Waste sand management system and waste sand management method

Abstract

To provide a waste sand management system and a waste sand management method, capable of tracking manufacturing steps for recycled sand.SOLUTION: A waste sand management system includes a removal device that removes contained metal from a predetermined amount of waste sand, an inspection device that inspects the waste sand from which the contained metal is partially removed by the removal device for whether or not to contain a harmful metal component, a first measuring device that measures the waste sand inspected by the inspection device, and a storage unit that stores a set of an amount of the waste sand measured by the first measuring device and an inspection result by the inspection device.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a waste sand management system and a waste sand management method. [Background technology]

[0002] Molten metal is cast using molds made of solidified sand such as silica sand. When these molds are disassembled, waste sand (also called waste foundry sand) containing metal and other foreign matter is generated. Currently, a method is known in which this waste sand is collected and recycled to produce recycled sand (also called recycled foundry sand), which can then be reused as mold material (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent Publication No. 2021-102215 Summary of the Invention [Problem to be solved by the invention]

[0004] There is a problem in that it is not possible to track whether the recycled sand produced has been properly inspected.

[0005] An object of the present invention is to provide a waste sand management system and a waste sand management method that can track the manufacturing process of recycled sand. [Means for solving the problem]

[0006] A waste sand management system according to one aspect of the present invention is characterized by having a removal device that removes contained metals from a predetermined amount of waste sand, an inspection device that inspects the waste sand from which some of the contained metals have been removed by the removal device to determine whether it contains harmful metal components, a first measuring device that measures the waste sand inspected by the inspection device, and a memory unit that stores the amount of waste sand measured by the first measuring device and the inspection results from the inspection device in pairs.

[0007] In one aspect of the waste sand management system of the present invention, it is preferable that the system further includes a second measuring device that measures a predetermined amount of waste sand introduced into the removal device, and that the removal device, inspection device, and first measuring device remove, inspect, and measure the predetermined amount of waste sand measured by the second measuring device as a processing unit.

[0008] In a waste sand management system according to one aspect of the present invention, the waste sand is tailings, and the removal device preferably includes a magnetic material removal unit that removes magnetic materials including iron lumps and iron sand, and / or a non-magnetic material removal unit that removes non-magnetic materials including aluminum, copper, brass, and magnesium.

[0009] In a waste sand management system according to one aspect of the present invention, the inspection device preferably includes an X-ray irradiation unit that irradiates X-rays onto the waste sand, a detection unit that detects X-ray photons emitted from the waste sand irradiated with X-rays by the X-ray irradiation unit, and a determination unit that determines whether the waste sand contains harmful metal components based on the detection results of the X-ray photons by the detection unit.

[0010] In a waste sand management system according to one aspect of the present invention, it is preferable that the specified amount is the amount that can be loaded onto one truck, the amount that can fit into one flexi-bag package, the amount that can be loaded into one iron box, the amount that can be loaded into one container vehicle equipped with a detachable device, or the amount that can be loaded into one powder and granular material transport vehicle.

[0011] A waste sand management method according to one aspect of the present invention is characterized in that it removes contained metals from a predetermined amount of waste sand using a removal device, inspects the waste sand from which some of the contained metals have been removed using an inspection device to determine whether it contains harmful metal components, measures the inspected waste sand using a measuring device, and stores the measured amount of waste sand and the inspection results in a memory unit as a pair. [Effects of the Invention]

[0012] According to the present invention, the waste sand management system and waste sand management method can track the manufacturing process of recycled sand. [Brief explanation of the drawings]

[0013] [Figure 1] FIG. 1 is a diagram illustrating an example of a schematic configuration of a waste sand management system. [Figure 2] FIG. 2 is a block diagram showing the configuration of a removal device. [Figure 3] FIG. 2 is a block diagram showing the configuration of an inspection device. [Figure 4] FIG. 2 is a block diagram showing the configuration of a management device. [Figure 5] 1 is a flowchart showing a manufacturing process of recycled sand in a waste sand management system. [Figure 6] This is a database that stores the execution time of each process and additional information. DETAILED DESCRIPTION OF THE INVENTION

[0014] Various embodiments of the present invention will be described below with reference to the drawings. Please note that the technical scope of the present invention is not limited to these embodiments, but extends to the inventions described in the claims and their equivalents.

