WO2024137597A1

WO2024137597A1 - Systems and methods for controlling molten metal discharge from a furnace

Info

Publication number: WO2024137597A1
Application number: PCT/US2023/084774
Authority: WO
Inventors: Cameron J. KOENTOPP; Brad D. Burridge; Donnie L. NORTHERN; John Robert Buster Mccallum; Nicholas CALLIES
Original assignee: Novelis Inc.
Priority date: 2022-12-21
Filing date: 2023-12-19
Publication date: 2024-06-27

Abstract

A metal processing system includes a metal melting furnace, and the metal melting furnace includes a tap outlet. The metal processing system also includes a metal discharge machine for performing an operation related to tapping of the metal melting furnace. A method of performing an operation related to tapping of a metal melting furnace of a metal processing system includes receiving input for the operation related to tapping of the metal melting furnace and/or automatically determining an operation related to tapping of the metal melting furnace. The method includes controlling the metal discharge machine to perform the operation related to tapping of the metal melting furnace based on the received input and/or automatically determined operation.

Description

SYSTEMS AND METHODS FOR CONTROLLING MOLTEN METAL DISCHARGE

FROM A FURNACE

FIELD OF THE INVENTION

[0001] This application relates to metal processing of metals such as but not limited to aluminum and aluminum alloys. More particularly, the application relates to systems and methods for controlling molten metal discharged from a metal melting furnace.

BACKGROUND

[0002] Metals such as but not limited to aluminum and aluminum alloys are commonly melted in metal melting furnaces. A metal melting furnace may be tapped by removing a plug, which then allows for the molten metal to flow to equipment such as but not limited to a casting mold or apparatus, holding furnace, and/or other process equipment as desired, often using elongated troughs (sometimes called launders, runners, etc.). Traditionally, to tap the furnace, a human operator must manually remove the plug, and after the metal transfer is complete, the human operator must manually reinsert the plug. Such traditional approaches present a significant safety issue to the human operator due to the proximity of the human operator to the molten metal, and the human operator risks suffering burns (among other issues) due to molten metal splashing as it is discharged and/or due to potential explosions.

SUMMARY

[0003] Embodiments covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various embodiments and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings, and each claim.

[0004] According to certain embodiments, a metal processing system includes a metal melting furnace with a tap outlet and a metal discharge machine for performing an operation related to tapping of the metal melting furnace. [0005] According to some embodiments, a metal processing system includes a metal discharge machine for performing an operation related to tapping of a metal melting furnace. The metal processing system also includes an operator module communicatively coupled to the metal discharge machine and with an interface for receiving an input from an operator for controlling the metal discharge machine.

[0006] According to various embodiments, a method of performing an operation related to tapping of a metal melting furnace of a metal processing system includes receiving input for the operation related to tapping of the metal melting furnace at a location remote from a metal discharge machine. The method includes controlling the metal discharge machine to perform the operation related to tapping of the metal melting furnace based on the received input.

[0007] Various implementations described herein may include additional systems, methods, features, and advantages, which cannot necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The specification refers to the following appended figures, in which use of like reference numerals in different figures is intended to illustrate like or analogous components.

[0009] FIG. 1 illustrates a metal processing system with a metal discharge machine according to embodiments.

[0010] FIG. 2 illustrates the metal processing system of FIG. 1 with a plug removed from a tap outlet.

[0011] FIG. 3 illustrates the metal processing system of FIG. 1 and a change in position of the metal discharge machine according to embodiments.

[0012] FIG. 4 illustrates a metal processing system with a metal discharge machine according to embodiments.

[0013] FIG. 5 is another view of the metal processing system of FIG. 4. DETAILED DESCRIPTION

