; - Skimming can be carried out from one mould to the next without the need to guide the trolley and therefore without the associated waiting time; - Allows the skimmer to be tilted away from the crucible; - Robust, as a problem anywhere in the system will not interrupt the skimming process of the ingot 4, thus reducing the risk of unskimmed, rejected ingots; - The number of skimmers can be easily increased to increase capacity or add redundancy; and - A variety of skimming methods are available, such as fixed robotic, mobile robotic, gantry, single blade, and double blade. Cooling Station

[0139] Now refer to Figure 1A -B and Figure 7 An exemplary layout of a cooling station 32 is shown.

[0140] After the skimming operation, the liquid metal will be cooled until it is completely solidified and can be removed from the mold 3.

[0141] Previously, using prior art machines, water cooling was sometimes required to remove heat. Due to safety and corrosion issues, such machines are less common. With modern, automated machines, cooling is more commonly achieved through a combination of forced air cooling, natural convection, and radiation. A common demolding method is vacuum lifting, during which the ingot 4 is lifted from the mold 3. Therefore, sufficient time is required between pouring and demolding to ensure that the ingot 4 cools sufficiently during lifting to be structurally supportive.

[0142] Existing automated air-cooling machines using rails achieve the necessary cooling time by extending the rails. Longer rails provide more positions between the pouring station and the demolding station, thereby extending the cooling time. Larger capacity machines require faster cycle times. To achieve the same overall cooling time, more positions are required before demolding. As the ingots 4 cool, they are uniformly guided to their next position. Fans or blowers can be installed at various positions to increase the cooling rate.

[0143] The system of the present invention features a dedicated cooling station 32, which acts as a parking lot for the ingot molds 3 and their supports. AGVs 1 remove the skimmed ingots from the skimming station and transport them to an unoccupied location within cooling station 32. The AGVs are then free to leave, allowing the ingots 4 to cool and begin performing other tasks. After a specified period of time, when the ingots 4 have properly solidified and cooled, the AGVs pick them up and transport them from cooling station 32 to the demolding station.

[0144] The cooling stations 32 can be optimized for cooling, setting the necessary airflow to improve cooling and curing. As a result, the cooling process can occur in a more centralized area, rather than distributed linearly along tracks as in prior art machines, so an entire area can be easily dedicated to cooling. This also minimizes the required floor space.

[0145] Prior art machines mount the mold linearly on the trolley track. The mold has a large corner radius so it can be properly guided around the track. This results in a larger footprint, with space often wasted in the middle of the track loop, which can only be accessed through the intersection.

[0146] The centralized cooling station 32 of the system of the present invention significantly reduces the area required for this operation, thereby enabling a more compact system or a higher capacity system.

[0147] There are many options to choose from to accommodate production capacity or a specific layout. Since there are no cart chains, any large number of arrangements of the cooling station 32 are possible, given that the cooling station 32 provides the necessary AGV access. While square or rectangular shapes for the cooling station 32 make good use of space, L-shaped or split cooling stations 32 are also available and can be easily customized to fit a specific factory layout. Other factors, such as cooling components (e.g., fans), may influence the layout selection.

[0148] The purpose of the cooling station 32 is to solidify the material by lowering the temperature of the ingot 4 .

[0149] With prior art machines, the guidance of the mould creates unwanted movements which can produce waves on the top surface of the ingot.

[0150] The system of the present invention allows the ingot 4 to remain stationary during most of the cooling period; it is only moved when the ingot containing liquid aluminum is moved into the cooling station 32. As a result, the quality of the top surface of the ingot 4 is improved.

[0151] This also improves the wear of moving and guide components.

[0152] The trolley chains of prior art machines require guidance during every cycle. Consequently, they are a high-wear item. The rails themselves are also susceptible to wear and tear, requiring constant tensioning and adjustment to ensure the trolley chains remain tight and can safely and smoothly guide the mold without derailing.

[0153] The system of the present invention eliminates the risk of uneven movement and derailment. It further eliminates the maintenance associated with guide components and tracks, thereby reducing the associated upfront costs.

[0154] Rapid changes in mold temperature can also cause wear and deformation of the mold. These changes in mold temperature are the main cause of mold failure.

[0155] When production rates do not require the use of all available molds 3, individually actuating the molds 3 allows the system of the present invention to better utilize the molds 3 by allowing selection of the group and number of molds 3. It can control the delay between demolding and pouring (pouring) into the same mold by using only the necessary number of molds 3. Thus, the system of the present invention extends mold life. It can also shorten warm-up times, thereby reducing the associated energy required. Thus, it is possible to vary the number of molds 3 in production to suit the production rate of a particular casting.

