SYSTEMS AND METHODS FOR STEREOSCOPIC IMAGING OF ALUMINUM ELECTROLYSIS POT TENDING OPERATIONS

Systems and methods for stereoscopic imaging and viewing of aluminum electrolysis and related operation and/or maintenance activities are disclosed. The system may produce stereoscopic images based at least in part on images obtained from two or more imaging devices. The system may display the stereoscopic images for viewing to facilitate aluminum electrolysis cell operation and/or maintenance.

DETAILED DESCRIPTION

Reference will now be made in detail to the accompanying drawings, which at least assist in illustrating various pertinent embodiments of the new technology provided for by the present disclosure.

Referring now toFIG. 1, one embodiment of a system1for producing stereoscopic images to facilitate the operation and/or maintenance of aluminum electrolysis cells is illustrated. The illustrated system1comprises an aluminum electrolysis cell10, an imaging target8associated with the aluminum electrolysis cell10, an imaging system100, an image processor200, and a display device300. The imaging system100is in electronic communication110with the image processor200, and the image processor200is in electronic communication210with the display device300.

In the illustrated embodiment, the imaging system100comprises a first imaging device102and a second imaging device103. The first imaging device102is operable to obtain a first image of the imaging target8. The second imaging device103is operable to obtain a second image of the imaging target8. The image processor200is operable to receive, via electronic communication110(e.g., wired and/or wireless electronic communication), the first and second images from the imaging system100and produce one or more stereoscopic image(s)310(hereinafter “stereoscopic images(s)”) of the imaging target8, based at least in part on the first and second images. As used herein, “stereoscopic image(s)” is/are a visual representation of the three-dimensional (i.e., respecting the x, y, and z spatial dimensions) configuration of matter and/or objects based at least part on a first and a second image, wherein the first image is taken from a different perspective than the second. These stereoscopic image(s)310may be displayed via display device300, which may facilitate the operation and/or maintenance of the aluminum electrolysis cell10. For example, the display of stereoscopic image(s)310of the interior of the aluminum electrolysis cell10may facilitate the removal and/or replacement of an anode from the aluminum electrolysis cell10by allowing the operator, for instance, in a location remote to the aluminum electrolysis cell10, to visualize the removal and/or replacement operation, and in three dimensions. Additionally, display of stereoscopic image(s)310may facilitate other operations performed in relation to the aluminum electrolysis cell10, sometimes referred to herein as “pot tending operations,” including breaking the crust of an aluminum electrolysis cell, raising a first anode out of the molten bath of an aluminum electrolysis cell, removing the first anode, scooping up the broken crust, inserting a second anode into an aluminum electrolysis cell, and covering the second anode with alumina, to name a few. In one embodiment, one or more of these pot tending operations is performed using a pot tending machine (“PTM”).

The display device300may be located remote of the imaging system100and/or the image processor200. In one embodiment, the display device300is associated with (e.g., located in; mounted to) a PTM. The display device300is operable to receive and display the stereoscopic image(s)310. In one embodiment, the display device300may display the stereoscopic image(s)310for viewing (e.g., by an operator). The display device300may receive the stereoscopic image(s)310from the image processor200via electronic communication210. Electronic communication210may occur over a wireless and/or wired network. In one embodiment, the display device300may be a separate component of the system. In one embodiment, the image processor200may be a separate component of the system. In one embodiment, the display device300may comprise the image processor200and/or the imaging system100.

As used herein, an “imaging system” is a system adapted to obtain an image of at least a portion of an electrolysis cell from at least a first imaging position and a second imaging position, wherein the first is a different position then the second. Referring now toFIGS. 2a,2b,2c, and3, the imaging system100may comprise a first imaging device102and a second imaging device103. As used herein, an “imaging device” is a device adapted to obtain an image of an electrolysis cell. For example, the imaging device may comprise one or more digital or analog imaging devices. In turn, the image or images may be in a binary or analog format. In one embodiment, the first and second imaging devices102,103are digital imaging devices and the images are digital images. The imaging system100may be operable to move at least one of the first and second imaging devices102,103. The moving may comprise, for example, rotating and/or translating an imaging device. As used herein, “translating” is changing the position of an object in space without rotation. In one embodiment, the imaging system100may be a separate component of the system. In one embodiment, the imaging system100may comprise the image processor200and/or the display device300.