[0015] FIG. 1 is a diagram showing an example of the schematic configuration of a waste sand management system 1. The waste sand management system 1 is a system for producing recycled sand 200 (also called foundry recycled sand) from waste sand 100 (also called foundry waste sand), which is slag, and for managing the quality of the produced recycled sand 200. For ease of explanation, the sand produced by this waste sand management system 1 is called recycled sand 200. However, sand produced by transporting the sand produced by the waste sand management system 1 to another location and further processing the transported sand may also be called recycled sand 200. The waste sand management system 1 is configured to include a pre-inspection measuring device 2, a belt conveyor 3, a removal device 4, an inspection device 5, a post-inspection measuring device 6, a confirmation device 7, and a management device 8.

[0016] The pre-inspection measuring device 2 measures a predetermined amount of waste sand 100 to be introduced into the removal device 4. After measuring the predetermined amount of waste sand 100, the pre-inspection measuring device 2 puts this waste sand 100 onto the belt conveyor 3. Here, the removal device 4, inspection device 5, and post-inspection measuring device 6 remove, inspect, and measure the predetermined amount of waste sand 100 measured by the pre-inspection measuring device 2 as a processing unit. The predetermined amount is the amount that can be loaded onto one container vehicle 300 with a detachable device (also called a hook roll (registered trademark)). The pre-inspection measuring device 2 transmits at least the time when the predetermined amount of waste sand 100 was measured and measurement information regarding the waste sand 100 to the management device 8.

[0017] The belt conveyor 3 transports the predetermined amount of waste sand 100 measured by the pre-inspection measuring device 2 to the post-inspection measuring device 6. A removal device 4 and an inspection device 5 are provided on the transport path of the waste sand 100 by the belt conveyor 3.

[0018] The removal device 4 removes contained metals from a predetermined amount of waste sand 100 transported by the belt conveyor 3. The removal device 4 transmits at least the time when contained metals have been removed from the predetermined amount of waste sand 100 to the management device 8. The timing at which the operation of the removal device 4 starts may be triggered by the detection of waste sand 100 on the belt conveyor 3 by an object detection sensor 45 (described later), the receipt of a start signal from the management device 8, or a user input from the operation unit 43 (described later).

[0019] The inspection device 5 is installed downstream of the removal device 4 on the transport path of the waste sand 100 by the belt conveyor 3. The inspection device 5 inspects the waste sand 100 from which some of the contained metals have been removed by the removal device 4 to determine whether it contains hazardous metal components. Based on the inspection results, the inspection device 5 determines whether the waste sand 100 from which some of the contained metals have been removed is recycled sand 200 that can be reused as a mold material, or waste sand 400 that cannot be used as a mold material. The inspection device 5 transmits at least the time of inspection and the inspection results to the management device 8. The start timing of the removal device 4 may be triggered by detection of the waste sand 100 on the belt conveyor 3 by an object detection sensor 55 (described later), receipt of a start signal from the management device 8, or user input from the operation unit 53 (described later).

[0020] The post-inspection measuring device 6 measures the waste sand 100 inspected by the inspection device 5. After measuring the waste sand 100, the post-inspection measuring device 6 puts the waste sand 100 into a container 500. The post-inspection measuring device 6 transmits at least the time when the waste sand 100 inspected by the inspection device 5 was measured and measurement information regarding the waste sand 100 to the management device 8. An identification number 600 is assigned to the container 500.

[0021] The confirmation device 7 is a camera that photographs the container 500 containing the waste sand 100 measured by the post-inspection measuring device 6 and generates a confirmation image. The confirmation device 7 transmits at least the time the container 500 was photographed and the confirmation image to the management device 8. The confirmation image generated by the confirmation device 7 includes a pixel area corresponding to the identification number 600 of the container 500. After the confirmation device 7 photographs the container 500 containing the recycled sand 200, it is loaded onto a container vehicle 300 with a detachable device and transported to a factory or the like for creating molds using the recycled sand 200 as a mold material. After the confirmation device 7 photographs the container 500 containing the waste sand 400, it is stored on the premises. The waste sand 400 is later treated as industrial waste. The confirmation device 7 is not limited to a camera, as long as it can confirm the identification number 600 of the container 500 and the inspection results of the waste sand 100 placed in the container 500 in association with each other in a database described below. For example, the confirmation device 7 may be a code reader or the like that reads the identification number 600 of the container 500 from an information holder (one-dimensional code, two-dimensional code, etc.) attached to the container 500.