[0156] The cooling operation is typically long and requires little intervention during this operation. Therefore, the cooling station 32 can be located away from the slag skimming station 6. The ingot 4 can be easily transported to other parts of the facility where cooling may be more efficient or where space is available.

[0157] One possible solution is to use water to increase heat dissipation, thereby reducing cycle time and increasing cooling capacity. Since the ingot 4 can be transported to the cooling station 32, it does not need to be located near the pouring station 5, thus avoiding the risk of water spraying and contacting the pouring station 5, thus limiting the related problems.

[0158] According to an embodiment, the cooling process can also be adjusted between air cooling and water cooling, while reducing the risk of water coming into contact with the liquid metal.

[0159] Thus, the described embodiment differs from prior art machines by at least one of the following features: - Keep the ingot 4 still during most of the cooling operation, reducing unnecessary movement and improving ingot quality; - immediately after the skimming operation, the ingots 4 are transported to the cooling station 32 and remain there until they are suitable for demoulding; - Use available ground space more efficiently, so that space is not wasted for example inside tracks; - The configuration can be easily customized to suit specific factory layout; - Easily increase capacity by increasing cooling station allocation; - Reduced costs due to the elimination of supply and maintenance of guides, trolley chains, rails, tensioners, hydraulics and tensioning devices; - Eliminate the risk of derailment; - controlling the number of moulds 3 used in a given pour, thereby reducing temperature variations across the moulds 3; and - Locating the cooling station 32 at one or more locations within the facility, possibly remote from the pouring station and / or the skimming station. Demolding station

[0160] See also Figure 1A -B and Figure 8A -B, shows the general layout of the demoulding station according to one embodiment.

[0161] Removing large aluminum ingots 4 from the mold 3 can be a difficult process due to their large size and mass. Turning the mold 3 over is logistically very difficult and fraught with risk. With manual casting, the ingot can be removed after pouring by adding aluminum handles or other lifting devices. Alternatively, steel wedges can be inserted into the top surface before solidification and removed after solidification to create grooves in the top surface for the device to snap into and lift. However, modifying the top surface can affect stacking capabilities, can be undesirable for customers, create locations where moisture can linger, create safety hazards, and is difficult and costly to automate.

[0162] Prior art automated machines typically use a vacuum lift to initially remove the ingot from the mold. A trolley chain is guided on rails to allow the ingot to cool properly at the demolding station and be ready for removal. A vacuum head, suspended from a lifting mechanism, is then lowered onto the top surface while vacuum is applied. The mechanism then rises, removing the ingot while leaving the mold and trolley in place.

[0163] The ingot is taken to the handling station where it is weighed, marked and stacked. Once the ingot and demoulding device have left the mould and trolley chain, the trolley chain can be guided so that the newly solidified ingot appears again at the demoulding station.

[0164] A recent improvement and trend is to use a vacuum head attached to a large payload robot to perform this demolding function.

[0165] The demolding process in the system of the present invention proceeds in a similar manner to the automation described above, except that the ingot 4 is moved to the demolding station 9 by an AGV 1. Using a demolding robot for demolding allows for multiple demolding locations, as long as they are within the robot's operating range. This eliminates the need for induction or travel time in and out of this area, increasing capacity. This also means that if demolding fails, it can be retried without impacting upstream operations.

[0166] With the system of the present invention, since there is no trolley chain passing underneath, the design of the demoulding station is simpler and more modular. It can be designed specifically for the demoulding function.

[0167] It also makes it easy to extend the duration of the cooling process, thereby potentially reducing the temperature of the ingot, and since premature wear of the chucks increases with increasing ingot temperature, this reduces wear of the chucks without reducing overall productivity.

[0168] If higher capacity or redundancy is required, multiple stripping units can be included or added with little or no impact on the rest of the system.

[0169] Since there is no continuous chain passing near the demoulding station 9, the only hot ingot 4 nearby is the ingot 4 waiting to be demoulded, so the radiant heat effect on the equipment is relatively small.

[0170] One embodiment is to use suction to initially lift the ingot 4, and when the ingot 4 is lifted above the mold 3, place physical protrusions between the ingot 4 and the mold 3, thereby minimizing the contact time between the suction cup and the ingot 4. Thereafter, the ingot 4 is moved using a physical component (e.g., an automatic forklift) rather than a pneumatic component (e.g., a suction cup).

