Automated installation in an alloy manufacturing workshop, corresponding workshop and automated methods of implementation thereof

Abstract

The installation (I) comprises a main storage area (2) provide with a plurality of stands (2A - 2P), adapted for receiving a respective alloying assembly (7 A - 7P), a transportation station (3) and a sorting station (4), said transportation station being intended to transport alloying assemblies (7 A - 7P) from main storage area (2) towards sorting station, said sorting station being provided with unpacking means (41, 404) adapted to provide access to solid pieces, with picking means (405) adapted to pick solid pieces, and with sorting means (49) adapted to sort an appropriate number of solid pieces of each component. Moreover, a transit vehicle is adapted to exit a hopper (6) filled with sorted solid pieces, whereas control means (8) permit an automated implementation.

Description

[0001] INSTALLATION FOR THE PREPARATION OF ALLOYING ADDITIVES FOR AN ALLOY MANUFACTURING WORKSHOP, CORRESPONDING WORKSHOP AND AUTOMATED METHODS OF IMPLEMENTATION THEREOF

[0002] Technical field of the invention

[0003] The invention relates to the preparation of alloying additives, intended to be part of the elaboration of aluminium alloys. The invention pertains first to an installation for the preparation of such alloying additives, as well as to an automated implementation method of this installation. The invention also relates to an alloy manufacturing workshop, which is provided with such a preparation installation.

[0004] State of the art

[0005] Typically, aluminium alloys can be elaborated from scrap metal or from pure aluminium. Pure aluminium can be provided to the casthouse in liquid form or in solid form, as remelting ingots. In any case, the composition of the liquid metal in the furnace must be adjusted such as to meet the target alloy composition. This adjustment is done in a furnace, by adding an appropriate quantity of alloying elements. Other functional additives can be added, too, such as grain refiners. Alloying elements are added in solid forms, typically as bars or ingots. Depending on the alloying element, such bars or ingots can be substantially pure elements, or can be so-called master alloys, that is to say aluminium alloys with a high content of the targeted alloying element. As an example, while magnesium is often added in the form of magnesium bars or ingots, metallic copper is not soluble in liquid aluminium and needs to be added as a master alloy, that is to say in the form of a solid alloy aluminium-copper alloy which is soluble in liquid aluminium.

[0006] The quantity of alloying elements to be added to a batch of liquid metal may be considerable, and the more so if aluminium is provided as pure (primary) aluminium. For a given quantity of liquid metal, the kind and number of alloying metal ingots to be added is determined as a function of the target alloy composition. The addition of alloying elements is usually carried out in the alloy workshop, by providing an aluminium basket or frame in which the bars or ingots of alloying elements or master alloys are positioned one by one. The number of bars or ingots of a given kind must be monitored. The filled basket or frame is then transferred to the furnace area and introduced into the liquid metal bath using a forklift.

[0007] According to the state of the art, the filling of the basket or frame is carried out manually in an alloy workshop close to the metal storeroom, where all alloying metal bars or ingots are stored. This implies heavy manual work and repetitive movements of the body, while requiring a lot of attention and record-keeping.

[0008] CN 115 744 149 discloses an installation for the preparation of an alloying additive from several alloying components, which is equipped with a belt conveyor comprising stand columns. Furthermore, there are provided a conveying belt installation frame installed on the stand columns, a conveying belt installed on the conveying belt installation frame and a driving device for driving the conveying belt to operate on the conveying belt installation frame. A plurality of partition plates are evenly installed on the conveying belt, and an ingot block containing space used for containing ingot blocks is formed between every two adjacent partition plates. Baffles are arranged on the two sides of the conveying belt and installed on the conveying belt installation frame. An infrared counter used for sensing the number of conveyed ingots is arranged at one end of the conveying belt mounting frame and electrically connected with the driving device.

[0009] A first purpose of the present invention is to eliminate physical risk to workers. In particular, the picking up, carrying and handling of heavy objects (such as alloy ingots or alloy boxes) may represent a physical risk. This risk may be due to accidents relating to the objects themselves, such as objects falling down, or may be due to accidental musculoskeletal injury when lifting a heavy object. The risk may also relate to long-term (chronic) musculoskeletal conditions.

[0010] A second purpose of the present invention is to reduce psychological pressure to workers. The process of weighing and collecting alloy ingots must be carried out fast and in a limited time frame. Furthermore, the slightest error in selecting the right ingots may have severe consequences for the quality of the metal obtained from such alloys. This pressure may be the cause of errors due to lack of attention.

[0011] A third purpose of the present invention is to prevent accidents related to liquid metal splashed when charging the hopper in the furnace.

[0012] Another purpose of the present invention is to improve accuracy of data recording, in particular regarding the weight of the alloying elements.