[0022] The management device 8 manages various information and data transmitted from each component included in the waste sand management system 1. For example, the management device 8 includes a memory unit 81 that stores the amount of waste sand 100 measured by the post-inspection measuring device 6 and the inspection results by the inspection device 5 as a pair.

[0023] Fig. 2 is a block diagram showing the configuration of the removal device 4. As shown in Fig. 2, the removal device 4 includes a magnetic material removal unit 41, a non-magnetic material removal unit 42, an operation unit 43, a processing unit 44, and the like.

[0024] The magnetic material removal unit 41 removes magnetic materials including iron lumps and iron sand. For example, the magnetic material removal unit 41 is equipped with a magnetic separator that generates a magnetic field with a magnetic flux density of approximately 1500 G to 3000 G, and uses this magnetic separator to remove large magnetic materials such as iron lumps and slightly smaller magnetic materials such as iron sand from the waste sand 100 transported by the belt conveyor 3.

[0025] The non-magnetic material removal unit 42 removes non-magnetic materials, including aluminum, copper, brass, and magnesium. For example, the non-magnetic material removal unit 42 generates a magnetic field by rotating a roll-type magnetic pole rotor incorporating a permanent magnet of approximately 3,000 to 10,000 G at 1,800 to 2,500 rpm. This magnetic field generates eddy currents in the non-magnetic metals contained in the waste sand 100, such as aluminum, copper, brass, and magnesium. Furthermore, the non-magnetic material removal unit 42 utilizes the repulsive force due to the electromagnetic force generated between the eddy currents and the magnetic field of the magnetic pole rotor to send non-magnetic materials that generate eddy currents to the left and right of the belt conveyor 3, and separates non-magnetic materials that do not generate eddy currents (i.e., waste sand 100 from which contained metals have been removed).

[0026] This allows the removal device 4 to remove magnetic materials including iron lumps and iron sand, and non-magnetic materials including aluminum, copper, brass, and magnesium from the waste sand 100. The removal device 4 shown in Fig. 2 includes both a magnetic material removal unit 41 and a non-magnetic material removal unit 42, but may include either the magnetic material removal unit 41 or the non-magnetic material removal unit 42 as necessary.

[0027] The operation unit 43 accepts input operations by the user to the removal device 4. The operation unit 43 includes, for example, a keypad or a keyboard. The operation unit 43 may include a touch panel integrated with the display unit. The operation unit 43 generates a signal according to the input operation by the user and supplies the signal to the processing unit 44.

[0028] The processing unit 44 is configured to include one or more processors and their peripheral circuits that comprehensively control the operation of the removal device 4. The processing unit 44 includes, for example, a CPU (Central Processing Unit). The processing unit 44 controls the operation of each component and executes various processes so that various processes of the removal device 4 are automatically executed in the appropriate order, triggered by the detection of waste sand 100 on the belt conveyor 3 by the object detection sensor 45 or the reception of a start signal from the management device 8. The processing unit 44 may also control the operation of each component and execute various processes based on input from the operation unit 43. The processing unit 44 may control the operation of each of the magnetic material removal unit 41 and the non-magnetic material removal unit 42, or may control the operation of only the magnetic material removal unit 41 or only the non-magnetic material removal unit 42.

[0029] Fig. 3 is a block diagram showing the configuration of the inspection device 5. This inspection device 5 is an X-ray fluorescence analysis device that uses X-ray fluorescence analysis. As shown in Fig. 3, the inspection device 5 is configured to include an X-ray irradiation unit 51, a detection unit 52, an operation unit 53, and a processing unit 54.

[0030] The X-ray irradiation unit 51 irradiates the waste sand 100 with X-rays. The X-ray irradiation unit 51 is configured to include an X-ray tube that generates X-rays, a high-voltage generation unit that generates a high voltage to be applied to the X-ray tube, and a cooling mechanism for dissipating heat generated by the X-ray tube and the high-voltage generation unit. These components are housed in a housing. The X-ray irradiation unit 51 irradiates the waste sand 100 with X-rays, for example, by setting the tube voltage to 40 kV and the tube current to 95 mA.

