System and method for automated waste submersion device

Abstract

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

Description

Citation of relevant applications

[0001] This application claims the benefit and priority of U.S. Provisional Patent Application No. 63 / 597,430, filed November 9, 2023, entitled “Systems and methods for Automating Scrap Submergence Device,” the contents of which are hereby incorporated by reference in their entirety. Technical Field

[0002] This application relates generally to metallurgy, and more specifically to apparatus, systems and methods for furnaces, molten metal containment structures and waste immersion devices for mixing, conveying, handling and / or holding molten metal. Background Technology

[0003] Metals such as aluminum and aluminum alloys are frequently melted in metal furnaces. For example, aluminum and copper scrap, as well as pure metals, are often melted in reverberatory furnaces for final use or reuse by metal manufacturers. To produce high-quality products suitable for subsequent casting or other processing, it may be necessary to allow the molten material to flow within the furnace. In particular, stirring, circulating, and / or otherwise inducing movement of the molten metal can distribute the material within the furnace, help homogenize the temperature of the material, and / or provide improved melting of solid materials. Adding flux can further remove contaminants and oxides from the metal, thereby improving metal quality and metal recovery rates. Summary of the Invention

[0004] The embodiments covered by this patent are defined by the following claims, not by the content of this invention. The content of this invention is a high-level generalization of various embodiments and introduces some concepts that will be further described in the following detailed description section. The content of this invention is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used alone to define the scope of the claimed subject matter. This subject matter should be understood by referring to the appropriate portions of the entire specification of this patent, any or all of the drawings, and each claim.

[0005] According to some embodiments, the molten metal handling system includes a waste immersion device for mixing molten metal in a furnace and a waste immersion control system. The waste immersion control system includes one or more sensors for acquiring position information about the waste immersion device. The waste immersion control system further includes a controller that can receive data from the one or more sensors and determine the position of the waste immersion device within the furnace based on the data from the one or more sensors.

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

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

[0008] According to some embodiments, a method for controlling a waste immersion device in a molten metal processing system includes receiving information from one or more sensors regarding at least one processing parameter of the molten metal processing system, and determining a control response for the waste immersion device based on the information received from the one or more sensors. The method includes controlling the waste immersion device according to the determined control response.

[0009] The various embodiments described herein may include additional systems, methods, features, and advantages that are not necessarily explicitly disclosed herein, but will be apparent to those skilled in the art upon review of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages are included within this disclosure and protected by the appended claims. Attached Figure Description

[0010] This specification refers to the following figures, in which the same reference numerals are used in different figures to illustrate the same or similar parts.

[0011] Figure 1 It is a representation of a molten metal processing system with a waste immersion control system according to the implementation plan.

[0012] Figure 2 The implementation scheme is shown. Figure 1 A molten metal processing system.

[0013] Figure 3 It shows Figure 2It is part of a molten metal processing system.

[0014] Figure 4 It shows Figure 2 It is part of a molten metal processing system.

[0015] Figure 5 It shows Figure 2 Waste immersion device of molten metal processing system.

[0016] Figure 6 The use according to the implementation scheme is shown. Figure 1 The waste immersion system is used to control the process of the waste immersion device. Detailed Implementation

[0017] This document describes systems and methods for controlling a waste immersion device in a molten metal processing system. In some embodiments, the systems and methods described herein utilize a waste immersion control system, which may include one or more sensors and a controller communicatively coupled to the one or more sensors. In various embodiments, the one or more sensors may acquire information about at least one processing parameter of the molten metal processing system, and the controller may determine a control response to the waste immersion device based on data from the one or more sensors. Additionally, or alternatively, other control responses may include controlling other devices and / or components of the molten metal processing system and / or generating warnings and / or alarms. The at least one processing parameter may be various characteristics and / or parameters of the molten metal processing system, including but not limited to the characteristics of the metal processed by the molten metal processing system and / or the characteristics of the waste immersion device. As a non-limiting example, the at least one processing parameter may be the feed rate of metal into the metal receiving structure of the metal processing system, the type of material supplied to the metal receiving structure, the molten metal level within the metal receiving structure, the temperature of the molten metal, the size of the eddies in the molten metal, the size and / or characteristics of the scum balls in the molten metal, the vertical position of the waste immersion device, the horizontal position of the waste immersion device, the tilt angle of the waste immersion device, the rotational speed of the waste immersion device, the torque on the waste immersion device (measured directly or indirectly), the depth of the waste immersion device in the molten metal, combinations of these parameters, and / or any other processing parameters as needed. The processing parameters described herein may be directly measured or indirectly determined as needed. For example, the vertical position of the waste immersion device may be directly measured or determined as needed based on actuator coding and / or using various reference points. As another non-limiting example, the torque on the waste immersion device may be directly measured and / or indirectly determined based on the motor power, current, ampere rating, and / or as needed. In various embodiments, the control response may include maintaining the current operating state of the waste immersion apparatus and / or may include controlling, adjusting, and / or modifying one or more characteristics of the waste immersion apparatus. As a non-limiting example, the control response may include adjusting and / or controlling the rotational speed of the waste immersion apparatus, the tilt angle of the waste immersion apparatus, the vertical position of the waste immersion apparatus, the horizontal position of the waste immersion apparatus, the duration of vertical movement, the duration of horizontal movement, and / or the duration of rotation of the waste immersion apparatus.

