Steel Coil Cutting Apparatus and Method

Abstract

A method of cutting a steel coil with an axial center located within a bore of the steel coil. The method comprises the steps of positioning a cutting apparatus near the axial center of the steel coil, utilizing an imaging device as a sensor that is attached to the cutting apparatus for detecting the axial center of the steel coil, and aligning the cutting apparatus to be co-axial with the axial center. The method further comprises the steps of providing the cutting apparatus with a cutting device, radially directing the cutting device, and axially cutting an entire length of the steel coil by activating the cutting device, and axially moving the cutting device through the bore of the steel coil from a first end of the steel coil to a second end of the steel coil.

Description

FIELD OF THE INVENTION

The present invention relates generally to the field of steel cutting devices and more particularly to a steel coil cutting apparatus and method.

BACKGROUND OF THE INVENTION

Steel coils that are defective are cut into smaller section of scrap to be fed and re-melted in a BOF (Blast Oxygen Furnace) or electric arc furnace. In most steel producing factories the process of cutting the defective steel coil is a manual process. A worker uses a single hand held torch to accomplish the task of cutting the coil into smaller parts by cutting the coil along it length from top to bottom along the exterior of the coil, As the coil is being cut, the coil opens up and additional cuts are required. This process can be time consuming and frustrating.

Thus there exists a need for a steel coil cutting apparatus that saves time, money and reduces the frustration of workers assigned this task.

SUMMARY OF INVENTION

A steel coil cutting apparatus that overcomes these and other problems has an automated arm having a free end. At least two cutting heads are attached to the free end of the automated arm. The cutting heads may be torches. A cooling system may cool the cutting heads. A housing holds the automated arm. A low melting point starter may be attached to one of the cutting heads. A regulator regulates a flow of gases to the torches. The arm may have a centering detection device.

In one embodiment, a method of cutting a steel coil includes the steps of aligning a number cutting heads to a center of the steel coil. The cutting heads are passed through the center of the steel coil. A speed at which the cutting head pass through the center of the steel coil may be regulated. A flow of gas to each of the cutting heads may be regulated. A flow of oxygen to each of the cutting heads may be regulated. The steel coil may be placed vertically on blocks. A low melting point starter may be placed near the cutting heads. The cutting heads may be cooled.

In one embodiment, a steel coil cutting apparatus has a platform. An arm has a first end attached to the platform. A number cutting torches are attached to a second end of the arm. The arm may be controlled by an electronic controller. A low melting point starter may be attached to the second end of the arm. A cooling system may cool the cutting torches. A centering detection device may be coupled to the second end of the arm. A flow regulator may regulating a flow of gas to one of the plurality of cutting torches.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of a steel coil cutting apparatus in accordance with one embodiment of the invention;

FIG. 2 is a side view of a steel coil cutting apparatus in accordance with one embodiment of the invention;

FIG. 3 is a side view of a steel coil cutting apparatus in accordance with one embodiment of the invention; and

FIG. 4 is a top view of the cutting torch heads in accordance with one embodiment of the invention.

DETAILED DESCRIPTION OF THE DRAWINGS

The present invention is an apparatus and method for cutting steel coils that are defective. Once the steel coils are cut they can be fed into a steel furnace for reuse of the materials. The steel coil cutting apparatus uses a number of cutting heads or torches to make multiple cuts in the steel coil with a single pass of the cutting heads along an axis, A-A, extending through the center of the coil of steel.

FIG. 1 is a block diagram of a steel coil cutting apparatus 10 in accordance with one embodiment of the invention. The steel coil cutting apparatus 10 has a platform or housing 12. A controllable or automated arm 14 has a first end 16 coupled to the platform 12 and a second end 18 with a number of cutting heads 20. Usually there are two to four diametrically opposite cutting heads 20 which are commonly oxygen torches. Note the torch heads essentially point perpendicular to the length of the arm 14. A sensor 22 is attached to the cutting heads or second end 18 of the arm 14. The sensor 22 is part of centering detection system that determines the center of the steel coil. The other part of the centering detection system is controller 24. The sensor 22 may be a laser and photo-detectors or it may be a camera system. A cooling system 26 is attached to the arm 14 and cools the arm 14 and the cutting torches 20 by circulating water over these parts in one embodiment. A regulator 28 regulates the supply of oxygen and gas to the cutting torches 20. A low melting point starter 29 is placed adjacent to the cutting edges. The starter system 29 may use a low melting point wire rod feed or powder injection to enable a rapid start of the fusion or cutting of high alloy steels.

