Technical field

[0001] The present invention relates to a refractory walls and, more particularly, to assembly of refractory walls.

Background

[0002] The Hall-Heroult process is the most common industrial process for smelting aluminum. The following simplified reactions take place at the carbon electrodes in an electrolytic bath, comprising alumina (AI2O3), contained in cells:

Cathode: Ah ⁺ + 3 e" — > Al

Anode: O ² ' + C — > CO + 2 e

Overall: AI2O3 + 3 C 2 Al + 3 CO

[0003] In reality, much more CO2 is formed at the anode than CO: 2 O ² ' + C CO2 + 4 e and 2 AI2O3 + 3 C 4 Al + 3 CO2

[0004] The electrolytic bath is electrolyzed using a low voltage (under 5 V) direct current at 100-300 kA. Liquid aluminum metal is deposited at the cathode, while the oxygen from the alumina combines with carbon from the anode to produce mostly carbon dioxide.

[0005] To avoid solidification of the aluminum, cells are operated 24 hours a day. The electrical resistance within the cell is sued to regulate temperature of the electrolytic bath. Electrodes in cells are form mostly from purified coke. A binder such as pitch resin or tar is typically used. There are two primary anode technologies using the Hall-Heroult process: Soderberg technology and prebaked technology. Soderberg or self-baking anodes are not subject to the present discussion.

[0006] Very large ovens are used to bake the anodes (e.g., gas-fired at high temperature). The oven comprises refractory brick walls arranged to receive the anodes having a predetermined shape. No matter what shape the anodes are expected to take, the assembly of the brick walls in the oven is labor intensive and leads to varying tolerances therethrough.

[0007] Such issues are addressed, at last partly, in the present disclosure. Summary

[0008] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0009] A system of one or more computers can be configured to perform particular operations or actions by virtue of having software, firmware, hardware, or a combination of them installed on the system that in operation causes or cause the system to perform the actions. One or more computer programs can be configured to perform particular operations or actions by virtue of including instructions that, when executed by data processing apparatus, cause the apparatus to perform the actions. One general aspect includes a method of vertically positioning a brick in a refractory wall. The method also includes using a mechanical arm, moving the brick to a first position above a final position for the brick on a the refractory wall; using the mechanical arm, landing the brick onto a mortar layer over the final position with a vertical landing force; and controllably oscillating the brick while applying a vertical oscillation force by the mechanical arm to fit a determined vertical position, within a tolerance, for the brick. Other embodiments of this aspect include corresponding computer systems, apparatus, and computer programs recorded on one or more computer storage devices, each configured to perform the actions of the methods. Implementations may include one or more of the following features. The method may include, before landing the brick, computing a landing force vector and, before oscillating the brick, computing a plurality of oscillation force vectors. At least one of computing the landing force vector and computing the oscillation force vectors may be performed based on one or more previously obtained measurements of the brick. Landing the brick may be performed directly above the final position and controllably oscillating the brick may then be performed with a net force vector having only a vertical component. Landing the brick may be performed with a horizontal offset from the final position and controllably oscillating the brick may then be performed with a net force vector having a vertical component and a horizontal component. The method may include: after controllably oscillating the brick, determining an error distance from the final position; when the final distance is outside of a tolerance value, computing a corrective force vector having a corrective vertical component, equal to or greater than null and a corrective horizontal component, equal to or greater than null, to achieve the final position; and controllably oscillating the brick with the corrective force vector. Determining the error distance, computing the corrective force vector and controllably oscillating the brick with the force corrective vector may be repeated until the final distance is within the tolerance value. Controllably oscillating the brick may be performed avoiding disruption of an inter-brick gap distance between the brick and adjacent bricks. In some embodiments, a processor module may be configured to: after landing the brick, determine a horizontal distance from the final position; and compute a force vector having a vertical component, greater than null and a horizontal component, equal to or greater than null, to achieve the final position; where the mechanical arm is further operable to controllably oscillate the brick with the force vector. The processor module may further be configured to: after controllably oscillating the brick, determine an error distance from the final position; and when the final distance is outside of a tolerance value, compute a corrective force vector having a corrective vertical component, equal to or greater than null and a corrective horizontal component, equal to or greater than null, to achieve the final position; where the mechanical arm is further operable to controllably oscillate the brick with the corrective force vector. Implementations of the described techniques may include hardware, a method or process, or computer software on a computer-accessible medium.