[0018] In some embodiments, the systems and methods described herein determine the position of the waste immersion apparatus in both horizontal and vertical directions. In some embodiments, the systems and methods described herein can automatically position the waste immersion apparatus based on data from one or more sensors to provide the required metal melting, mixing, conveying, processing, and / or insulation within the metal containment structure. The systems and methods described herein can provide benefits such as improved molten metal circulation, improved homogenization of molten material, allowing for reduced power consumption, allowing for reduced salt consumption, increasing the lifespan of the waste immersion apparatus, and / or reducing gas consumption during processing. Various other benefits and advantages can be achieved using the systems and methods described herein, and these benefits and advantages should not be considered limiting.

[0019] Figures 1 to 5 An example of a system 100 for processing molten metal according to an embodiment is shown. System 100 can process various metals and / or other molten materials as needed, including but not limited to aluminum, aluminum alloys, steel, or other metals as required. In some examples, the molten metal may be aluminum or aluminum alloys of the 1xxx, 2xxx, 3xxx, 4xxx, 5xxx, 6xxx, 7xxx, and 8xxx series, and / or any other aluminum or aluminum alloy as required.

[0020] like Figures 1 to 5 As shown, system 100 typically includes a metal containment structure 102, a waste immersion device 104, and a waste immersion control system 116.

[0021] The metal containment structure 102 can be a variety of structures suitable for containing molten metal and / or for processing and / or handling molten metal. As a non-limiting example, the metal containment structure 102 can be a furnace 106, such as, but not limited to, a melting furnace or a holding furnace, and includes one or more heating elements for directing heat into the furnace 106. Figure 1 and Figure 2As shown, in some embodiments, the metal receiving structure 102 includes multiple chambers for receiving molten material, such as a main chamber 108 and side chambers 110. In this embodiment, the volume of the side chamber 110 may be smaller than the volume of the main chamber 108, but this is not necessary in other embodiments. In various embodiments, the side chamber 110 may be used to house the waste immersion device 104, thereby accommodating a location where flow or circulation occurs, as discussed in detail below. Alternatively, the side chamber 110 may be a location for introducing additional materials, such as scrap metal (e.g., used beverage cans or others), salt solvents, alloying elements, and / or other materials for processing and incorporating into the molten metal. In other embodiments, the metal receiving structure 102 may have any number of chambers for receiving molten metal as needed, including a single chamber, two chambers, three chambers, etc. In embodiments with multiple chambers (such as... Figure 1 and Figure 2 As shown), ports 111 and 113 allow molten material to flow between the chambers.

[0022] like Figure 5 As shown, the waste immersion apparatus 104 typically includes a shaft 122 and an impeller 124 with one or more blades 126. In some embodiments, the waste immersion apparatus 104 may optionally include a plate 128. In some embodiments, the waste immersion apparatus 104 may be similar to the waste immersion apparatus described in U.S. Patent Application No. 17 / 904,909, filed April 29, 2021, entitled “Scrapsubmergence Device and Relatively Processes,” the contents of which are hereby incorporated by reference in their entirety. The waste immersion apparatus 104 may be used in conjunction with a metal containment structure 102 for mixing, circulating, and / or otherwise moving molten metal within the metal containment structure 102 from a first location (e.g., a side well chamber 110) to a second location (e.g., a main chamber 108). Alternatively, a waste immersion device 104 may be provided for mixing and / or immersing waste materials (e.g., used beverage cans, metal fragments, etc.), salt fluxes, alloying elements, and / or other elements for processing and handling. In various embodiments, the waste immersion device 104 generates a downward vortex circulation of material from an upper region to a lower region, thereby mixing and immersing the material within the metal containment structure 102.

[0023] In various embodiments, the support structure 112 may support the waste immersion device 104 relative to the metal receiving structure 102. In some embodiments, an actuator 114 is provided for controlling the position and / or other operating characteristics of the waste immersion device 104 and / or the support structure 112. In some embodiments, the waste immersion device 104 and / or the support structure 112 is freely movable and / or adjustable. In other embodiments, the waste immersion device 104 and / or the support structure 112 may have one or more restrictions on movement. As a non-limiting example, the waste immersion device 104 and / or the support structure 112 may have a range of movement in the XY plane as needed using tracks, stops, and / or other features. As another non-limiting example, the waste immersion device 104 and / or the support structure 112 may include a pivot point with a defined range of pivoting movement (e.g., allowing the waste immersion device 104 to tilt or pivot). As another non-limiting example, the waste immersion device 104 and / or support structure 112 may include horizontally extending structures and / or vertically extending structures, each movable between a retracted position and an extended position. Various other features may be utilized to control the movement of the waste immersion device 104 and / or support structure 112 as needed. As discussed in detail below, in various embodiments, the waste immersion device 104 and / or associated components may be selectively controlled by the waste immersion control system 116.