[0171] Thus, the described embodiment differs from prior art machines by at least one of the following features: - The cooled ingot 4 is moved to the demoulding station 9 by the AGV 1; -Flexibility in demoulding methods, such as vacuum and robotic demoulding systems; - Multiple demoulding positions are available within the demoulding operating range of system components (e.g. robots), thus reducing cycle times by eliminating the need to wait for guidance; - The design is simpler because there is no trolley chain passing underneath; - The number of stripper units can be easily increased if redundancy or capacity improvements are required; and - Reduce radiant heat on demoulding equipment. Stacking, weighing, marking stations

[0172] See also Figure 1A -B and Figure 9, depicting an exemplary general layout of an area where stacking, weighing, and labeling operations are performed.

[0173] Once the ingots 4 are removed from the mold 3, they are processed. This involves weighing them, marking them, determining whether they are good or bad, and stacking them at a weighing and marking station 10 for transport. These operations performed on the ingots 4 after they have been removed from the mold 3 are not significantly affected by the system of the present invention. They are processed in the same manner as in prior art machines. Preheating Station

[0174] Now refer to Figure 1A -B and Figure 10 , showing an exemplary overall layout of the preheating station 12 .

[0175] When any surface comes into contact with liquid aluminum, it's common practice to preheat it to remove any moisture and minimize thermal shock. When water comes into contact with liquid aluminum, it instantly turns to steam, expanding in volume and throwing the liquid aluminum in all directions. This is dangerous for both operators and equipment and must be avoided. Water can be sprayed onto the aluminum or used in large pools to safely instantaneously quench it, but problems arise when water becomes entrained with the liquid aluminum. This can occur when pouring liquid aluminum onto a damp, inadequately preheated mold. Therefore, mold 3 must be preheated before use.

[0176] The molds of existing machines are typically preheated using gas burners or electric infrared heaters. These are placed on top of the mold to heat the inner surface where the liquid metal is poured. It is generally desirable to raise the mold temperature above 100°C, as water turns to steam at this temperature. For safety reasons, eliminating any moisture from the inner surface of the mold is paramount. Furthermore, a higher overall mold temperature minimizes the thermal shock experienced during pouring, so a higher temperature can be advantageous. However, the mold is large, requiring significant energy to raise the temperature.

[0177] Prior art automated machines have a trolley chain and track beneath the mold, so heating occurs entirely above the mold. Heaters are arranged at several locations before pouring, allowing the mold to be heated and poured without significant cooling between stations. The mold is placed under the first heater and then guided to the next heater until it reaches the final heater and is ready for pouring. Some casting machines require multiple passes around the track to bring the mold to the appropriate temperature, while others only require a single pass under the heater before pouring. The heaters are positioned to maximize heat transfer to the mold while stationary, often without regard for achieving maximum heating during the guiding process. After the mold is poured and the ingot is removed, the mold is often much higher than the specified preheat temperature, as there is no significant machine downtime. Therefore, the heaters can be turned off or switched to a low-energy "standby" mode. The number of heaters required depends on the size of the mold, the strength of the individual heaters, and the overall machine capacity. Larger machines require more frequent guiding, requiring more heaters to heat the mold within a given timeframe.

[0178] The system of the present invention also requires preheating the mold 3 before pouring. Heating the mold can be accomplished by, but is not limited to, gas burners or electric radiant heaters. The mold 3 is moved to a preheating station 12, forming a closable compartment. At the start of casting, when the mold 3 is cold, the AGV 1 moves the cold mold 3, resting on its support structure, to the preheating station 12. Providing multiple preheating stations 12 allows the preheater to keep pace with the overall system's production rate, even during system startup.

[0179] The mold 3 moved by the AGV 1 can enter and exit the preheating station 12 using the same path or direction. This allows the use of insulation on the remaining sides of the mold 3 to capture and reflect heat, thereby improving the heating process; the process is more efficient, similar to placing the mold 3 in and removing it from an oven. On the open side of the preheating station 12, an insulated door can be used to further optimize heat and energy conservation.

[0180] It is worth mentioning that this cannot be achieved with the machines of the prior art, since the dies are continuously introduced on rails from one direction and removed from the other.

[0181] Using the system of the present invention, the controller monitors which preheating stations 12 are empty and which already have molds 3. The AGV 1 can only move molds 3 to empty preheating stations 12. The molds 3 can then remain in the preheating stations 12 for the duration of their heating cycle without having to move (e.g., from one preheating station to the next). This maximizes preheating efficiency for the molds 3 throughout their entire heating cycle.

[0182] Once the AGV 1 has placed the cold mold at the designated preheating station 12, the AGV 1 will leave the preheating station 12 to perform other tasks. This avoids the AGV 1 going through the heating phase with the mold 3, reducing the risk of damaging the equipment.

[0183] With prior art machines, there is a risk of heating the trolley and tracks beneath the heaters, particularly if the mould is not correctly positioned beneath its designated heater causing the trolley tracks to stop.