[0013] Objects of the invention

[0014] Under these circumstances, a first object of the invention is an automated installation for the preparation of an alloying additive from several alloying components, said installation comprising:

[0015] - a peripheral enclosure delimiting a working zone, said enclosure being provided with at least one aperture, - a main storage area comprising a plurality of stands, each adapted for receiving a respective alloying assembly, said alloying assembly comprising solid pieces of one alloying component as well as a peripheral packaging,

[0016] - a transportation station and a sorting station, said transportation station being intended to transport alloying assemblies from main storage area towards sorting station,

[0017] - said transportation station being provided with catching means adapted to catch one alloying assembly and with transportation means adapted to transport caught alloying assembly towards sorting station,

[0018] - said sorting station being provided with unpacking means adapted to unpack said packaging so as to provide access to solid pieces, with picking means adapted to pick solid pieces, and with sorting means adapted to sort an appropriate number of solid pieces made of each component,

[0019] - a hopper adapted to accommodate said appropriate number of solid pieces sorted by sorting station,

[0020] - a transit vehicle, adapted at least to exit said hopper filled with said accommodated solid pieces through said at least one aperture; and control means comprising: a human machine interface, control lines adapted, upon receipt of inputs actuated by an operator, to transmit control orders to at least said transit vehicle, said catching means, said unpacking means and said sorting means.

[0021] According to a first advantageous aspect of the invention, transportation means comprise a first robot provided with catching means, as well as a track along which said first robot is adapted to run, said track extending between the vicinity of main storage area and the vicinity of sorting station.

[0022] According to another aspect of the invention, the plurality of stands are arranged along at least two rows, in particular two rows, said rows defining at least one longitudinal pathway as well as a plurality of transversal pathways.

[0023] According to still another aspect of the invention, unpacking means comprise cutting tools adapted to cut packaging, as well as taking means adapted to take off top and / or bottom of said cut packaging.

[0024] According to an advantageous embodiment sorting station comprises a second robot provided with said picking means.

[0025] According to an aspect of the invention, sorting means comprise weighing means adapted to measure the weight of each solid piece picked out alloying assembly, and wherein control means further comprise a first information line adapted to transmit information from weighing means to said computer.

[0026] Advantageously, sorting means may comprise a temporary storage area provided with at least one container, said picking means being adapted to place each solid piece either in a container or in a discharge chute extending downwards from sorting station.

[0027] According to a particularly advantageous aspect of the invention, control means are configured to calculate the sum of all the weighed solid pieces of one given component and to compare it with a predetermined value.

[0028] Advantageously, each alloying assembly and / or each stand may be provided with an identification code and said installation is provided with at least one checking camera adapted to read said identification code, and control means may further comprise at least one supplementary information line adapted to transmit information from said checking camera to computer.

[0029] According to another aspect of the invention, said installation further comprises removing means adapted to remove a wrap surrounding each solid piece.

[0030] A second object of the invention is an automated implementation method of an installation as defined here above, said method comprising the following steps, carried out under control of said control means:

[0031] - providing a plurality of alloying assemblies, each assembly comprising solid pieces of one alloying component as well as a peripheral packaging;

[0032] - positioning each of said plurality of alloying assemblies on a respective one of said plurality of stands, i) catching, under use of catching means, a first alloying assembly; ii) transporting, under use of transporting means, said first alloying assembly towards said sorting station; iii) unpacking, under use of said unpacking means, said packaging of said first alloying assembly iv) sorting, under use of sorting means, an appropriate number of solid pieces made of said first component corresponding to a predetermined proportion of said first component in said alloying additive, and loading said appropriate number of solid pieces into said hopper if any repeating steps i) to iv) for at least another alloying assembly

[0033] - displacing said hopper loaded with solid pieces outside said working zone and unloading said solid pieces into a furnace.

[0034] Advantageously positioning each of said plurality of alloying assemblies and displacing said hopper loaded with solid pieces are carried out both with said transit vehicle. According to another aspect of the invention, said method further comprises picking, under use of picking means, the solid pieces of alloying assembly free from its packaging, and placing said solid pieces in a predetermined arrangement, in particular the one behind the others, before sorting said solid pieces.

[0035] According to still another aspect of the invention, said method further comprises entering the predetermined composition of alloying additive to control module, controlling transportation station so that it transports target alloying assemblies, the components thereof are part of said composition, controlling sorting station so that it transfers said predetermined number of solid pieces of each alloying assemblies to said hopper.

[0036] According to still another aspect of the invention, said method further comprises calculating the sum of all the weighed solid pieces of one given component and comparing it with a predetermined value; and displacing solid pieces towards said hopper as long as said calculated sum is inferior to said predetermined value.

[0037] Advantageously, said method comprises temporarily store solid pieces in at least one container of temporary storage area, when said calculated sum is superior to said predetermined value.

[0038] A third object of the invention is a workshop comprising a receiving section such as a dock, adapted to receive alloying assemblies, a furnace adapted to prepare alloys from aluminium as well as from alloying additives, said workshop comprising also a preparation installation as defined here above, said preparation installation being functionally interposed between said receiving section and said furnace.

[0039] Brief description of figures

[0040] Figure 1 is a schematic view, illustrating an alloy manufacturing workshop equipped with an installation according to the invention, in view of the preparation of alloying additives.

[0041] Figure 2 is a perspective view, showing more in detail the preparation installation according to the invention.

[0042] Figure 3 is a top view, showing in a schematic way the main operating areas and stations of this preparation installation.

[0043] Figure 4 is a schematic view of an alloying assembly intended to be processed by the installation according to the invention.

