Claims:
1. A system for engaging hooks (101) with a ladle, the system comprises:
a transmitter (103A) and a receiver (103B) associated with radar (103), wherein one of the transmitter (103A) or the receiver (103B) is positioned on a crane (102) comprising a plurality of hooks (101) and another of the receiver (103B) or the transmitter (103A) is positioned at a fixed location in a gantry area;
a plurality of cameras (105), provided at predetermined locations, wherein at least two cameras (105C and 105D) of the plurality of cameras (105) are associated with each ladle from one or more ladles (104); and
a control system (106) comprising:
a processor (106A); and
a memory (106B) communicatively coupled to the processor (106A), wherein the memory (106B) stores the processor (106A) instructions, which, on execution, causes the processor (106A) to:
select the at least two cameras (105C and 105D) based on a distance between the transmitter (103A) and the receiver (103B); and
provide a real-time video captured by the at least two cameras (105C and 105D) to a display unit (107) for enabling an operator to engage the plurality of hooks (101) of the crane (102) with the ladle, wherein the real-time video provides current position of hooks (101) with respect to the ladle to the operator.

2. The system as claimed in claim 1, wherein selecting the at least two cameras (105C and 105D) by the control system (106) comprises:
receiving the distance between the transmitter (103A) and the receiver (103B) associated with the radar (103);
determining a location of the crane (102) based on the distance; and
identifying an Internet Protocol (IP) address of the at least two cameras (105C and 105D) associated with the location.

3. The system as claimed in claim 1, wherein the distance between the transmitter (103A) and the receiver (103B) is determined as a product of speed of radar (103) signal and time taken for a radar (103) signal to travel from the transmitter (103A) to the receiver (103B).

4. The system as claimed in claim 1, wherein the at least two cameras (105C and 105D) associated with each ladle is provided to capture the engagement of the plurality of hooks (101) at the left side and the right side of the ladle.

5. The system as claimed in claim 1, wherein providing the real-time video captured by the at least two cameras (105C and 105D) comprises:
receiving the real-time video from the at least two cameras (105C and 105D) using a wireless communication interface;
sending the real-time video to the display unit (107) using at least one of a wired communication interface and the wireless communication interface.

6. A method of engaging a hook with a ladle, the method comprising:
selecting, by a control system (106), at least two cameras (105C and 105D) based on a distance between a transmitter (103A) and a receiver (103B), wherein the transmitter (103A) and the receiver (103B) is associated with radar (103), wherein one of the transmitter (103A) or the receiver (103B) is positioned on a crane (102) and another of the receiver (103B) or the transmitter (103A) is positioned at a fixed location in a gantry area, wherein a plurality of cameras (105) are provided at a predetermined location, wherein the at least two cameras (105C and 105D) from the plurality of cameras (105) are associated with each ladle from one or more ladles (104); and
providing, by the control system (106), a real-time video captured by the at least two cameras (105C and 105D) to a display unit (107) for enabling an operator to engage a plurality of hooks (101) of the crane (102) with the ladle.

7. The method as claimed in claim 6, wherein selecting the at least two cameras (105C and 105D) comprises:
receiving the distance between the transmitter (103A) and the receiver (103B) associated with the radar (103);
determining a location of the crane (102) based on the distance; and
identifying an Internet Protocol (IP) address of the at least two cameras (105C and 105D) associated with the location.

8. The method as claimed in claim 6, wherein the distance between the transmitter (103A) and the receiver (103B) is determined as a product of speed of radar (103) signal and a time taken for a radar (103) signal to travel from the transmitter (103A) to the receiver (103B).

9. The method as claimed in claim 6, wherein the at least two cameras (105C and 105D) associated with each ladle is provided to capture the engagement of the plurality of hooks (101) at the left side and the right side of the ladle.