[0031] The detection unit 52 detects X-ray photons (fluorescent X-rays) emitted from the waste sand 100 irradiated with X-rays by the X-ray irradiation unit 51. The detection unit 52 is an energy dispersive X-ray detector such as a semiconductor detector or a proportional counter, and generates an electric charge proportional to the energy of the incident X-ray photons. The detection unit 52 converts this electric charge into a voltage signal proportional to the amount of electric charge, and further A / D converts the voltage signal to output it as a digital value. The detection unit 52 may also be a wavelength dispersive X-ray detector.

[0032] The operation unit 53 accepts input operations by the user to the inspection device 5. The operation unit 53 includes, for example, a keypad or a keyboard. The operation unit 53 may include a touch panel integrated with the display unit. The operation unit 53 generates a signal according to the input operation by the user and supplies the signal to the processing unit 54.

[0033] The processing unit 54 is configured to include one or more processors and their peripheral circuits that comprehensively control the operation of the inspection device 5. The processing unit 54 includes, for example, a CPU. The processing unit 54 is triggered by the detection of waste sand 100 on the belt conveyor 3 by the object detection sensor 55 or the reception of a start signal from the management device 8, and automatically controls the operation of each component and executes various processes so that the various processes of the inspection device 5 are automatically executed in the appropriate order. Note that the processing unit 54 may also control the operation of each component and execute various processes so that the various processes of the inspection device 5 are executed in the appropriate order based on input from the operation unit 53.

[0034] The processing unit 54 includes a determination unit 541 as a functional block. The determination unit 541 determines whether the waste sand 100 contains hazardous metal components based on the detection result of the X-ray photons by the detection unit 52. For example, the processing unit 54 obtains the height of a voltage pulse from the voltage signal generated by the detection unit 52 to generate an energy spectrum. The processing unit 54 discriminates the X-ray photon signals output from the detection unit 52 by energy, counts the number of incidents for each energy, and obtains an energy spectrum as X-ray intensity. Furthermore, the processing unit 54 generates a mapping image from this energy spectrum to visually confirm the element distribution in the waste sand 100, and determines whether the waste sand 100 contains hazardous metal components based on this mapping image. Note that hazardous metal components that may be contained in the waste sand 100 are cadmium, lead, mercury, and / or chromium.

[0035] Fig. 4 is a block diagram showing the configuration of the management device 8. As shown in Fig. 4, the management device 8 is configured to include a storage unit 81, a display unit 82, an operation unit 83, and a control unit 84. The storage unit 81, the display unit 82, the operation unit 83, and the control unit 84 are connected to each other via a bus 85.

[0036] The memory unit 81 includes, for example, a semiconductor memory device, and stores programs and data used in processing by the control unit 84. For example, the memory unit 81 stores a pair of the amount of waste sand 100 measured by the post-inspection measuring device 6 and the inspection results by the inspection device 5. The memory unit 81 stores an operating system program, driver programs, application programs, data, etc. used in processing by the control unit 84. Programs are installed into the memory unit 81 using a known setup program or the like from a computer-readable, non-transitory, portable storage medium such as a CD (Compact Disc)-ROM (Read Only Memory) or a DVD (Digital Versatile Disc)-ROM.

[0037] The display unit 82 displays an image. The display unit 82 includes, for example, a liquid crystal display or an organic EL (Electro-Luminescence) display. The display unit 82 displays an image based on display data supplied from the control unit 84.

[0038] The operation unit 83 accepts input operations by the user to the management device 8. The operation unit 83 includes, for example, a keypad, a keyboard, or a mouse. The operation unit 83 may include a touch panel integrated with the display unit 82. The operation unit 83 generates a signal according to the input operation by the user and supplies the signal to the control unit 84.

[0039] The control unit 84 is configured to include one or more processors and their peripheral circuits that comprehensively control the operation of the management device 8. The control unit 84 includes, for example, a CPU. The control unit 84 controls the operation of each component and executes various processes so that the various processes of the management device 8 are executed in an appropriate order based on the programs stored in the storage unit 81 and input from the operation unit 83.