[0014] Described herein are metal processing systems with metal discharge machines for performing operations related to the discharge of molten metal from a metal melting furnace. In some non-limiting examples, the metal discharge machine may perform one or more operations related to tapping of the metal melting furnace, such as but not limited to removing a plug from a tap outlet of the metal melting furnace, reaming, and cleaning the tap outlet, and/or reinserting the plug into the tap outlet. Additionally or alternatively, the metal discharge machine may perform one or more operations such as but not limited to raking molten metal in a trough, paddling metal in the trough, lancing metal out of the tap outlet, adjusting and/or positioning sensors relative to the tap outlet and/or the trough, removing obstructions in the trough, slowing and/or controlling metal flow and/or metal level, painting and/or coating the trough, powdering the trough, filling trough joints, preheating the trough or tap outlet, adding alloys to the trough, combinations thereof, and/or various other operations related to the discharge of molten metal from the metal melting furnace and tapping of the metal melting furnace. In certain embodiments, the metal melting furnaces described herein include a tool interface, and the metal melting machines described herein may engage a tool (e.g., plug, hammer, rod, paddle, etc.) for performing the one or more operations. The metal processing systems described herein allow a human operator to be in a location remote from the tap outlet while still providing the required activities associated with metal discharge from the metal melting furnace, thereby reducing and/or minimizing risks due to splashing, explosions, and/or other conditions from the hazardous environment. The systems described herein may further allow for improved control of the metal discharged from the metal melting furnace. Various other advantages and benefits may be realized with the systems and methods described herein, and the aforementioned benefits should not be considered limiting.

[0015] FIGS. 1-3 illustrate a metal processing system 100 according to embodiments. The metal processing system 100 generally includes a metal melting furnace 102 having one or more tap outlets 104. A plug 106 is positionable within the tap outlet 104 to control the flow of molten metal from the tap outlet 104. FIG. 1 illustrates the plug 106 positioned within the tap outlet 104 and preventing the flow of molten metal, and FIG. 2 illustrates the plug 106 completely removed from the tap outlet 104 thereby allowing the flow of molten metal from the tap outlet 104 (metal flow represented by arrows 108). In certain embodiments, the molten metal may flow from the tap outlet 104 into a trough 110 or other similar structure, which may direct the metal to a casting mold, casting apparatus, holding furnace, and/or other process equipment as desired. A working area 101 of the metal processing system 100 is generally the environment near the tap outlet 104 and/or molten metal during normal operation of the metal processing system 100. Hazards such as splashing of molten metal may be present in the working area 101 during operation of the metal processing system 100.

[0016] In various embodiments, the metal processing system 100 includes a metal discharge machine 112 for performing one or more operations related to discharge of metal from the metal melting furnace 102. In various embodiments, the metal discharge machine 112 may perform one or more operations related to tapping the metal melting furnace 102.

[0017] The metal discharge machine 112 generally includes an interface 114 that is movable via one or more machine sections 116. While a single interface 114 is illustrated in FIGS. 1- 3, in other embodiments, the metal discharge 112 may include any number of interfaces 114 as desired, and the type of one interface 114 need not be the same as another interface 114. The interface 114 may include various features or components for engaging a component of the metal processing system 100 (e.g., the metal melting furnace 102, the plug 106, the trough 110, etc.), engaging a tool (e.g., a heater, a hammer, a rod, a paddle, a ladle, a sensor, a probe, etc.), and/or performing other operations as desired. As non-limiting examples, the interface 114 may include various features or components for selectively engaging and actuating (e.g., removing and inserting) the plug 106, cleaning the tap outlet 104, lancing the tap outlet 104, engaging and positioning a probe in the trough 110 at a desired height, engaging and manipulating a visual sensor such as a camera, removing an obstruction in the trough 110, controlling the flow and/or metal level in the trough 110, reaming the tap outlet 104, moving along the trough 110, examining the trough 110, coating or painting the trough 110, powdering the trough 110, filling joints of the trough 110, positioning heaters to preheat the trough 110 and/or tap outlet 104, activating and deactivating heaters, positioning trough covers relative to the trough 110, positioning sensors in the molten metal, positioning sensors at locations in proximity to the tap outlet 104, inserting alloys into the trough 110, positioning a dam in the trough 110, ladling metal from the trough 110 to a dump bin and/or for sampling, inspecting conditions of the trough 110, repairing the trough 110, various combinations thereof, and/or other operations as desired. In the embodiment of FIGS. 1-3, the interface 114 includes a gripper 118 at least for selectively engaging the plug 106.

[0018] The machine sections 116 may be various devices or components suitable for moving the interface 114 to perform the one or more operations related to metal discharge from the metal melting furnace 102. As non-limiting examples, the machine sections 116 may provide twisting movements, linear pulling movements, linear pushing movements, changing angle of attack movements, vertical and/or horizontal movements, accelerating movements, decelerating movements, quick movements, slow movements, combinations thereof, and/or other types of movements as desired. Any number of machine sections 116 may be used as desired, and when a plurality of machine sections 116 are utilized, the type of one machine section 116 need not be the same as another machine section 116.