[0010] One general aspect includes a system for vertically positioning a brick in a refractory wall a mechanical arm operable to: move the brick to a first position above a final position for the brick on a the refractory wall; land the brick onto a mortar layer over the final position with a vertical landing force; and controllably oscillate the brick while applying a vertical oscillation force to fit a determined vertical position, within a tolerance, for the brick. Other embodiments of this aspect include corresponding computer systems, apparatus, and computer programs recorded on one or more computer storage devices, each configured to perform the actions of the methods. Implementations may include one or more of the following features. The system may include a processor module configured to, before landing the brick, compute a landing force vector and, before oscillating the brick, compute a plurality of oscillation force vectors. At least one of computing the landing force vector and computing the oscillation force vectors may be performed based on one or more previously obtained measurements of the brick. Landing the brick may be performed directly above the final position and controllably oscillating the brick is performed with a net force vector having only a vertical component. Landing the brick may be performed with a horizontal offset from the final position and controllably oscillating the brick may then be performed with a net force vector having a vertical component and a horizontal component. The mechanical arm may further be operable to controllably oscillate the brick while avoiding disruption of an inter-brick gap distance between the brick and adjacent bricks. Implementations of the described techniques may include hardware, a method or process, or computer software on a computer-accessible medium. Brief description of the drawings

[0011] Further features and exemplary advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the appended drawings, in which:

[0012] Figure 1 presents views of an exemplary refractory wall in accordance with the teachings of the present invention;

[0013] Figure 2 presents views of a first layer of the refractory wall of Figure 1 in accordance with the teachings of the present invention;

[0014] Figure 3 presents views of a second layer of the refractory wall of Figure 1 in accordance with the teachings of the present invention;

[0015] Figure 5 presents views of a fourth layer of the refractory wall of Figure 1 in accordance with the teachings of the present invention;

[0016] Figure 6 is a perspective view of the exemplary refractory wall of Figure 1 in accordance with the teachings of the present invention;

[0017] Figure 7 is a front view of the exemplary refractory wall of Figure 1 in accordance with the teachings of the present invention;

[0018] Figure 8 is a side view of the exemplary refractory wall of Figure 1 in accordance with the teachings of the present invention;

[0019] Figure 9 is a sectional side view of the exemplary refractory wall of Figure 1 along the cut line defined in Figure 7 in accordance with the teachings of the present invention;

[0020] Figure 10 presents views of a first exemplary refractory brick in accordance with the teachings of the present invention;

[0021] Figure 11 presents views of a second refractory brick in accordance with the teachings of the present invention;

[0022] Figure 12 is a flow chart of an exemplary method in accordance with the teachings of the present invention;

[0023] Figure 13 is a logical representation of an exemplary system in accordance with the teachings of the present invention;

[0024] Figure 14 is a modular representation of an exemplary controller in accordance with the teachings of the present invention; and

[0025] Figure 15 is a representation of an exemplary brick prior to positioning in the refractory wall in accordance with the teachings of the present invention. Detailed description

[0026] In a set of embodiments in accordance with a set of invention points, refractory bricks are positioned vertically to form a layer of refractory wall in order to create a controlled horizontal surface therebeween. For each of the bricks to be positioned, one or more forces are calculated considering the height to be achieved by a given brick. That is, considering the characteristics of the brick to be positioned (e.g., weight, length, width, height, etc.) a mechanical robot arm is provided with instructions to deposit the brick at the proper position with a certain vertical landing force. Once landed, the brick is controllably shaken or oscillated while applying a vertical positioning force by the mechanical robot arm to fit the determined height, within a tolerance.

[0027] Reference is made to the drawings in which Figure 1 shows an exemplary refractory wall 90 with four layers 92, 94, 96 and 98(see concurrently Figures 2 to 11). Figures 1 to 5, 10 and 11 are divided into four (4) views A, B, C and D respectively representing a perspective view, a top view, a front view and a side view. Figure 6 is a close-up perspective view of the refractory wall 90. Figure 7 is a close-up side view of the refractory wall 90 showing cut line A- A. Figure 8 is a close-up side view of the refractory wall 90. Figure 9 is a close-up side view of the refractory wall 90 along the cut line A-A from Figure 7.