[0040] 5 is a flowchart showing the manufacturing process of the recycled sand 200 in the waste sand management system 1. The waste sand management system 1 is executed mainly by the control unit 84 in cooperation with each element of the waste sand management system 1 based on a program stored in advance in the storage unit 81.

[0041] First, the pre-inspection measuring device 2 measures a predetermined amount of waste sand 100. The pre-inspection measuring device 2 transmits the time when the predetermined amount of waste sand 100 was measured and measurement information related to the waste sand 100 to the management device 8 (step S1). Furthermore, the memory unit 81 of the management device 8 stores the time when the predetermined amount of waste sand 100 was measured and the measurement information related to the waste sand 100 transmitted from the pre-inspection measuring device 2.

[0042] Next, the removal device 4 removes contained metals from a predetermined amount of waste sand 100 transported by the belt conveyor 3. The removal device 4 transmits the time at which the contained metals were removed from the predetermined amount of waste sand 100 to the management device 8 (step S2). The memory unit 81 of the management device 8 stores the time at which the contained metals were removed from the predetermined amount of waste sand 100 transmitted from the removal device 4.

[0043] Next, the inspection device 5 inspects the waste sand 100 from which some of the contained metals have been removed by the removal device 4 to determine whether or not it contains hazardous metal components. If the waste sand 100 does not contain hazardous metal components, the inspection device 5 determines that the waste sand 100 is recycled sand 200. If the waste sand 100 contains hazardous metal components, the inspection device 5 determines that the waste sand 100 is discarded sand 400. The inspection device 5 transmits the time when the inspection was performed and the inspection results to the management device 8 (step S3). The memory unit 81 of the management device 8 stores the time when the inspection was performed and the inspection results transmitted from the inspection device 5 in the management device 8.

[0044] Next, the post-inspection measuring device 6 measures the waste sand 100 inspected by the inspection device 5. The post-inspection measuring device 6 transmits the time when the waste sand 100 inspected by the inspection device 5 was measured and measurement information regarding the waste sand 100 to the management device 8 (step S4). In addition, the memory unit 81 of the management device 8 stores the time when the waste sand 100 was measured and the measurement information regarding the waste sand 100 transmitted from the post-inspection measuring device 6.

[0045] Finally, the confirmation device 7 photographs the container 500 into which the waste sand 100 measured by the post-inspection measuring device 6 has been placed, and generates a confirmation image. The confirmation device 7 transmits at least the time the container 500 was photographed and the confirmation image to the management device 8 (step S5). The memory unit 81 of the management device 8 stores the time the container 500 was photographed and the confirmation image transmitted from the confirmation device 7, and the series of steps for producing the recycled sand 200 is completed.

[0046] Fig. 6 is a database that stores the execution time and accompanying information of each process in the manufacturing process of the recycled sand 200. The database shown in Fig. 6 is for centrally managing various information and data sent to the management device 8 from each of the pre-inspection measuring device 2, removal device 4, inspection device 5, post-inspection measuring device 6, and confirmation device 7 of the waste sand management system 1.

[0047] As shown in Fig. 6, the database stores the processing details performed in each component of the waste sand management system 1, the associated information corresponding to these processing details, and the time when the processing was performed, in association with each other. Also, a management number is assigned to each processing detail performed in each component of the waste sand management system 1. This management number includes a set number corresponding to the series of manufacturing steps for the recycled sand 200 shown in Fig. 5, and an individual number corresponding to each step (processing detail) included in this manufacturing step. In other words, the database manages each step included in the series of manufacturing steps for the recycled sand 200 for each series of manufacturing steps for the recycled sand 200.

[0048] The database shown in Figure 6 centrally manages the processing details included in each series of recycled sand 200 manufacturing processes for each series of recycled sand 200 manufacturing processes, allowing users to instantly grasp the information and data obtained through the series of recycled sand 200 manufacturing processes.

[0049] For example, the user can instantly grasp the inspection results of the inspection device 5 for each processing unit of waste sand 100. The user can also grasp the amount of recycled sand 200 produced in the series of recycled sand 200 manufacturing processes, as well as the inspection results of the recycled sand 200. Furthermore, because the inspection results of the recycled sand 200 and the identification numbers 600 of the containers 500 are centrally managed, the user can grasp the identification numbers 600 of the containers 500 loaded with recycled sand 200 or waste sand 400. Furthermore, because the amount of waste sand 100 measured before inspection and the amount of waste sand 100 measured after magnetic and non-magnetic materials have been removed and inspection has been performed are centrally managed, the user can grasp the amount of contained metals removed from the waste sand 100 in the series of recycled sand 200 manufacturing processes.