[0044] Figure 5 is a perspective view of a sorting station, which is part of the installation according to the invention.

[0045] Figure 6 is a schematic view, illustrating the control system which is part of the installation according to the invention. Figure 7 is a perspective view, illustrating a transit vehicle which is part of the installation according to the invention.

[0046] Figure 8 is a perspective view, illustrating in a schematic way a first step of the implementation method of the installation according to the invention, wherein the alloying assembly of figure 4 is lifted by a first robot.

[0047] Figure 9 is a top view, illustrating in a schematic way a further step of this implementation method, wherein assembly of figure 4 is displaced by said first robot towards sorting station.

[0048] Figures 10a to 10e are perspective views illustrating several steps of the implementation of this sorting station.

[0049] Figure 10f is a schematic view, illustrating the two different ways of processing solid pieces accommodated in one single assembly of figure 4.

[0050] The following reference numerals are used on the figures and throughout the present description:

[0051] 1000 Workshop - 1010 Receiving area - 1050 Truck - 1100 Furnace

[0052] 1 Installation - 1 peripheral enclosure - 10 and 11 longitudinal walls - 12 and 13 transversal walls - 18 working zone - 14 entrance - 15 exit aperture - 16 magnesium aperture

[0053] 2 main storage area - 2A to 2N Stands - 21 and 22 Rows - 23 longitudinal pathway - 24 transversal pathways

[0054] 3 transportation station - 30 first robot - 39 track - 31 distal arm of robot 3 - 32 catch member - 33 camera on 30

[0055] 4 sorting station - 40 second robot - 400 base of 40 - 401 proximal arm of 40 - 402 distal arm of 40 - 403 terminal head - 405 picking member

[0056] 410 taking device - 404 taking member

[0057] 41 unpacking device - 42 frame - 4344 cutting tools

[0058] 45 removing device - 46 frame - 47 cutting members - 48 sucking members

[0059] 49 weighing device

[0060] 5 Platform - 50 51 upstream and downstream ends of 5 - 52 conveyor - 53 mid region of 5 - 54 carrier - 55 camera on 50 - 56 temporary storage area - 57 containers - 58 conveyor to packaging bin - 59 plastic bin

[0061] 6 hopper - 60 metallic body - 61 feet - 62 discharge chute from 5 to 6 - 65 transit vehicle - 66 chassis of 65 - 67 forks of 65

[0062] 7A Alloying assembly - 70A solid pieces - 79A wrap - 74A packaging - 740, 741 top / bottom of 74A - 76A identification code - 78A grab device

[0063] OPE Operator

[0064] 8 control module - 80 computer 82, 83, 84, 85 Information lines between respectively OPE, 33, 55, 49 and computer 80 90, 91 , 92, 93, 94, 95, 96 Control lines between computer 80 and respectively 65, 30, 52, 41, 40, 54, 45

[0065] 100 Magnesium assembly - 102 partition - 103 storage area partition - 104 magnesium area - 106 magnesium carriage

[0066] Detailed description of the invention

[0067] The present invention deals with a workshop for manufacturing solid unwrought aluminium alloys obtained by solidification of molten aluminium alloys, such as remelting ingots, castings, billets, bars, rolling ingots or extrusion ingots. In a way known as such said workshop 1000, schematically represented on figure 1, first comprises a so-called receiving area 1010, which is typically formed by a dock. The latter may receive material delivered for example from a transportation vehicle such as a truck 1050, a railway vehicle and possibly a boat. Workshop 1000 of figure 1 also comprises a known as such furnace 1100, wherein solid material is melted, typically by adding it to liquid material, to form final alloys with controlled chemical composition. On this figure 1 the successive arrows represent the classical flow of processed material. Any downstream processing units such as the casthouse itself have been omitted.

[0068] Said final alloy is usually obtained by adding so-called alloying additives to a base metal, which is substantially formed by aluminium. The charge of alloying additives is prepared from several alloying base components that are provided in the form of solid pieces, such as ingots, bars or tablets. To this end the workshop is equipped with an intermediate so- called preparation installation according to the invention, referenced I as a whole, which permits successive automated preparations of so-called alloying additives.

[0069] Each base component can be in an elementary form, namely as substantially pure chemical element, or in the form of a so-called master alloy formed by a mix of pure chemical elements. Hereunder we will suppose that alloying additive is prepared from a number N of base alloying components, referenced A to P. Weight proportions of the several alloying components, in said alloying additive, are predetermined.

[0070] Figures 2 and 3 show a general view of an installation according to the invention, referenced I as a whole. Said installation first comprises a peripheral enclosure 1, including four main walls 10 to 13. Parallel walls 10 and 11 are called longitudinal walls with reference to the motion of a hereunder described robot, whereas supplementary parallel walls 12 and 13 are called transversal walls. Said enclosure 1 defines a so-called working zone 18. Several apertures are provided in the above walls. A first aperture, here after called entrance 14, is provided in wall 10, another aperture, hereafter called exit aperture 15, is provided in adjacent wall 13, whereas a third aperture 16 is provided in opposite transverse wall 12. As will be explained hereunder, said aperture 16 is called “magnesium aperture”. The motions across said apertures are advantageously monitored by optical barriers (not shown on the figures), of any appropriate type. There may be additional apertures 17,18, in particular for maintenance.