[0184] The ability of the AGV 1 using the system of the present invention to vary system capacity allows for the use of only a portion of the available molds 3 (a subset of the available molds 3). This reduces wear on the molds 3 while also reducing the number of molds 3 that need to be preheated during startup. Consequently, with a reduced number of molds 3, the efficiency of the preheating process increases, and the energy required is significantly reduced.

[0185] Once the preheating phase is complete and the mold 3 has reached the set temperature, the heaters of the preheating station 12 can be turned off or set to a low power state.

[0186] The modular nature of the preheating stations 12, where each heater has a separate designated preheating station 12, allows capacity to be easily increased or modified simply by adding more preheating stations 12.

[0187] Thus, the described embodiment differs from prior art machines by at least one of the following features: - Moving the mold 3 in and out from one direction allows for a more efficient preheating design (including insulation walls); - Keep the mold 3 in place during the preheating process, thus improving efficiency; - the AGV 1 leaves the mold 3 in the preheating station 12 to perform other tasks, thus reducing the risk of damage due to overheating of surrounding equipment; - Heating capacity is easily expandable by adding additional modular preheating stations; and -Have time dedicated to warming up modularity, rather than by introducing setup. Metal processing equipment

[0188] Now refer to Figure 11 and Figure 12 , which depicts an apparatus designed to hold, mix, and maintain sufficient temperature for large quantities of metal; and an exemplary multi-pour metal processing station.

[0189] In some cases, aluminum producers want to control or increase purity or add specific elements to the metal before casting to produce alloys or higher grades of aluminum for more specific applications. This increases the value of the metal produced and creates higher returns for the producer.

[0190] This can be achieved in a variety of ways, but typically involves mixing large quantities of liquid metal together to create a homogenous batch, followed by degassing, filtering, and skimming. This ensures that the composition is consistent from one ingot to the next. Specific elements can then be added to the batch in controlled amounts to create an alloy.

[0191] To make the process compatible with the ingot casting system of the present invention, additional means may be included to hold, mix and maintain the appropriate temperature of the bulk metal ( Figure 11 This device serves as a holding vessel 19 for metal processing, similar to a holding furnace, but specifically designed to be centered around the AGV 1. This allows for single or multiple pouring locations. This intermediate vessel is directly connected to the AGV 1 and fills the ingot mold 3. At the end of the pour, when the ingot 4 reaches its specified height, the flow can be stopped. This allows pouring into a single or multiple molds 3 at any time, enabling high-capacity pouring from a single device.

[0192] Thus, the described embodiment differs from prior art machines by at least one of the following features: -Compatible with AGV use; -Can degas and filter the molten metal before casting; - No need to pour directly from the crucible tilting table; - bulk mixing to produce homogeneous ingots; - production of alloys, thereby adding value to the ingots produced; and -Has the capability to cast multiple ingots from one container. Casting the mold directly from the electrolytic cell

[0193] Traditionally, in the prior art, aluminum is produced through an electrolytic reduction process in a reduction unit 14 or "electrolyzer." An electrolytic bath fills the entire cell, and current flows from the anode to the cathode, creating a conductive environment at a temperature of approximately 950°C. The current then breaks down aluminum oxide into pure aluminum, which precipitates at the bottom of the cell.

[0194] The cells are arranged in rows, one behind the other, in a long rectangular building. These buildings can house between one and 500 cells, which are known globally as a potline. A typical aluminum smelter may have many potlines and often hundreds of cells operating in the same facility.

[0195] Because the electrolytic reduction process is a chemical reaction, controlling the amount of reactants is crucial. Ideally, alumina would be added and aluminum extracted in a continuously controlled manner to maintain a perfect balance of concentrations. However, from an operational and logistical perspective, this is not feasible due to a number of reasons, including labor costs, efficiency, and safety.

[0196] Logistical and operational limitations dictate how often the cell can be siphoned. Each time the cell is siphoned, thousands of kilograms of aluminum are removed, removing significant amounts of heat energy and reducing the metal content in the cell, potentially destabilizing the reaction.

[0197] In prior art systems, molten aluminum is extracted by using vacuum pressure in a sealed container to create suction in a tube inserted into the electrolytic cell. The aluminum is drawn through a siphon into a suitable container and then transported to a location where it can be processed or cast. The complexity of this operation makes it difficult to automate, and therefore still relies on the availability and cost of skilled labor. These containers (usually crucibles) can be operated by large trucks or mobile overhead cranes. The ability to remove large amounts of metal reduces the number of tapping operations, thereby reducing the number of operators required to complete the task and thus reducing costs. However, as mentioned above, the optimal state of electrolytic cell efficiency is to remove as little metal as possible at a time, bringing it closer to continuous steady-state operation. Therefore, aluminum smelters must strike a balance between removing a large amount of aluminum at once and reducing electrolytic cell efficiency, or removing smaller amounts more frequently and increasing labor costs.