[0028] Figure 10 and Figure 11 present views of two exemplary refractory bricks 2000, 3000 in accordance with the teachings herefrom. The brick 2000 has top ridges 2100, 2120 and bottom channels 2200, 2220 while the brick 3000 has top ridges 3100, 3120 without bottom channels. The brick 3000 presents a configuration that would typically be used for foundation bricks, such as the bricks 1 to 5 of the refractory wall 90, while the brick 2000 would typically be used everywhere else. In some embodiments, the brick 2000 may be used everywhere, including for the foundation. In the depicted example of Figure 10 and Figure 11, a single configuration of the ridges and channels 2100, 2120, 2200, 2220, 3100, 3120 is presented at the center of their respective faces. In typical embodiments where ridges and channels are used, the ridges and channels 2100, 3100, 2200 parallel to a longitudinal axis of the refractory wall 90 may be positioned at a predetermined distance from a reference edge of the brick 2000, 3000 or of the refractory wall 90 (e.g., outer perimeter edge of the refractory wall 90) thereby allowing for varying brick configurations without creating additional alignment issues (e.g., transverse bricks). Likewise, the ridges and channels 2120, 3120, 2220 may be positioned at a predetermined intervals from a reference edge of the refractory wall 90 (e.g., outer edge of the refractory wall 90) considering the expected position of the brick once positioned in the refractory wall 90, thereby allowing for varying brick configurations. Alternatively or in addition, only certain ones of the bricks may be provided with the ridges and channels 2100, 3100, 2200 and/or 2120, 3120, 2220. Furthermore, positioning and dimensioning of the ridges and channels 2100, 3100, 2200 and/or 2120, 3120, 2220 is done considering a target adjustability in lateral and/or longitudinal adjustment of the theoretical position of the bricks. Said differently, if the ridges and channels 2100, 3100, 2200 and/or 2120, 3120, 2220 were of the same dimension, it would be more complicated to adjust the position of the bricks as the bricks would tend to move, after positioning, towards corresponding ones of the ridges and channels.

[0029] As can be appreciated from Figures 1 to 9, bricks 1 - 60 of the refractory wall 90 do not show ridges and channels as they are optional and could clutter the views, but skilled persons will recognize that such features may optionally be provided, in one direction (e.g., 2100, 3100 or 2220, 3220) or in both directions (2100, 2120, 2200 and 2220) without departing from the teachings presented herein. For greater certainty concerning the ridges and channels, it may be added that position and sizes of the ridges and channels as well as physical characteristics of the mortar (e.g., thickness, fluidity, ... ) should be chosen considering expected variability of brick positioning, as will be detailed described hereinbelow.

[0030] Exemplary measurements are added to different bricks 1 to 60 of the refractory wall 90 to enhance the understandability of the description and not as a limitation to the present teachings. Likewise, only the four layers 92, 94, 96 and 98 are presented, for conciseness and clarity, while typical actual refractory walls comprise many more layers (e.g., 55), which may also be built in accordance with teachings found herein, as skilled persons will readily recognize. In the depicted example, the refractory wall 90 measures 1472mm x 400mm. The measurements of the bricks 1-60 and the refractory wall 90 were chosen to illustrate the teachings presented herein and skilled persons will readily recognize that many other options are possible while remaining within such teachings. Furthermore, actual measurements of bricks are expected to vary and teachings are presented to accommodate such variations, as will described in greater details in relation to different embodiments.

[0031] Layer 92 comprises bricks 1 to 5 of equivalent size (290,40mm x 400mm x 76mm, as indicated by measurements added on the figures). In the depicted example, the layer 92 represents a foundation of the refractory wall 90. Typically, the foundation bricks are bigger than other bricks, as depicted, but skilled persons will readily recognize that many other possibilities exist that do not affect the present teachings.

[0032] Layer 94 comprises bricks 6 to 23 of equivalent size (180mm x 100mm x 76mm, as indicated by measurements added on the figures). Such dimensions were chosen as a means of illustration and skilled persons will readily recognize that other possibilities exist that do not affect the present teachings.

[0033] Layer 96 comprises bricks 24 to 42 of various sizes, as indicated by measurements added on the figures. Again, such dimensions were chosen as a means of illustration and skilled persons will readily recognize that other possibilities exist that do not affect the present teachings.

[0034] Layer 96 comprises bricks 43 to 60 of two sizes, as indicated by measurements added on the figures. Again, such dimensions were chosen as a means of illustration and skilled persons will readily recognize that other possibilities exist that do not affect the present teachings.

[0035] The layers 92-98 are shown with a vertical distance of 4mm therebetween. Again, this has been chosen as an illustrative value and other possibilities exist that do not affect the present teachings. The exemplary uniform vertical distance of 4mm has been chosen as an illustrative value and may be seen, with reference to the following description of different embodiments, as a target vertical value. Likewise, the bricks 1 to 60 are shown with a uniform horizontal distance of 4mm therebetween chosen to illustrate the present teachings. In exemplary refractory walls built in accordance with the teachings of the present invention, a target vertical distance may be determined and provided to the system based on different factors. Skilled persons will recognize that other possibilities exist and that the present teachings can readily be adapted thereto.

[0036] Figure 13 shows a specific embodiment, in the form of a logical representation, of an exemplary system 1000 of positioning a sequence of bricks in a refractory wall.