[0071] A partition 103 (which may be a fence), called here “storage area partition”, delimits a so- called main storage area 2, which is illustrated in mixed traits on figure 3. The latter, which is substantially rectangular, is provided facing the entrance 14. Main storage area includes several stands 2A to 2P, the structure of which is known as such and will not be described in further detail. These stands, each intended to receive a respective alloying assembly, are provided along two rows 21 and 22. In this respect stands 2A to 2I are part of first row 21 , whereas stands 2J to 2P are part of the other row 22.

[0072] In the present example, main storage area 2 is formed by two rows each comprising eight stands. As not shown variants, each row may comprise a different number of stands or, as further alternatives, only one single row or more than two rows can be provided. Adjacent stands are separated by a longitudinal pathway 23, separating rows 21 and 22, as well as by a plurality of transversal pathways 24 which separate adjacent stands of one given row. Said pathways 23 and 24 permit the displacement of further described robot 30 and, if any, the motion of operators in particular in case of maintenance of the installation. Figure 3 voluntary does not represent the installation I at a correct scale, so as to better illustrate in particular main storage area 2.

[0073] Figure 4 illustrates a so-called alloying assembly, intended to rest on one of the above stands, said alloying assembly being also intended to be processed with the preparation installation I. As explained here above, the purpose of the invention is to prepare an alloying additive from several alloying components A to P. In this respect, alloying assembly of figure 4 includes only one single component, for example the one A, so that this assembly is referenced 7A. The latter first comprises solid pieces 70A shown in phantom, each made of component A. In the present example, each solid piece is a tablet, bearing in mind that ingots, bars and so on can be used in any shape. The different solid pieces are stacked the one on the others, in any appropriate way. Each solid piece is typically protected by a wrap 79A made of plastic material, which is represented only on figure 10b.

[0074] Said assembly 7A also comprises a packaging 74A, which surrounds the pieces 70A. This packaging is made of any appropriate material, such as cardboard. In the presently described embodiment, packaging 74A is provided with an individual identifier, or identification code 76A. Said identification code can be of any suitable type, such as a bar code, a QR code, an alphanumerical code or analogous. Packaging 74A can be provided with an appropriate grab device, schematically represented and referenced 78A. Said grab device 78A can comprise a vacuum suction member, connected to a vacuum line (not shown on the figures).

[0075] Preparation installation I further comprises a transportation station, referenced 3 as a whole, as well as a sorting station, referenced 4 as a whole. The purpose of transportation station is to transport at least part of the above-described assemblies 7, from main storage area 2 towards sorting station. Moreover the purpose of sorting station 4 is to process each assembly, including in particular unpacking and weighing operations, so as to prepare target alloying additive from said assemblies.

[0076] Said transportation station 3 includes a first robot 30, which is movable on a track 39 running along longitudinal wall 10 (see in particular figure 3). Motion of said robot with respect to said track is ensured by any appropriate displacement means, not represented on figures 2 and 3. Robot 30 is of a type known as such, in particular a six-axis robot. It is typically provided with a base plate attached to track 39, with a body rotating with respect to baseplate, with a proximal arm mounted on said body, as well as with a distal arm, mounted on said proximal arm. The above components, which are known as such and used in robots, are not illustrated in detail on figure 3.

[0077] With reference to figure 8 distal arm of robot 3, partly represented and referenced with number 31, is equipped with a mechanical member schematically shown and referenced with number 32. This member, which is called catch member, is adapted to catch an alloying assembly which will be described hereunder. Robot is also provided with a camera 33, which is adapted to read an identification code, such as the one 76A mentioned here above.

[0078] With reference in particular to figure 5, sorting station 4 comprises a second robot 40, the structure of which is substantially similar to that of first robot 30. Said robot 40 comprises in particular a base 400, which rests on a platform 5, a proximal arm 401 as well as well as a distal arm, 402. The latter is provided with a terminal head 403 which is provided with picking member 405, adapted to pick solid pieces accommodated in the packaging of alloying assembly. Robot 40 is associated with a taking device 410, of any appropriate type, which includes a taking member 404, schematically illustrated on figure 10b. Said member 404 is adapted to take off top 740 and / or bottom 741 of packaging, once the latter has been cut off. Said picking member 405 and / or said taking member 404 can comprise a vacuum suction member, connected to a vacuum line (not shown on the figures).

[0079] Platform 5 comprises two opposite so-called longitudinal ends, respectively an upstream end 50 as well as a downstream end 51, with reference to the motion of solid pieces across said platform. Upper surface of platform is provided first with a conveyor 52, which runs from upstream end 50 towards a mid-region 53, located on the vicinity of robot 40. Said upstream end 50 is provided with a camera 55 adapted to read the identification code 76 of the assembly, in view of a supplementary checking further to that of camera 33. Moreover, said upper surface receives also a carrier 54, which extends from said mid region towards downstream end 51.

