Key information

Title: A method and a cutter inspection apparatus for inspecting cutters on a rotating saw blade cutting slots in carbonaceous anode blocks
Application number: 20201335
Case type: National
Status: 20.05.2023 P.g.a. manglende svar. Søker har ikke begjært gjenopptakelse
Filed: 04.12.2020
Effective date: 04.12.2020
Publicly available: 06.06.2022
Applicant: IMPEC AS (NO)
Inventor: Ernst Ståle Øvstetun (NO)
Agent: ACAPO AS (NO)

Abstract and drawing

Disclaimer: This text has been machine-scanned and may contain errors – please refer to "Publications" for legally binding content.

A cutter inspector apparatus for inspecting cutters (22) on a rotating saw blade (20) cutting slots in carbonaceous anode blocks, comprising an optical scanner (10) placed adjacent said saw blade (20), said scanner (10) is a scanner for creating digital profile shapes of each cutters (22) on the rotating saw blade (20), and a control system receiving and storing said digital profile shapes of each cutters (22). The control system comprises a controller for comparing a first digital reference profile shape of a fresh cutter (22) with a second digital used profile shape of the same cutter, said first digital reference profile shape being taken prior to the second digital used profile shape, and the controller is arranged to identify deviations on the cutters (22) based on said digital profile shapes.

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Date

Date	Doc. No.	Process	Case number	In/Out	Journal description	To/from
22.09.2023	10-01	Saksbehandling	20201335	UT	Endelig Henleggelse	ACAPO AS
30.06.2023	09-01	Saksbehandling	20201335	UT	Henlagt manglende svar NO	ACAPO AS
20.02.2023	08-01	Saksbehandling	20201335	UT	20201335_1676558_PT 08	ACAPO AS
02.03.2022	06-01	Saksbehandling	20201335	INN	Korrespondanse (Hovedbrev inn)	ACAPO AS
13.01.2022	07-04	Saksbehandling	20201335	INN	P20019NO00 reviderte patentkrav	ACAPO AS
13.01.2022	07-03	Saksbehandling	20201335	INN	P20019NO00 endringsmarkerte krav	ACAPO AS
13.01.2022	07-02	Saksbehandling	20201335	INN	P20019NO00 Besvarelse 130122	ACAPO AS
13.01.2022	07-01	Saksbehandling	20201335	INN	Korrespondanse (Hovedbrev inn)	ACAPO AS
02.07.2021	05-02	Saksbehandling	20201335	UT	PT report 05:52:09
02.07.2021	05-01	Saksbehandling	20201335	UT	Realitet patent	ACAPO AS
15.12.2020	04-03	Saksbehandling	20201335	INN	P20019NO00 Overdragelse	ACAPO AS
15.12.2020	04-02	Saksbehandling	20201335	INN	P20019NO00 Fullmakt	ACAPO AS
15.12.2020	04-01	Saksbehandling	20201335	INN	Korrespondanse (Hovedbrev inn)	ACAPO AS
08.12.2020	03-01	Saksbehandling	20201335	UT	Formalia 1	ACAPO AS
08.12.2020	02-01	Saksbehandling	20201335	UT	Infobrev til oppfinner	ACAPO AS
04.12.2020	01-03	Saksbehandling	20201335	INN	P20019NO00 patentsøknad	ACAPO AS
04.12.2020	01-02	Saksbehandling	20201335	INN	P20019NO00 figurer	ACAPO AS
04.12.2020	01-01	Saksbehandling	20201335	INN	Søknadsskjema Patent	ACAPO AS

Description, claims and drawings

Disclaimer: This text has been machine-scanned and may contain errors – please refer to "Publications" for legally binding content.

Description

Field of the invention

The present invention relates to a method and a cutter inspection apparatus for inspecting cutters on a rotating saw blade cutting slots in carbonaceous anode blocks.

Background of the invention

The invention relates to the field of the production of carbon blocks intended for electrometallurgy, and more particularly to the field of the manufacture of carbon anodes and cathodes intended for the production by electrolysis of aluminium.

The electrolysis of aluminium may require the prior manufacture of carbon anodes. For this purpose, typically, the anodes are manufactured in a production workshop from a liquid pitch and crushed coke, mixed and kneaded to form a homogeneous paste. This paste is then compacted in order to obtain blocks with standard dimensions and properties, called green anodes. The green anodes then undergo a heat treatment in a baking oven in order to increase their mechanical resistance, to lower their chemical reactivity and their resistivity.