[0037] The numbering of the elements on Figure 13 is done for different categories of equipment. More specifically, items 000 are part of a general or overview category. Items 100 are part of the loading / storing raw materials category. Items 200 are part of a feeding / characterising raw materials (RBR/RER) category. Items 300 are part of a preparing raw materials; general wall building equipment category. Items 400 are part of a brick placement system (RBR or BPR) category. Items 500 are part of a mortar spreading system (RER or MSR) category. Items 700 are part of an equipment related to the wall category. Items 800 are part of a general equipment for control / automation category.

[0038] More specifically, in the category 000, a water supply / pressurization module 040 may be provided (optional). In the category 200, a brick loading station 210 (optional), a loading collection conveyor 220 (optional) may be provided, a measurement station 230, an inspection station 240 (optional), a sorting station 250 (optional), a rejection bin 255 (optional), a brick cleaning station 260 (optional), an elevating conveyor 270, a production collection conveyor 280 (optional) and a positioning station 290 may be provided. In some embodiments, a structure 280-S (optional) for the production collection conveyor 280 may also be provided. In the 300 category, a safety enclosure 310, a vertical mortar station 320 (optional), a linear rail 330 and a maintenance station 350 may be provided. In some embodiments, a brick placement robot (RBR or BPR) superstructure 330-S (optional) may also be provided. In the 400 category, a brick placement controller 402, a BPR 410, BPR claws 420, and a BPR tool stand 430 (optional) may be provided. In the 500 category, a mortar spreading controller 502 (optional), a mortar spreading robot (RER or MSR) 510 (optional), a MSR spreader head 520 (optional), a MSR tool stand 530 (optional) and a MSR filling station 540 (optional) may be provided. In the 700 category, a wall superstructure 710-S, a wall cleaning station 720 (optional), a quality management system 730 (optional) and a quality control system 740 (optional) may be provided. In the 800 category, a programmable logic controller (PLC) 810 and a Human Machine Interface (HMI) 820 may be provided.

[0039] Figure 14 shows a modular representation of the system 1000 for positioning of bricks 1 - 60 in a refractory wall 90, in accordance with the teachings of the present invention. A controller 1100 is presented on Figure 14 (not shown on Figure 13) logically representing different elements of the system 1000 (e.g., as depicted on Figure 13) as well as showing logical interactions between modules. The controller 1100, as will be explained hereinbelow, comprises the brick placement controller 402 and the PLC 810 and, in some embodiments, the mortar spreading controller 502. The system 1000 may also comprise a remote monitoring station 1600 not presented in Figure 13. In some embodiments, the controller 1100 may exchange data with the remote monitoring station 1600 and the controller 1100 is therefore able to exchange one or more message and/or one or more commands with the remote monitoring station 1600 (e.g., via a network 1400).

[0040] In the depicted example of Figure 14, the controller 1100 comprises a memory module 1120, a processor module 1130 and a network interface module 1140. The modules 1120, 1130 and 1140 may be dedicated or distributed over different ones of the elements of Figure 13. The processor module 1130 may represent a single processor with one or more processor cores or an array of processors, each comprising one or more processor cores. The memory module 1120 may comprise various types of memory (different standardized or kinds of Random Access Memory (RAM) modules, memory cards, Read-Only Memory (ROM) modules, programmable ROM, etc.). The network interface module 1140 represents at least one physical interface that can be used to communicate with other network nodes. The network interface module 1140 may be made visible to the other modules of the controller 1100 through one or more logical interfaces. The actual stacks of protocols used by the physical network interface(s) and/or logical network interface(s) 1142, 1144, 1146, 1148 of the network interface module 1140 do not affect the teachings of the present invention. The variants of processor module 1130, memory module 1120 and network interface module 1140 usable in the context of the present invention will be readily apparent to persons skilled in the art.

[0041] A bus 1170 is depicted as an example of means for exchanging data between the different modules of the controller 1100. The bus 1170 or another logical connections may be provided between elements of Figure 13. The present invention is not affected by the way the different modules exchange information between them. For instance, the memory module 1120 and the processor module 1130 could be connected by a parallel bus, but could also be connected by a serial connection or involve an intermediate module (not shown) without affecting the teachings of the present invention.

[0042] Likewise, even though explicit mentions of the memory module 1120 and/or the processor module 1130 are not made throughout the description of the various embodiments, persons skilled in the art will readily recognize that such modules are used in conjunction with other modules of the controller 1100 to perform routine as well as innovative steps related to the present invention.