[0019] Optionally, the metal discharge machine 112 includes one or more sensors for gathering data about the metal discharge machine 112, the molten metal, and/or the components of the metal processing system 100. Such sensors may include but are not limited to visual sensors, temperature sensors, position sensors, combinations thereof, and/or other sensors as desired.

[0020] In the embodiment illustrated, the metal discharge machine 112 includes a visual sensor 120 for gathering information about molten metal and the components of the metal processing system 100 as the metal discharge machine 112 performs various operations. In this embodiment, the visual sensor 120 may be various types of cameras including but not limited to optical or video cameras, single or multi-stereo cameras, RGB-D cameras, laserbased sensors, thermal (e.g., infrared) cameras, visible light cameras, other wavelength cameras, machine vision cameras, combinations thereof, and/or other visual sensors as desired. In various embodiments, the data gathered by the visual sensor 120 may be provided to a human operator, used to predict or determine an operating condition of the metal processing system 100, and/or be used to control one or more operations of the metal discharge machine 112. As a non-limiting example, the information from the visual sensor 120 may identify an obstruction in the tap outlet 104 and/or the trough 110, and the detection of the obstruction may be provided to the human operator and/or used by the metal discharge machine 112 (e.g., to perform an operation to automatically remove the obstruction).

[0021] Additionally, or alternatively, the metal discharge machine 112 may include one or more position sensors for detecting a position of the metal discharge machine 112 relative to another component of the metal processing system 100 (e.g., relative to the tap outlet 104) and/or for detecting relative positionings of components of the metal discharge machine 112 itself (e.g., the position of the interface 114 relative to one of the machine sections 116). The position information may be provided to a human operator, used to predict or determine an operating condition of the metal processing system 100, and/or be used to control one or more operations of the metal discharge machine 112. Referring to FIG. 3, in one non-limiting example, a change in position of the metal discharge machine 112 (represented by arrow 124) from a first position (represented in solid lines) to a second position (represented in dash-dot lines) to perform a same tapping operation may be used to predict or determine degradation of the tap outlet 104 and/or trigger cleaning of the tap outlet 104.

[0022] Referring to FIGS. 1 and 2, in certain embodiments, the metal processing system 100 optionally includes an associated user interface 122, including but not limited to a human machine user interface, for obtaining information from a human operator to control the metal discharge machine 112 and/or to provide information to the human operator via the user interface 122. The user interface 122 may be communicatively coupled to the metal discharge machine 112 using systems and mechanisms enabling wired communication and/or wireless communication (e.g., Industrial Ethernet, Profibus®, near field, cellular, Wi-Fi, Bluetooth®, Bluetooth Low Energy (BLE), etc.). Optionally, various control or output responses may be provided to the human operator via the user interface 122. In some embodiments, the output response may include providing the visual image of the tap outlet 104, the trough 110, molten metal, etc. in the working area 101 to the human operator, thereby allowing the operator to view the equipment and/or metal. Additionally, or alternatively, the control response may include generating an alert or notification on the user interface 122. As illustrated, the user interface 122 may be remote from the working area 101. The remote user interface 122 may allow for the human operator to perform operations related to metal discharge (via the metal discharge machine 112) and/or to obtain information about the metal processing system 100 while being remote from the molten metal, thereby providing improved safety for the human operator.

[0023] FIGS. 4 and 5 illustrate another metal processing system 400 according to embodiments. The metal processing system 400 is substantially similar to the metal processing system 100 except that a metal discharge machine 412 with a different interface 414 and different machine sections 416 compared to the metal discharge machine 112 is provided. Similar to the metal discharge machine 112, the metal discharge machine 412 is adapted to perform at least a tapping operation by selectively engaging and positioning the plug 106. As illustrated in FIGS. 4 and 5, a human operator 403 may control the metal discharge machine 412 and/or receive information about the metal discharge machine 412 and/or about operations performed by the metal discharge machine 412 using the remote user interface 122. [0024] Referring to FIGS. 1-3, non-limiting examples of operations related to discharge of metal from the metal melting furnace 102 using the metal discharge machine 112 are described in greater detail below. The operations may be performed automatically and/or based on input from a human operator using the remote user interface 122.

