Patent Grant
12070830
The present invention relates to buffing systems. More particularly, the present invention relates to systems for buffing a cathode for subsequent electro-winning.
Electro-winning is a process, similar to electroplating, that uses an electric current to reduce dissolved metal cations to form a thin metal coating on a cathode. Electro-winning is primarily used to change the surface properties of an object (such as abrasion and wear resistance, corrosion protection, lubricity, or aesthetic qualities), and may also be used to increase the thickness of undersized parts. Some conventional materials used for cathodes include copper, titanium, platinum, and steel. Effectively buffing the cathode prior to electro-winning is important in order to create a cathode surface that is smooth and free from irregularities. In one conventional cathode buffing process, the cathode is held horizontally while being buffed on one side, and then the cathode must be turned over to buff the other side. In another conventional cathode buffing process, an orbital buffer is used to buff the cathode in a circular motion, leaving an irregularly buffed surface for electro-winning.
Various embodiments provide a buffing system. The system includes a frame defining a slot sized and configured to receive a cathode and a lifting assembly secured to the frame and configured to transport the cathode in a substantially vertical direction. The system further includes a carriage assembly coupled to the lifting assembly and configured to secure the cathode during the buffing process. A buffing assembly is rotatably coupled to the frame, the buffing assembly including a motor coupled to a buffing shaft, and a buffing wheel coupled to the buffing shaft. The buffing wheel is configured to buff the cathode as the lifting assembly moves the cathode in the substantially vertical direction.
Additional embodiments provide a system for buffing a cathode. The system includes a frame defining a slot sized and configured to receive a cathode. A lifting assembly is secured to the frame and is configured to transport the cathode in a substantially vertical direction. The lifting assembly includes a first rail assembly and a second rail assembly positioned opposite the first rail assembly. A carriage assembly is positioned between the first rail assembly and the second rail assembly, the carriage assembly sized and configured to secure the cathode during the buffing process. A buffing assembly is configured to buff the cathode.
Still other embodiments provide a buffing system. The system includes a frame defining a slot, the slot sized and configured to receive a cathode. A lifting assembly is secured to the frame and is configured to transport the cathode in a substantially vertical direction. A carriage assembly is slidably coupled to the lifting assembly, the carriage assembly sized and configured to secure the cathode during the buffing process. A buffing assembly includes a pivot shaft rotatably coupled to the frame. A pivot frame is rotatably coupled to the pivot shaft, the pivot frame configured to be positioned by a buffing cylinder. A buffing wheel is rotatably coupled to the pivot frame, the buffing wheel configured to buff the cathode.
These and other features, together with the organization and manner of operation thereof, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, wherein like elements have like numerals throughout the several drawings described below.
The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the disclosure will become apparent from the description, the drawings, and the claims, in which:
The frame 116 may be constructed of, for example, metallic materials such as stainless steel, aluminum, or other metals suitable for manufacturing. The choice of material may depend on the particular manufacturing environment. The frame 116 is rotatably coupled to the first door 104 and the second door 106 such that the first door 104 and the second door 106 are configured to open to expose the interior of the buffing system 100 for maintenance purposes. The frame 116 is also rotatably coupled to the cylinders 202, the buffing assemblies 204, and the buffing cylinders 208. The frame 116 defines a space allowing the lifting assembly 102 to move within the frame in a substantially vertical direction (e.g., plus or minus five degrees of vertical). The frame 116 is also rigidly coupled to the air knives 110, the sensor 108, and the dust collection adapter 112. The slot 118 is defined by the frame 116 and is sized and configured to receive a cathode 206 for the cathode buffing process.