FIG. 2 is a side view of a steel coil cutting apparatus 10 in accordance with one embodiment of the invention. This figure shows a cross section of the steel coil 40 that has a bore 42. The torch cutting heads 20 move vertically from the top of the steel coil to the bottom of the steel coil, in this embodiment. The invention may also be used to cut the steel coil 40 in a horizontal direction. FIG. 3 is a side view of a steel coil cutting apparatus 10 in accordance with one embodiment of the invention. This figure shows the steel coil 40 mounted a number of blocks 44. The blocks 44 allow the torch heads to cut all the way to the bottom of the steel coil 40. The platform has a place for an operator to stand and control the apparatus. In operation the apparatus 10 may be on wheels 46 and may be moved about the factory to cut defective steel coils in place. Once the apparatus 10 is next to the steel coil, the centering system is used to center the cutting torches along the axis, A-A extending within the bore 42 of the coil 40. The torches 20 are turned on and the automated arm 14 starts to move down into the bore 42. The automated arm 14 may be controlled by programmable logic controller 24 controls or similar controls so that the speed of entry and traverse of the arm 14 in the bore 42 can be precisely controlled. The arm control allows different speeds for the start, accelerated ramp speed and deceleration. The arm also controls the speed of the multiple torch heads 20 during cutting as different coil widths require different cutting speeds. The regulator 28 is used to adjust the flow of gases and oxygen to the cutting torch heads 20. The cooling system 26 cools the arm 14 and the cutting torches 20. Once the steel coil 40 has been cut, the apparatus 10 maybe wheeled to the next steel coil to be cut.

FIG. 4 is a top view of the cutting torch heads 20 in accordance with one embodiment of the invention. The individual torch heads 50, 52, 54, 56 extend radially in a radial cutting direction, R1, R2, R3, R4 from a point 58 co-axial with the axis, A-A. Note that the torch heads 50 and 52 are diametrically opposite of each other and torch heads 54 and 56 are diametrically opposite of each other.

Thus there has been described an apparatus and method for cutting steel coils that saves time, money and reduces the frustration of workers assigned this task.

While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alterations, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alterations, modifications, and variations in the appended claims.

Claims

1-20. (canceled)

21. An apparatus for cutting a steel coil having an axial center, an axial length extending between a first axial end and a second axial end, an outer side surface, and a bore having an inner bore surface, comprising: an axial arm;a cutting head connected to a distal end of the axial arm; andan imaging sensor connected to the cutting head.

22. The apparatus according to claim 21, wherein the imaging sensor defines: means for detecting the axial center of the steel coil without physically engaging the steel coil.

23. The apparatus according to claim 21, wherein the imaging sensor defines: means for non-contactively detecting the axial center of the steel coil.

24. The apparatus according to claim 21, wherein the cutting head defines: means for cutting the steel coil in a radially outward direction from the inner bore surface of the steel coil to the outer side surface of the steel coil.

25. The apparatus according to claim 24, wherein the axial arm defines: means for axially moving the cutting head through the bore of the steel coil from the first axial end of the steel coil to the second axial end of the steel coil; andmeans for permitting the cutting head to axially cut the axial length of the steel coil from the first axial end of the steel coil to the second axial end of the steel coil as the axial arm axially moves the cutting head through the bore of the steel coil from the first axial end of the steel coil to the second axial end of the steel coil as the cutting head cuts the steel coil in the radially outward direction.

26. The apparatus according to claim 25, further comprising: a plurality of blocks positioned adjacent the second axial end of the steel coil, wherein the plurality of blocks define means for vertically elevating the steel coil at a distance from a support surface by providing the plurality of blocks between the support surface and the second axial end of the steel coil.

27. The apparatus according to claim 21, further comprising: a controller connected to the axial arm, wherein the controller defines means for controlling spatial movement of the axial arm, wherein the spatial movement of the axial arm includes three-dimensional Cartesian coordinates including an X-coordinate, a Y-coordinate and a Z-coordinate.