The raw anodes are transferred to the baking workshop by conveyors. They are associated in packs of several anodes. A handling system collects each package and positions it in a cell of the oven. At the end of the heat treatment, each package is extracted from the cell by the handling system and is positioned on a conveyor. The baked anodes of each pack are separated from each other and are transferred by a set of conveyors to a sealing workshop to be assembled to electrolysis rods

In the above described process large saw blades are used to cut slots in the anodes. Normally, two large saw blades are used to cut the slots. The slots are also normally cut with a small inclination, in order to evacuate gas during the electrolysis process.

Each saw blade is equipped with many cutters, and the cutters get worn down during operation and need to be exchanged. If not exchanged in time, unnecessary stress is put on the other cutters and their expected lifespan is shortened.

Today the cutters are inspected manually.

Such cutters are diamond coated and thus very expensive, and the lifespan is therefore economically important.

Objects of the present invention

The present invention provides an automated system and method with a cutter inspection apparatus that possibly is faster and can be applied in-line in the production process.

The present invention makes possible shorter time between inspections, and provides longer lifespan for cutters.

Summary of the invention

The present invention provides a method and apparatus in where the fresh cutters are scanned and a reference for each cutter is created. Performing a rescan after use and compare with cutters with references, and then mark cutter for replacement if cutter deviate too much from reference.

More specifically, the present invention provides a method for inspecting cutters on a rotating saw blade cutting slots in carbonaceous anode blocks, comprising the steps:

a) placing an optical scanner adjacent said saw blade,

b) scanning the cutters and creating digital reference profile shapes of fresh cutters on the rotating saw blade, based on data collected from the scanner,

c) receipt and storing of said digital reference profile shapes of each fresh cutter in a control system,

d) subsequent scanning of the cutters after a predetermined time creating digital used profile shapes of used cutters on the rotating saw blade, based on 3D data collected along the laser line emitted from the laser scanner,

e) receipt and storing of said digital used profile shapes of each used cutter in the control system,

f) comparing the digital reference profile shapes of the fresh cutters with the subsequent digital used profile shapes of the used cutters,

h) identify deviations of the used cutters based on said digital profile shapes, and

i) marking the used cutters for replacement if the identified deviations deviate more than a predetermined worn-out value.

In one embodiment of the method according to the invention, said scanner can be placed in line with the rotating saw blade, measuring the digital profile shapes along the direction of rotation of the saw blade and collecting image data to provide a profile for each cutter.

In a second embodiment of the method according to the invention, said scanner may be placed facing the rotating saw blade, measuring the digital profile shapes perpendicular to the direction of rotation of the saw blade and collecting data to provide several profiles for each cutter.

Steps d) to i) are preferably repeated as necessary or at regular intervals to check if the cutters are worn or not.

A laser line emitted from the scanner can be focused in or adjacent a center line of the saw blade.

The present invention also provides a cutter inspection apparatus for inspecting cutters on a rotating saw blade cutting slots in carbonaceous anode blocks, comprising an optical scanner placed adjacent said saw blade, said scanner being a scanner for creating digital profile shapes of each cutters on the rotating saw blade, and a control system receiving and storing said digital profile shapes of each cutters. The control system comprises a controller for comparing a first digital reference profile shape of a fresh cutter with a second digital used profile shape of the same cutter, said first digital reference profile shape being taken prior to the second digital used profile shape, and the controller is arranged to identify deviations on the cutters based on said digital profile shapes.

Said optical scanner can be a triangulating 3D laser scanner for creating digital reference profile shapes of fresh cutters on the rotating saw blade based on 3D data collected along a laser line emitted from the laser scanner.

Description of the figures

Embodiments of the present invention will now be described, by way of example only, with reference to the following figures, wherein:

Figure 1 shows a saw blade for cutting slots in carbonaceous anode blocks and a 3D laser scanner.

Figure 2 shows a cutout of a part of the saw blade with cutters.

Figure 3 shows a perspective view a cutter for the saw blade.

Figure 4 shows a side view of the cutter for the saw blade.

Figure 5 shows a first example of a digital profile shape of a cutter.

Figure 6 shows a second example of a digital profile shape of a cutter.

Figure 7 shows a cutout of a part of the saw blade with worn and not worn cutters.

Description of preferred embodiments of the invention

Figure 1 shows a typical saw blade 20 for cutting slots in carbonaceous anode blocks. The anodes are not shown. Next to the saw blade 20 is an optical scanner 10 placed, wherein the optical scanner 10 can be placed in line with the saw blade 20, for instance above the saw blade and scanning down, or the optical scanner 10 can be placed facing the saw blade 20 scanning perpendicular to the saw blade.

