FIELD OF THE INVENTION

The present invention relates to a system for conveying a ladle containing molten metal in a truck or such other vehicle for locomotion by land, a method for conveying a ladle containing molten metal in a truck or such other vehicle for locomotion by land, and more particularly to a system and method of conveying a ladle in a truck wherein the ladle contains molten metal.

BACKGROUND OF THE INVENTION

In a foundry, a high-temperature molten metal melted in a melting furnace or the like is carried to a pouring facility and the product is cast by pouring the molten metal into the mold in the pouring facility.

These days, due to space constraint and other reasons, different functions involved in manufacture of the final product are carried out at different locations, thus requiring the need for transportation of molten metal from one factory location to the other. Moreover, at times, the raw material, for example motel metal is also procured from different suppliers, leading to the inherent requirement of transportation of molten metal from one location to the other. More particularly, as factory(s) of most suppliers are located in close proximity to each other, the transportation by way of vehicles for locomotion by land becomes the most preferred mode of transportation.

Recently, transporting of molten metal in a ladle has acquired growing acceptance in the industry. The ladle accommodates molten metal, which is then transported from one factory of a material supplier to a molding factory. Transportation in the ladle allows the molten metal to be preserved in the form which is required in the next step of manufacturing i.e. to die-cast machines. Moreover, transportation in a ladle provides for ease of pouring the molten metal in the die-cast machines and therefore is more desirable.

However, transportation of molten metal in a Ladle by road has its own inherent risks. The biggest risk of such mode of transportation being the danger of falling of ladle and spillage of molten metal during the course of transportation. Accordingly, securing the ladle to the vehicle has been traditionally used to minimize the risks associated with such means of transportation.

Conventionally, in order to transport the molten metal from a melting furnace or the like to the pouring facility, the molten metal is received by a ladle, and the ladle is transported to the pouring facility by a truck, wherein the ladle is secured by way of chains.

However, in such conventional system and method of transportation of ladle, there remains a risk that the chains become lose, particularly while movement of vehicle over paved and unpaved roads, thus posing a continuous challenge and risk associated with fall of ladle and consequential spillage of molten metal.

Therefore, in conventional system and method, the transportation staff is required to be a well-trained staff which is required to keep a constant physical check on the state of the ladle and ensure that the ladle is firmly secured by the chains. At times, the staff has to comprise of multiple persons, some of which have to perform the sole duty of keeping a watch on the ladle.

Still further, the conventional system and method requires frequent physical checks of the ladle by the transportation staff to ensure that the chains are securely fastened. However, said frequent checks requires stopping the vehicle and inspection consume a lot of time. As time is the essence in transportation of molten metal, frequent stops leads to delays in transportation which is not desirable. However, even after following the process of regular checks, provisioning of additional staff, the possibility of a lose chain and potential accident cannot be ruled out. In many cases, due to the road and traffic conditions, the ladle wobbles. As the molten metal in the container held by lose chains is wobbled, the molten metal is spattered outside of the vehicle leading to risk. Moreover, the wobbling also leads to jolt splashes, which leads to further loosening of chains, instability and eventual fall of the ladle, which is not desired. Many accidents have been reported in the past wherein the ladle filled with molten metal has fallen on the road as the chains holding the ladle had become lose while transportation.

Therefore, there is a need in the art for a system and method for safe, secure, easy to use, economical, reliable and fast delivery of molten metal in a ladle.

CN102381229B discloses a two-man ladle transportation vehicle, which relates to a transportation vehicle and comprises a weighing system and a tilting prevention device. It discloses that the weighing system comprises a weighing sensor, an installing module, a weighing controller and a weight information display screen.

However, the said utility model is different from our invention in that the solution envisaged in the said utility model is an anti-tilting system. Moreover, the anti-tiling system disclosed in the said utility model is a clamping oil cylinder which is different from the solution envisaged in the present invention. In the present invention, Load Cells have been provided which are placed on Ratchet Chains. The said means when connected to the other means described in detail herein after allows provision of dynamic information of the change of pressure to the transportation staff. The invention of the present invention provides a simple, cost effective, safe and reliable solution to the problem in the art.

CN208840500U relates to molten aluminum casting ladle transport protection device and transport vehicle. The molten aluminum casting ladle transportation protection device comprises a fixed base, two inserting groove guide roller sets, a front hoop, a rear hoop assembly and a locking assembly. The two inserting groove guide roller sets are used for guiding the corresponding forklift inserting grooves.

