Titanium Scrap Recycling via IC Tag Identification and Automated Feed Control
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Solution Overview
Problem
The recycling of titanium metal scraps is inefficient due to manual sorting and re-melting errors, leading to quality issues in titanium ingots, and there is a shortage of raw materials like rutile and ilmenite, necessitating improved recycling methods to meet increasing demand.
Innovation Solution
A method and apparatus that automatically reads identification information from titanium scraps, calculates the necessary combination of scraps and additives using a data server, and controls the feed rates to produce ingots with accurate chemical composition, incorporating process profile information to account for impurities and variations during processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual sorting of titanium scraps is performed, then scraps can be classified by alloy composition, but sorting efficiency is low and mistakes occur
Solution Approach 1:
The patent replaces manual mechanical sorting with an automatic identification system using IC tags and reading devices. The system reads individual identification information from IC tags attached to scraps, automatically identifies alloy composition, and controls feeding without human intervention, thereby eliminating sorting mistakes and improving efficiency
Solution Approach 2:
The patent uses IC tags that contain copied information about the scrap's individual identification and alloy composition. This digital copy allows the system to accurately identify and classify scraps without physical inspection, replacing manual analysis with automated data retrieval
2Ease of manufacture
If titanium scraps are recycled without accurate composition control, then production cost is reduced, but ingot quality deteriorates
Solution Approach 1:
The patent implements a feedback control system where the reading device reads IC tag information about scrap composition, the control device calculates required additive amounts based on this feedback, and the feeding device automatically adjusts material input to achieve target composition, ensuring both cost efficiency and quality
Solution Approach 2:
The patent performs preliminary identification and composition analysis by reading IC tags before the melting process. This advance knowledge of scrap composition allows the system to pre-calculate additive requirements and control feeding rates, ensuring quality ingots are produced efficiently
3Manufacturing precision
If additives are manually added to scraps, then composition can be adjusted, but feeding rate control is imprecise
Solution Approach 1:
The patent replaces manual additive addition with an automated feeding system. The control device calculates precise additive requirements based on IC tag data and automatically controls the feeding device to add exact amounts, eliminating imprecision in both composition control and feeding rate
Solution Approach 2:
The patent dynamically adjusts feeding rate parameters based on real-time scrap composition data from IC tags. The control device modifies additive feeding rates according to the specific composition of each scrap batch, achieving precise chemical composition control through automated parameter adjustment
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the efficient recycling and reuse of titanium scraps, reducing production costs and ensuring high-quality ingots by accurately controlling chemical composition and feed rates, thereby addressing the shortage of raw materials and improving recycling efficiency.
Implementation Method 1
a hearth (30) in which a raw material including the titanium scrap (13), titanium sponge, and additives is melted by an electron beam
Implementation Method 2
a mold (31) into which the molten metal is poured
Data Source
AI summary
High quality titanium ingot is produced by using recovered titanium scrap as a raw material and adding additives. Scrap, each having individual information of identification and process profile information, is passed through automatic reading means to obtain the information and to store it in a data server. A calculating means calculates a combination of the scrap, titanium sponge and additives and feed rate of each of them so as to satisfy chemical composition and producing rate of a target ingot product using the individual identification pieces of information stored in the data server, during a beginning step of the ingot production, and transmits electrical signals corresponding to calculated results of the combination and the feed rates from the calculating means to a feed rate controlling means of each feed means of the titanium scrap, titanium sponge, and additives and then starting supply of them, and detecting means equipped at an extracting part of the ingot product reads actual producing rate of the ingot product, after the beginning step of the ingot production. The calculating means controls feed rate of the titanium scrap, titanium sponge, and/or additives based on the actual producing rate.