[0080] Conveyor 52, which is driven by any appropriate not represented means, is adapted to move each assembly 7. In this respect, said conveyor is dimensioned wide enough to fulfil this function. On the other hand carrier 54, also driven by any appropriate not represented means, is adapted to displace solid piece is a one behind the others. In this respect, the width of said carrier is far inferior to that of conveyor. Moreover carrier 54 is advantageously U shaped, so as to avoid any lateral fall of solid pieces out of the carrier.

[0081] Beside carrier 54, upper surface of platform 5 delimits a second so-called temporary storage area 56. The latter is provided with a plurality of containers 57, the function of which will be described hereafter.

[0082] Sorting station 4 is provided with a plurality of equipments, that are located along respectively conveyor 52 and carrier 54. Said sorting station 4 comprises first an unpacking device 41, known as such, which is provided with a frame 42 that extends above conveyor 52. Frame 42 supports two pairs of mobile cutting tools 43 and 44, shown in particular on figurelOa.

[0083] Sorting station 4 further comprises a so-called removing device 45, also known as such, which is located at the upstream part of carrier 54. Said removing device comprises a frame 46 extending above carrier 54, as well as two mobile cutting members 47 provided the one behind the other along main axis of carrier (see in particular figure 10c). Frame 46 finally supports two sucking members 48, also shown on this figure 10c, which are provided on both sides of carrier 54. Said sucking members 48 are connected to a vacuum line (not shown on the figures).

[0084] Sorting station 4 further comprises a weighing device 49, located downstream with respect to removing device 45. This weighing device 49, placed on the lower face of carrier 54 as shown on figure 10e, is of any appropriate type. Said figure 10e makes it also possible to clearly recognise the U shape of carrier 54. The installation according to the invention also comprises a hopper 6, which is adapted to receive solid pieces which have been sorted in sorting station 4. Said hopper 6, which is of any appropriate type, is provided with a metallic body 60 resting on feet 61 , so that this hopper may be lifted by a transit vehicle 65. A discharge chute 62 extends from downstream end of carrier 54 to body of said hopper 6, so as to permit solid pieces to move by gravity from platform 5 to hopper 6. Said transit vehicle 65 comprises a chassis 66 mounted on not shown wheels or analogous, as well as forks 67 making it possible to lift hopper 6 (see in particular figure 7). As will be described hereafter, transit vehicle is also adapted to further functions, in particular displacing each assembly 7.

[0085] Preparation installation I is advantageously provided with a so-called magnesium assembly 100, provided beside aperture 16. A partition 102 separates an area 104 specifically dedicated to magnesium processing (see in particular figure 3), with respect to the other areas of working zone. Magnesium provided under any appropriate form, such as bars or ingots, will be filled into a basket or cage and can be transported through aperture 16 via a specific carriage 106, illustrated in particular on figure 2. As will be explained below, the introduction of magnesium in the furnace is carried out separately from the introduction of the other alloying additives. In fact, solid magnesium having a density less than that of liquid aluminium, it needs to be immersed in the liquid metal bath, and to be kept immersed until its complete melting, such as to avoid its combustion at the surface of the liquid aluminium bath.

[0086] Preparation installation I is finally provided with a control module 8, shown on figure 6. The latter comprises first a human machine interface, in the form of a computer 80. Said computer is associated with Programmable Logic Controller (abridged PLC), with a motor control centre (abridged MCC) as well as with artificial vision device. Computer 80 may be schematically divided into three regions, namely a so-called information region adapted to receive information from some structural members of the installation through information lines, a so-called control region adapted to send control orders towards some other structural members of the installation through control lines, as well as a data storage region.

[0087] On figure 6 the operator as well as mechanical members, connected with computer 80, are schematically illustrated by corresponding blocks. More in detail computer is intended to receive inputs from operator OPE, via a first information line 82. Said computer is connected with camera 33 provided on the robot 30, via another information line 83. It is also connected with camera 55 of platform 5 via information line 84, whereas said computer is finally connected with weighing device 49 via a supplemental information line 85. On the other hand first control line 90 connects computer with transit vehicle 65, so as to actuate its motion. Other control line 91 connects computer 80 with robot 30, in particular with the driving means thereof as well as with catch member 32. Still other control line 94 connects computer 80 with robot 40, in particular the driving means thereof as well as with picking member 405. Several lines connect computer 80 with further members of the installation according to the invention, namely line 32 with conveyor 52, line 93 with unpacking device 41, line 95 with carrier 54 and line 96 with the removing device 45. Finally control line 97 connects computer 80 with taking device 410.

[0088] An implementation of the above installation, according to the invention, will now be described.

[0089] According to the invention, the alloying additive is prepared from components A to P, each with a predetermined weight respectively Wp(A), Wp(B), ... , Wp(0) and Wp(P). These predetermined weights correspond to predetermined numbers nA, nB, ... , nO and nP of solid pieces 70A, 70B, ... , 700 and 70P. Some of these predetermined weights may be equal to 0: in other words, if Wp(l) is equal to 0, it means that final alloying additive does not include said component I. In a preliminary step, the predetermined composition of said final additive is entered by an operator to control module 8, via line 80.