10. A control system (106) for engaging hooks (101) with a ladle, the control system (106) comprises:
a processor (106A); and
a memory (106B) communicatively coupled to the processor (106A), wherein the memory (106B) stores the processor (106A) instructions, which, on execution, causes the processor (106A) to:
receive a distance between a transmitter (103A) and a receiver (103B) associated with radar (103), wherein one of the transmitter (103A) or the receiver (103B) is positioned on a crane (102) comprising a plurality of hooks (101) and another of the receiver (103B) or the transmitter (103A) is positioned at a fixed location in a gantry area;
determine a location of the crane (102) based on the distance;
select at least two cameras (105C and 105D) from a plurality of cameras (105), provided at predetermined locations by identifying an Internet Protocol (IP) address of the at least two cameras (105C and 105D) associated with the location; wherein the at least two cameras (105C and 105D) are associated with each ladle from one or more ladles (104); and

provide a real-time video captured by the at least two cameras (105C and 105D) to a display unit (107) for enabling an operator to engage the plurality of hooks (101) of the crane (102) with the ladle, wherein the real-time video provides current position of hooks (101) with respect to the ladle to the operator.
, Description:TECHNICAL FIELD

The present subject matter generally relates to a steel plant. More particularly, but not exclusively, the present disclosure discloses a system and method for engaging hooks with a ladle in a steel plant.

BACKGROUND

At present, the steel plants comprise one or more cranes to transport the molten metals from a ladle to the caster. The cranes have designated places for lifting and placing the ladles in ladle cars. The crane is operated by an operator to engage hooks of the crane to the ladle for lifting and placing the ladle. The operator while trying to engage the hooks with the ladle, gets the view of the engagement of hook from one direction only. Further, the operator relies on ground staff to provide a confirmation regarding the engagement of the hook with the ladle on the other side of the ladle. The ground staff or the foreman watches the engagement of the hook to the ladle from a close vicinity to the ladle and communicates the confirmation of the engagement via a handheld device such as walkie-talkie to the operator.

Further, both the operator and the ground staff do not get the view of the engagement of the hooks with the ladle from both directions. Therefore, the operator relies on the confirmation of the ground staff to lift and place the ladle. Further, disengagement of one side of the hook with the ladle due to miscommunication (or misjudgment) between the operator and the ground staff tilts the ladle causing splashes of hot molten liquid steel contained at 1700 degree Celsius, leading to loss of material and life.

The information disclosed in this background of the disclosure section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.

SUMMARY
Disclosed herein is a system for engaging hooks with a ladle. The system comprises a transmitter and a receiver associated with radar. One of the transmitter or the receiver is positioned on a crane comprising a plurality of hooks and another of the receiver or the transmitter is positioned at a fixed location in a gantry area. Further, a plurality of cameras is provided at predetermined locations. At least two cameras of the plurality of cameras are associated with each ladle from one or more ladles. Furthermore, the system includes a control system comprising a processor and a memory communicatively coupled to the processor. The memory stores the processor instructions, which, on execution, causes the processor to select the at least two cameras based on a distance between the transmitter and the receiver. Further, the instructions cause the processor to provide a real-time video captured by the at least two cameras to a display unit for enabling an operator to engage the plurality of hooks of the crane with the ladle, wherein the real-time video provides current position of hooks with respect to the ladle to the operator.

In an embodiment, the present disclosure discloses a method of engaging a hook with a ladle. The method comprises selecting at least two cameras based on a distance between a transmitter and a receiver. The transmitter and the receiver are associated with radar. One of the transmitter or the receiver is positioned on a crane and another of the receiver or the transmitter is positioned at a fixed location in a gantry area. Further, a plurality of cameras is provided at a predetermined location. The at least two cameras from the plurality of cameras are associated with each ladle from one or more ladles. Finally, the method comprises providing a real-time video captured by the at least two cameras to a display unit for enabling an operator to engage a plurality of hooks of the crane with the ladle.