28. The apparatus according to claim 27, wherein the controlled spatial movement of the axial arm conducted by the means for controlling includes: a change of the Z-coordinate from a first Z-coordinate to a second Z-coordinate defining axial movement of the axial arm relative the steel coil.

29. The apparatus according to claim 28, wherein the axial movement of the axial arm relative the steel coil includes the changing of the Z-coordinate from the first Z-coordinate to the second Z-coordinate while the X-coordinate and the Y-coordinate remain unchanged.

30. The apparatus according to claim 27, wherein the controller is connected to the imaging sensor, wherein the controller and imaging sensor define: a centering detection system.

31. The apparatus according to claim 30, wherein the imaging sensor defines: means for determining the axial center of the steel coil, and, upon determining the axial center of the steel coil, the imaging sensor communicates the determined axial center of the steel coil to the controller, wherein the controlled spatial movement of the axial arm conducted by the means for controlling includesa change of one or more of the X-coordinate from a first X-coordinate to a second X-coordinate and the Y-coordinate from a first Y-coordinate to a second Y-coordinate defining movement of the axial arm from a non-axial center of the steel coil tothe determined axial center of the steel coil.

32. The apparatus according to claim 31, wherein the movement of the axial arm from the non-axial center of the steel coil to the determined axial center of the steel coil includes the change of one or more of the X-coordinate from the first X-coordinate to the second X-coordinate and the Y-coordinate from the first Y-coordinate to the second Y-coordinate while the Z-coordinate remains unchanged.

33. The apparatus according to claim 21, further comprising: a cooling system attached to one or more of the cutting head and the axial arm, wherein the cooling system definesmeans for cooling one or more of the cutting head and the axial arm.

34. The apparatus according to claim 21, wherein the cutting head includes: at least one cutting device, wherein the at least one cutting device includes at least one pair of cutting devices, wherein the at least one pair of cutting devices includes a first cutting device, anda second cutting device that is diametrically arranged with respect to the first cutting device.

35. The apparatus according to claim 21, wherein the imaging sensor includes: a laser and photo-detectors.

36. The apparatus according to claim 21 wherein the imaging sensor includes: a camera system.

37. The apparatus according to claim 21, wherein the cutting head is perpendicularly arranged in a radially outward direction relative the distal end of the axial arm.

38. The apparatus according to claim 21, wherein the cutting head includes: one or more torches.

39. The apparatus according to claim 38, wherein the cutting head further includes: a fuel supply connected to the one or more torches, wherein the fuel supply includes fuel, anda regulator connected to the fuel supply.

40. The apparatus according to claim 39, wherein the regulator defines: means for regulating a flow of the fuel from the fuel supply to the one or more torches.

41. The apparatus according to claim 39, wherein the fuel includes: oxygen, wherein the one or more torches define one or more oxygen torches.

42. The apparatus according to claim 39, wherein the fuel includes: gas.

43. An apparatus for cutting a steel coil having an axial center, an axial length extending between a first axial end and a second axial end, an outer side surface, and a bore having an inner bore surface, comprising: at least one radially outwardly directed cutting device arranged within the bore of the steel coil, wherein the at least one radially outwardly directed cutting device defines means for radially cutting the steel coil from the inner bore surface to the outer side surface, andaxially cutting the axial length of the steel coil by axially moving the at least one radially outwardly directed cuttingdevice through the bore of the steel coil from the first axial end of the steel coil tothe second axial end of the steel coil.

44. The apparatus according to claim 43, further comprising: an axial arm;a cutting head connected to a distal end of the axial arm, wherein the at least one radially outwardly directed cutting device is connected to the cutting head; andan imaging sensor connected to the cutting head.

45. The apparatus according to claim 44, wherein the imaging sensor defines: means for detecting the axial center of the steel coil without physically engaging the steel coil.

46. The apparatus according to claim 44, wherein the imaging sensor defines: means for non-contactively detecting the axial center of the steel coil.

47. The apparatus according to claim 44, wherein the axial arm defines: means for axially moving the cutting head and the at least one radially outwardly directed cutting device through the bore of the steel coil from the first axial end of the steel coil to the second axial end of the steel coil.