[0024] like Figure 1 As shown, for example, a waste immersion control system 116 typically includes one or more sensors 118 and a controller 120. In various embodiments, the one or more sensors 118 may monitor or detect one or more processing parameters of the system 100, and the controller 120 may determine one or more control responses of the waste immersion device 104 based on information from the one or more sensors 118. Additionally, or alternatively, the controller 120 may determine one or more control responses for use with other equipment and / or for generating alerts and / or alarms to a user. Optionally, the controller 120 may control the waste immersion device 104 and / or other equipment based on the determined control responses.

[0025] Although Figure 1Three sensors 118A-C are shown, but in other embodiments, any number of sensors 118 may be used as needed. As a non-limiting example, in other embodiments, the waste immersion control system 116 may include one sensor 118, two sensors 118, three sensors 118, and / or more than three sensors 118. In embodiments with multiple sensors 118, the sensors 118 do not need to be the same type of sensor and / or do not need to detect the same processing parameters. As an example, and discussed in more detail below, sensor 118A may be a position sensor, sensor 118B may be a temperature sensor, and sensor 118C may be a flow sensor. Sensors 118 may be located at various locations and / or on various structures of the system 100 as needed. Figure 1 In the example, sensor 118A is located on waste immersion device 104, sensor 118B is located at a first position away from waste immersion device 104, and sensor 118C is located at a second position away from waste immersion device 104. However, the specific positions shown should not be considered as limitations.

[0026] One or more processing parameters detected by one or more sensors 118 may be various characteristics of the waste immersion device 104, the metal processed by the system 100, and / or other components of the system 100; therefore, the one or more sensors 118 may be various types of sensors as needed. As a non-limiting example, one or more processing parameters may be operating characteristics of the waste immersion device 104, such as, but not limited to, the horizontal position of the waste immersion device 104 (e.g., position in the X and / or Y directions), the vertical position of the waste immersion device 104 (e.g., position in the Z direction), the rotational speed of the waste immersion device 104, the tilt angle of the waste immersion device 104 (e.g., angle relative to the vertical axis), the direction of rotation of the waste immersion device 104, the depth of the waste immersion device 104 within the molten metal, the torque or other force (measured indirectly or directly) on the waste immersion device 104, combinations of these parameters, and / or other characteristics as required. As an additional, non-limiting example, one or more processing parameters may be characteristics of the metal processed by system 100, such as, but not limited to, the feed rate of the metal entering system 100, the type of material supplied to system 100, the level or depth of the molten metal within the metal containment structure 102, the temperature of the metal, the size of the eddies in the molten metal, the size of the scum balls in the metal, the metal flow rate, combinations of these parameters, and / or other characteristics as required. As a further, non-limiting example, one or more processing parameters may be characteristics of other equipment of system 100, such as, but not limited to, furnace temperature, furnace conditions (e.g., burner status, atmospheric composition within the metal containment structure 102, etc.), current furnace operation, combinations of these parameters, and / or other characteristics as required. Therefore, non-limiting examples of sensors 118 suitable for monitoring and / or detecting one or more processing parameters of system 100 include position sensors, optical sensors, laser sensors, temperature sensors, flow sensors, force sensors, vibration sensors, combinations of these sensors, or other devices or systems as required.

[0027] In some embodiments, one or more sensors 118 include at least a position sensor for detecting the position of the waste immersion device 104. In various embodiments, the position sensor can detect and / or acquire information related to the position of the waste immersion device 104 in the horizontal direction (e.g., the X and / or Y directions) and / or the vertical direction (e.g., the Z direction). The position sensor can use various technologies as needed to detect the position of the waste immersion device 104, including but not limited to laser, radar, ultrasonic, radio frequency, image or visual data, GPS, Wi-Fi, LiFi, ultra-wideband, Bluetooth®, cellular, encoder feedback, combinations of these technologies, and / or other technologies as needed. In various embodiments, the position sensor can directly measure the position of the waste immersion device 104, while in other embodiments, the information acquired by the position sensor can be used to determine the position of the waste immersion device 104.

[0028] Alternatively, one or more sensors 118 may include optical sensors, such as one or more cameras, adapted to capture one or more images of system 100. As a non-limiting example, the optical sensor may be a visible light camera, such as a grayscale, color, RGB, and / or other visible light camera. In some embodiments, the optical sensor may be a camera capable of observing light beyond the visible spectrum, such as an infrared, near-infrared, or ultraviolet camera. In some embodiments, the optical sensor may include a camera capable of recording distance or ranging information, such as a time-of-flight camera or a lidar (LIDAR) sensor. Such one or more time-of-flight or lidar sensors or cameras can be used to provide precise distance, size, shape, dimensions, and other important physical information about components in the field of view, as discussed in detail below. In some embodiments, the optical sensor may include a camera array, a wide-angle camera, a 360-degree camera, or other such image capture devices. The optical sensor may be a camera, a camera that captures still images, or a combination thereof. In some embodiments, by including a plurality of cameras, aspects of this disclosure can resist the failure of a single camera by switching to use another camera that has not failed as input. In some implementations, interpretive processing can be used to fill in gaps in image data caused by transmission loss, blind spots, or other occlusions to monitor aspects of the optical sensors in system 100 that are temporarily or permanently invisible. Any number of optical sensors can be used, and when multiple optical sensors are used, they do not need to be of the same type. As a non-limiting example, one optical sensor could be a visible light camera, another could be an infrared camera, and yet another could be a video camera.