The first door 104 and the second door 106 may be constructed of, for example, metallic materials such as stainless steel, aluminum, or other metals suitable for manufacturing. The choice of material may depend on the particular manufacturing environment. The first door 104 and the second door 106 are rigidly coupled to the cylinders 202 and are rotatably coupled to the frame 116. The first door 104 and the second door 106 are configured to substantially enclose the buffing system 100 when the buffing system 100 is operating. Enclosing the buffing system 100 during operation prevents injuries, decreases noise, and prevents debris from escaping the buffing system 100. When the first door 104 and the second door 106 are opened, access to the interior of the buffing system 100 is provided such that repairs or regular maintenance activities can be conducted.
The cylinders 202 are rigidly coupled to the first door 104 and the second door 106 and are rotatably coupled to the frame 116. The cylinders 202 may be hydraulic actuators, pneumatic actuators, or any other type of device configured to actuate and provide a force to maintain the first door 104 and the second door 106 in a substantially open configuration.
The sensor 108 is rigidly coupled to the frame 116 and is in electrical communication with the electrical panel 114. The sensor is configured to determine whether the cathode 206 is present in the buffing system 100 and provide information about the presence of the cathode 206 to the electrical panel 114. The sensor may be an optical sensor, a force sensor, or any other sensor that may be configured to detect the presence of the cathode 206 in the buffing system 100.
The air knives 110 are rigidly coupled to the frame 116 and are in electrical communication with the electrical panel 114. The air knives 110 are configured to direct air over the cathode 206 as the cathode 206 is removed from the buffing system 100 to remove any remaining debris on the cathode 206 from the buffing process. The air knives 110 can be air knives, compressed air blowers, or any other type of device capable of removing debris from the cathode 206 as it is removed from the buffing system 100.
The dust collection adapter 112 is rigidly coupled to the frame 116 and is configured to receive the debris from the buffing process. The dust collection adapter 112 may be coupled to a dust removal system that includes a vacuum to transport the debris from the dust collection adapter 112 to the dust removal system.
The electrical panel 114 is rigidly coupled to the frame 116 and is configured to control the buffing system 100. The electrical panel is in electrical communication with the sensor 108, the air knives 110, an operator that may be operating the buffing system 100, and any other electrical equipment included in the buffing system 100. The electrical panel is configured to receive and send electrical signals to control the buffing system 100.
The cathode 206 generally includes a sheet and a header bar coupled to the sheet. The sheet may be any metal suitable for an electro-winning process (e.g., copper, zinc, platinum, etc.). The header bar is an attachment that facilitates cathode cleaning, buffing, and/or electro-winning processes by allowing the cleaning, buffing, and/or electro-winning equipment to manipulate the cathode sheet by the header bar without contacting the cathode sheet with unwanted materials. The slot 118 is sized and configured to fit a plurality of sizes of the cathode 206.
The buffing cylinders 208 are rotatably coupled to the buffing assemblies 204 and are rotatably coupled to the frame 116. The buffing cylinders 208 are sized and configured to raise and lower the buffing assemblies 204. The buffing cylinders 208 may be hydraulic actuators, pneumatic actuators, or any other type of device configured to actuate and provide a force to raise and lower the buffing assemblies 204.
The ventilation assembly 304 is rigidly coupled to the frame 116 and may be constructed of, for example, metallic materials such as stainless steel, aluminum, or other metals suitable for manufacturing. The ventilation assembly 304 may also be constructed of, for example, plastic materials such as polycarbonate, ABS, or other plastics suitable for manufacturing. The ventilation assembly 304 is sized and configured to receive the lifting assembly 102 and receive debris generated during the buffing process. The ventilation assembly will be further described with reference to
The bearings 306 are rigidly coupled to the frame 116 and are sized and configured to receive the buffing assemblies 204 such that the buffing assemblies 204 can rotate with respect to the frame 116. The bushings 308 are rigidly coupled to the frame 116 and are sized and configured to rotatably couple to the cylinders 202 such that the cylinders 202 can rotate with respect to the frame 116.
