Automated Copper Cathode Sampling Carousel
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Solution Overview
Problem
Current sampling methods for copper cathode production disrupt production lines due to frequent bucket emptying and require extensive supervision, leading to productivity losses and increased costs.
Innovation Solution
An automated apparatus featuring a rotating carousel with sorting containers, sample transfer chutes, and a control panel for continuous, unattended collection, sorting, and storage of copper cathode samples, minimizing supervision and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual sampling with buckets is used, then sample collection is simple, but production line is disrupted frequently and supervision is required
Solution Approach 1:
The automated sampling system performs sample collection, sorting, and storage operations autonomously without requiring human intervention. The system serves itself by automatically transferring samples between containers, rotating the carousel to position containers, and managing the sampling workflow without supervision, thereby eliminating production disruptions while maintaining operational simplicity
Solution Approach 2:
The patent replaces the manual mechanical system of bucket-based sampling with an automated mechanical system featuring an electric motor-driven carousel, automated transfer mechanisms, and programmable control. This substitution eliminates the need for human operators to manually empty and replace buckets, continuing production without interruption while maintaining ease of operation through automated control
2Reliability
If frequent bucket emptying is performed to prevent sample mixing, then sample purity is maintained, but production time is lost
Solution Approach 1:
The system divides the sampling process into segmented operations: sample collection in one container, automatic transfer to another, and storage in designated containers. Multiple sorting containers are used simultaneously, allowing one to be emptied while another collects samples, eliminating the need to stop production for bucket emptying while maintaining sample purity through dedicated collection vessels
Solution Approach 2:
The automated system enables continuous sampling operations without interruption to production. The carousel rotates continuously or in sequence, transferring samples without stopping the production line. Sample collection, transfer, and storage occur in continuous sequence, eliminating idle time while maintaining sample integrity through automated container management
3Measurement precision
If larger sampling regime is implemented, then better quality control is achieved, but more supervision and disruptions are required
Solution Approach 1:
The system autonomously manages complex sampling regimes without supervision. It automatically collects samples according to programmed specifications, rotates the carousel to position appropriate containers, transfers samples between containers, and stores them in designated locations. The system handles increased sampling volumes and complex quality control requirements independently, eliminating the need for additional supervisory personnel while improving measurement precision
Data Source
AI summary
An apparatus and method for collecting, sorting and storing samples from multiple batches of copper cathode is disclosed. Samples are collected at a sampling station and transferred to a collection container. The samples are then transferred to a sorting container by way of chutes forming a continuous path from the collection container to the sorting container. The sorting container is affixed on the top surface of an automated carousel having a plurality of sorting containers for sorting samples from multiple batches. Samples in the sorting containers are recovered into storage containers through an access door panel and a funnel placed beneath the access door.