[0029] One or more optical sensors may be positioned at different locations and / or in different orientations relative to system 100, such that each of the one or more optical sensors has a field of view of at least a portion of system 100. In this respect, the one or more optical sensors can observe and / or monitor portions of system 100 within the field of view. In some embodiments, one or more optical sensors are arranged to have a field of view of a specific component, device, or mechanism of system 100. In the embodiments shown and described herein, at least one optical sensor is arranged to have a field of view of at least a portion of waste immersion device 104 and / or molten metal in the vicinity of waste immersion device 104. However, in other embodiments, one or more optical sensors may be arranged as needed to have a field of view including other portions of system 100 and / or multiple components, devices, or mechanisms of system 100.

[0030] As mentioned earlier, other types of sensors 118 can be used, and the above examples should not be considered as limitations.

[0031] In addition to one or more sensors 118, as previously described, in various embodiments, the waste immersion control system 116 also includes a controller 120 communicatively coupled to one or more sensors 118. In some embodiments, the controller 120 may selectively control the waste immersion apparatus 104 based on information from one or more sensors 118.

[0032] Controller 120 may include one or more processing units and / or one or more memory devices. Processing units may be a variety of suitable processing devices or combinations thereof, including but not limited to one or more application-specific integrated circuits, digital signal processors, digital signal processing devices, programmable logic devices, field-programmable gate arrays, processors, controllers, microcontrollers, microprocessors, other electronic units, and / or combinations thereof. One or more memory devices may be any machine-readable medium accessible by a processor, including but not limited to any type of long-term, short-term, volatile, non-volatile, or other storage media, and are not limited to any particular type or number of memories, or the type of medium storing the memory. Furthermore, as disclosed herein, the terms “storage medium,” “storage device,” or “memory” may refer to one or more memories used for storing data, including read-only memory (ROM), random access memory (RAM), magnetic RAM, magnetic core memory, magnetic disk storage media, optical storage media, flash memory devices, and / or other machine-readable media used for storing information. The term “machine-readable medium” includes, but is not limited to, portable or fixed storage devices, optical storage devices, wireless channels, and / or various other storage media capable of storing instructions and / or data.

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

[0034] In some embodiments, controller 120 may receive information from one or more sensors 118 and may determine a control response to waste immersion apparatus 104 based on the information from the one or more sensors 118. As previously described, determining a control response may include maintaining current operating parameters or characteristics and / or controlling, modifying, and / or adjusting one or more operating parameters or characteristics. Optionally, controller 120 may implement a control response. Non-limiting examples of a control response may include adjusting and / or controlling the rotational speed of the waste immersion apparatus, the tilt angle of the waste immersion apparatus, the horizontal position of the waste immersion apparatus, the duration of vertical movement, the duration of horizontal movement, the duration of rotation, and / or the vertical position of the waste immersion apparatus. Optionally, a control response may include controlling other equipment and / or generating warnings and / or alarms. Feedback control of the waste immersion apparatus 104 by controller 120 based on information from one or more sensors 118 may allow for improved control of the mixing, conveying, handling, and / or holding of molten metal (e.g., real-time control), and / or may allow for additional control of the process by system 100.

[0035] Figure 6 An example of the process of controlling the waste immersion device 104 using the waste immersion control system 116 is shown.

[0036] In block 602, the method includes receiving data from one or more sensors 118 by controller 120 regarding one or more processing parameters of system 100. In some embodiments, block 602 may include receiving information from one or more sensors 118 regarding operating characteristics of the waste immersion device 104, such as, but not limited to, the horizontal position of the waste immersion device 104, the vertical position of the waste immersion device 104, the rotational speed of the waste immersion device 104, the tilt angle of the waste immersion device 104, the torque or force acting on the waste immersion device 104, the depth of the waste immersion device 104 in molten metal, combinations of this information, and / or other characteristics as needed. As previously stated, such operating characteristics of the waste immersion device 104 may be measured directly and / or indirectly as needed. Alternatively, block 602 may include receiving information about the metal entering the system 100, such as, but not limited to, the feed rate of the metal into the system 100, the type of material supplied to the system 100, the metal level within the metal containment structure 102, the flow rate of the molten metal, the size of the eddies in the molten metal, the size of the scum balls, the temperature of the molten metal, combinations of this information, and / or other characteristics as needed. Alternatively, block 602 may include receiving information about other equipment and devices of the system 100, such as, but not limited to, the operating stage of the process, the status of the burner, the temperature of the furnace, the atmospheric conditions within the furnace, combinations of this information, and / or other characteristics as needed.