[0043] The system 1000 may comprise a data storage system 1500 that comprises data related to brick positioning and may further log data while the production is performed. The data storage system is not depicted on Figure 13. Figure 14 shows examples of the storage system 1500 as a distinct database system 1500A, a distinct module 1500B of the controller 1100 or a sub-module 1500C of the memory module 1120 of the controller 1100. The storage system 1500 may also comprise storage modules (not shown) on the remote monitoring station 1600. The storage system 1500 may be distributed over different systems A, B, C and/or the remote monitoring station 1600 or may be in a single system. The storage system 1500 may comprise one or more logical or physical as well as local or remote hard disk drive (HDD) (or an array thereof). The storage system 1500 may further comprise a local or remote database made accessible to the controller 1100 by a standardized or proprietary interface or via the network interface module 1140. The variants of the storage system 1500 usable in the context of the present invention will be readily apparent to persons skilled in the art.

[0044] The controller 1100 may also comprise an optional Human machine Interface (HMI) module 820, which may comprise one or more graphical user interfaces (GUI), comprising one or more display screen(s) forming a display system, for the controller 1100. The HMI module 820 could also comprise functions such as Report Management and Operator Desk Control. Data stored in the data storage system 1500 can then be used to display trends of process data on charts, create reports, or perform data analysis. The display screens of the HMI module 820 could be split into one or more display elements, but could also be a single flat or curved screen visible from an expected user position (not shown). The Operator Desk Control function may be used, for instance, to input commands towards the control module 1161 described hereinbelow.

[0045] The HMI module 820 may be linked to a historian database stored in the storage system 1500. The historian database may be provided as a time-series database designed to efficiently collect and store process data from a Supervisory Control and Data Acquisition (SCAD A) or automation system (e.g., measurements module 1160 and control module 1161 described hereinbelow). The stored data from the historian database may be used to display trends of process data on charts, create reports, or perform data analysis (e.g., through the Report Management function of the HMI module 820). Skilled persons will readily understand that the HMI module 820 may be used in a variety of contexts not limited to the previously mentioned examples. In some embodiments, the HMI module 820 is distributed over elements of Figure 13 and/or the remote monitoring station 1600 (e.g., partially distributed and/or made available using remote desktop capabilities or the likes). In some other embodiments, the HMI module 820 is implemented in the remote monitoring station 1600 and the linked to the controller 1100 through the network 1400.

[0046] A measurement input module 1160 and a control module 1161 are provided in the controller 1100. The measurements module 1160 and the control module 1161 will be referred to hereinbelow as distinct logical modules, but skilled person will readily recognize that a single logical module may have been shown instead.

[0047] In some embodiment, an optional external input/output (I/O) module 1162 and/or an optional internal input/output (I/O) module 1164 may be provided with the measurement input module 1160 and the control module 1161. The external I/O module 1162 may be required, for instance, for interfacing with one or more robots, one or more input device (e.g., measurement probe) and/or one or more output device (e.g., printer).

[0048] In the context of the example of Figure 13 and Figure 14, the measurements module

1160 may have capacities distributed between different elements of Figure 13. For instance, the measurement module 1160 has one or more measurement function implemented at the measuring station 230 and may have additional measuring functions at the inspection station 240 (when present). Furthermore, the BPR 410 and MSR 510 may also have measurement capabilities (e.g., using different tools or as a permanent feature) and therefore implement one or more measurement functions of the measurement module 1160. The BPR 410 and MSR 510 have registered positions at all time in the system 1000 (typically stored in the data storage system 1500). The position itself may be considered when taking different measurements from the BPR 410 and/or the MSR 510.

[0049] Likewise, the control module 1161 may have capacities distributed between different elements of Figure 13. The brick placement controller 402 and the mortar spreading controller 502 (when present) implement one or more of the control function of the control module 1161 and, in doing so, interact with different elements from Figure 13 in order to provide the control functions. For instance, the brick loading station 210, the loading collection conveyor 220, the sorting station 250, the brick cleaning station 260, the elevating conveyor 270, the production collection conveyor 280, the positioning station 290 and the maintenance station 350 just like the BPR 410 and the MSR 510 (when present) may receive commands from the brick placement controller 402 and/or the mortar spreading controller 502 and react accordingly. The brick placement controller 402 and the mortar spreading controller 502 also store current position and related data for the BPR 410 and the MSR 510 in one or more position registers of the storage system 1500. Control functions from the control module 1161 may include, for instance, advancing a brick on the brick loading station 210 to a designated position; verifying conformity of a brick at the inspection station 240 (e.g., using one or more measurement functions); positioning a brick from the positioning station 290 by the BPR 410 into the refractory wall 90 (e.g., further using a path management function and a brick handling function), ...