[0198] Furthermore, the cost of transporting liquid aluminum in crucibles is high. Before the molten metal can be safely introduced into the crucible, the inner surface of the crucible must be preheated, as any moisture trapped between the crucible surface and the molten aluminum could cause splashing and explosions. As the crucible is used and the molten metal cools within, alumina and electrolyte bath fluid tend to precipitate and accumulate on the inner surface, requiring periodic scraping, either manually or using expensive machinery. Removing this precipitate also wears the refractory lining, leading to its premature replacement.

[0199] See also Figures 13 to 19 , these figures depict an embodiment of the system.

[0200] The system of the present invention provides a solution for removing the intermediate molten metal transport container and replacing it with an AGV 1 that transports the ingot mold 3. Molten aluminum from the pot is transferred directly into the ingot mold 3 and transported to the necessary subsequent location using the AGV 1. Thus, all costs associated with using crucibles and workers to transfer the metal from the pot chamber to the casting facility are avoided.

[0201] This system is integrated with the above components to create a process for casting ingots directly from the aluminum reduction unit. This is done in a fully automated manner, using AGV 1 to transport the metal from production in the electrolytic cells directly to the finished product for shipment and sale.

[0202] Conceptual variants are proposed and described below, explaining how the molten aluminum is transferred from the reduction unit to the ingot mold 3 .

[0203] refer to Figures 13 to 16 , these figures show a first embodiment.

[0204] To fully automate the process, an automated guided vehicle (AGV) 1 and a robot are used. The first embodiment utilizes a mobile extraction device 15 consisting of an AGV with a robot mounted on top. The mobile extraction device 15 moves from one pot to the next, extracting a specified amount of aluminum. This mobile extraction device 15 can skim the ingots 4 directly after they are dumped and can be battery-powered, provided charging stations are available throughout the pot room.

[0205] The robot can be used to extract the metal from the electrolytic cell using various tools to accommodate different cell types. One variant uses a robot-controlled ladle 16 to scoop the metal and pour it into the mold. Another method uses a siphon tool 17, which operates under negative pressure to extract a defined amount of metal and direct the liquid metal directly into the mold.

[0206] Working in conjunction with the mobile extraction device 15, the AGV 1 transporting the ingot molds 3 moves in the pot chamber and fills its respective mold 3. These filled molds 3 can then be "integrated" into the ingot casting process by the AGV 1, as described earlier in this article.

[0207] refer to Figures 17 to 19 A second embodiment is shown.

[0208] This second embodiment incorporates an automated siphoning device 13 that uses the ingot mold 3 as a receiver. This device can be mounted on an AGV 1 or integrated into the overhead cranes already used in many smelters and other locations to tend to the pots. The AGV 1 transports the mold 3 to the pot. The device lowers, seals against the mold surface, and siphons metal from the pot directly into the ingot mold.

[0209] refer to Figure 28A 、 28B and 29, another concept involves moving the extraction device 38 ( Figure 29 The extraction device is shown in FIG. Figure 28A and 28B The extraction device 37 is installed on the AGV, see Figure 28AA mobile AGV 1) in FIG. 1 is using a molten metal pump 35. A mobile extraction device 38 is designed to be moved from one electrolytic cell to another on a mobile device such as an AGV 1, a manned vehicle, or an overhead crane.

[0210] The pump inlet pipe (not labeled) is inserted into the aluminum outlet hole (not labeled) of the electrolytic cell. In this way, the outlet of the molten metal pump 35 is tilted in such a way as to leave room for the AGV 1 to bring the empty mold 3 to be filled 4.

[0211] The metal pump preheater 36 is used to ensure that there is no moisture on the pump tubing before it is inserted into the electrolyser.

[0212] Unlike prior art systems, the use of ingot molds 3 eliminates the need for transport containers. Once the amount required to fill the ingot mold is removed from the electrolytic cell, the lid sealing the mold 3 is lifted, and the AGV 1 can transport the filled mold 3 to the next station. Multiple molds 3 can be filled before moving on to the next electrolytic cell. Therefore, the amount of metal removed from each electrolytic cell is calculated in increments of ingot size.

[0213] The process described completely eliminates the need for a crucible and can be fully automated.

[0214] It is not necessary to equip the entire smelter with these machines; only the amount required to meet the ingot casting needs of that particular smelter needs.