However, the said utility model does not envisage the ladle safety monitoring system comprising Load Cells, Ratchet Chains, Relay Module as envisaged in the present invention.

Thus, there is an unmet need in the art for a system and method by way of which the risk of fall of ladle because of unmonitored loosening of chain(s) holding the ladle is precluded. There is a need in the art for a system and method which continuously monitors pressure on each individual chain(s) holding the ladle, particularly when the vehicle is in motion, thus ensuring ladle safety while transportation of molten metal. Further, there is a need in the art for a system and method for safe, secure, easy to use, economical, reliable and fast delivery of molten metal in a ladle.

OBJECT OF THE INVENTION

The main object of the present invention is to provide a system and method for supplying or transportation of molten metal in a vehicle for locomotion by land, with high reliability, certainty, cost-efficiency and in a timely manner.

Another object of the invention is to provide a system and method for supplying or transportation of molten metal in a vehicle for locomotion by land, with high reliability, certainty, cost-efficiency and in a timely manner, wherein such vehicle is a truck.

In addition, the object of the present invention is to offer a system for supplying or transportation of molten metal which enables monitoring the pressure on each individual chain(s) holding the ladle on a real-time basis.

Another object of the present invention is to provide a molten metal supplying or transportation system and method capable of displaying to the transportation staff, the pressure on each individual chain(s) holding the ladle in real-time while the truck is in motion.

Another object of the present invention is to provide a molten metal supplying or transportation system and method capable of alerting the transportation staff, by way of audio and visual alarms, if there is an drop in pressure on any of the chains holding the ladle.

Still further object of the invention is to provide a molten metal supplying or transportation system which provides the opportunity to the staff to identify exact chain having drop in pressure, thus assisting the staff in rectifying the pressure quickly rather than physical inspection of each individual chain to identify possible faults as required in the conventional system.

Still further object of the invention is to come up with a system and method which helps in transportation of molten metal in a time efficient manner. Reduction in time involved in transportation is especially desirable as it leads to reduction of heat loss and less use of fuel to heat the transported metal. Reduction in time involved in transportation is achieved as the system and method disclosed in the invention helps avoids frequent physical checking of chain(s) holding the ladle which is an inherent part of the conventional transportation system and methods.

Still another object of the present invention is to come up with a system and method which is driver-friendly, by providing displays and alarms to monitor the safety of the ladle closely while the truck is in motion.

SUMMARY OF THE INVENTION

The present invention relates to a system for conveying a ladle containing molten metal in a truck or such other vehicle for locomotion by land, a method for conveying a ladle containing molten metal in a truck or such other vehicle for locomotion by land, and more particularly to a system and method of conveying a ladle in a truck wherein the ladle contains molten metal.

In an embodiment, the present invention provides a system for conveying a ladle on a truck comprising, (1) securing means for securing the ladle on frame; (2) sensing means for sensing the pressure on the securing means; and (3) monitoring means for converting the signals obtained from sensing means and displaying it in real time to the driver of the vehicle in the form of audio and visual signals.

In one embodiment, the present invention provides a system for conveying a ladle on a truck, comprising as securing means, a plurality of rachet chains (4), a plurality of swivel eye-bolts (10) and a plurality of means for fastening the chain(9).

In one embodiment, the present invention provides a system for conveying a ladle on a truck, comprising sensing means, consisting of load cells (2).

In another embodiment, the present invention provides a system for conveying a ladle on a truck, comprising an electronic system consisting of (i) means for reading load cells to measure weight, consisting of load cell amplifier breakout board; (ii) means for receiving input from breakout board and controlling relay module and means for audio and visual signals, being a microcontroller; (iii) means for switching ON/OFF the alarm system consisting of Relay Module with Opto Coupler; (iv) means for display of pressure on load cells, being connected to Microcontroller; and (v) means for display of audio alarm, being connected to Microcontroller and Relay module.

In another embodiment, the present invention provides a system for conveying a ladle on a truck, comprising of monitoring means, consisting of means for switching ON/OFF the electrical system consisting of Relay Module with Opto Coupler; means for reading load cells (2) to measure weight, consisting of load cell amplifier breakout board HX711 IC; means for sensing receiving input from HX711 IC and controlling means for audio and visual signals, consisting of microcontroller board Arduino Uno R3; means for display of pressure on load cells, consisting of LCD- 1602 with key pad; and means for display of audio alarm, consisting of alarm, being connected to microcontroller Arduino Uno R3. In another embodiment, the present invention provides a method for conveying a ladle on a truck, comprising securing the ladle on the frame by securing means; analyzing the pressure on the securing means by way of sensing means and analyzing the data obtained from sensing means and displaying it by way of audio and visual signals to the driver of the truck.