[0037] In some implementations, the data received in block 602 may be the processing parameter data itself. As a non-limiting example, if sensor 118 is a temperature sensor and the processing parameter is the temperature of the molten metal, then the data received in block 602 may be the temperature measured by the temperature sensor. Alternatively, controller 120 may determine the processing parameters based on the data received in block 602.

[0038] As a non-limiting example, sensor 118 could be a camera, and the processing parameter could be the position of the waste immersion device 104. In this example, in block 602, the data from sensor 118 could be visual data, and based on the visual data, controller 120 could use various techniques as needed to determine the position of the waste immersion device 104. As an example, controller 120 could determine the position of the waste immersion device 104 based on a reference frame (e.g., the furnace itself), real or virtual reference points on the waste immersion device 104 and / or other structures, and / or other techniques or combinations thereof as needed.

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

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

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

[0042] Block 602 may include various other determinations made by controller 120 to receive and / or acquire specific processing parameters as needed.

[0043] In block 604, the method includes determining whether a control response of the waste immersion device 104 needs to be controlled based on processing parameters received and / or determined in block 602. In various embodiments, block 604 may include comparing the processing parameters received and / or determined in block 602 with desired values ​​of one or more processing parameters of system 100. As a non-limiting example, block 602 may include: comparing a determined melting rate with a desired melting rate; comparing a determined position of the waste immersion device 104 with a desired position of the waste immersion device 104; comparing a determined eddy size with a desired eddy size; comparing a determined metal depth and a determined speed of the waste immersion device 104 with a desired rotational speed at that metal depth; combinations of the foregoing; and / or other operations as needed. Such desired values ​​may be thresholds or expected values, mass, etc., and may be input by a user, determined by controller 120, and / or determined as needed.

[0044] If no control response is required (e.g., controller 120 determines that the current operating state should be maintained based on the received processing parameters within a threshold or tolerance of the expected value), the process can return to block 602.

[0045] If control of the response is required (e.g., based on received processing parameters outside a threshold or tolerance), in block 606, the method includes determining the control response of the waste immersion device 104. In some embodiments, block 606 includes determining control, regulation, and / or modification of one or more of the following: the rotational speed of the waste immersion device, the tilt angle of the waste immersion device, the vertical position of the waste immersion device, the horizontal position of the waste immersion device, the duration of vertical movement of the waste immersion device, the duration of horizontal movement, and / or the duration of rotation. As a non-limiting example, based on a comparison of the determined position of the waste immersion device 104 with a desired position within the metal containment structure 102 to achieve a desired melting rate, block 606 may include determining changes in the horizontal and / or vertical position of the waste immersion device 104.

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

[0047] In block 610, the method includes determining whether system 100 is still in use in order to determine whether the method should continue or end.

[0048] Other examples of control are discussed below, but these examples should not be considered limiting. Various other control responses of the waste immersion device 104 can be utilized by the waste immersion control system 116 based on measured and / or determined processing parameters. Furthermore, various other processes can utilize measured processing parameters as needed.

[0049] In some implementations, one or more operating characteristics of the waste immersion device 104 (e.g., horizontal position, vertical position, speed, tilt angle, etc.) can be automatically controlled by the controller 120 based on one or more characteristics of the feed provided to the system (e.g., feed rate, material type, etc.).

[0050] In various implementations, one or more operating characteristics of the waste immersion device 104 can be automatically controlled by the controller 120 based on the changing metal liquid level.

[0051] In some embodiments, one or more operating characteristics of the waste immersion apparatus 104 can be automatically controlled by the controller 120 based on varying furnace temperature and / or varying furnace conditions.

[0052] In some implementations, one or more operating characteristics of the waste immersion device 104 can be automatically controlled by the controller 120 based on the current furnace operation, and the waste immersion device 104 can be positioned in an ideal location within the furnace.

[0053] In some embodiments, one or more operating characteristics of the waste immersion device 104 may be automatically controlled by the controller 120 based on measured torque and / or current of the waste immersion device 104 to improve the service life of the waste immersion device 104. Alternatively, the measured torque and / or current may be monitored to detect or estimate events such as motor failure, equipment damage, and / or other events as needed.

[0054] In various embodiments, one or more operating characteristics of the waste immersion device 104 can be automatically controlled by the controller 120 based on measured temperature readings. As a non-limiting example, the position of the waste immersion device 104 within the side well chamber 110 can be controlled based on temperature readings from multiple locations (e.g., at ports 111, 113, and the main chamber 108). For example, the waste immersion device 104 can continuously move a predetermined distance toward a predetermined location and remain at the predetermined location for a period of time until the temperature gradient is controlled (e.g., the temperature difference at the location is 10 degrees or less).