Multiple cutters 22, for instance fifty-four, are mounted on each saw blade 20, preferably as shown in figure 2 in rows on each side of the saw blade. An example of the cutters 22 is shown in figures 3 and 4. As seen, the cutters 22, which also can be called saw tooth, can be diamond coated and comprise a main part that is fixed to the saw blade 22 and a protruding cutting edge 24 for cutting the anodes. The cutting edge 24 is protruding somewhat upwards and forwards in the direction of movement, and is the part been worn.

The optical scanner 10 can be a scanner that creates an image profile of the cutters 22. The optical scanner can for instance be a 3D scanner such as a programmable 3D camera with laser triangulation technology that provides color-independent, contrast-independent, and true object shape data in millimeters. Such a laser scanner 10 can operate stand-alone and contains imaging, lighting, and analysis in a single housing, and which can have integrated communication. The laser scanner 10 can further be able to take up to 5000 profiles/s, but that during normal conditions takes around 1000 profiles/s, and with for instance 20 µm to 50 µm depth resolution and about 50 µm pixel resolution.

One or more 3D scanners 10 can be used, depended on solution requirements. Since the 3D scanner 10 has integrated laser, there is no requirement for external lighting. It is however preferable with shielding from surrounding light, to reduce interference and optimize signal quality

Figure 5 shows on configuration in where the 3D laser scanner 10 is placed above the saw blade 20 and creates digital profile shapes of each cutters 22 on the rotating saw blade 20, along the direction of rotation of the saw blade 20. In this configuration 3D data is only collected along the laser line, resulting in a 3D profile for each cutter. The measurement can be performed at 50 RPM of the saw blade 20.

The upper profile on the right-hand side of figure 5 indicates a cutting edge 24 that is OK, i.e. that is not worn-out and don't need replacement. The lower profile on the right-hand side of figure 5 indicates a cutting edge 24 that is not OK and that is wornout. The cutter 24 is then marked for replacement.

Figure 6 shows on configuration in where the 3D laser scanner 10 is placed next to and facing the saw blade 20 and creates digital profile shapes of each cutters 22 on the rotating saw blade, perpendicular to the direction of rotation of the saw blade 20. In this configuration 3D data is collected along the laser line, which creates several profiles, resulting in a 3D point cloud for each cutter 22.

The upper profile on the right-hand side of figure 6 indicates a cutting edge 24 that is OK, i.e. that is not worn-out and don't need replacement. The lower profile on the right-hand side of figure 6 indicates a cutting edge 24 that is not OK and that is wornout. The cutter 24 is then marked for replacement.

Scanning across cutters 22 might be more preferably, as it provides better data. From several profiles across the cutter 22, the profile along the cutter can easily be calculated.

Figure 7 shows in white cutters 22 that are not worn-out (marked OK) and in grey worn-out cutters (marked NOK) indicated by reference number 22'.

In the method and the cutter inspection apparatus according to the invention, the triangulating 3D laser scanner 20 is firstly placed adjacent the saw blade 10. In a first step, to create reference data, the cutters 22 are scanned and reference digital profile shapes of fresh cutters on the rotating saw blade is created, based on 3D data collected along a laser line emitted from the laser scanner. Thereafter are the reference digital profile shapes of each fresh cutter 22 received and stored in a control system. The control system (not shown) can be an external processing unit or an integrated part of the 3D laser scanner 10.

Then in a second step, subsequent scanning of the cutters 22 after a predetermined time is performed, creating digital profile shapes of used cutters 22 on the rotating saw blade 10, based on 3D data collected along the laser line emitted from the laser scanner 10. The digital profile shapes of each used cutter 22 is received and stored in the control system. Thereafter, the reference digital profile shapes of the fresh cutters 22 are compared with the subsequent digital profile shapes of the used cutters 22', and deviations of the used cutters 22' are identified based on said digital profile shapes. The worn-out cutter(s) 22' are then marked for replacement if the identified deviations deviate more than a predetermined worn-out value.

The cutter inspector apparatus comprises, in addition to the laser generating 3D scanner 10 placed adjacent said saw blade 20, the control system receiving and storing said digital profile shapes of each cutters 22. The control system comprises a controller (not shown) for comparing a first digital reference profile shape of the fresh cutter 22 with a subsequent taken second digital used profile shape of the same cutter 22', said first digital reference profile shape being taken prior to the second digital used profile shape, wherein the controller is arranged to identify deviations on the cutters 22 based on said digital profile shapes.