[0090] As shown on figure 2 several alloying assemblies 7A to 7P are placed on respective stands 2A to 2P, the structure of further alloying assemblies 7B to 7P being analogous to that of assembly 7A of figure 4. To this end module 8 controls transit vehicle 65, via line 90, so that it successively loads these assemblies on their intended respective stand. During this operation vehicle 65 is driven back and forth through entrance 10.

[0091] Said module then controls first robot 30, via line 91, so that the latter might catch a first alloying assembly. To this end, catch member 32 of robot 3 is driven towards this first assembly, so that it cooperates with grab device 78 (see figure 8, where this operation is schematically illustrated). The geometric arrangement of the stands is known by control module 8, so that there is in theory no risk of confusion. Typically, each alloying assembly 7A to 7P is placed on a dedicated stand 2A to 2P, and this allocation can be entered into a computer program of control module 8.

[0092] So as to improve the reliability of this grab operation, camera 33 may read the identification code 76 of the assembly, so as to make sure that the processed assembly is the correct one (see also figure 8). To further improve reliability, the stand 2 supporting the assembly may also be provided with a further identification code (not represented on figures) for double checking by camera 33. If one of the above checking operations lead to an identification error, i.e. the identified assembly is not the predetermined one, camera 33 sends the corresponding information to computer 80 via line 83. The process is then stopped so as to ensure that the operator may fix this error. Once catch member has grasped grab device 78A, robot lifts assembly 7 away from its stand (arrow f7 on figure 8). Said robot 30 is then driven along track 39 towards upstream end 50 of platform 5 (see arrow f30 on figure 9), and distal arm 31 is moved downwards until assembly 7A rests on the conveyor 52. The final position of robot 30, of its arm 31 and of assembly 7A is shown in phantom on figure 9. Identification code 76 is monitored by camera 55 so as to check that the appropriate alloying assembly is actually processed by this sorting station. In the same way as above, if not, camera 55 sends information to computer 80 via line 84, so as to stop the process.

[0093] Conveyor 52 is then driven, under control of computer 80 via line 92, so that assembly 7A reaches unpacking station 41. As shown on figure 10a the tools 43 and 44 move along arrows F43 and F44, in a way known as such, so as to cut packaging 74A off. This operation, which is carried out under control of computer 80, via line 93, makes it possible to separate top 740 and bottom 741 of said packaging. Under control of computer 80 via line 97, device 410 removes said top 740, typically using vacuum action, and places it in a conveyor 58 according to arrow F58 (figure 10b). Using its picking member 405, still under control of computer 80 via line 94, robot 40 thereafter picks solid pieces 70A still accommodated in bottom of packaging 74A, also typically using vacuum action. Robot 40 places then solid pieces the one behind the other on the carrier 54 (see arrow F70 also on figure 10b). Bottom 741, now free from solid pieces, is taken by member 404 and placed onto conveyor 58. The latter leads to a specific bin, not illustrated on figures.

[0094] Carrier 54 is driven under control of computer 80, via line 95, so that each solid piece is processed by removing station 45. In this respect, under control of computer 80 via line 96, members 47 cut wrap 79A off, according to arrows F47 in a way known as such. Members 48 suck then this wrap, using vacuum action, according to arrows F48. This wrap is finally thrown away into a specific bin 59 dedicated to collection of plastic material which is schematically represented, according to arrow F59 also on figure 10c. In case solid pieces are not wrapped with plastic material, above removing station is optional).

[0095] On figure 10f, all the solid pieces of first component A are schematically represented and referenced 70(1) to 70(n). The first solid piece 70(1) passes above weighing device 49, which measures its effective weight W(1) and sends the corresponding information to control module 8 via line 85. This first piece 70(1) is picked by robot and placed into discharge chute 62, so as to be accommodated into hopper 6.

[0096] Thereafter second piece 70(2) is also weighed by device 49, which sends the value W(2) to computer 80. The latter calculates the sum noted Wc (so-called current sum) which corresponds to W(1)+W(2). Said current sum Wc is compared to the predetermined weight Wp of said material previously entered into said control module. If current sum is inferior to predetermined weight, solid piece 70(2) is picked by robot and placed into discharge chute 62, so as to be accommodated into hopper 6. On the contrary, if current sum is superior to predetermined weight, it means that the latest solid piece does not have to be introduced into hopper. Otherwise, the weight of given component would be superior to predetermined value. Under these circumstances, said solid piece 70(2) is directed into one of the containers of temporary storage area 56, i.e. the one noted 57A with reference to component A.

[0097] With reference to figure 10f, let us suppose that (W(1)+... ,+W(i)) is inferior to predetermined weight Wp, but (W(1)+... +W(j)) is superior to predetermined weight Wp. Under these circumstances, solid pieces 70(1) to 70(i) are accommodated into hopper 6 according to arrow F70. On the contrary, further solid pieces 70(j) to 70(n) are placed into container 57A according to arrow G70. Handling of said solid pieces is still carried out typically under vacuum action.

[0098] Once all solid pieces of first component have been transferred either to hopper 6 or to temporary storage area 56, solid pieces of second component are processed the same way. Successively all the solid pieces of all the components, part of the target final alloying additive, are also processed this way. After these steps, the hopper is loaded with solid pieces of predetermined components, the solid pieces of each component having a respective predetermined respective weight.

