Anode handling system and method of use

Abstract

The invention provides an anode replacement system for electrolytic cells of an aluminum production plant, the system comprises a support frame and at least one movable member mounted on the support frame wherein the at least one movable member supports at least one anode gripping apparatus. Each of the at least one anode gripping apparatus is configured to grip a shaft of at least one anode assembly at any position along the shaft of the at least one anode assembly. The system comprises a sensor system configured to generate or collect position information to control the position of the at least one anode gripping apparatus.

1 . An anode replacement system for electrolytic cells of an aluminium production plant, the system comprising:
 a support frame;   at least one movable member mounted on the support frame wherein the at least one movable member supports at least one anode gripping apparatus; wherein each of the at least one anode gripping apparatus is configured to grip a shaft of at least one anode assembly at any position along the shaft of the at least one anode assembly; and   a sensor system configured to generate or collect position information to control the position of the at least one anode gripping apparatus.   
     
     
         2 . The system according to  claim 1  wherein the at least one anode gripping apparatus is configured to grip the shaft by contacting and/or clamping at least two surfaces or sides of the shaft of at least one anode assembly. 
     
     
         3 . The system according to  claim 1  wherein the at least one anode gripping apparatus is configured to grip the shaft by applying or exerting opposing forces on two or more surfaces or sides of the shaft of at least one anode assembly. 
     
     
         4 . The system according to  claim 1  wherein the sensor system is configured to generate or collect position information to control the position of the at least one movable member. 
     
     
         5 . The system according to  claim 1  further comprising a control system configured to move the support frame, the at least one movable member, the at least one anode gripping apparatus and/or the position of the at least one anode assembly. 
     
     
         6 . The system according to  claim 1  wherein the at least one movable member is at least one telescopic member or a robot assembly. 
     
     
         7 . The system according to  claim 1  wherein the at least one anode gripping apparatus comprises at least one grip member operable to move between an open condition and a closed condition. 
     
     
         8 . (canceled) 
     
     
         9 . The system according to  claim 1 , further comprising at least one scoop apparatus and/or at least one crust breaker apparatus. 
     
     
         10 . The system according to  claim 1  wherein the sensor system comprises at least one sensor selected from the group comprising: optical sensor, camera, vision system, time of flight camera, depth sensor, distance sensor, laser, ultrasound, momentum sensor, accelerometer, rotary position sensor, gyroscopic position sensor, global positioning sensor, infra-red sensor, thermal sensor, load cell and/or LIDAR. 
     
     
         11 . The system according to  claim 9  wherein the at least one sensor is mounted on the support frame, on at least one movable member, on at least one anode gripping apparatus, on at least one functional module, on an anode assembly, in a potroom, on a pot and/or a component of the pot. 
     
     
         12 . The system according to  claim 1  wherein the support frame is movably mounted on a support, vehicle, crane, positioning system or at least one positioning member of a positioning system. 
     
     
         13 . The system according to  claim 11  wherein the support, vehicle, crane, positioning system, or positioning member comprises a plurality of positional markers selected from the group comprising barcodes, data matrix codes, quick response codes and/or color codes. 
     
     
         14 . (canceled) 
     
     
         15 . The system according to  claim 12  wherein the sensor system is configured to detect at least one of the plurality of positional markers to accurately locate and/or move the position of the support, vehicle, crane, positioning system and/or at least one positioning member. 
     
     
         16 . The system according to  claim 1  wherein sensor system is configured to generate 3D position information of components of the support frame, at least one movable member and/or at least one anode gripping apparatus in relation to each other and/or to the work environment of the pot room. 
     
     
         17 . The system according to  claim 1  comprising at least one processing unit configured to process a movement path for the support frame, at least one movable member, at least one anode gripping apparatus and/or a gripped anode assembly based on the position information generated by the sensor system. 
     
     
         18 . The system according to  claim 1  wherein the anode gripper apparatus is configured to position a replacement anode assembly at an optimal position in the pot using data from the sensor system. 
     
     
         19 . The system according to  claim 1  wherein the sensor system is configured to track at least one marking or position on a spent anode in relation to a at least one marking or position on a pot structure. 
     
     
         20 . The system according to  claim 1  wherein the sensor system is configured to track and/or measure the height of an anode block of a spent anode. 
     
     
         21 . The system according to  claim 1  wherein the anode gripper apparatus comprises one or more mechanisms to adjust the tilt angle of the anode gripper apparatus and/or to adjust the vertical position of an attached anode assembly. 
     
     
         22 . An anode gripping apparatus handling for handling anodes in an aluminium production plant comprising:
 a support frame;   at least one grip member wherein the at least one grip member is configured to grip a shaft of at least one anode assembly at any position along the shaft of the at least one anode assembly.   
     
     
         23 . A method of replacing an anode in a pot in an aluminium production plant; the method comprising:
 providing an anode replacement system comprising;   at least one anode gripper apparatus configured to grip a shaft of at least one anode assembly at any position along the shaft of the at least one anode assembly; and a sensor system;   generating position data for at least one anode and anode shaft in the pot;   actuating the at least one anode gripper apparatus to grip the at least one anode shaft; and   
       lifting the at least one anode shaft to remove the anode assembly from the pot;
 positioning a replacement anode in the pot. 
 
     
     
         24 . The method according to  claim 21  comprising measuring and/or calculating a position of the spent anode assembly, a position of the shaft of the spent anode assembly and/or a position of an anode block of the spent anode assembly in the pot. 
     
     
         25 . The method according to  claim 21  comprising measuring, calculating or estimating a distance between a lower surface of an anode block of a spent anode assembly and an upper surface of a cathode in the pot. 
     
     
         26 . The method according to  claim 21  comprising identifying an optimal position for a replacement anode assembly in the pot and actuating the anode replacement system to locate the replacement anode assembly in the pot at the optimal position. 
     
     
         27 . The method according to  claim 21  comprising verifying, using data acquired by the sensor system, that the replacement anode is located at a correct position in the pot. 
     
     
         28 . The method according to  claim 21  comprising detecting one or more reference points or markings on an anode and/or a pot structure and calculating an optimal position or orientation for a replacement anode assembly in the pot based on the one or more references points or markings. 
     
     
         29 . The method according to  claim 21  comprising adjusting the height and/or position of the replacement anode assembly in the pot after the replacement anode assembly is clamped to the pot structure.