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

[0056] In some embodiments, the waste immersion device 104 may be controlled by a controller 120 to perform various other operations within the system 100. As a non-limiting example, the waste immersion device 104 may be controlled to perform refractory wear checks and / or detection. In this example, the waste immersion device 104 may extend vertically (e.g., lower, optionally from a known and / or starting position) until a torque limit is reached in the vertical direction (directly or indirectly determined), meaning the bottom surface of the side well chamber 110 has been reached. Therefore, the vertical distance traveled by the waste immersion device 104 to reach the torque limit can be used to determine the current height of the refractory and / or wear on the refractory. As an example, a user can provide the baseline height of the refractory by correlating a baseline height with a baseline travel distance. In this example, the measured travel distance can be compared to the baseline travel distance to determine the change in the height of the refractory material. As another non-limiting example, the baseline height can be determined directly or indirectly by the waste immersion control system 116 (e.g., during the extension of the initial installation of the waste immersion device 104 and / or before use, based on input data, etc.), and the determined height of the refractory material can be compared with the baseline height. In some embodiments, the waste immersion control system 116 can perform refractory material wear checks and / or detection at multiple locations (e.g., by changing the horizontal position of the waste immersion device 104), and optionally can generate a distribution map or marker of refractory material wear or height changes. Various other processes can be utilized to determine the current height and / or wear of the refractory material.

[0057] As previously mentioned, various other control responses of the waste immersion apparatus 104 can be utilized by the waste immersion control system 116 based on measured and / or determined processing parameters.

[0058] The following provides a collection of exemplary embodiments, including at least some embodiments that are explicitly listed as “examples” providing further descriptions of various exemplary embodiments in accordance with the concepts described herein. These examples are not intended to be mutually exclusive, exhaustive, or limiting; and this disclosure is not limited to these exemplary examples, but covers all possible modifications and variations within the scope of the proposed claims and their equivalents.

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

[0060] Example 2. A molten metal processing system as described in any of the foregoing or subsequent examples or combinations thereof, wherein one or more sensors are located on the waste immersion device.

[0061] Example 3. A molten metal processing system as illustrated in any of the foregoing or subsequent examples or combinations thereof, wherein one or more sensors are located remotely from the waste immersion device.

[0062] Example 4. A molten metal processing system as illustrated in any of the foregoing or subsequent examples or combinations thereof, wherein the one or more sensors are optical sensors.

[0063] Example 5. A molten metal processing system as described in any of the foregoing or subsequent examples or combinations thereof, wherein the controller is configured to determine the position of the waste immersion device in at least two directions.

[0064] Example 6. A molten metal processing system as described in any of the foregoing or subsequent examples or combinations thereof, wherein the controller is configured to determine the position of the waste immersion device at least in the vertical direction.

[0065] Example 7. A molten metal processing system as described in any of the foregoing or subsequent examples or combinations thereof, wherein the controller is further configured to compare a determined position with a desired position and to control the position of the waste immersion device based on the difference between the determined position and the desired position.

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

[0067] Example 9. A molten metal processing system as described in any of the foregoing or subsequent examples or combinations thereof, wherein the at least one processing parameter is at least one characteristic of the metal being processed by the furnace.

[0068] Example 10. A molten metal processing system as described in any of the foregoing or subsequent examples or combinations thereof, wherein the at least one characteristic of the molten metal includes at least one of the following: the feed rate of the metal into the furnace, the type of material supplied to the furnace, the molten metal level in the furnace, the temperature of the molten metal, the size of the eddies in the molten metal, or the size of the scum balls in the molten metal.

[0069] Example 11. A molten metal processing system as described in any of the foregoing or subsequent examples or combinations thereof, wherein the at least one processing parameter is at least one characteristic of the waste immersion apparatus.

[0070] Example 12. A molten metal processing system as described in any of the foregoing or subsequent examples or combinations thereof, wherein the at least one characteristic of the waste immersion device includes at least one of the following: the vertical position of the waste immersion device, the horizontal position of the waste immersion device, the tilt angle of the waste immersion device, the rotational speed of the waste immersion device, the torque on the waste immersion device, or the depth of the waste immersion device in the molten metal.

[0071] Example 13. A molten metal processing system as described in any of the foregoing or subsequent examples or combinations thereof, wherein the controller is configured to determine the control response by determining an adjustment or change to at least one of the following: the rotational speed of the waste immersion device, the tilt angle of the waste immersion device, the vertical position of the waste immersion device, the horizontal position of the waste immersion device, the duration of vertical movement, the duration of horizontal movement, or the duration of rotation.

[0072] Example 14. A molten metal processing system as described in any of the foregoing or subsequent examples or combinations thereof, wherein the controller is configured to perform a refractory wear check on the refractory material of the furnace by controlling the vertical position of the waste immersion device up to the torque limit.

[0073] Example 15. A waste immersion control system comprising: at least one camera having a field of view of at least a portion of a furnace and a waste immersion apparatus; a controller communicatively coupled to the at least one camera, the controller being configured to: receive visual data from the at least one camera; identify at least one of a characteristic of the waste immersion apparatus or a characteristic of molten metal in a region near the waste immersion apparatus; compare the identified characteristic of the waste immersion apparatus or the characteristic of the molten metal with a desired characteristic; and implement a control response through the waste immersion apparatus in response to a difference between the identified characteristic of the waste immersion apparatus or the characteristic of the molten metal and the desired characteristic.

