Systems and methods for galvanizing objects

Abstract

Systems and methods for galvanizing objects are described. In some aspects, systems and methods incorporate a trough configured to hold a molten galvanization material. The trough can include connected walls configured to hold a molten galvanization material within the trough. In some aspects, the trough further includes a first end comprising a first gate system. The trough can further include a second end, opposing the first end, comprising a second gate system. The trough further includes a roller connected, inside the trough, to opposing inside walls of the plurality of connected walls. The trough further includes a sump disposed within the trough. The trough further includes an inlet connected to the sump.

1 . A system comprising:
 a trough comprising a plurality of connected walls configured to hold a molten galvanization material within the trough, the trough further comprising
 a first end and a second end, opposing the first end; 
 a roller connected, inside the trough, to opposing inside walls of the plurality of connected walls; 
 a sump disposed within the trough; and 
 an inlet connected to the sump. 
   
     
     
         2 . The system of  claim 1 , wherein the trough further comprises:
 a plurality of side braces connected to an outside wall of the plurality of connected walls, the plurality of side braces extending outwardly from the outside wall,   wherein the inlet is disposed at a perpendicular angle relative to the outside wall and is further disposed between the plurality of side braces.   
     
     
         3 . The system of  claim 2 , further comprising:
 a pump disposed between the plurality of side braces,   wherein the pump is in fluid communication with the inlet.   
     
     
         4 . The system of  claim 1 , wherein the inlet is disposed at a bottom of the sump, relative to a location of the roller within the trough. 
     
     
         5 . The system of  claim 1 , wherein the first gate system comprises a gate removably secured to the first end using a key that locks the gate in place. 
     
     
         6 . The system of  claim 1 ,
 wherein the trough comprises a hook retainer extending outwardly from the first end and further comprises a slotted holder extending outwardly from the first end, and   wherein the first gate system comprises:
 a gate comprising a guide pin and a top shelf, the guide pin disposed in the slotted holder; and 
 a key disposed between the top shelf and the hook retainer such that the key secures the gate between the top shelf and the hook retainer. 
   
     
     
         7 . The system of  claim 1 ,
 wherein the first gate system comprises a gate, and   wherein the gate comprises a workpiece channel disposed in a side wall of the gate, wherein the workpiece channel is disposed in the gate to align with a groove of the roller along a horizontal axis of the trough.   
     
     
         8 . The system of  claim 1 ,
 wherein the first gate system comprises a gate, and   wherein the gate comprises:
 an outlet disposed in a side wall of the gate; and 
 a workpiece channel disposed in the side wall of the gate below the outlet, relative to a direction of gravity when the gate is installed in the trough for use, wherein the workpiece channel is disposed in the gate to align with a groove of the roller along a horizontal axis of the trough. 
   
     
     
         9 . The system of  claim 1 ,
 wherein the first gate system comprises a gate, and   wherein the gate comprises:
 a holding tab extending from a side wall of the gate; and 
 a workpiece channel disposed in the side wall of the gate below the holding tab, relative to a direction of gravity when the gate is installed in the trough for use, wherein the workpiece channel is disposed in the gate to align with a groove of the roller along a horizontal axis of the trough. 
   
     
     
         10 . The system of  claim 1 ,
 wherein the first gate system comprises a gate, and   wherein the gate comprises:
 a workpiece channel disposed in a side wall of the gate, wherein the workpiece channel is disposed in the gate to align with a groove of the roller along a horizontal axis of the trough; and 
 a bottom shelf disposed below the workpiece channel relative to a direction of gravity when the gate is installed in the trough for use, wherein the bottom shelf comprises a sloped ramp. 
   