[0215] The described concept variants differ from prior art machines in at least one of the following features: - Crucibles and / or Crucible Transporters are no longer required; - Preventing the monopoly of foundry floor space and potentially eliminating the need for foundries; - Reduce volume while increasing metal removal frequency; -Automatic removal of molten aluminum from electrolytic cells; - Improved security through process automation; and - Optionally, the ingot casting process can be performed close to the electrolytic cells using the same AGV. AGV modification

[0216] In order to operate the system of the present invention, the prior art machine equipment is modified, as can be understood from the above description, such as the preheating station. Some of the AGV-specific modifications are described in more detail below.

[0217] Automated guided vehicles (AGVs) are becoming increasingly common in industries that require moving objects around a factory. With increasing automation and payloads, the use of these autonomous devices is growing. Companies have previously used AGVs to provide pallet transport solutions, moving packaged pallets from one location to another. However, existing AGVs are generally not suited to operate in the harsh environments of aluminum smelters or recycling facilities, where high and low temperatures can occur, exposure to molten metal is possible, and other contaminants are ubiquitous on surfaces and in the air.

[0218] Therefore, the AGV 1 designed for the present system incorporates innovative features that allow it to operate in this harsh environment. The AGV 1 is equipped with improvements that ensure this type of autonomous vehicle can adapt to the environment of aluminum facilities, whether it is a casting room, a potline, a recycling center, or other places where liquid aluminum may be present.

[0219] See also Figures 21 to 23 In the first embodiment, the AGV 1 can accurately pick up, place down, and manipulate the mold 3. The AGV 1 is equipped with a support structure 20 that can be mounted on its top, and the support structure 20 includes forks 21 extending on four sides of the space suitable for accommodating the mold 3, thereby hindering the horizontal movement of the held mold 3. The support structure 20 further elevates the mold 3 and separates it from the top of the AGV 1, thereby limiting the amount of heat transferred to the AGV 1 from the mold 3 when filled with metal. Since the temperature of the contents of the mold 3 when clamped by the AGV 1 ranges from 850°C during pouring to about 660°C at the beginning of solidification, the outer surface temperature of the mold 3 may rise to about 500°C, and the AGV 1 needs to be adjusted accordingly to transfer limited heat to the AGV 1.

[0220] According to one embodiment, the support structure 20 includes a frame 22 providing space therein or below so that the forks of a forklift can be placed therein or below and lift the support structure 20 and the mold 3 that may be held thereon to release the AGV 1 from the mold 3.

[0221] See also Figure 30 and 31 According to an embodiment, the support structure 20 includes members such as legs 23 (e.g., Figure 19 、 Figure 30 and Figure 31 These components provide clearance underneath, allowing the AGV 1 to enter underneath the mold 3. The AGV 1 includes a lifting platform capable of lifting the support structure 20 to elevate the legs above the ground, enabling the AGV 1 to grasp or grab the combination of the support structure 20 and the mold 3, move between workstations, and autonomously leave the support structure 20. Figure 31On the left side, AGV 1 is depicted moving under support table 2 before it is raised, while on the right side, AGV 1 is depicted under support table 2 with the support table raised, ready to move to another station.

[0222] According to one embodiment, the AGV 1 includes a deflection shield 24 that extends from the top toward the ground in an outwardly inclined manner over a portion of the height of the AGV 1. The functions of the deflection shield 24 include protecting the main body of the AGV 1 from spillage of liquid metal and deflecting radiant heat from the mold away from the AGV 1.

[0223] According to one embodiment, the AGV 1 is suitable for moving payloads of approximately 1200 kg or more. Therefore, the AGV is equipped with two independently driven directional drive wheels 25 and four non-motorized wheels 26. The speed and direction differences between the motorized drive wheels 25 (also known as ground-contacting drive wheels) enable the AGV 1 to be driven and steered, while the non-motorized ground-contacting wheels 26 located near the corners of the AGV 1 provide stability.

[0224] For example, a broom-style skirt 27 is mounted on the bottom edge of the AGV 1 to operate as a scraper, isolating the wheels 25, 26 from debris that may be present on the floor.

[0225] According to one embodiment, the AGV 1 is equipped with an autonomous cooling system (not shown). The AGV is equipped with a temperature sensor (not shown) and a blower (not shown) designed to cool sensitive components of the AGV 1, such as the battery (not shown), drive motor (not shown), lift motor (not shown), controller (not shown), etc.

[0226] According to one embodiment, when the AGV is charging (e.g., physically connected or wirelessly charged, such as inductive charging, resonant charging, or radio frequency charging), the blower of the AGV 1 operates at a lower temperature trigger, thereby optimizing energy management between energy storage and immediate energy use.