In an embodiment, the present disclosure discloses a control system for engaging hooks with a ladle. The control system comprises a processor and a memory communicatively coupled to the processor. The memory stores the processor instructions, which, on execution, causes the processor to receive a distance between a transmitter and a receiver associated with radar. One of the transmitter or the receiver is positioned on a crane comprising a plurality of hooks and another of the receiver or the transmitter is positioned at a fixed location in a gantry area. Further, instructions cause the processor to determine a location of the crane based on the distance. Furthermore, instructions cause the processor to select at least two cameras from a plurality of cameras, provided at predetermined locations by identifying an Internet Protocol (IP) address of the at least two cameras associated with the location. The at least two cameras are associated with each ladle from one or more ladles. Thereafter, the instructions cause the processor to provide a real-time video captured by the at least two cameras to a display unit for enabling an operator to engage the plurality of hooks of the crane with the ladle. The real-time video provides current position of hooks with respect to the ladle to the operator

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate exemplary embodiments and, together with the description, serve to explain the disclosed principles. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system and/or methods in accordance with embodiments of the present subject matter are now described, by way of example only, and with reference to the accompanying figures, in which:

Fig.1A illustrates an exemplary environment for engaging hooks with a ladle in accordance with some embodiments of the present disclosure;

Fig.1B illustrates an exemplary environment for selecting at least two cameras in accordance with some embodiments of the present disclosure;

Fig.2 shows an exemplary mapping table for selecting at least two cameras in accordance with some embodiments of the present disclosure;

Fig.3 shows an exemplary real-time video provided to the display device in accordance with some embodiments of the present disclosure; and

Figs.4 shows a flowchart illustrating a process of engaging a hook with a ladle in accordance with some embodiments of the present disclosure;

It should be appreciated by those skilled in the art that any block diagrams herein represent conceptual views of illustrative systems embodying the principles of the present subject matter. Similarly, it will be appreciated that any flow charts, flow diagrams, state transition diagrams, pseudo code, and the like represent various processes which may be substantially represented in computer readable medium and executed by a computer or processor, whether or not such computer or processor is explicitly shown.

DETAILED DESCRIPTION
In the present document, the word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments.

While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however that it is not intended to limit the disclosure to the specific forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.
The terms “comprises”, “comprising”, “includes”, “including” or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, device, or method that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or device or method. In other words, one or more elements in a system or apparatus proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or method.
In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration of embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.

Fig.1A illustrates an exemplary environment for engaging hooks with a ladle in accordance with some embodiments of the present disclosure.

The present disclosure relates to a system for engaging plurality of hooks (101) with a ladle. In an embodiment, a steel plant as shown in Fig.1A, comprises one or more ladles (104A, … 104N collectively referred as 104). A ladle (104A) is a vessel used to transport and pour out molten metals from a blast furnace. An operator associated with a crane (102) operates the plurality of hooks (101) for engaging the plurality of the hooks (101) to the ladle. The steel plant may comprise one or more cranes for transporting the one or more ladles (104). Further, each crane comprises the plurality of hooks (101) for engaging with the ladle. Further, the crane (102) is associated with a Radio Detection and Ranging (radar) (103). The radar (103) comprises a transmitter (103A) and a receiver (103B). One of the transmitter (103A) or the receiver (103B) is positioned on the crane (102) as shown in Fig.1A. Another of the receiver (103B) or the transmitter (103A) is positioned at a fixed location in a gantry area. The gantry area includes the blast furnace, one or more cranes, and one or more ladles (104). The transmitter (103A) and the receiver (103B) are positioned to have a line-of-sight contact. The transmitter (103A) associated with the radar (103) is configured to transmit a radar signal. The frequency of the radar signal varies from 3 megahertz to 110 gigahertz. The receiver (103B) associated with the radar (103) is configured to receive the transmitted radar signal and determine a distance between the transmitter (103A) and the receiver (103B). The distance is determined as a product of speed of radar signal and time taken for a radar signal to travel from the transmitter (103A) to the receiver (103B) using the equation:
D = s * t ……………………………………………………………………………… (1)
where “D” denotes the distance, “s” denotes the speed of radar signal, “t” is the time taken for the radar signal to travel from the transmitter (103A) to the receiver (103B). In an embodiment, the speed of the radar signal is equal to the speed of light i.e. 3 * 108 meters per second. The transmitter (103A) and the receiver (103B) includes a synchronized clock to determine the time taken for the radar signal to travel from the transmitter (103A) to the receiver (103B). The person skilled in the art appreciates the use of one or more techniques to determine the time taken. For example, if the time taken for the radar signal to travel from the transmitter (103A) to the receiver (103B) is 10 microseconds, then the distance between the transmitter (103A) and the receiver (103B) computed using the equation (1) is 30 meters. The distance measured by the receiver (103B) is sent to a control system (106) via at least one of a wired interface or a wireless interface.