[0050] As described above in detail, the waste sand management system 1 manages various information and data transmitted to the management device 8 from each of the pre-inspection measuring device 2, the removal device 4, the inspection device 5, the post-inspection measuring device 6, and the confirmation device 7. At this time, the waste sand management system 1 centrally manages each step included in the series of manufacturing processes of the recycled sand 200 using a database for each series of manufacturing processes of the recycled sand 200. This allows the waste sand management system 1 to track the manufacturing process of the recycled sand 200 and to track whether the manufactured recycled sand has been properly inspected.

[0051] Here, the specified amount as a processing unit may be the amount that can be loaded onto one container vehicle 300 with detachable device, the amount that can be loaded onto one truck, the amount that can be packed into one flexi-bag package, the amount that can be loaded into one iron box, or the amount that can be loaded onto one powder and granular material transport vehicle (also known as Jet Pack (registered trademark)).

[0052] In addition, the processing unit 34, the processing unit 44, and the control unit 84 may be equipped with a GPU (Graphics Processing Unit), a DSP (Digital Signal Processor), an LSI (Large Scale Integration), an ASIC (Application Specific Integrated Circuit), an FPGA (Field Programmable Gate Array), etc.

[0053] It should be understood by those skilled in the art that various changes, substitutions, and alterations can be made to the present invention without departing from the spirit and scope of the present invention. For example, the processes of the above-described parts may be executed in a different order as appropriate within the scope of the present invention. Furthermore, the above-described embodiments and modifications may be combined as appropriate within the scope of the present invention. [Explanation of symbols]

[0054] 1. Waste sand management system 2 Pre-inspection measuring device 4 Removal device 5. Inspection equipment 6 Post-inspection measuring device 7. Verification device 8 Management device 41 Magnetic material removal section 42 Non-magnetic material removal part 51 X-ray irradiation section 52 Detection unit 81 Storage section 541 Judgment section

Claims

1. 1. A waste sand management system, comprising: a removal device for removing contained metals from a predetermined amount of waste sand; an inspection device that inspects whether or not the waste sand from which a portion of the contained metals has been removed by the removal device contains harmful metal components; A first measuring device that measures the waste sand inspected by the inspection device; a memory unit that stores the amount of waste sand measured by the first measuring device and the inspection result by the inspection device as a pair; A waste sand management system comprising:

2. The apparatus further includes a second measuring device for measuring the predetermined amount of waste sand introduced into the removing device, The removal device, the inspection device, and the first measurement device perform removal, inspection, and measurement using the predetermined amount of waste sand measured by the second measurement device as a processing unit. The waste sand management system according to claim 1 .

3. the waste sand is slag; The removal device includes a magnetic material removal unit that removes magnetic materials including iron lumps and iron sand, and / or a non-magnetic material removal unit that removes non-magnetic materials including aluminum, copper, brass, and magnesium.

3. The waste sand management system according to claim 1 or 2.

4. The waste sand management system described in claim 3, characterized in that the inspection device includes an X-ray irradiation unit that irradiates X-rays onto the waste sand, a detection unit that detects X-ray photons emitted from the waste sand irradiated with X-rays by the X-ray irradiation unit, and a judgment unit that determines whether the waste sand contains harmful metal components based on the detection results of the X-ray photons by the detection unit.

5. The waste sand management system according to claim 1 or 2, characterized in that the specified amount is the amount that can be loaded onto one truck, the amount that can be packed into one flexible container, the amount that can be loaded into one iron box, the amount that can be loaded into one container vehicle with a detachable device, or the amount that can be loaded into one powder and granular material transport vehicle.

6. 1. A waste sand management method comprising: removing contained metals from a predetermined amount of waste sand by a removal device; The waste sand from which some of the contained metals have been removed is inspected using an inspection device to determine whether it contains any harmful metal components. The inspected waste sand is measured using a measuring device. The measured amount of waste sand and the inspection result are stored in a memory unit as a pair. A waste sand management method characterized by:

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