[0099] Control module 8 controls then transit vehicle 65, so that it lifts loaded hopper with its forks. Vehicle 65 is thereafter driven out of enclosure 1, through aperture 15 according to arrow F65 on figure 2. The components are finally unloaded from hopper 6 to furnace 1100: this unloading operation, which is known as such, is not illustrated on the figures.

[0100] Solid pieces stored in temporary storage area 56 may be further processed in two main different ways. At least some of these temporarily stored pieces may first be returned to a packaging. As an alternative, at least some of these temporarily stored pieces may be kept in the container and moved towards the hopper at a later stage.

[0101] The invention brings about several advantages with respect to the prior art. As explained above, prior art processes are essentially based on manual operations. The installation and method according to the invention enable the user to facilitate the preparation of alloying additives.

[0102] The invention renders first the tasks of the workers far less arduous than in prior art, due to this automation. In particular not only lifting operations of heavy loads but also frequent handlings of solid pieces are carried out by mechanical members of the installation. In addition, the invention makes it possible to protect these workers from potentially dangerous products. In this respect, according to the invention, the solid pieces part of target alloying additive are unloaded into the furnace with a guided vehicle, which avoids prior splashing of the operators.

[0103] Moreover, the invention confers a far better reliability, with respect to prior art process based on human intervention. Indeed, some of the steps, part of monitoring method according to the invention, are rendered much more accurate due to automation. Amongst other, prior selection errors of appropriate ingots are avoided according to the invention, since this selection is implemented in a completely automated way.

[0104] As mentioned several times throughout this description, it is highly desirable to individually identify certain functional members of the installation according to the invention, i.e. to allocate a unique identification code to all parts of certain types of components. This applies in particular to the above-described alloying assemblies 7. Said identification code can be of any suitable type, such as a bar code, a QR code, an alphanumerical code, and it can be of any suitable kind, such as an affixed label printed on a suitably heat-resistant material. It is highly advantageous to be able to keep track of each functional member bearing a unique identification code, both for the sake of its localisation within the workshop and for the sake of tracking its history of use.

[0105] The installation according to the present invention is not designed to handle alloying additives in the form of granular materials, such as silicon. Silicon may be used in large quantities (up to 15 wt.-% or even more) in certain casting alloys and will normally be introduced into the furnace as granules. Storing of silicon, as well as weighing and introduction of the appropriate quantity of silicon as an alloying additive will be done outside of the installation according ot the present invention. Likewise, this installaton is not designed to handle scrap as a raw material for introduction into a furnace.

[0106] Hopper 6 has advantageouly a dimension that is chosen such that one single hopper can contain the total amount of alloying additives that is needed for a given furnace load, except magnesium (which is loaded into a specific basket or cage) and granular material.

Claims

CLAIMS1. An automated installation (I) for the preparation of an alloying additive from several alloying components, said installation comprising:- a peripheral enclosure (1) delimiting a working zone (19), said enclosure being provided with at least one aperture (14, 15, 16),- a main storage area (2), said main storage area comprising a plurality of stands (2A - 2P), each adapted for receiving a respective alloying assembly (7A - 7P), said alloying assembly comprising solid pieces (70A - 70P) of one alloying component (A - N) as well as a peripheral packaging (74A - 74P),- a transportation station (3) and a sorting station (4), said transportation station being intended to transport alloying assemblies (7A - 7P) from main storage area (2) towards sorting station,- said transportation station being provided with catching means (32) adapted to catch one alloying assembly and with transportation means (30, 39) adapted to transport caught alloying assembly towards sorting station,- said sorting station being provided with unpacking means (41, 404) adapted to unpack said packaging so as to provide access to solid pieces, with picking means (405) adapted to pick solid pieces, and with sorting means (49) adapted to sort an appropriate number of solid pieces made of each component,- a hopper (6) adapted to accommodate said appropriate number of solid pieces sorted by sorting station,- a transit vehicle (65), adapted at least to exit said hopper filled with said accommodated solid pieces through said at least one aperture (15); and control means (8) comprising: a human machine interface (80), control lines (90, 91, 93, 94) adapted, upon receipt of inputs actuated by an operator (OPE), to transmit control orders to at least said transit vehicle (65), said catching means (32), said unpacking means (41) and said sorting means (40).

2. An installation according to preceding claim, wherein said transportation means comprise a first robot (30) provided with said catching means (32), as well as a track (39) along which said first robot is adapted to run, said track extending between the vicinity of main storage area and the vicinity of sorting station.

3. An installation according to any of preceding claims, wherein said plurality of stands are arranged along at least two rows (21, 22) in particular two rows, said rows defining at least one longitudinal pathway (23) as well as a plurality of transversal pathways (24).

4. An installation according to any of preceding claims, wherein said unpacking means (41 , 404) comprise cutting tools (43, 44) adapted to cut said packaging, as well as taking means (404) adapted to take off top (740) and / or bottom (741) of said cut packaging.

5. An installation according to any of preceding claims, wherein said sorting station comprises a second robot (40) provided with said picking means (405).