Claims

1. A method for inspecting cutters (22) on a rotating saw blade (20) cutting slots in carbonaceous anode blocks, comprising the steps:

a) placing an optical scanner (10) adjacent said saw blade (20),

b) scanning of the cutters (22) and creating digital reference profile shapes of fresh cutters (22) on the rotating saw blade (20), based on data collected from the scanner (10),

c) receipt and storing of said digital reference profile shapes of each fresh cutter (22) in a control system,

d) subsequent scanning of the cutters (22) after a predetermined time creating digital used profile shapes of cutters (22) on the rotating saw blade (10), based on 3D data collected along the laser line emitted from the laser scanner (10),

e) receipt and storing of said digital used profile shapes of each used cutter (22) in the control system,

f) comparing the digital reference profile shapes of the fresh cutters (22) with the subsequent digital used profile shapes of the used cutters (22),

h) identify deviations of the used cutters (22) based on said digital profile shapes, and

i) marking of used cutter(s) (22') for replacement if the identified deviations deviate more than a predetermined worn-out value.

2. The method according to claim 1, wherein said scanner (10) is placed in line with the rotating saw blade (20), measuring the digital profile shapes along the direction of rotation of the saw blade (20) and collecting image data to provide a profile for each cutter (22).

3. The method according to claim 1, wherein said scanner (10) is placed facing the rotating saw blade (20), measuring the digital profile shapes perpendicular to the direction of rotation of the saw blade (20) and collecting image data to provide several profiles for each cutter.

4. The method according to claim 1, wherein steps d) to i) are repeated as necessary or at regular intervals to check if the cutters (22) are worn or not.

5. The method according to claim 1, wherein a laser line emitted from the scanner (10) is focused in or adjacent a center line of the saw blade (20).

6. A cutter inspector apparatus for inspecting cutters (22) on a rotating saw blade (20) cutting slots in carbonaceous anode blocks, comprising

an optical scanner (10) placed adjacent said saw blade (20),

said optical scanner (10) is a scanner for creating digital profile shapes of each cutter (22) on the rotating saw blade (20),

a control system receiving and storing said digital profile shapes of each cutter (22), wherein

the control system comprises a controller for comparing a first digital reference profile shape of a fresh cutter (22) with a second digital used profile shape of the same cutter, said first digital reference profile shape being taken prior to the second digital used profile shape, and

the controller is arranged to identify deviations on the cutters (22) based on said digital profile shapes.

7. The cutter inspector apparatus according to claim 6, wherein said optical scanner is a triangulating 3D laser scanner (10) for creating digital reference profile shapes of fresh cutters (22) on the rotating saw blade (20) based on 3D data collected along a laser line emitted from the laser scanner (10).

8. The cutter inspector apparatus according to claim 6, wherein said scanner (10) is placed in line with the rotating saw blade (20) and is measuring the digital profile shapes along the direction of rotation of the saw blade (20).

9. The cutter inspector apparatus according to claim 8, wherein said scanner (10) is a triangulating 3D laser scanner (10) for collecting 3D data along a laser line to provide a 3D profile for each cutter (22).

10. The cutter inspector apparatus according to claim 6, wherein said scanner (10) is placed facing the rotating saw blade (20) and is measuring the digital profile shapes perpendicular to the direction of rotation of the saw blade (20).

11. The cutter inspector apparatus according to claim 10, wherein said scanner (10) is a triangulating 3D scanner for collecting 3D data along a laser line to provide several profiles with a 3D point cloud for each cutter (22).

Drawings

Priority

No priority

Patent classes

IPC classes

G01S 17/48

G01S 17/894

G01S 17/88

B23D 63/00

CPC classes

G01S 17/48

G01S 17/894

G01S 17/88

B23D 63/005

Citations

DE 102006002282 A1 (A1)

US 5825017 A (A)

US 4031368 A (A)

Applicants, owners and inventors

Applicants

IMPEC AS

Postboks 131

6882 ØVRE ÅRDAL

NO (ÅRDAL Municipality, Vestland county)

Org. number: 987084723

Inventors

Ernst Ståle Øvstetun

Volldalsvegen 1 C

6884 ØVRE ÅRDAL

NO (ÅRDAL Municipality, Vestland county)

Agent

ACAPO AS

Edvard Griegs vei 1

5059 BERGEN

NO (BERGEN Municipality, Vestland county)

Org. number: 915113737

Reference: P20019NO00

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Payment history

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No oppositions or appeals

Administrative limitation

No administrative limitation

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No liens or licenses registered

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Only events from 2024.03.04 and onwards are shown.

A method and a cutter inspection apparatus for inspecting cutters on a rotating saw blade cutting...