[0050] The internal input/output (I/O) module 1164 may be required, for instance, for interfacing the controller 1100 with one or more instruments or controls (not shown) typically used in the context of brick positioning. The I/O module 1164 may comprise necessary interface(s) to exchange data, set data or get data from such instruments or controls.

[0051] The PLC 810 is implemented as a function over the controller 1100 and therefore is performed thereon, e.g., through the processor module 130 using the memory module 1120 and the data storage system 1500 as well as other module of the controller 1100.

[0052] For instance, Brick IDs and related specifications may be stored in the data storage system 1500. The desired layout of the refractory wall 90 may also be stored therein. The PLC 810 may then implement different functions of the system 1000 such as a sequence management function, a brick sourcing management function, a brick tolerance anticipated positioning function, a mortar disposition function, etc. [0053] In some embodiments, the HMI 820 allow one or more operator to interact with the system 1000 to access and/or provide information to the system 1000 and to provide instructions and receive feedback from the instructions. The PLC 810, using different modules of the controller 1100 and elements of the system 1000, implement the instructions.

[0054] The measurement input module 1160 and the control module 1161 are tightly related to the positioning of bricks. In the example of the system 1000, the measurement input module 1160 and the control module 1161 may be involved in various step of a method 1200 described herein below.

[0055] Reference is now concurrently made to Figures 1 to 9, 12, 13, 14 and 15. An exemplary method 1200 is depicted on Figure 12 for vertically positioning a brick 60 in a refractory wall. In the context of the method 1200, the brick 60 to be positioned has a predetermined position in the refractory wall 90. That is, it is possible to determine a position for each brick where the brick is meant to be positioned in the refractory wall 90, which could mean that each brick has one and only one position being predetermined, that each type of brick (e.g., all bricks of equivalent theoretical measurements) is associated to predetermined positions or that the predetermined position can be computed knowing one or more dimensions of the brick 60 and reference points (e.g., the first and last brick in a sequence). The layout of the refractory wall 90 may be retrieved from the storage system 1500.

[0056] The method 1200 comprises moving 1220 the brick 60 to a first position above a final position for the brick on the refractory wall 90 and landing 1230 the brick 60 onto a mortar layer over the final position. Both moving 1220 and landing 1230 the brick 60 are performed by a mechanical arm such as the BPR 410. A layer of mortar has already been applied at the position of the brick 60 before landing 1230 thereof, which may have been done by the MSR 510. Once landing, the brick 60 is controllably oscillated 1260 while applying a vertical oscillation force by the mechanical arm to fit a determined vertical position, within a tolerance, for the brick 60. The oscillating 1260 of the brick 60 is performed to facilitate vertical positioning of the brick 60.

[0057] In some embodiments, the vertical landing force and/or the vertical oscillation force may be determined by the PLC 810 for the system 1000 as a whole and used as a constant parameters. In some other embodiments, the vertical landing force and the vertical oscillation force may be computed 1210 once by the PLC 810 for the system as a whole 1000 based on known characteristics of the refractory wall 90 (e.g., thickness and characteristics of mortar layer, brick material, etc.). In some other embodiments, the vertical landing force and/or the vertical oscillation force may be computed 1210 once by the PLC 810 for each brick type or for each brick individually (or brick ID) in the refractory wall 90 based on known characteristics of the mechanical arm 410 and the refractory wall 90 and/or the brick(s) (e.g., weight (and the likes) of the mechanical arm 410, thickness and characteristics of mortar layer, brick material, weight of brick types, position of bricks, etc.). In some other embodiments, the vertical landing force and/or the vertical oscillation force may be computed 1210 (e.g. computed from scratch or adjusted from an expected value) by the PLC 810 for each brick individually in the refractory wall 90, in real-time prior to moving 1220 or prior to landing 1230 or prior to oscillating 1260, based on known characteristics of the refractory wall 90 and/or the individual brick to be positioned (e.g., weight (and the likes) of the mechanical arm 410, thickness and characteristics of mortar layer, brick material, weight of the brick (e.g., variation from expected value based on brick type or brick ID or net weight), position of bricks, etc.). The computation 1210 by the PLC 810 may involve referencing one or more lookup table (e.g., from the storage system 1500) values. Additionally or alternatively, the computation 1210 by the PLC 810 may involve computation from mathematical formulas describing the relation(s) between relevant characteristics. Additionally or alternatively, the computation 1210 by the PLC 810 may involve interpolation/extrapolation (linear or non-linear) from data points taken from one or more lookup tables (e.g., from the storage system 1500). Skilled persons will readily understand that different embodiments from the examples provided hereinabove may be used separately for the determination of the vertical landing force and the vertical oscillating force (e.g., system-wide constant parameter for the vertical oscillating force but computed 1210 vertical landing force based one of the above embodiments, or vice-versa). In the context of the example of Figure 13 and Figure 14, the brick placement controller 402 and the PLC 810 would be involved in the optional computation 1210, in the moving 1220, in the landing 1230 and in the oscillating 1260 of the brick 60.