The present invention will become fully understood from the detailed description given below. However, the detailed description of the specific embodiments are only illustrations of the desired embodiments of the present invention, and are given so only for explanation. Various possible changes and modifications will be apparent to those of ordinary skill in the art on the basis of the detailed description.

The applicant has no intention to dedicate to the public any disclosed embodiment. Among the disclosed changes and modifications, those which may not literally fall within the scope of the present claims constitute, therefore, a part of the present invention in the sense of the doctrine of equivalents.

The use of the articles “a”, “an” and “the” and similar referents in the specification and claims are to be construed to cover both the singular and the plural form of the noun, unless otherwise indicated herein or clearly contradicted by the context. The use of any and all examples, or exemplary language (e.g. “such as”) provided herein is intended merely to better illuminate the invention, and so does not limit the scope of the invention, unless otherwise stated.

BRIEF DESCRIPTION OF THE DRAWINGS

A complete understanding of the system and method of the present invention may be obtained by reference to the following drawings: Figure 1 is a diagrammatic perspective view of the ladle transport system according to an embodiment of the present invention.

Figure 2 is a diagrammatic side view of the ladle transport system according to an embodiment of the present invention.

Figure 3 is a diagrammatic top view of the ladle transport system according to an embodiment of the present invention.

Figure 4 is a diagrammatic front view of the ladle transport system according to an embodiment of the present invention.

Figure 5 is a diagrammatic back view of the ladle transport system according to an embodiment of the present invention.

Figure 6 is an electrical chart explaining the various components in the monitoring means according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be described hereinafter with reference to the accompanying drawings in which a preferred embodiment of the invention is shown. This invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough, and will fully convey the scope of the invention to those skilled in the art.

Many aspects of the invention can be better understood with references made to the drawings below. The components in the drawings are not necessarily drawn to scale. Instead, emphasis is placed upon clearly illustrating the components of the present invention. Moreover, like reference numerals designate corresponding parts through the several views in the drawings. Before explaining at least one embodiment of the invention, it is to be understood that the embodiments of the invention are not limited in their application to the details of construction and to the arrangement of the components set forth in the following description or illustrated in the drawings. The embodiments of the invention are capable of being practiced and carried out in various ways. In addition, the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

The inventors of the present invention have developed a mechatronic system which consists of Tension Load cell (load sensor) which is suitable for detecting tension in Ratchet Chain. The inventors have programmed the threshold limit of Tension on Ratchet chain, for activation of Relay Module as 250 kgf. The decoded signal is sent to the Indicator in front of driver to light up the red/green light. If the tension in Ratchet chain falls below the threshold limit from the load cell then red light will come on and buzzer will blow. This will indicate that ladle is not fully tight with Ratchet chain. If on the contrary, the system detects the tension above the threshold limit, the green light will be on and buzzer will be off. This would indicate that the ladle is fully tight with Ratchet chain. The system is integrated with all four Ratchet chain(s) which are used to tighten the ladle with truck. Thus, the driver of the truck can be updated on the exact chain which becomes lose in transit, which can then be manually tightened, thus preventing potential accidents associated with falling of ladle from trucks.

As shown in Figure 1, the present invention provides a system for conveying a ladle on a truck comprising, a plurality of ratchet chain (4), which are connected on one end to the load cell (2) and on the other end to the ladle (1) by way of a plurality of swivel eye-bolts (10) and further comprising means for fastening the chains (9). The invention further comprises a pressure sensing means which is a load cell (2), said load cell being connected to ratchet chain (4) through swivel eye-bolt (10) on one side and frame of the truck (3) through a platform (11) on the other side.

Figure 2 is a diagrammatic side view of the ladle transport system according to an embodiment of the present invention. Figure 3 is a diagrammatic top view of the ladle transport system according to an embodiment of the present invention.

Figure 4 is a diagrammatic front view of the ladle transport system according to an embodiment of the present invention.

Figure 5 is a diagrammatic back view of the ladle transport system according to an embodiment of the present invention.

The load cell is a force gauge that consists of a transducer that is used to create an electrical signal whose magnitude is directly proportional to the force being measured.

There are four common types of these sensors; they are: Pneumatic, Hydraulic, Strain gauge and Capacitance. The inventors of the present invention discovered that the strain gauge type load cell is the most optimum for the functioning of the present invention.