[0227] According to one embodiment, the environment is equipped with cooling components (not shown), such as under the grille and in place of floor-level blowers, for sending forced cooling air into the AGV 1 , thereby cooling the AGV 1 without cooling the mold 3 .

[0228] According to one embodiment, the AGV 1 is also designed to ensure safety and interact with the operator and surrounding equipment to reduce risks and related hazards. Safety-related components are installed on the AGV 1, such as a proximity sensor (not shown), a radar (not shown), an optical sensor (not shown), a contact sensor (not shown), an emergency stop device (not shown), and a radio communication component (not shown).

[0229] According to one embodiment, the AGV 1 of the present system is also equipped with an accelerometer (not shown), for example to measure the effects of movement on the liquid metal, thereby ensuring smooth transport of the liquid metal inside the mold 3 without causing spillage or excessive fluctuations during displacement.

[0230] This embodiment of the AGV 1 differs from prior art AGVs by at least one of the following features: - Protect the AGV's components from ambient heat and ambient dust characteristic of the harsh environment associated with liquid metal casting ingots; - Protect AGV components from liquid metal splashes; - Capable of transporting liquid metal in open containers without spillage by controlling at least acceleration / deceleration / turning and emergency stopping; -Capable of cooling batteries and electrical / electronic components, enabling AGVs to operate in close proximity to equipment at very high temperatures; - Capable of reliable and safe operation, charging, and maintenance in a foundry environment; and - Use at least 4 contact points and 2 drive points to move, turn and maintain its stability and the stability of the mold. mold design

[0231] Additionally, some improvements to the mold 3 are provided in more detail below.

[0232] See also Figure 24 and 25 In order to achieve automation and ease of demoulding, the mold 3 has slightly outwardly inclined side walls 31, allowing the ingot to be demoulded from the mold 3 by suction at the demoulding station. Therefore, the mold 3 must not have any inward protrusions or shapes at the interface of the walls below the maximum filling level.

[0233] According to one embodiment, the mold 3 is connected to the detachable anti-overflow ring 28 ( Figure 25 3 (a cross-section of a portion of the overflow ring is depicted in FIG), the overflow ring having the depicted shape, which is intended to redirect the liquid metal wave that hits the overflow ring 28 to the center of the mold 3. The exemplary removable overflow ring 28 has the same dimensions as the flange 29 of the mold 3 and is designed to be placed on the flange 29 of the mold 23, with its deflection surface 30 extending inwardly from the flange 29 of the mold. The overflow ring 28 is designed to be removed before or when the ingot 4 is ejected from the mold 3 and placed in place on the flange 29 of the mold 3 before filling the mold 3.

[0234] According to one embodiment, the mould 3 is made of cast steel with a thickness between 50 and 80 mm.

[0235] According to one embodiment, a portion of the exterior of the floor of the mould 3 is covered with some insulating material in order to limit the heat transferred to the AGV 1 .

[0236] According to one embodiment, the mold 3 is designed to be forcedly cooled in a cooling station, including air cooling and indirect water cooling (also known as a water cooling component in contact with the mold in the cooling station). How to operate

[0237] Now refer to Figure 26 , considering for example Figure 26 , for example, consider Figure 26 ,UML sequence diagram describes this method and the workstations involved.

[0238] The UML sequence diagram lists the workstations that participate in the process and are accessed by AGV 1, namely preheating station 12, pouring station 5, slag skimming station 6, cooling station 32, demoulding station 9 and weighing and marking station 10. The AGV passes through the general station-free area (part of which is through Figure 20 The reference numeral 99 on the figure) moves between stations.

[0239] It's important to note that UML sequence diagrams are a tool for illustrating routes and do not limit the stations or actors involved to the list they provide. For example, additional stations, such as charging stations, storage and maintenance stations, are planned to be added to UML sequence diagrams and other diagrams. Furthermore, since the movement of AGV 1 is primarily intended to move mold 3 and support structure 20 between stations, mold 3 and potential support structure 20, as passive actors, are not depicted. Finally, for simplicity, components of the workstations that could be considered actors, such as the skimming robot at skimming station 6, are not depicted, as they are dedicated to a single task and have a single location associated with them.

[0240] Therefore, see Figure 27 , a method for producing an ingot from liquid metal poured into a mold, the method comprising:

[0241] 81: having at least three workstations for performing different tasks in ingot production, each workstation having a dedicated position and operating at a dedicated rate of number of ingots per unit time, wherein during the ingot production process, tasks associated with producing the ingots are performed in a pre-set sequence;

[0242] 82: having a plurality of dies movable between dedicated positions at a workstation; and

[0243] 83: Having multiple automatic guided vehicles (AGVs) that can move independently between workstations, the AGV can move any mold from any dedicated position of the workstation to any other dedicated position of the workstation.