[0074] Example 16. A waste immersion control system as described in any of the foregoing or subsequent examples or combinations thereof, wherein the control response includes control over the following: the rotational speed of the waste immersion device, the tilt angle of the waste immersion device, the vertical position of the waste immersion device, the horizontal position of the waste immersion device, the duration of vertical movement, the duration of horizontal movement, or the duration of rotation.

[0075] Example 17. A waste immersion control system as described in any of the foregoing or subsequent examples or combinations thereof, wherein the control response includes activating an alarm.

[0076] Example 18. A method for a waste immersion apparatus for a molten metal processing system, the method comprising: receiving information from one or more sensors regarding at least one processing parameter of the molten metal processing system by a controller; determining a control response for the waste immersion apparatus based on the information received from the one or more sensors; and controlling the waste immersion apparatus according to the determined control response.

[0077] Example 19. The method as described in any of the foregoing or subsequent examples or combinations thereof, wherein the at least one processing parameter is at least one characteristic of the metal being processed by the molten metal processing system, and wherein the at least one characteristic of the molten metal includes at least one of the following: the feed rate of the metal into the furnace, the type of material supplied to the furnace, the molten metal level in the furnace, the temperature of the molten metal, the size of the eddies in the molten metal, or the size of the scum balls in the molten metal.

[0078] Example 20. The method as described in any of the foregoing or subsequent examples or combinations thereof, wherein the at least one processing parameter is at least one characteristic of the waste immersion apparatus, and wherein the at least one characteristic of the waste immersion apparatus includes at least one of the following: the vertical position of the waste immersion apparatus, the horizontal position of the waste immersion apparatus, the tilt angle of the waste immersion apparatus, the rotational speed of the waste immersion apparatus, the torque on the waste immersion apparatus, or the depth of the waste immersion apparatus in the molten metal.

[0079] Example 21. The method as described in any of the foregoing or subsequent examples or combinations thereof, wherein controlling the waste immersion device includes controlling at least one of the following: the rotational speed of the waste immersion device, the tilt angle of the waste immersion device, the vertical position of the waste immersion device, or the horizontal position of the waste immersion device.

[0080] Example 22. A method for controlling a waste immersion device in a molten metal processing system, the method comprising: lowering the waste immersion device from a starting position until a torque limit is reached; determining the vertical distance traveled by the waste immersion device from the starting position until the torque limit is reached; and determining the current height of the refractory material of the molten metal processing system based on the determined vertical distance traveled.

[0081] Example 23. The method as described in any of the foregoing or subsequent examples or combinations thereof, wherein the torque limit is measured directly or indirectly.

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

[0083] In this specification, references are made to alloys identified by AA numbers and other relevant designations such as “Series” or “5xxx”. For information on the most commonly used numerical designation systems for naming and identifying aluminum and its alloys, see the Aluminum Association’s “International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys” or “Registration Record of Aluminum Association Alloy Designations and Chemical Composition Limits for Aluminum Alloys in the Form of Castings and Ingots”.

[0084] All ranges disclosed herein should be understood to encompass any and all subranges to which they are included. For example, the specified range “1 to 10” should be considered to include any and all subranges between the minimum value of 1 and the maximum value of 10 (and including end values); that is, all subranges begin with a minimum value of 1 or a number greater than 1, such as 1 to 6.1, and end with a maximum value of 10 or a number less than 10, such as 5.5 to 10.

[0085] As used herein, unless the context clearly indicates otherwise, “an,” “a,” and “the” refer to both singular and plural references.

[0086] The elements included in the illustrations herein may not be drawn to scale. For example, drawings depicting waste immersion apparatus and / or furnaces may include exaggerated features for illustrative purposes.

[0087] The subject matter of embodiments of this disclosure is specifically described herein to satisfy statutory requirements, but such description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in combination with other existing or future technologies. This description should not be construed as implying any particular order or arrangement of the various steps or elements, except where the order or arrangement of the individual steps of an element is clearly described. Directional references such as “up,” “down,” “top,” “bottom,” “left,” “right,” “vertical,” “horizontal,” “lateral,” “longitudinal,” “front,” and “rear” are intended to refer to the orientation shown and described in one or more of the accompanying drawings to which the component and orientation are referenced.

[0088] The terms “comprising,” “having,” “including,” and “containing” should be interpreted as open-ended terms (i.e., meaning “including but not limited to”) unless otherwise noted. All methods described herein may be performed in any suitable order unless otherwise specified herein or otherwise clearly contradicted by the context. Any and all examples or exemplary language (e.g., “such as”) provided herein are intended only to better illustrate embodiments of the invention and, unless otherwise required, do not limit the scope of the invention. The language in this specification should not be construed as indicating any non-claimed element as necessary for practicing the invention.

[0089] The foregoing aspects are merely possible examples of embodiments, set forth only for the purpose of clearly understanding the principles of this disclosure. Many changes and modifications may be made to the embodiments described above without departing substantially from the spirit and principles of this disclosure. All such modifications and changes are intended to be included within the scope of this disclosure, and all possible claims relating to aspects or combinations of elements or steps are intended to be supported by this disclosure. Furthermore, although specific terminology is used herein and in the appended claims, such specific terminology is used in a general and descriptive sense only and is not intended to limit the described embodiments or the purpose of the appended claims.