The first imaging device102has a first imaging axis104and the second imaging device103has a second imaging axis105. As used herein, the “imaging axis” of an imaging device is an axis that extends from the focal point of the imaging device and through the imaging target. In one embodiment, the imaging axis is the optical axis (i.e., the line that passes through the center of curvature of the lens surface) of a camera lens. The first imaging axis104is contained in a first vertical plane (extending out of the page inFIGS. 2a,2b, and2c). Similarly, the second imaging axis105is contained in a second vertical plane (extending out of the page inFIGS. 2a,2b, and2c).

In one embodiment, and as illustrated inFIGS. 2aand2b, the first and second imaging devices102,103may be positioned such that the first and the second vertical planes intersect proximal the imaging target8to form angle n. Stereoscopic image(s) useful in accordance with this embodiment may be produced using an angle α of from 0.01 to 10 degrees. In one embodiment, the angle α may be not greater than 9 degrees. In other embodiments, the angle α may be not greater than 8 degrees, or not greater than 7 degrees, or not greater than 6 degrees, or not greater than 5 degrees, or less. In one embodiment, the angle α may be at least 0.1 degrees. In other embodiments, the angle α may be at least 0.2 degrees, or at least 0.3 degrees, or at least 0.4 degrees, or at least 0.5 degrees, or more.

In another embodiment, and as illustrated inFIG. 2c, the first and second imaging devices102,103may be positioned such that the first vertical plane is parallel to the second vertical plane. Stereoscopic image(s) useful in accordance with this embodiment may be produced via software such as StereoPhoto Maker.

In the illustrated embodiment ofFIG. 2a, the imaging system100includes an imaging device mount120and a motorized device106. The first and the second imaging devices102,103are interconnected to the imaging device mount120. As used herein an “imaging device mount” is a device adapted to support at least one imaging device. The imaging device mount120is interconnected to the motorized device106. The motorized device106is operable to move the position of the imaging device mount120, thereby changing the imaging positions of the first and the second imaging devices102,103. As used herein, a “motorized device” is a device adapted to manipulate the position of an imaging device mount using one or more motors. In one embodiment, the motorized device may comprise one or more motors (e.g., servo motor(s), DC current motor(s), among others) interconnected to at least one imaging device mount and adapted to position (e.g., rotationally position) at least one imaging device, thereby changing its imaging position. As used herein, “imaging position” is the position of an imaging device relative to an imaging target. A change in the imaging position of an imaging device may produce a corresponding change in the position of the imaging axis of the imaging device.

One specific imaging device mount120is illustrated inFIG. 3. In the illustrated embodiment, the imaging device mount120comprises an upper bracket122joined about an upper pivot126to a lower bracket124. The first imaging device102and the second imaging device103may be mounted to the upper bracket122. The lower bracket may be fixed to a stable base (not illustrated) via a lower pivot128. The imaging positions of the first and second imaging devices102,103may be adjusted rotationally in a vertical plane via rotation of the upper bracket122about the upper pivot126. The imaging positions of the first and second imaging devices102,103may be adjusted rotationally in a horizontal plane via rotation of the lower bracket124about the lower pivot128. The motorized device106may be operable to facilitate such rotational adjustments of the imaging positions of the first and second imaging devices102,103. For example, the motorized device106may comprise a first motor adapted to rotationally adjust the position of the upper bracket122about the upper pivot126and a second motor adapted to rotationally adjust the position of lower bracket124about the lower pivot128.