[0244] The method may include moving a first AGV without a mold to a first workstation, grabbing a mold located at the first workstation, and moving the mold to a second workstation according to a preset sequence;

[0245] The method may include causing the first AGV to release the mold at the second workstation and leave the second workstation without the mold.

[0246] The method may include having a first number of molds at a first workstation, a second number of molds at a second workstation, and a third number of molds at a third workstation at a certain moment, wherein at least one of the first number, the second number, and the third number is at least 2.

[0247] The method may include having fewer AGVs than a plurality of molds, for example, a ratio of AGVs between 1 AGV for every 5 molds and 1 AGV for every 25 molds.

[0248] The method may include, at a buffer station, moving the first mold to the buffer station and then moving the second mold to the buffer station, and the first mold leaving the buffer station after the second mold leaves the buffer station.

[0249] The method may include: a first AGV moving the first mold to a first workstation, and a second AGV moving the first mold out of the first workstation.

[0250] Although the preferred embodiment has been described above and shown in the accompanying drawings, it will be apparent to those skilled in the art that various modifications can be made without departing from the present disclosure. Such modifications are considered possible variations within the scope of the present disclosure.

Claims

1. A method for producing an ingot by casting liquid metal into a mold, characterized in that: The method comprises: providing at least three workstations for performing different tasks in the production of said ingots, each of said workstations having one or more dedicated positions and operating at a dedicated rate of number of ingots per unit time, wherein during the production of said ingots, tasks associated with producing the ingots are performed in a pre-set sequence; providing a plurality of molds movable between said dedicated positions at said workstation; and A plurality of automatic guided vehicles (AGVs) capable of independently moving between the workstations are provided, wherein the AGVs are capable of moving a mold from any one of the dedicated positions of the workstations to any other dedicated position of the workstations.

2. The method according to claim 1, characterized in that The AGV can grasp a mold located at a first dedicated position, move the grasped mold to a second dedicated position, and release the grasped mold at the second dedicated position.

3. The method according to claim 1, characterized in that Also included is a mold having a first number of molds at a first workstation at a first time, a second number of molds at a second workstation, and a third number of molds at a third workstation, wherein at least one of the first number, the second number, and the third number is at least 2.

4. The method according to claim 1, wherein Also included are AGVs having fewer than a plurality of the dies.

5. The method according to claim 1, characterized in that Also included is a buffer station, wherein a first mold is moved into the buffer station after a second mold, and the first mold exits the buffer station before the second mold.

6. The method according to claim 1, characterized in that The method further includes causing a first AGV to move the first mold to a first workstation and release the first mold at the first workstation, and causing a second AGV to grab the first mold at the first workstation and move the first mold out of the first workstation.

7. The method according to claim 1, characterized in that The AGV includes a lifting top, wherein by raising and lowering the top, the AGV is able to grab and release the mold.

8. The method according to claim 1, characterized in that The AGV includes at least two ground-contacting drive wheels and at least four additional ground-contacting wheels.

9. The method according to claim 8, characterized in that The ground contact drive wheels of the AGV are driven by independent motors.

10. The method according to claim 9, characterized in that The ground-contacting drive wheels of the AGV may be driven in reverse.

11. The method according to claim 1, characterized in that One of the workstations includes a robot controlled to perform predetermined movements.

12. The method according to claim 1, characterized in that The invention also comprises a supporting structure, on which a gripped mold can be placed separately, and the supporting structure comprises a fork extending upwards for preventing the gripped mold from moving in a horizontal direction.

13. The method according to claim 12, characterized in that The AGV may grasp the grasped mold by lifting one of the support structures supporting the grasped mold.

14. The method according to claim 12, characterized in that The support structure includes a member configured to provide space underneath so that any one of the AGVs can travel thereunder.

15. The method according to claim 14, characterized in that The AGV may grasp the grasped mold by lifting one of the support structures so that the member loses contact with the ground.

16. The method according to claim 12, characterized in that When the first support structure is held by the first AGV, the first support structure separates the first grasped mold in the first support structure from the first AGV.

17. The method according to claim 1, wherein The AGV and the workstation are automatically operated.

18. The method according to claim 1, wherein One of the workstations is a preheating station comprising a closable heated inner compartment, wherein the inner compartment is closed between two tasks of preheating the first and the second mould, thereby saving energy.

19. The method according to claim 1, wherein The workstations occur in an environment having a layout that includes station-free areas connecting the workstations and used by the AGVs to move between the workstations.

20. The method according to claim 1, wherein Also included is placing the first AGV in a charging state and cooling the first AGV during the charging state.

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