[0058] The moving 1220 of the brick 60 and initial movement of the brick 60 during the landing 1230 are expected to be performed using the mechanical arm 410 considering best practices in the art. More specifically, once the vertical landing force has been determined (e.g., computed 1210), ensuring that the mechanical arm 410 proceeds with the landing 1230 of the brick 60 using the vertical landing force is expected to be within grasp of a person skilled in the art. Furthermore, while the moving 1220 and the landing 1230 of the brick 60 are described herein as discrete steps, the PLC 810 and the BPC 402 may cause the moving 1220 and the landing 1230 to be performed in a single motion of the mechanical arm 410.

[0059] Following the landing 1230 of the brick and before oscillating 1260 of the brick 60, the method 1200 may comprise determining 1240 one or more distances of the brick 60 compared to the expected position and, when the determined distance(s) fall outside of tolerance range(s), computing 1250 by the PLC 810 one or more force vectors to rectify the position. At this point in time (i.e., after landing 1230 and before oscillating 1260), it may be beneficial to adjust the position of the brick 60 rotationally and/or laterally (e.g., considering an expected or adjusted horizontal position and/or to ensure uniform j oints therearound). In some embodiments, the computed 1250 force vectors by the PLC 810 may be added to the vertical positioning force to position the brick 60 while the oscillating 1260 takes place.

[0060] Following oscillating 1260 of the brick 60, the method may loop by moving 1262 to the next brick. It is also possible, before moving 1262 to the next brick, to determine 1270 an error distance between the final position of the brick 60 and the determined position for the brick 60 (e.g., by a specific tool adapted for the BPR 410, the MSR 510, a quality control robot (not shown) and/or various captors/detectors, e.g., disposed around the refractory wall 90). When 1280 the final distance is determined to be within a tolerance value 1282, the method continues with moving 1262 to the next brick. When 1280 the final distance is determined not to be within the tolerance value 1284, the PLC 810 may compute 1290 a corrective force vector before controllably oscillating 1260 the brick 60 with the newly computes corrective force vector. In some embodiments, the optional determination 1270 of the error distance may be performed on a subset of the bricks (i.e., only the comer bricks or one brick out of four, one brick per layer, one layer out of three, etc.). In some embodiments, the optional determination 1270 may be systematically performed.

[0061] The example drawn from Figures 1 to 9, 12, 13 and 14 and the exemplary refractory wall 90 will be used with the brick 60 as the single brick remaining to be positioned with the refractory wall 90, which implies that the layer 97 has been previously completed (i.e., with or without using the technology described herein). In the example, an overall design of the refractory wall 90 is known because each of the bricks 1 to 60 have a respective predetermined position. As such, before receiving any bricks, the controller 1100 can perform a mapping of the bricks 1 to 60 to predetermined position.

[0062] With reference to the example of Figures 1 to 9, 12, 13 and 14, in typical installations, the brick 60 may be loaded onto the brick loading station 210 by an operator and/or by a programmable automate. The brick 60 may then be transferred to the measurement station 230 by the loading collection conveyor 220. In other embodiments, the measurement station 230 and the brick loading station 210 may form a single station that does not require the loading collection conveyor 220. The measurement station 230 may provide actual measurements using one or a combination of measurements techniques. [0063] In some embodiments, the brick 60 is measured before being transferred to the production collection conveyor 280 or, when there is a need for matching different heights between the stations 230-280, the elevating conveyor 270.

[0064] In some embodiments, an inspection station 240 may be provided for inspecting the brick 60 before and/or after measurement. The inspection may be related to respect for expected measurement tolerance (e.g., plus or minus 1 mm), edges quality of the brick (e.g., edges not having chips larger than a maximum of 3 mm for example), ... Should the bricks 60 be considered unfit, it may be treated at an optional sorting station 250 (integrated or not with the sorting station 250) and rejected into a rejection bin 255. An optional brick cleaning station 260 may also be provided for cleaning the brick 60 (e.g., air-based and/or water-based cleaning) at any point between the brick loading station 210 and the production collection conveyor 280.