The header bar 406 is coupled to the cathode sheet 404 and is sized and configured to secure the cathode sheet 404 such that the cathode sheet 404 can be inserted into, and be removed from, the buffing system 100. The header bar 406 may be constructed of any material suitable for supporting the cathode 206. In some embodiments, the header bar 406 is sized and configured to support the cathode 206 when it is inserted into the buffing system 100 by an operator. In some embodiments, the header bar 406 is sized and configured to support the cathode 206 when it is inserted into the buffing system 100 by a robot or other automated means.
The rail assembly 408 and the rail assembly 410 are rigidly coupled to the frame 116. The rail assembly 408 and the rail assembly 410 may be constructed of, for example, metallic materials such as stainless steel, aluminum, or other metals suitable for manufacturing. Cam rails 412 and followers 416 are sized and configured to be linearly coupled to the carriage assembly 402 to provide for the substantially vertical travel of the carriage assembly 402. The stops 414 are rigidly coupled to the rail assembly 408 and the rail assembly 410 and are configured to set a fixed position and to prevent the carriage assembly 402 from an uncontrolled fall in case of a failure of the buffing system 100.
The actuator 418 is rigidly coupled to the actuator tab 420 and is sized and configured to transport the carriage assembly 402 in a substantially vertical direction. The actuator 418 may be a hydraulic, pneumatic, electric, thermal, magnetic, or any other type of actuator capable of moving in a substantially vertical direction.
The actuator tab 420 is rigidly coupled to the actuator 418 and is sized and configured to contact the carriage assembly 402 such that when the actuator 418 moves in a substantially vertical direction, the actuator tab 420 moves the carriage assembly in the vertical direction. The interaction between the actuator tab 420 and the carriage assembly 402 will be further described with reference to
The carriage assembly 402 is sized and configured to receive the cathode 206 when the cathode 206 is secured by header bar supports and is transported in the substantially vertical direction by the lifting assembly 102. The carriage assembly 402 will be further described with reference to
The frame 502 may be constructed of, for example, metallic materials such as stainless steel, aluminum, or other metals suitable for manufacturing. The frame 502 is rigidly coupled to the edge guards 506, the strip guards 508, the cam rails 510, the header bar supports 512, and the actuator slot 514. The frame 502 is rotatably coupled to the followers 504.
The edge guards 506 are sized and configured to receive the cathode 206 and maintain the cathode 206 in a substantially vertical orientation. The edge guards 506 define a space configured to receive vertical edges of the cathode 206 such that the cathode 206 is prevented from rotation about a vertical axis.
The strip guards 508 are sized and configured to receive the cathode 206 and maintain the cathode 206 in a substantially vertical orientation. The strip guards 508 define a space configured to receive a bottom edge of the cathode 206 such that if required the cathode 206 is prevented from rotation about a horizontal axis.
The header bar supports 512 are sized and configured to receive the header bar 406 and maintain the cathode sheet 404 in a substantially vertical orientation. The header bar supports 512 define a space configured to receive the header bar 406 such that the cathode sheet 404 is prevented from rotation about a horizontal axis.
The cam rails 510 are sized and configured to be linearly coupled to the followers 416 such that, as the carriage assembly 402 moves in a substantially vertical direction, the followers 416 rotate as the cam rails 510 move with the carriage assembly 402. The followers 416 are also sized and configured to maintain the carriage assembly 402 in a substantially vertical orientation.
The followers 504 are sized and configured to be linearly coupled to the cam rails 412 such that, as the carriage assembly 402 moves in a substantially vertical direction, the followers 504 rotate along the cam rails 412 as the carriage assembly 402 moves.
The actuator slot 514 is a cutout in the carriage assembly 402 that is sized and configured to fit around the actuator tab 420 such that movement of the actuator tab 420 results in movement of the carriage assembly 402.
The collection wall 602 is configured to contact debris that may be generated from the buffing process. The collection wall 602 is angled such that the debris that contacts the collection wall 602 will be directed toward the collection funnel 604 at the bottom of the ventilation assembly 304. The collection funnel 604 is configured to further direct the debris from the collection wall 602 into the dust collection adapter 112.