A strain gauge load cell is a transducer that changes in electrical resistance when under stress or strain. The electrical resistance is proportional to the stress or strain placed on the cell making it easy to calibrate into an accurate measurement. The electrical resistance from the strain gauge is linear therefore it can be converted into a force and then a weight if needed.

A strain gauge load cell is made up of 4 strain gauges in a “Wheatstone” bridge configuration. A Wheatstone bridge is an electrical circuit that measures unknown electrical resistance by balancing two legs of a bridge circuit, one of the legs contains the unknown component. The “Wheatstone bridge” circuit provides incredibly accurate measurements. The strain gauges that are in the Wheatstone bridge are bonded onto a beam which deforms when weight is applied. Tension load cells which are also commonly called compression load cells are ideal for applications where the load may go from tension to compression, or from compression to tension. They are very suitable for environments that restrict space, and their threaded ends allow for easy installation.

Some advantages of tension load cells include easy installation, high accuracy, reliability, ability to be customized, high side load reduction, better sealing and protection, small, and inexpensive. Some downsides of the tension load cell are that the strain gauges are exposed and require protection, no load movement is allowed and the loads must be centered.

The inventors of the present invention used load cell with capacity of 2 Ton.

The swivel eye bolt (10) used in the invention is sometimes referred to as a swivel hoist ring — is a piece of rigging hardware that screws into an engineered lifting point on a load. This lifting point allows the rigging coming off of the hoist to connect to the load.

The function of a hoist ring is similar to an eye bolt. However, a swivel hoist ring has the capability of pivoting and/or swiveling to accommodate lifting at angles without incurring damage to the device. Whereas, eye bolts are stationary and can only accommodate angular lifts by factoring in a significant reduction to the WLL (working load limit).

Swivel hoist rings can pivot 180° and/or swivel 360° from the screw’s axis to accommodate load movement while maintaining the full WLL.

Further, the present invention envisages an electronic system which is suitable for detecting the tension on the Ratchet Chain. Figure 6 is an electrical chart explaining the various components in the monitoring means according to an embodiment of the present invention.

The said electronic system contains several components such as: (i) means for reading load cells to measure weight, consisting of load cell amplifier breakout board HX711 IC;

(ii) means for sensing receiving input from HX711 IC and controlling means for audio and visual signals, consisting of microcontroller board Arduino Uno R3;

(iii) means for switching ON/OFF the alarm system consisting of Relay Module with Opto Coupler;

(iv) means for display of pressure on load cells, consisting of LCD- 1602 with key pad, being connected to Microcontroller;

(v) means for display of audio alarm, consisting of alarm, being connected to Microcontroller and Relay module; and

(vi) means for connecting the electrical components, being wires and such other components.

Further details of the electronic components used in the Mechatronic system are provided herein below:

(i) HX711 module: HX711 module is a Load Cell Amplifier breakout board for the HX711 IC that allows one to read load cells to measure weight. This module uses 24 high precision A/D converter chip HX711. It is a specially designed for the high precision electronic scale design, with two analog input channel, the internal integration of 128 times the programmable gain amplifier. The input circuit can be configured to provide a bridge type pressure bridge (such as pressure, weighing sensor mode), is of high precision, and low cost is an ideal sampling front-end module. The inventors of the present invention found that the HX711 is an optimum IC component which allows one to integrate load cell into your system. By the use of the HX711 system, the need for any amplifiers or dual power supply are bypassed and it was interfaced to micro controller to measure weight.

The HX711 uses a two wire interface (Clock and Data) for communication. Compared with other chips, HX711 has added advantages such as high integration, fast response, immunity, and other features improving the total performance and reliability. The chip lowers the cost of the electronic scale, at the same time, improving performance and reliability

(ii) Microcontroller: The Arduino Uno R3 is a microcontroller board based on a removable, dual-inline package (DIP) ATmega328 AVR microcontroller. It has 20 digital input/output pins (of which 6 can be used as PWM outputs and 6 can be used as analog inputs). Programs can be loaded on to it from the easy-to-use Arduino computer program. The R3 is the third, and latest, revision of the Arduino Uno.

(iii) Relay Module 5v with Opto Coupler: It is a 4 Channel Isolated 5V 10A Relay Module, A wide range of microcontrollers such as Arduino, AVR, PIC, ARM etc. can control the Relay Module. It is also able to control various appliances and other types of equipment with a large current.