Claims

1. A molten metal processing system, comprising: Waste immersion device, used for mixing molten metal in a furnace; as well as The waste immersion control system includes: One or more sensors are configured to acquire location information about the waste immersion device; as well as A controller communicatively coupled to the one or more sensors, wherein the controller is configured to receive data from the one or more sensors and determine the position of the waste immersion device within the furnace based on the data from the one or more sensors.

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

3. The molten metal processing system of claim 1, wherein the one or more sensors are located remotely from the waste immersion device.

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

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

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

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

8. A molten metal processing system, comprising: Waste immersion device, used for mixing molten metal in a furnace; as well as The waste immersion control system includes: One or more sensors are configured to acquire information about at least one processing parameter of the molten metal processing system; as well as A controller communicatively coupled to the one or more sensors, wherein the controller is configured to receive acquired information from the one or more sensors and determine a control response for the waste immersion apparatus based on the acquired information from the one or more sensors.

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

10. The molten metal processing system of claim 9, wherein the at least one characteristic of the molten metal includes at least one of the following: the feed rate of metal into the furnace, the type of material supplied to the furnace, the molten metal level in the furnace, the temperature of the molten metal, the size of the eddies in the molten metal, or the size of the scum balls in the molten metal.

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

12. The molten metal processing system of claim 11, wherein the at least one characteristic of the waste immersion device includes at least one of the following: the vertical position of the waste immersion device, the horizontal position of the waste immersion device, the tilt angle of the waste immersion device, the rotational speed of the waste immersion device, the torque on the waste immersion device, or the depth of the waste immersion device in the molten metal.

13. The molten metal processing system of claim 8, wherein the controller is configured to determine the control response by determining an adjustment or change to at least one of the following: the rotational speed of the waste immersion device, the tilt angle of the waste immersion device, the vertical position of the waste immersion device, the horizontal position of the waste immersion device, the duration of vertical movement, the duration of horizontal movement, or the duration of rotation.

14. The molten metal processing system of claim 8, wherein the controller is configured to perform a refractory wear check on the refractory material of the furnace by controlling the vertical position of the waste immersion device up to the torque limit.

15. A waste immersion control system, comprising: At least one camera, the at least one camera having a field of view of at least a portion of the furnace and waste immersion device; A controller, communicatively coupled to the at least one camera, is configured to: Receive visual data from the at least one camera; The characteristics of the waste immersion device or the characteristics of the molten metal in the vicinity of the waste immersion device are identified by at least one of the following: The identified characteristics of the waste immersion device or the characteristics of the molten metal are compared with the desired characteristics; and A control response is implemented through the waste immersion device in response to the difference between the identified characteristics or the characteristics of the molten metal and the desired characteristics.

16. The waste immersion control system of claim 15, wherein the control response includes control over the following: the rotational speed of the waste immersion device, the tilt angle of the waste immersion device, the vertical position of the waste immersion device, the horizontal position of the waste immersion device, the duration of vertical movement of the waste immersion device, the duration of horizontal movement of the waste immersion device, or the duration of rotation of the waste immersion device.

17. A method for controlling a waste immersion apparatus in a molten metal processing system, the method comprising: The controller receives information from one or more sensors regarding at least one processing parameter of the molten metal processing system; The controller determines the control response to the waste immersion device based on information received from the one or more sensors; as well as The waste immersion device is controlled according to a determined control response.

18. The method of claim 17, wherein the at least one processing parameter is at least one characteristic of the metal being processed by the molten metal processing system, and wherein the at least one characteristic of the molten metal includes at least one of the following: the feed rate of the metal into the furnace, the type of material supplied to the furnace, the molten metal level in the furnace, the temperature of the molten metal, the size of the eddies in the molten metal, or the size of the scum balls in the molten metal.

19. The method of claim 17, wherein the at least one processing parameter is at least one characteristic of the waste immersion device, and wherein the at least one characteristic of the waste immersion device includes at least one of the following: the vertical position of the waste immersion device, the horizontal position of the waste immersion device, the tilt angle of the waste immersion device, the rotational speed of the waste immersion device, the torque on the waste immersion device, or the depth of the waste immersion device in the molten metal.

20. The method of claim 17, wherein controlling the waste immersion device includes controlling at least one of the following: the rotational speed of the waste immersion device, the tilt angle of the waste immersion device, the vertical position of the waste immersion device, or the horizontal position of the waste immersion device.

21. A method for controlling a waste immersion device in a molten metal processing system, the method comprising: Lower the waste immersion device from the starting position until it reaches the torque limit; Determine the vertical distance traveled by the waste immersion device from the starting position until the torque limit is reached; as well as The current height of the refractory material in the molten metal processing system is determined based on the determined vertical distance traveled.

22. The method of claim 21, wherein the torque limit is measured directly or indirectly.

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