[0025] In some embodiments, the metal discharge machine 112 may perform a tapping operation. In such embodiments, the metal discharge machine 112 may engage the plug 106 positioned within the tap outlet 104 using the interface 114. Optionally, the metal discharge machine 112 may directly engage the plug 106 (e.g., using the gripper 118), or the metal discharge machine 112 may engage a tool (e.g., hammer, rod, paddle, etc.) and use the tool to engage the plug 106. The metal discharge machine 112 may perform various movements or motions to remove the plug 106 from the tap outlet 104, such as but not limited to twisting the plug 106, pulling the plug 106, pushing the plug 106, moving the plug 106 linearly or with a changing direction, changing a speed or force of moving the plug 106, combinations thereof, and/or other movements or motions as desired. In various embodiments, molten metal may flow out of the tap outlet 104 and into the trough 110 once the plug 106 is removed. Optionally, the metal discharge machine 112 may partially position the plug 106 within the tap outlet 104 to control a flow rate of the molten metal from the metal melting furnace 102 and/or a metal level in the trough 110. Optionally, when the metal transfer from the tap outlet 104 is complete, the metal discharge machine 112 may clean the tap outlet 104 directly or using a tool (e.g., by reaming or lancing the tap outlet 104). The metal discharge machine 112 may reposition the plug 106 within the tap outlet 104 and/or may obtain a replacement plug 106 and position the replacement plug 106 within the tap outlet 104. The cleaning of the tap outlet 104 and/or positioning of the plug 106 optionally may be performed after a determined time period and/or as otherwise desired. In certain embodiments, the metal discharge machine 112 may perform tapping operations on a plurality of tap outlets 104, either concurrently or independently.

[0026] Additionally, or alternatively, the metal discharge machine 112 may engage a paddle or other suitable tool using the interface 114 and/or may use the interface 114 to rake molten metal down the trough 110 and/or from the tap outlet 104 at the end of the transfer of molten metal from the tap outlet 104.

[0027] In certain embodiments, in the event of a freeze up of the tap outlet 104, the metal discharge machine 112 may ream (e.g., by melting, by prodding, and/or by scraping) the metal out of the tap outlet 104 using the interface 114 and/or using a tool engaged by the metal discharge machine 112.

[0028] In various embodiments, the metal discharge machine 112 may engage a temperature probe (directly or using a tool) and may position the temperature probe as desired within the molten metal. In some embodiments, the metal discharge machine 112 may position the temperature probe at a desired height within the trough 110, tap outlet 104, and/or the metal melting furnace 102 to minimize adverse effects from a high molten metal level.

[0029] In some embodiments, the metal discharge machine 112 may identify an obstruction in the tap outlet 104 and/or the trough 110 and may remove the obstruction directly or using a tool. In some embodiments, the metal discharge machine 112 may examine the length of the trough 110 and/or the tap outlet 104 before metal discharge to determine whether any obstructions are present.

[0030] In certain embodiments, the metal discharge machine 112 may paint the trough 110, coat the trough 110, powder the trough 110, and/or fill joints of the trough 110 directly using the interface 114 and/or using a tool engaged by the metal discharge machine 112.

[0031] In various embodiments, the metal discharge machine 112 may preheat the tap outlet 104 and/or the trough 110 by engaging and positioning a heater relative to the tap outlet 104 and/or the trough 110 to preheat the trough 110 and/or tap outlet 104. Optionally, the metal discharge machine 112 may selectively activate and/or deactivate the heater.

[0032] In some embodiments, the metal discharge machine 112 may engage and position covers of the trough 110 to selectively open or close the trough 110.

[0033] In various embodiments, the metal discharge machine 112 may selectively insert specific alloys into the molten metal in the trough 110 by engaging a container with such alloys and/or engaging the alloys themselves using the interface 114 and inserting the alloys into the molten metal.