Further in an embodiment, the gantry area includes a plurality of cameras (105). The plurality of cameras (105A, …, 105N collectively referred as 105) is provided at predetermined locations in the gantry area in the vicinity of the one or more ladles (104). At least two cameras (105C and 105D) from the plurality of cameras (105) are associated with each ladle from one or more ladles (104) as shown in Fig.1A. Further, the at least two cameras (105C and 105D) associated with each ladle is provided to capture the engagement of the plurality of hooks (101) at the left side and the right side of the ladle as shown in Fig.1A. The plurality of cameras (105) is configured to capture a real-time video. The real-time video captured by the plurality of cameras (105) is sent to the control system (106) via at least one of a wired interface or a wireless interface.

In an embodiment, a yard of a steel plant includes seven predefined locations as shown in Fig.1B. Each predefined location includes the ladle (104). The predefined locations are denoted by a location icon ( ) and a name associated with the predefined locations is denoted at the top of the enclosed dotted area as shown in Fig.1B. For example, a first ladle (104) is present in the predefined location with the name “INTER WAY” and the like. The yard includes two cranes (102) denoted by HI-1 and HI-2 as shown in FIG.1B. The HI-1 crane (102) has a resting point towards the Side - 2 and the HI-2 crane has the resting point towards the Side - 1. The resting point indicates a starting point for the operation of the crane (102). Each crane (102) includes a radar (103) (i.e. the transmitter (103A) or the receiver (103B)) mounted on the crane (102). The radar (103) (i.e. the receiver (103B) or the transmitter (103A)) is mounted on the fixed end of the yard i.e. gantry area (denoted by Side – 1 and Side – 2) as shown in Fig.1B. Further, the distance of the predefined locations from a side - 1 and side – 2 is denoted using Xi and Yi respectively as shown in Fig.1B. The distance indicates the position for the crane to engage the plurality of hooks (101) to the ladle (104). For example, the distance X5 = 185 indicates the distance of the predefined location with the name “LF-1.2” from the Side – 1 and the distance Y5 = 77 indicates the distance of the predefined location with the name “LF-1.2” from the Side – 2. Further, the cranes (102) HI-1 and HI-2 is operated by a user to move the cranes (102) from the resting position to the one of the predefined location to pick up the ladle (104) by engaging plurality of hooks (101) with the ladle (104) and place the ladle (104) in a ladle car. Further, each of the predefined locations includes the at least two cameras from the plurality of cameras (105) as shown in Fig.1B. The plurality of the cameras (105) are connected to an access point (108) via at least one of a wired interface and the wireless interface as shown in Fig.1B. Further, the access point provides the real-time video received from the plurality of the cameras (105) to the control system (106). For example, the at least two cameras denoted by numbers “9” and “10” is used to capture the real-time video of engaging the plurality of hooks (101) with the ladle (104) present in the predefined location with the name “LF-1.2” and send the real-time video to access point (108).