[0065] The production collection collector 280 may deliver the brick 60 to the positioning station 290. In some embodiments, a structure 280-S may be provided to mechanically support, for instance, the production collection conveyor 280 and / or the positioning station 290. In some embodiments, the positioning station 290 may not be required at all when, for instance, the brick 60 may have a defined transit position throughout the path between the stations 230-280 (e.g., between the measurement station 230 and the production collection conveyor 280, between the elevation conveyor 270 and the production collection conveyor 280, ... ), whereby the brick placement robot (BPR) 410 is able to pick the brick 60 based on the known transit position.

[0066] Concerning the conveyors 220, 270, 280, skilled persons will recognize that various technologies may be used without fundamentally affecting the teachings found herein and that different technologies may be used for different ones of the conveyors 220, 270 and 280 considering design choices made on peripheral elements of the innovative solutions described herein. More than one conveyor may form any one of the conveyors 220, 270, 280 even though reference is made to individual conveyors 220, 270, 280, for the sake of readability. As examples of conveyor technologies, bidirectional and/or unidirectional belt or chain conveyors having one or more tracks, with or without sorting capabilities, may be used. Additionally or alternatively, motorized rollers (e.g., individually, in groups or as a whole) and/or gravitational roller conveyors may be used. Of course, skilled persons will understand that the conveyor technologies may be mixed together, considering usual engineering practices. Furthermore, one or more of the conveyors 220, 270, 280 may be operable to allow for eventual gaps between bricks while on the conveyors 220, 270 and/or 280 to be partially or completely eliminated during displacement of the bricks thereon. [0067] The example of Figure 13 also depicts a safety enclosure 310 that would typically be present to protect people around the system 1000, but that is not required in regards to the teachings presented herein. One or more linear rails 330 may be provided when appropriate for the technology of the BPR 410 and/or the mortar spreading robot (RER or MSR) 510 (e.g., for longitudinal movements of the BPR 410 and/or MSR 510 along the refractory wall 90). A maintenance station 350 may be provided. A BPR structure 330-S may be provided to mechanically position and support the BPR 410. A vertical mortar station 320 may be provided when some of the bricks need to receive mortar on vertical surfaces.

[0068] A brick placement controller 402 is provided for controlling the BPR 410. BPR claws 420 are provided with the BPR 410 and operable to controllably manipulate the bricks 1- 60. A BPR tool stand 430 may be provided if and when more than one attachment tool is to be actuated by the BPR 410. Of course, skilled persons will understand how to select and dimension various elements related to the BPR 410 considering the task expected to be performed thereby. [0069] The refractory wall 90 to be built using the teachings found herein has horizontal mortar layers. While the mortar layers may be applied manually, there are advantages, albeit no necessity, to provide a mortar spreading robot (RER or MSR) 510. A mortar spreading controller 502, an MSR spreader head 520, an MSR tool stand 530 and an MSR Filling station 540 may also be provided. In the example discussed herein, for simplicity and clarity, the mortar will be considered in place before bricks are lowered onto the refractory wall 90.

[0070] In the example of Figures 1 to 9, 12, 13 and 14, the refractory wall 90 has a wall superstructure 710-S, which may be a metal tray having forklift pockets, allowing movement of the wall once completed. A wall cleaning station 720, a quality management system 730 and a quality control system 740 may be provided.

[0071] The BPR 410 may induce a potential positioning error within an error range. The error range may therefore be taken into account when computing 1210, 1250 and/or 1290 force vector(s). Furthermore, a target inter-brick gap for each of the brick to be positioned may be taken into consideration when computing 1210, 1250 and/or 1290 force vector(s).

[0072] Various network links may be implicitly or explicitly used in the context of the present invention. While a link may be depicted as a wireless link, it could also be embodied as a wired link using a coaxial cable, an optical fiber, a category 5 cable, and the like. A wired or wireless access point (not shown) may be present on the link between. Likewise, any number of routers (not shown) may be present and part of the link, which may further pass through the Internet. [0073] The present invention is not affected by the way the different modules exchange information between them. For instance, the memory module and the processor module could be connected by a parallel bus, but could also be connected by a serial connection or involve an intermediate module (not shown) without affecting the teachings of the present invention. [0074] A method is generally conceived to be a self-consistent sequence of steps leading to a desired result. These steps require physical manipulations of physical quantities. Usually, though not necessarily, these quantities take the form of electrical or magnetic/ electromagnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated. It is convenient at times, principally for reasons of common usage, to refer to these signals as bits, values, parameters, items, elements, objects, symbols, characters, terms, numbers, or the like. It should be noted, however, that all of these terms and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. The description of the present invention has been presented for purposes of illustration but is not intended to be exhaustive or limited to the disclosed embodiments. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiments were chosen to explain the principles of the invention and its practical applications and to enable others of ordinary skill in the art to understand the invention in order to implement various embodiments with various modifications as might be suited to other contemplated uses.