     
     
         11 . The system of  claim 1 ,
 wherein the first gate system comprises a gate, and   wherein the gate comprises:
 a side wall; 
 a holding tab extending outwardly from the side wall; 
 a pair of opposed vertical braces connected to opposing ends of the side wall; 
 a pair of guide pins extending outwardly from the pair of opposed vertical braces; 
 a top shelf connected to the side wall and to the pair of opposed vertical braces; 
 an outlet disposed in a side wall of the gate, under the top shelf relative to a direction of gravity when the gate is installed in the trough for use; 
 a workpiece channel disposed in the side wall of the gate below the outlet, relative to the direction of gravity, wherein the workpiece channel is disposed in the gate to align with a groove of the roller along a horizontal axis of the trough; 
 a brace shelf connected to the side wall and to the pair of opposed vertical braces, the brace shelf disposed between the outlet and the workpiece channel; and 
 a bottom shelf disposed below the workpiece channel relative to the direction of gravity, wherein the bottom shelf comprises a sloped ramp. 
   
     
     
         12 . The system of  claim 1 ,
 wherein the first gate system comprises a gate, and   wherein the gate comprises a plurality of workpiece channels disposed in a side wall of the gate,
 wherein the plurality of workpiece channels are disposed in the gate to align with a plurality of grooves of the roller along a horizontal axis of the trough, and 
 wherein the plurality of workpiece channels are sized and dimensioned to pass a pre-determined range of sizes of a plurality of workpieces. 
   
     
     
         13 . The system of  claim 1 , further comprising:
 a kettle, wherein the trough is disposed partially within the kettle, and wherein the trough is connected to a kettle flange of the kettle.   
     
     
         14 . The system of  claim 1 , further comprising:
 a kettle, wherein the trough is disposed partially within the kettle, and wherein the trough is connected to a kettle flange of the kettle; and   a canopy mount connected to the kettle flange, wherein the canopy mount is disposed about adjacent the trough.   
     
     
         15 . The system of  claim 1 , further comprising:
 a kettle, wherein the trough is disposed partially within the kettle, and wherein the trough is connected to a kettle flange of the kettle;   a canopy mount connected to the kettle flange, the canopy mount disposed about adjacent the trough; and   a second roller connected to the canopy mount,
 wherein the roller comprises first grooves, 
 wherein the second roller comprises second grooves, and 
 wherein the first grooves align with the second grooves, 
   wherein the first gate system is disposed between the roller and the second roller.   
     
     
         16 . The system of  claim 1 , further comprising:
 a kettle, wherein the trough is disposed partially within the kettle, and wherein the trough is connected to a kettle flange of the kettle; and   a canopy mount connected to the kettle flange, the canopy mount disposed about adjacent the trough;   a pair of opposed roller mounts connected to the canopy mount, the pair of opposed roller mounts slidable with respect to the canopy mount; and   a second roller connected to the pair of opposed roller mounts, wherein the roller comprises first grooves,
 wherein the second roller comprises second grooves, and 
 wherein the first grooves align with the second grooves, 
   wherein the first gate system is disposed between the roller and the second roller.   
     
     
         17 . The system of  claim 1 , further comprising:
 a kettle, wherein the trough is disposed partially within the kettle, and wherein the trough is connected to a kettle flange of the kettle;   a canopy mount connected to the kettle flange, the canopy mount disposed about adjacent the trough, the canopy mount comprising a canopy mounting brace having tines; and   a bolt and a nut and washer assembly connecting the canopy mounting brace and the kettle flange through the tines, the nut and washer assembly operable to adjust a height of the canopy mount relative to the kettle flange.   
     
     
         18 . The system of  claim 1 , wherein the roller comprises:
 a shaft having a shaft groove;   a roller body rotatable about the shaft, the roller body comprising a plurality of grooves and a plurality of flat sections between the plurality of grooves;   a bushing connected to the shaft at an end of the shaft;   an outer bearing hub connected to the bushing and to the roller body;   a split retaining ring disposed at an end of the roller body, wherein an inner circumference of the split retaining ring fits within the shaft groove; and   a bolt connecting the split retaining ring, the outer bearing hub, and the roller body.   
     
     
         19 . The system of  claim 1 , wherein the first end comprises a first gate system and/or the second end comprises a second gate system. 
     
     
         20 . The system of  claim 1 , wherein the bushing is formed from graphite or other high temperature resistant material.