In an embodiment, the control system (106) includes a processor (106A) and a memory (106B) communicatively coupled to the processor (106A). The memory (106B) stores the processor (106A) instructions, which, on execution, causes the processor (106A) to select the at least two cameras (105C and 105D) based on a distance between the transmitter (103A) and the receiver (103B). For example, if the distance is 30 meters the control system (106) selects at least two cameras (105C and 105D). In an embodiment, the control system (106) may determine a location of the crane (102) based on the distance using a mapping table stored in the memory (106B) of the control system (106) as shown in Fig.2. In an embodiment, the mapping table generally includes a plurality of parameters, including, but are not limited to Location Name (i.e. name of the predefined location), distance, switching range and IP address of the plurality of cameras (105). The location name indicates a name associated with the ladle or a name associated with the portion of the gantry area in the steel plant, the distance indicates a width from the Side – 1 or Side – 2 to the ladle (104). For example, if the distance measured using the radar (103) is 68 meters from the Side - 1, then the location is determined as “LF 2.1” using the mapping table. Further, the control system (106) identifies an Internet Protocol (IP) address of the at least two cameras (105C and 105D) associated with the location using the mapping table as shown in Fig.2. For example, if the determined location is “LF 2.1”, at least two cameras (105C and 105D) having the IP address “192.168.1.3” and “192.168.1.4” is identified by the control system (106). The control system (106) may be implemented using at least one of a server, a laptop, a computer system, and the like. Further, the switching range indicates a range of values for selecting the at least two cameras associated with the location name. For example, when the crane (102) HI-2 is being operated to pick up the ladle (104) from predefined location “Vessel 1” and the distance between the transmitter (103A) and the receiver (103B) associated with crane (102) HI-2 indicates a value in a range of 101 to 145, the at least two cameras with IP addresses 192.168.1.5 and 192.168.1.6 is selected by the computing system (106). Further, the moment the distance between the transmitter (103A) and the receiver (103B) associated with crane (102) HI-2 is 146, the crane (102) HI-2 is at the predefined location denoted by “Vessel 1” and the computing system (106) selects the at least two cameras with the IP address 192.168.1.7 and 192.168.1.8.
Referring back to Fig.1A, in an embodiment, the control system (106) after selecting the at least two cameras (105C and 105D), provides the real-time video captured by the at least two cameras (105C and 105D) to a display unit (107). The display unit (107) may be housed in the control system (106) or remotely connected to the control system (106) via at least one of a wired interface and a wireless interface. In an embodiment, the display unit (107) may be associated with at least one of a smartphone, a tablet computer, a standalone monitor and the like. The display unit (107) enables the operator to engage the plurality of hooks (101) of the crane (102) with the ladle using the real-time video. The real-time video provides current position of the plurality of hooks (101) with respect to the ladle to the operator.

In an embodiment, the control system (106) receives the real-time video from the at least two cameras (105C and 105D) using a wireless communication interface as shown in Fig.3. Further, the control system (106) sends the real-time video to the display unit (107) using at least one of the wired communication interface and the wireless communication interface as shown in Fig.3. The operator by watching the real-time video in the display unit (107) operates the crane (102) to engaging the plurality of hooks (101) with the ladle.

Fig.4 shows a flowchart illustrating a process of engaging hooks (101) with a ladle in accordance with some embodiments of the present disclosure.

As illustrated in Fig.4, the method 400 comprises one or more blocks for engaging plurality of hooks (101) with a ladle. The method 400 may be described in the general context of computer executable instructions. Generally, computer executable instructions can include routines, programs, objects, components, data structures, procedures, modules, and functions, which perform particular functions or implement particular abstract data types.

The order in which the method 400 is described is not intended to be construed as a limitation, and any number of the described method blocks can be combined in any order to implement the method. Additionally, individual blocks may be deleted from the methods without departing from the scope of the subject matter described herein. Furthermore, the method can be implemented in any suitable hardware, software, firmware, or combination thereof.

