Semi-automated Ladle Drawer Maintenance Robot
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Solution Overview
Problem
Manual maintenance of ladle drawers in the steel industry is inefficient, hazardous, and prone to errors, leading to accidents and production disruptions due to the need for workers to handle heavy refractory components in harsh conditions, with limited precision and repeatability.
Innovation Solution
A semi-automated system utilizing a robotic device equipped with various instruments for precise maintenance operations, including viewing, maintenance, and repair tools, which operates within a controlled environment to perform maintenance tasks with reduced human intervention, ensuring safety and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual maintenance operations are performed by workers, then flexibility and adaptability are maintained, but safety risks increase and precision decreases
Solution Approach 1:
A robotic device acts as an intermediary between the maintenance operator and the drawer components. The robot executes precise movements and operations while the operator controls from a safe distance, eliminating direct exposure to hazards like molten metal and heavy weights.
Solution Approach 2:
Manual mechanical operations by workers are replaced with automated robotic systems. The robotic device performs cleaning, inspection, and maintenance tasks that were previously done manually, eliminating safety risks associated with human exposure to extreme conditions.
2Ease of operation
If workers manually handle heavy refractory components, then maintenance can be performed, but worker fatigue and stress-related injuries increase
Solution Approach 1:
The robotic device autonomously performs maintenance operations including picking up, moving, and positioning heavy refractory components. The system serves itself by automatically executing the maintenance sequence without requiring workers to physically handle heavy weights.
Solution Approach 2:
The robotic device counteracts the weight of heavy refractory components through its automated manipulation system. Instead of workers bearing the physical burden, the robot's mechanical system handles the weight, eliminating fatigue and stress-related injuries.
3Manufacturing precision
If manual maintenance operations are performed, then human judgment and adaptability are utilized, but precision and repeatability decrease
Solution Approach 1:
A control system with feedback mechanisms monitors and adjusts the robotic device's operations in real-time. Sensors detect the state of drawer components and provide feedback to the control system, which automatically adjusts parameters to achieve precise and repeatable maintenance operations.
Solution Approach 2:
The robotic system incorporates dynamic adjustment capabilities that allow it to adapt to varying maintenance conditions while maintaining precision. The system can modify its operations based on real-time conditions, achieving both precision and adaptability through automated control.
4Productivity
If workers operate in harsh environmental conditions, then maintenance can be performed, but exposure to heat and dust increases
Solution Approach 1:
The robotic device serves as an intermediary that performs maintenance operations in harsh environments without exposing workers to heat and dust. The robot operates directly in the ladle maintenance area while workers remain in protected control stations.
Solution Approach 2:
Manual operations in harsh conditions are replaced with automated robotic systems. The robotic device performs cleaning, inspection, and maintenance tasks in high-temperature and dusty environments, eliminating worker exposure to these harmful factors.
Data Source
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AI summary
The present invention concerns a semi-automated system (1) for performing maintenance operations of a drawer (100) of a ladle (200) in safety conditions. According to the invention, the semi-automated system (1) comprises a robotic device (2) adapted for carrying out a plurality of operations on said drawer (100) through a plurality of instruments (5, 7, 9, 11, 13, 15, 17, 19, 21, 23, 25, 27) housed in a store (3) and able to be picked up by said robotic device (2). The plurality of instruments (5, 7, 9, 11, 13, 15, 17, 19, 21, 23, 25, 27) comprises: - at least one viewing instrument (5) adapted for detecting points of interest of said drawer (100) and/or of components of said drawer (100); - at least one maintenance instrument (7, 9, 11, 23, 25) adapted for carrying out the maintenance of said drawer (100) and/or of components of said drawer (100) based on said points of interest detected by said viewing instrument (5); - at least one manipulating instrument (13, 15, 17, 19, 21, 27) adapted for manipulating said drawer (100) and/or components of said drawer (100) based on said points of interest detected by said viewing instrument (5).