[0034] In certain embodiments, the metal discharge machine 112 may identify (e.g., using the visual sensor 120) a maintenance event (e.g., metal leakage from the tap outlet 104) and may place a dam in the metal melting furnace 102, remove and replace the plug 106, and remove the dam. In some embodiments, the metal discharge machine 112 may likewise selectively dam the trough 110. [0035] The metal discharge machine 112 may selectively remove molten metal from the trough 110. As non-limiting examples, the metal discharge machine 112 may ladle quantities of metal from the trough 110 to a dump bin in the event of a leak or overflow, and/or the metal discharge machine 112 may ladle a sample of metal from the trough 110 (e.g., for analysis, quality control, etc.).

[0036] In some embodiments, the metal discharge machine 112 may clean the trough 110 directly or using a tool. As an example, the metal discharge machine 112 may sweep dust, debris, remnant metal, dirt, and/or other material out of the trough 110 and/or off the trough 110.

[0037] In certain embodiments, the metal discharge machine 112 may examine the trough 110 and/or tap outlet 104, determine a condition of the trough 110 and/or tap outlet 104, and/or repair the trough 110 and/or tap outlet 104.

[0038] The above example examples are for illustrative purposes, and various other operations and/or combinations of operations related to discharge of metal from the metal melting furnace 102 may be performed as desired. As illustrated by the above examples, various operations related to metal discharge and transfer from the metal melting furnace 102 may be performed while the human operator is remote from the working area 101, thereby improving safety to the human operator, The metal discharge machine 112 may further allow for improved control of molten metal transfer by controlling the metal flow rate, controlling the metal level, allowing for alloy introduction into the metal, etc. Various other benefits and advantages may be realized using the metal processing system with the metal discharge machine.

[0039] A collection of exemplary embodiments is provided below, including at least some explicitly enumerated as “Illustrations” providing additional description of a variety of example embodiments in accordance with the concepts described herein. These illustrations are not meant to be mutually exclusive, exhaustive, or restrictive; and the disclosure not limited to these example illustrations but rather encompasses all possible modifications and variations within the scope of the issued claims and their equivalents.

[0040] Illustration 1. A metal processing system comprising: a metal melting furnace comprising a tap outlet; and a metal discharge machine configured to perform an operation related to tapping of the metal melting furnace. [0041] Illustration 2. The metal processing system of any preceding or subsequent illustrations or combination of illustrations, wherein the metal discharge machine comprises a tool interface and at least one of a visual sensor or a non-visual sensor.

[0042] Illustration 3. The metal processing system of any preceding or subsequent illustrations or combination of illustrations, wherein the metal discharge machine is configured to selectively engage a discharge tool using the tool interface.

[0043] Illustration 4. The metal processing system of any preceding or subsequent illustrations or combination of illustrations, wherein the metal discharge machine is configured to perform at least one of cleaning the tap outlet, reaming of the tap outlet, or plug the tap outlet with a plug as the operation related to tapping of the metal melting furnace.

[0044] Illustration 5. The metal processing system of any preceding or subsequent illustrations or combination of illustrations, further comprising a trough for receiving molten metal from the metal melting furnace, wherein the metal discharge machine is configured to rake molten metal down the trough or paddle the molten metal in the trough as the operation related to tapping of the metal melting furnace.

[0045] Illustration 6. The metal processing system of any preceding or subsequent illustrations or combination of illustrations, further comprising a plug positionable within the tap outlet, wherein the metal discharge machine is configured to tap the metal furnace by removing the plug from the tap outlet as the operation related to tapping of the metal melting furnace.

[0046] Illustration 7. The metal processing system of any preceding or subsequent illustrations or combination of illustrations, wherein the metal discharge machine is configured to control a flow rate of molten metal being discharged from the metal melting furnace or control a metal level by controlling a position of a plug relative to the tap outlet as the operation related to the tapping of the metal melting furnace.

[0047] Illustration 8. The metal processing system of any preceding or subsequent illustrations or combination of illustrations, further comprising a controller communicatively coupled to the metal discharge machine, wherein the controller is configured to receive data from the metal discharge machine about a position of the metal discharge machine relative to the tap outlet and determine a degradation of the tap outlet based on change in the position of the metal discharge machine. [0048] Illustration 9. The metal processing system of any preceding or subsequent illustrations or combination of illustrations, wherein the metal discharge machine is configured to maintain at least a predetermined distance from the tap outlet.