The collection outlet 608 is configured to couple with a debris removal system designed to remove the debris from the ventilation assembly 304. In some embodiments, the debris removal system may include a vacuum to pull the debris from the ventilation assembly 304 into the debris removal system.
The frame 702 may be constructed of, for example, metallic materials such as stainless steel, aluminum, or other metals suitable for manufacturing. The frame 702 is rigidly coupled to the dust flap 704, the pivot shaft 706, the motor 708, and the bearing 716. The frame 702 is also rigidly coupled to the buffing cylinder 208.
The dust flap 704 is coupled to the frame 702 and is configured to direct dust and debris from the buffing process to the ventilation assembly 304. The dust flap 704 may be constructed of, for example, metallic materials such as stainless steel, aluminum, or other metals suitable for manufacturing. The dust flap 704 may also be constructed of, for example, plastic materials such as polycarbonate, ABS, or other plastics suitable for manufacturing. The dust flap 704 may also be constructed of, for example, rubber materials such as natural rubber, synthetic rubber, vulcanized rubber, or other rubbers suitable for manufacturing.
The pivot shaft 706 is coupled to the frame 702 and is configured to couple with the bearings 306 on frame 116 such that the pivot shaft 706 rotates in the bearings 306. The pivot shaft 706 rotates in the bearings 306 when the buffing cylinders 208 impart a force to the frame 702, causing the frame 702, and thus the pivot shaft 706, to rotate. The pivot shaft 706 may be constructed of, for example, metallic materials such as stainless steel, aluminum, or other metals suitable for manufacturing.
The motor 708 is coupled to the frame 702 and is rotatably coupled to the buffing shaft 714, and is configured to rotate the buffing wheel 718 such that the buffing wheel 718 buffs the cathode 206. The motor 708 may be an electric motor, a pneumatic motor, or any other type of motor capable of rotating the buffing wheel 718 to buff the cathode 206.
The belt 712 is coupled to the motor 708 and the buffing shaft 714 such that the rotational motion from the motor 708 is transmitted to the buffing shaft 714. The belt 712 may be constructed from a rubber or other elastic material, or any other type of material capable of transmitting rotational motion from the motor 708 to the buffing shaft 714.
The buffing shaft 714 is rotationally coupled to the bearing 716 and the belt 712, and rigidly coupled to the buffing wheel 718. The buffing shaft 714 is configured to rotate based on motion of the belt 712 and transmit the motion to the buffing wheel 718 to cause the buffing wheel 718 to rotate. The buffing shaft 714 may be constructed of, for example, metallic materials such as stainless steel, aluminum, or other metals suitable for manufacturing.
The bearing 716 is rigidly coupled to the frame 702 and is rotatably coupled to the buffing shaft 714. The bearing 716 may be constructed of, for example, metallic materials such as stainless steel, aluminum, or other metals suitable for manufacturing. The bearing 716 is configured to allow the buffing shaft 714 to rotate and transmit the rotation to the buffing wheel 718.
The buffing wheel 718 is rigidly coupled to the buffing shaft 714 and is configured to rotate based on the rotational motion of the buffing shaft 714. The buffing wheel 718 is further configured to contact the cathode 206 while the buffing wheel 718 is rotating such that the cathode 206 is buffed by the buffing wheel 718 to prepare the cathode 206 for electro-winning. The buffing wheel may be constructed of any material capable of effectively buffing the cathode 206 without damaging the cathode 206. In some implementations, the buffing wheel 718 can buff the cathode 206 without using any additional buffing media. In other implementations, the buffing wheel 718 is used in conjunction with buffing media to buff the cathode 206. Some non-limiting examples of buffing media include aluminum oxide, chromium oxide, and iron oxide.