6. An installation according to preceding claim, wherein said sorting means comprise weighing means (49), adapted to measure the weight of each solid piece picked out alloying assembly, and wherein control means further comprise a first information line (85) adapted to transmit information from weighing means to said computer (80).

7. An installation according to claim 5 or 6, wherein sorting means comprise a temporary storage area (56) provided with at least one container (57), said picking means being adapted to place each solid piece either in a container or in a discharge chute (62) extending downwards from sorting station.

8. An installation according to any of preceding claims, wherein control means are configured to calculate the sum of all the weighed solid pieces of one given component and to compare it with a predetermined value.

9. An installation according to any of preceding claims, wherein each alloying assembly and / or each stand is provided with an identification code (76) and said installation is provided with at least one checking camera (33, 55) adapted to read said identification code, and wherein control means further comprise at least one supplementary information line (83, 84) adapted to transmit information from said checking camera (33, 55) to computer.

10. An installation according to any of preceding claims, further comprising removing means (45) adapted to remove a wrap (79) surrounding each solid piece.

11. An installation according to any of preceding claims,wherein control means are configured to receive an input constituted by the predetermined composition of alloying additive to control module, are further configured to control transportation station so that it transports target alloying assemblies, the components thereof are part of said composition, and are further configured to control sorting station so that it transfers said predetermined number of solid pieces of each alloying assemblies to said hopper.

12. An automated implementation method of an installation (I) according to any preceding claims, said method comprising the following steps, carried out under control of said control means (8):- providing a plurality of alloying assemblies (7A - 7P), each assembly comprising solid pieces (70A - 70P) of one alloying component (A - P) as well as a peripheral packaging (74A - 74P);- positioning each of said plurality of alloying assemblies on a respective one of said plurality of stands (2A - 2P), i) catching, under use of catching means (32), a first alloying assembly (7A); ii) transporting, under use of transporting means, said first alloying assembly towards said sorting station; iii) unpacking, under use of said unpacking means (41), said packaging (74A) of said first alloying assembly iv) sorting, under use of sorting means, an appropriate number of solid pieces made of said first component corresponding to a predetermined proportion of said first component in said alloying additive, and loading said appropriate number of solid pieces into said hopper if any repeating steps i) to iv) for at least another alloying assembly- displacing said hopper loaded with solid pieces outside said working zone wherein at least one of positioning each of said plurality of alloying assemblies and of displacing said hopper loaded with solid pieces are carried out with said transit vehicle.

13. A method according to preceding claim, further comprising: entering the predetermined composition of alloying additive to control module, controlling transportation station so that it transports target alloying assemblies, the components thereof are part of said composition, controlling sorting station so that it transfers said predetermined number of solid pieces of each alloying assemblies to said hopper.

14. A method according to any of claims 12 to 13, further comprising: calculating the sum of all the weighed solid pieces of one given component and comparing it with a predetermined value; displacing solid pieces towards said hopper as long as said calculated sum is inferior to said predetermined value.

15. A method according to preceding claim, further comprising temporarily store solid pieces in at least one container of temporary storage area, when said calculated sum is superior to said predetermined value.

16. A method according to preceding claim, further comprising: picking, under use of picking means, the solid pieces of alloying assembly free from its packaging, and placing said solid pieces in a predetermined arrangement, in particular the one behind the others, before sorting said solid pieces.

17. A method according to any of claims 12 to 16, wherein positioning each of said plurality of alloying assemblies and displacing said hopper loaded with solid pieces are carried out both with said transit vehicle.

18. Workshop comprising a receiving section (1010), such as a dock, adapted to receive alloying assemblies (7A - 7P), a furnace (1100) adapted to prepare alloys from aluminium as well as from alloying additives, said workshop comprising also a preparation installation (I) according to any of claims 1 to 11, said preparation installation being functionally interposed between said receiving section and said furnace.

19. An automated implementation method of a workshop according to preceding claim, said method comprising the following steps, carried out under control of said control means (8):- providing a plurality of alloying assemblies (7A - 7P), each assembly comprising solid pieces (70A - 70P) of one alloying component (A - P) as well as a peripheral packaging (74A - 74P);- positioning each of said plurality of alloying assemblies on a respective one of said plurality of stands (2A - 2P), i) catching, under use of catching means (32), a first alloying assembly (7A); ii) transporting, under use of transporting means, said first alloying assembly towards said sorting station;iii) unpacking, under use of said unpacking means (41), said packaging (74A) of said first alloying assembly iv) sorting, under use of sorting means, an appropriate number of solid pieces made of said first component corresponding to a predetermined proportion of said first component in said alloying additive, and loading said appropriate number of solid pieces into said hopper if any repeating steps i) to iv) for at least another alloying assembly- displacing said hopper loaded with solid pieces outside said working zone and unloading said solid pieces into a furnace (1100), wherein at least one of positioning each of said plurality of alloying assemblies and of displacing said hopper loaded with solid pieces are carried out with said transit vehicle.

20. An automated implementation method according to preceding claim, wherein positioning each of said plurality of alloying assemblies and displacing said hopper loaded with solid pieces are carried out both with said transit vehicle.

Images