At block 401, the method may comprise selecting at least two cameras (105C and 105D) based on a distance between a transmitter (103A) and a receiver (103B). The transmitter (103A) and the receiver (103B) are associated with radar (103). Further, one of the transmitter (103A) or the receiver (103B) is positioned on a crane (102) and another of the receiver (103B) or the transmitter (103A) is positioned at a fixed location in a gantry area. For example, when the transmitter (103A) is positioned on the crane (102) the receiver (103B) is positioned in the gantry area and vice versa. Furthermore, the plurality of cameras (105) is provided at the predetermined location. The predetermined location is in the vicinity of the one or more ladles (104). Thereafter, at least two cameras (105C and 105D) from the plurality of cameras (105) are associated with each ladle from one or more ladles (104).

In an embodiment, selecting the at least two cameras (105C and 105D) includes receiving the distance between the transmitter (103A) and the receiver (103B) associated with the radar (103). The distance between the transmitter (103A) and the receiver (103B) is determined as the product of the speed of radar signal and the time taken for the radar signal to travel from the transmitter (103A) to the receiver (103B) using the equation (1). The control system (106) may receive the distance from the receiver (103B) associated with the radar (103). Further, determining the location of the crane (102) based on the distance using the mapping table shown in Fig.2. Furthermore, identifying an Internet Protocol (IP) address of the at least two cameras (105C and 105D) associated with the location using the mapping table shown in Fig.2.

In an embodiment, the at least two cameras (105C and 105D) associated with each ladle is provided to capture the engagement of the plurality of hooks (101) at the left side and the right side of the ladle.

At block 402, the method may comprise providing a real-time video captured by the at least two cameras (105C and 105D) to a display unit (107) for enabling an operator to engage a plurality of hooks (101) of the crane (102) with the ladle.

In an embodiment, the control system (106) receives the real-time video from the at least two cameras (105C and 105D) using a wireless communication interface. Further, the control system (106) sends the real-time video to the display unit (107) using at least one of the wired communication interface and the wireless communication interface as shown in Fig.3. The operator by watching the real-time video in the display unit (107) operates the crane (102) to engaging the plurality of hooks (101) with the ladle.

The system and method of engaging the hooks (101) with the ladle provides the engagement of the hooks (101) with the ladle in both the directions to the operator. Further, the need of the ground staff for confirming the engagement of the hooks (101) with the ladle is eliminated. Furthermore, any loss of material and high risk to the life of the ground staff is eliminated.

The terms "an embodiment", "embodiment", "embodiments", "the embodiment", "the embodiments", "one or more embodiments", "some embodiments", and "one embodiment" mean "one or more (but not all) embodiments of the invention(s)" unless expressly specified otherwise.

The terms "including", "comprising", “having” and variations thereof mean "including but not limited to", unless expressly specified otherwise. The enumerated listing of items does not imply that any or all the items are mutually exclusive, unless expressly specified otherwise.

The terms "a", "an" and "the" mean "one or more", unless expressly specified otherwise.

A description of an embodiment with several components in communication with each other does not imply that all such components are required. On the contrary, a variety of optional components are described to illustrate the wide variety of possible embodiments of the invention.

When a single device or article is described herein, it will be clear that more than one device/article (whether they cooperate) may be used in place of a single device/article.

Similarly, where more than one device or article is described herein (whether they cooperate), it will be clear that a single device/article may be used in place of the more than one device or article or a different number of devices/articles may be used instead of the shown number of devices or programs. The functionality and/or the features of a device may be alternatively embodied by one or more other devices which are not explicitly described as having such functionality/features. Thus, other embodiments of the invention need not include the device itself.

Finally, the language used in the specification has been principally selected for readability and instructional purposes, and it may not have been selected to delineate or circumscribe the inventive subject matter. It is therefore intended that the scope of the invention be limited not by this detailed description, but rather by any claims that issue on an application based here on. Accordingly, the embodiments of the present invention are intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims.

While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

Referral Numerals:
Reference Number Description
101 Hooks
102 Crane
103 Radar
103A Transmitter
103B Receiver
104 Ladle
105 Plurality of Cameras
106 Control System
106A Processor
106B Memory
107 Display Unit
108 Access point