Torpedo Car Capping End Effector for High-Temperature Cover Handling
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Solution Overview
Problem
Current methods for capping the tank opening of a torpedo car in molten iron transportation are inefficient, unsafe, and unreliable due to the lack of a covering device, leading to pollution, energy waste, and safety risks for manual operations, and existing robot end effectors are not suitable for high-temperature applications or precise handling.
Innovation Solution
An end effector for a torpedo car capping robot equipped with a picking and releasing unit, buffer unit, thermal insulation cover distance detection unit, end effector structure protection unit, pneumatic actuator unit, end effector protective cover shell, and heat dissipation unit, along with visual systems for precise positioning and control, enabling automated and safe capping operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual capping operation is used, then the tank opening can be covered, but workers face safety risks such as burns from high temperature, dust and splashing of molten steel
Solution Approach 1:
The patent replaces the manual mechanical capping operation with an automated robot system. The robot end effector equipped with suction cups automatically picks up the thermal insulation cover and places it on the tank opening, eliminating worker exposure to high temperature, dust and molten steel splashing while maintaining the capping function.
Solution Approach 2:
The patent introduces a robot system as an intermediary between the thermal insulation cover and the tank opening. The robot end effector with suction cups serves as the mediating mechanism that handles the cover, preventing direct human contact with hazardous environments while achieving the capping operation.
2Manufacturing precision
If a robot end effector with suction cup is used for high-speed handling, then centering performance is good, but the rubber suction cup lacks high-temperature protection and cannot meet application requirements
Solution Approach 1:
The patent changes the material parameter of the suction cup from rubber to magnetically responsive material. This parameter change enables the suction cup to function in high-temperature environments by utilizing magnetic field interaction instead of rubber elasticity, while maintaining good centering performance through the positioning guide sleeve.
Solution Approach 2:
The patent uses a magnetic field (analogous to a strong field) to replace the mechanical suction mechanism. The permanent magnet generates a magnetic field that attracts the magnetically responsive suction cup, providing a reliable holding force that is not affected by high temperatures, thus resolving the temperature resistance issue while maintaining positioning accuracy.
3Device complexity
If a single suction cup device is used, then the structure is simple, but the weight of the object being picked up is limited and additional longitudinal-depth movement range expansion is not provided
Solution Approach 1:
The patent divides the single suction cup into multiple suction cups (first suction cup and second suction cup) arranged at different positions. This segmentation allows the end effector to handle heavier thermal insulation covers by distributing the load across multiple attachment points while maintaining structural simplicity.
Solution Approach 2:
The patent adds the longitudinal dimension to the robot system by incorporating a linear motor-driven moving platform. This dimensionality change expands the operating range of the end effector, allowing it to reach objects at different longitudinal positions while maintaining the simplicity of the end effector structure itself.
4Reliability
If the thermal insulation cover is transported manually by electric hoist, then the capping operation can be completed, but the process takes about 5 hours and efficiency is low
Solution Approach 1:
The patent replaces the manual electric hoist system with an automated robot system. The robot with end effector automatically picks up the thermal insulation cover, transports it to the tank opening, and places it, completing the capping operation in a fraction of the time required for manual operation, thus dramatically improving productivity.
Solution Approach 2:
The patent enables continuous automated operation of the capping process. The robot system can continuously pick up covers, transport them, and place them on tank openings without the interruptions and time losses associated with manual operation, achieving continuous useful action and high productivity.
5Ease of operation
If workers stand close to the torpedo car to work, then the capping operation can be performed, but operation scenarios of extreme high temperature pose safety risks such as burns
Solution Approach 1:
The patent introduces a robot system as an intermediary that performs the capping operation in the hazardous high-temperature environment. The robot end effector with magnetically responsive suction cups handles the thermal insulation cover, keeping workers at a safe distance while maintaining full operational capability.
Solution Approach 2:
The patent replaces human manual operation with an automated robot system that can withstand high-temperature environments. The robot's mechanical and magnetic systems are not affected by high temperature in the same way human operators are, eliminating burn risks while maintaining capping operation capability.
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
The end effector enables precise and efficient capping of the torpedo car tank opening, reducing safety risks and improving operational efficiency while ensuring the safety and reliability of the capping process.
Implementation Method 1
a picking and releasing unit for picking up and releasing the thermal insulation cover; including: a suction cup for picking up and releasing the thermal insulation cover
Implementation Method 2
a buffer unit to connect the suction cup with a component mounting plate on the end effector; including: a buffer support rod that can make a compression stroke between the suction cup and the component mounting plate
Implementation Method 3
a thermal insulation cover distance detection unit to detect a relative distance between the thermal insulation cover and the component mounting plate; including: a laser rangefinder for performing detection
Implementation Method 4
an end effector structure protection unit to detect the compression amount of the buffer support rod; including: a photoelectric sensor for performing detection
Data Source
AI summary
An end effector for a torpedo car capping robot and a capping method thereof. which effector and method belong to the field of robot control. The end effector at least comprises: a pickup and release unit, a buffer unit, a heat preservation cover distance measurement unit, an end effector structure protection unit and a pneumatic execution unit. The capping method comprises: by means of a heat preservation cover visual system, identifying the center of a heat preservation cover at the current position to be subjected to picking up, feeding back the center to a robot system, and a pickup center position of an end effector moving to the position right above the center of the heat preservation cover; by means of a numerical value which is fed back by a heat preservation cover distance measurement unit, driving the robot system to descend with the end effector and pick up the heat preservation cover; and a tank opening visual system identifying the current direction of a tank opening of a torpedo car, feeding back data to the robot system, guiding the robot system to move to the position above the tank opening, and releasing the heat preservation cover, so as to complete a capping operation. A robot is automatically guided to perform accurate capping operation on a tank opening of a torpedo car, thereby ensuring the safety of an operation device and an operated object during the whole operation process.