Throughout the description above, many elements were described as singular elements. However, as shown in
In operation, and with reference to
As the cathode 206 is lowered into the slot 118, the vertical edges of the cathode 206 are within the edge guards 506. When the cathode 206 has been fully lowered into the slot 118 and the header bar 406 is resting on the header bar supports 512, the bottom edge of the cathode sheet 404 is located within the strip guard 508. Once placed into the buffing system 100 as described, the cathode sheet 404 is held in a substantially vertical orientation and is prevented from rotating in any direction.
In some embodiments, to initiate the buffing process a user will press a button. In other embodiments, the buffing process will be initiated when the sensor 108 senses that a cathode 206 is in the appropriate position for the process to begin.
When the buffing process begins, the electrical panel 114 sends an electrical signal to both the actuator 418 and the motors 708. When the motors 708 receive the electrical signal, the motors 708 begin to rotate and the buffing cylinders 208 lift the frame 702 such that the buffing wheels 718 contact the cathode 206 to begin the buffing process.
The buffing wheels 718 are sized and configured to buff the entire width of the cathode 206 during the buffing process to eliminate the need for the buffing wheels to move in both the horizontal and vertical directions.
As the buffing process continues, the actuator 418 moves in the vertical direction. As the actuator 418 moves in the vertical direction, the actuator 418 contacts the actuator slot 514 such that, as the actuator 418 moves the carriage assembly 402 moves. Thus, as the actuator 418 moves up and down in the vertical direction, the carriage assembly 402 moves up and down in the vertical direction and causes the buffing wheels 718 to buff both sides of the cathode 206 along its entire length and width.
Throughout the buffing process, debris may be created either by the buffing media or impurities or surface imperfections that have been buffed off the cathode 206 by the buffing wheels 718. The debris is directed downward toward the ventilation assembly 304 based on the rotation of the buffing wheels 718. The debris is then directed further downward by the dust flaps 704 and into the collection wall 602. From the collection wall 602, the debris is directed toward the collection funnel 604 where the debris falls into the dust collection adapter 112. The dust removal system then uses a vacuum to remove the debris from the buffing system 100.
When the buffing process is complete, the cathode 206 is removed from the slot 118 by a user, in some implementations. In other implementations, the cathode 206 is removed from the slot 118 by a robot or other automated process. While the cathode 206 is removed from the slot 118, the air knives 110 direct pressurized air at the cathode 206 to remove any other remaining debris from the cathode 206. The pressurized air is directed downward such that any other debris is collected by the dust removal system.
After completion, it may be necessary to repair the buffing system 100 or otherwise perform preventive maintenance. To do so, the first door 104 and the second door 106 are lifted up, and as the first door 104 and the second door 106 are lifted up the cylinders 202 maintain the first door 104 and the second door 106 in the open position. In addition, the buffing assemblies 204 can be moved away from their buffing positions by rotating the buffing assemblies 204 downward by retracting the buffing cylinders 208, causing the pivot shaft 706 to rotate within the bearing 306.
After repairs or preventive maintenance is complete, the buffing assemblies 204 are returned to their upright positions by rotating the buffing assemblies 204 upward. The first door 104 and the second door 106 are then lowered back to their original positions to put the buffing system 100 in condition for subsequent buffing processes.
As utilized herein, the terms “substantially” and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of ordinary skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims.
References herein to the positions of elements (e.g., “top,” “bottom,” “upper,” “above,” “below,” etc.) are merely used to describe the orientation of various elements in the Figures. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.
Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes, and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. For example, elements shown as integrally formed may be constructed of multiple components or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any method processes may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes, and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention.
The present application claims priority to U.S. Provisional Patent Application No. 62/783,542, entitled “Automated Cathode Buffing System,” filed Dec. 21, 2018 and the contents of which are incorporated herein by reference.
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| 2220982 | Toney | Nov 1940 | A |
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| Number | Date | Country | |
|---|---|---|---|
| 62783542 | Dec 2018 | US |