[0049] Illustration 10. The metal processing system of any preceding or subsequent illustrations or combination of illustrations, wherein the metal discharge machine is configured to perform at least one of: coating a trough, powdering the trough, filling trough joints, picking up a heater to preheat the tap outlet or the trough, placing a dam in the trough, inserting an alloy into the trough, ladling a quantity of molten metal to a dump bin or to a sample station, or skimming the molten metal in the trough.

[0050] Illustration 11. A metal processing system comprising: a metal discharge machine configured to perform an operation related to tapping of a metal melting furnace; and an operator module communicatively coupled to the metal discharge machine, the operator module comprising an interface configured to receive an input from an operator for controlling the metal discharge machine.

[0051] Illustration 12. The metal processing system of any preceding or subsequent illustrations or combination of illustrations, wherein the operation related to the tapping of the metal melting furnace comprises a furnace operation or a trough operation.

[0052] Illustration 13. The metal processing system of any preceding or subsequent illustrations or combination of illustrations, wherein the metal discharge machine is configured to: remove a plug from a tap outlet of the metal melting furnace; clean the tap outlet after a determined time period; and reinsert the plug into the tap outlet.

[0053] Illustration 14. The metal processing system of any preceding or subsequent illustrations or combination of illustrations, wherein the metal discharge machine comprises a tool interface for handling a tool to perform the operation related to the tapping of the metal melting furnace.

[0054] Illustration 15. A method of performing an operation related to tapping of a metal melting furnace of a metal processing system, the method comprising: receiving input for the operation related to tapping of the metal melting furnace at a location remote from a metal discharge machine, wherein the metal discharge machine is a predetermined distance from a tap outlet of the metal melting furnace; and controlling the metal discharge machine to perform the operation related to tapping of the metal melting furnace based on the received input. [0055] Illustration 16. The method of any preceding or subsequent illustrations or combination of illustrations, wherein controlling the metal discharge machine comprises causing the metal discharge machine to interface with a discharge tool using a tool interface of the metal discharge machine.

[0056] Illustration 17. The method of any preceding or subsequent illustrations or combination of illustrations, wherein controlling the metal discharge machine comprises causing the metal discharge machine to perform at least one of: cleaning the tap outlet; reaming the tap outlet; plugging the tap outlet with a plug; or controlling a flow rate of molten metal being discharged from the metal melting furnace or control a metal level by controlling a position of a plug relative to the tap outlet.

[0057] Illustration 18. The method of any preceding or subsequent illustrations or combination of illustrations, wherein controlling the metal discharge machine comprises causing the metal discharge machine to perform at least one of: coating a trough of the metal processing system; powdering the trough; filling trough joints; moving a heater to preheat the tap outlet or the trough; placing a dam in the trough; inserting alloying element(s) into the trough; ladling a quantity of molten metal to a dump bin or to a sample station; or skimming the molten metal in the trough.

[0058] Illustration 19. The method of any preceding or subsequent illustrations or combination of illustrations, wherein controlling the metal discharge machine comprises causing the metal discharge machine to remove a plug from the tap outlet, clean the tap outlet after a time period, and reinsert the plug into the tap outlet.

[0059] Illustration 20. The method of any preceding or subsequent illustrations or combination of illustrations, further comprising receiving data from the metal discharge machine about a position of the metal discharge machine relative to the tap outlet; and determining a degradation of the tap outlet based on change in the position of the metal discharge machine.

[0060] The subject matter of embodiments is described herein with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. Directional references such as “up,” “down,” “top,” “bottom,” “left,” “right,” “front,” and “back,” among others, are intended to refer to the orientation as illustrated and described in the figure (or figures) to which the components and directions are referencing. In the figures and the description, like numerals are intended to represent like elements. As used herein, the meaning of “a,” “an,” and “the” includes singular and plural references unless the context clearly dictates otherwise.

[0061] The above-described aspects are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Many variations and modifications may be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure. Moreover, although specific terms are employed herein, as well as in the claims that follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described embodiments, nor the claims that follow.

Claims

CLAIMS That which is claimed:

1. A metal processing system comprising: a metal melting furnace comprising a tap outlet; and a metal discharge machine configured to perform an operation related to tapping of the metal melting furnace.

2. The metal processing system of claim 1, wherein the metal discharge machine comprises a tool interface and at least one of a visual sensor or a non-visual sensor.