48. The cutting apparatus according to claim 44, further comprising: a controller connected to the axial arm, wherein the controller defines means for controlling spatial movement of the axial arm, wherein the spatial movement of the axial arm includes three-dimensional Cartesian coordinates including an X-coordinate, a Y-coordinate and a Z-coordinate.

49. The cutting apparatus according to claim 48, wherein the controlled spatial movement of the axial arm conducted by the means for controlling includes: a change of the Z-coordinate from a first Z-coordinate to a second Z-coordinate defining axial movement of the axial arm relative the steel coil.

50. The cutting apparatus according to claim 49, wherein the axial movement of the axial arm relative the steel coil includes the changing of the Z-coordinate from the first Z-coordinate to the second Z-coordinate while the X-coordinate and the Y-coordinate remain unchanged.

51. The cutting apparatus according to claim 48, wherein the controller is connected to the imaging sensor, wherein the controller and imaging sensor define: a centering detection system.

52. The cutting apparatus according to claim 51, wherein the imaging sensor defines: means for determining the axial center of the steel coil, and, upon determining the axial center of the steel coil, the imaging sensor communicates the determined axial center of the steel coil to the controller, wherein the controlled spatial movement of the axial arm conducted by the means for controlling includes a change of one or more of the X-coordinate from a first X-coordinate to a second X-coordinate and the Y-coordinate from a first Y-coordinate to a second Y-coordinate defining movement of the axial arm from a non-axial center of the steel coil tothe determined axial center of the steel coil.

53. The cutting apparatus according to claim 52, wherein the movement of the axial arm from the non-axial center of the steel coil to the determined axial center of the steel coil includes the change of one or more of the X-coordinate from the first X-coordinate to the second X-coordinate and the Y-coordinate from the first Y-coordinate to the second Y-coordinate while the Z-coordinate remains unchanged.

54. An apparatus for cutting a steel coil having an axial center, an axial length extending between a first axial end and a second axial end, an outer side surface, and a bore having an inner bore surface, comprising: a controller;an axial arm connected to the controller;a cutting apparatus connected to the axial arm; andan imaging sensor connected to one or more of the controller and cutting apparatus, wherein the imaging sensor defines means for detecting the axial center of the steel coil, wherein the controller definesmeans for receiving the detected axial center of the steel coil from the imaging sensor, andcontrolling a spatial orientation of the axial arm responsive to the receipt of the detected axial center of the steel coil for aligning the cutting apparatus to be co-axial with the detected axial center.

55. The apparatus according to claim 54, wherein the imaging sensor defines: means for detecting the axial center of the steel coil without physically engaging the steel coil.

56. The apparatus according to claim 54, wherein the imaging sensor defines: means for non-contactively detecting the axial center of the steel coil.

57. The apparatus according to claim 54, wherein the cutting apparatus defines: means for cutting the steel coil in a radially outward direction from the inner bore surface of the steel coil to the outer side surface of the steel coil.

58. The apparatus according to claim 57, wherein the axial arm defines: means for axially moving the cutting apparatus through the bore of the steel coil from the first axial end of the steel coil to the second axial end of the steel coil; andmeans for permitting the cutting apparatus to axially cut the axial length of the steel coil from the first axial end of the steel coil to the second axial end of the steel coil as the axial arm axially moves the cutting apparatus through the bore of the steel coil from the first axial end of the steel coil to the second axial end of the steel coil as the cutting apparatus cuts the steel coil in the radially outward direction.

59. The apparatus according to claim 54, further comprising: a cooling system attached to one or more of the cutting apparatus and the axial arm, wherein the cooling system definesmeans for cooling one or more of the cutting apparatus and the axial arm.

60. The apparatus according to claim 54, wherein the cutting apparatus includes: one or more torches.

61. The apparatus according to claim 54, wherein the cutting apparatus further includes: a fuel supply connected to the one or more torches, wherein the fuel supply includes fuel, anda regulator connected to the fuel supply.

62. The apparatus according to claim 61, wherein the regulator defines: means for regulating a flow of the fuel from the fuel supply to the one or more torches.

63. The apparatus according to claim 61, wherein the fuel includes: oxygen, wherein the one or more torches define one or more oxygen torches.