Relay output maximum contact is AC250V 10A and DC30V 10A. One can connect a microcontroller with standard interface directly to it.

Each relay can individually switch on/off by an opto-isolated digital input, which that can connect directly to a microcontroller output pin. It only requires a voltage of approx. 1 0V to switch the inputs on but can handle input voltages up to 5V. This makes it ideal for 1.0V to 5V devices.

In the present invention, when the load passes the threshold limit (250 kgf), Relay Module is activated and green light is on and buzzer will not blow.

(iv) LCD-1602 with Key Pad: The LCD1602 16x2 Blue LCD with Keypad Shield provides a 16 character x 2 line LCD and keypad in an Arduino shield format for providing a user interface for a project. This shield provides an easy way to implement a user interface suitable for many projects such as having a user navigate through menus on the screen to select functions or setup a program such as for an automated lighting system. (v) Alarm and Indicator Lights: The Alarm and Indicator lights are connected to Microcontroller and Relay module. If the tension on the Ratchet Chains is above the threshold limit, the Green Light will be on and Buzzer will be off. However, as soon as the tension on any of the Ratchet chain(s) falls below the threshold limit, the Red light will light up and Buzzer will go off.

(vi) Wire(s): Wire(s) are routed and connected with the electrical components in a manner such that the system functions in the desired manner and also do not come in contact with ladle or with any moving part.

Also provided is a method a method for conveying a ladle containing molten metal in a truck or such other vehicle for locomotion by land.

The present invention aims to provide a method wherein the pressure on the chains used to fasten the ladle can be monitored in real-time while the truck is in motion. The present invention also provides a method wherein the chains are tightened at an optimum pressure and the driver is alerted, by way of an alert mechanism, as soon as there is a drop in pressure below a defined pressure range in any of the chain(s) so that the driver can stop the vehicle and tighten the chains immediately, thus preventing possible tilting and eventual spillage of molten metal.

In order to transport molten metal in a Ladle, the method of the present invention provides that the ladle containing molten metal be placed on the designated place on the loading bay of the truck. The ladle is then tied to the loading bay of a combination of ratchet chains (4), load cells (2) and means for fastening the chain (9). The assembly of the invention is such that the ratchet chains (4) are connected to the load cells (2) on one end by way of swivel eye bolt (10). On the other end, the ratchet chains are connected to the means for fastening the chain (9) which then is connected to the ladle by way of hooks. The load cells (2) are connected to rachtet chains (4) on one end and designated platforms on the bay of the truck (11) on the other end. The inventors have further, after rigorous experiments found the optimum tension on the ratchet chains for the system for activation of the relay module. In a fully activated system, the tension on the ratchet chains can be in the range of 0 to 2000 kgf, wherein threshold limit for activation of relay module is programmed as 250 kgf.

In one embodiment of the present invention, the ladle is placed on the designated spot on the loading bay of the truck. The ladle is then secured fully by way of the four ratchet chain and load cell assembly. Due care is taken that the threshold limit of tension on the ratchet chains is programmed as 250 kgf. Once the electrical system of the truck is activated and the truck is started, real time information about the tension on the ratchet chains holding the ladle are displayed to the transportation staff in the driver cabin by way of the use of the method of this invention. The method of the invention further provides audio and visual alarm systems to alert the transportation staff in the drivers cabin as soon as the pressure on any of the ratchet chains falls below the programmed pressure of 250 kgf provided in the invention.

In another embodiment of the present invention, a method is provided wherein when the pressure on the ratchet chains falls below the programmed pressure range of 250 kgf, red light is indicated on indicator and buzzer is blowing, which gives a signal to the transportation staff that the Ratchet chain(s) is/are not tightly secured with ladle.

In a further embodiment of the present invention, HX711 module reads load cells to measure weight. When the load is passes the threshold limit of 250 kgf, Relay Module is activated and green light is on and buzzer are silent.

In a further embodiment of the present method, the microcontroller Arduino Uno R3 keeps a constant watch on the pressure. The method provides that whenever the pressure is above the threshold limit, green light will be on and red light will off and buzzer will not blow.

In a still further embodiment of the method of the present invention, an LCD- 1602 is provided which displays the tension in Ratchet chain on a real time basis to the transportation staff. As soon as the tension on the Ratchet chains falls below the threshold limit, the same will be displayed on the LCD and relay module will be activated by which red light (7) will be displayed on the panel (5). Thus, the present invention provides a system and method for continuous monitoring of the ladle containing molten metal while transportation in a vehicle by land.