3. The metal processing system of claim 2, wherein the metal discharge machine is configured to selectively engage a discharge tool using the tool interface.

4. The metal processing system of claim 1, wherein the metal discharge machine is configured to perform at least one of cleaning the tap outlet, reaming of the tap outlet, or plugging the tap outlet with a plug as the operation related to tapping of the metal melting furnace.

5. The metal processing system of claim 1, further comprising a trough for receiving molten metal from the metal melting furnace, wherein the metal discharge machine is configured to rake molten metal down the trough or paddle the molten metal in the trough as the operation related to tapping of the metal melting furnace.

6. The metal processing system of claim 1, further comprising a plug positionable within the tap outlet, wherein the metal discharge machine is configured to tap the metal melting furnace by removing the plug from the tap outlet as the operation related to tapping of the metal melting furnace.

7. The metal processing system of claim 1, wherein the metal discharge machine is configured to control a flow rate of molten metal being discharged from the metal melting furnace or control a metal level by controlling a position of a plug relative to the tap outlet as the operation related to the tapping of the metal melting furnace.

8. The metal processing system of claim 1, further comprising a controller communicatively coupled to the metal discharge machine, wherein the controller is configured to receive data from the metal discharge machine about a position of the metal discharge machine relative to the tap outlet and determine a degradation of the tap outlet based on change in the position of the metal discharge machine.

9. The metal processing system of claim 1, wherein the metal discharge machine is configured to maintain at least a predetermined distance from the tap outlet.

10. The metal processing system of claim 1, wherein the metal discharge machine is configured to perform at least one of: coating a trough, powdering the trough, filling trough joints, picking up a heater to preheat the tap outlet or the trough, placing a dam in the trough, inserting an alloy into the trough, ladling a quantity of molten metal to a dump bin or to a sample station, or skimming the molten metal in the trough.

11. A metal processing system comprising: a metal discharge machine configured to perform an operation related to tapping of a metal melting furnace; and an operator module communicatively coupled to the metal discharge machine, the operator module comprising an interface configured to receive an input from an operator for controlling the metal discharge machine.

12. The metal processing system of claim 11, wherein the operation related to the tapping of the metal melting furnace comprises a furnace operation or a trough operation.

13. The metal processing system of claim 11, wherein the metal discharge machine is configured to: remove a plug from a tap outlet of the metal melting furnace; clean the tap outlet after a determined time period; and reinsert the plug into the tap outlet.

14. The metal processing system of claim 11, wherein the metal discharge machine comprises a tool interface for handling a tool to perform the operation related to the tapping of the metal melting furnace.

15. A method of performing an operation related to tapping of a metal melting furnace of a metal processing system, the method comprising: receiving input for the operation related to tapping of the metal melting furnace at a location remote from a metal discharge machine, wherein the metal discharge machine is a predetermined distance from a tap outlet of the metal melting furnace; and controlling the metal discharge machine to perform the operation related to tapping of the metal melting furnace based on the received input.

16. The method of claim 15, wherein controlling the metal discharge machine comprises causing the metal discharge machine to interface with a discharge tool using a tool interface of the metal discharge machine.

17. The method of claim 15, wherein controlling the metal discharge machine comprises causing the metal discharge machine to perform at least one of: cleaning the tap outlet; reaming the tap outlet; plugging the tap outlet with a plug; or controlling a flow rate of molten metal being discharged from the metal melting furnace or control a metal level by controlling a position of a plug relative to the tap outlet.

18. The method of claim 15, wherein controlling the metal discharge machine comprises causing the metal discharge machine to perform at least one of: coating a trough of the metal processing system; powdering the trough; filling trough joints; moving a heater to preheat the tap outlet or the trough; placing a dam in the trough; inserting one or more alloying elements into the trough; ladling a quantity of molten metal to a dump bin or to a sample station; or skimming the molten metal in the trough.

19. The method of claim 15, wherein controlling the metal discharge machine comprises causing the metal discharge machine to remove a plug from the tap outlet, clean the tap outlet after a time period, and reinsert the plug into the tap outlet.

20. The method of claim 15, further comprising: receiving data from the metal discharge machine about a position of the metal discharge machine relative to the tap outlet; and determining a degradation of the tap outlet based on change in the position of the metal discharge machine.