As noted above, the imaging target8is associated with the aluminum electrolysis cell10. As used herein, an “imaging target” is the target at which the first and second imaging devices are aimed so as to produce a stereoscopic image of that target. As used herein, an “aluminum electrolysis cell” (sometimes referred to herein as an “aluminum electrolysis pot”) is a container containing an electrolyte (e.g., cryolite) through which an externally generated electric current is passed via a system of electrodes (e.g., an anode and a cathode) in order to change the composition of an aluminum compound (e.g., Al2O3) into pure aluminum metal (Al). In one embodiment, the imaging target8may be at least a portion of one or more of an old anode, a new anode, an anode stem, the crust of the aluminum electrolysis cell10, and the tools of a PTM, among others. In one embodiment, the imaging target8may comprise a portion of a PTM performing one or more pot tending operations associated with the aluminum electrolysis cell10. The location of the imaging target8may be adjusted, for example, by adjusting the imaging positions of at least one of the first and second imaging devices102,103, depending on the stereoscopic image(s) desired. For example, to facilitate breaking the crust the of the aluminum electrolysis cell10, the imaging target8may be adjusted to include a portion of the crust. Similarly, to facilitate the removal of an old anode, the imaging target8may be adjusted to include the stem of the old anode.

While the above embodiments generally use separate imaging devices, a single imaging device may be used to produce stereoscopic image(s). For example, and as illustrated inFIG. 6, a first imaging device may be integral to a second imaging device. In this example, a single camera includes a plurality of lenses (i.e., a single camera comprises both the first and second imaging devices). In the illustrated embodiment, a stereoscopic camera160may comprise a left lens140having a first imaging axis104, and a left prism146. The stereoscopic camera160may also comprise a right lens142having a second imaging axis105, and a right prism148. The stereoscopic camera160may also comprise a main lens150and a single light, sensing surface154divided into a first light sensing surface152and a second light sensing surface153. A first image may be obtained by the left lens140and may be directed onto the light sensing surface152via left prism146and main lens150. A second image may be obtained by the right lens142and may be directed onto the light sensing surface153via right prism148and main lens150. The first and second images may be transmitted to the image processor200via electronic communication. The image processor200, as discussed above, may then produce stereoscopic image(s)310based at least in part on the first and second images. Referring now toFIGS. 4 and 5, one embodiment of a system2for producing stereoscopic images to facilitate the operation and/or maintenance of aluminum electrolysis cells is illustrated. The illustrated system2comprises an aluminum electrolysis cell10, an imaging target8associated with the aluminum electrolysis cell10, an imaging system100, an image processor200, and a display device300, as described above, the system2further comprising an operator400, a body tracking system500, and a controller600. The body tracking system500is in electronic communication510with the controller600, and the controller600is in electronic communication610with the imaging system100.

The body tracking system500is adapted to detect body positions of the operator400and produce body position information. As used herein, “body position information” is information related to one or more position(s) of one or more body pails of an operator. As used herein, an “operator” is a person who works with aluminum electrolysis cells. Body position information may comprise information related to movement of a body part. Body parts useful for producing body position information include the head and appendages (e.g., arms, hands, fingers, legs, and feet to name a few). In one embodiment, body position information may be related to the orientation of the head of the operator400.

In the illustrated embodiment ofFIG. 5, the body tracking system500comprises a camera501and a tracking marker502associated with a body part of an operator400. The camera501may be adapted to detect the orientation of the tracking marker502and thereby produce body position information related to the orientation of the operator's head402. In one embodiment, the camera501is an infrared camera and the tracking marker502is a dot applied to a hard hat504worn by the operator400. In one embodiment (not illustrated), the body tracking system500may comprise the display device300. For example, the body tracking system500may include a virtual reality helmet adapted to detect the orientation of the operator's head402and concurrently display the stereoscopic image(s)310to the operator400. In one embodiment, the body tracking system500may be a separate component of the system. In one embodiment, the body tracking system500may comprise the controller600and/or the display device300.

The controller600is operable to receive, via electronic, communication510, body position information from the body tracking system500and produce one or more control signal(s) (herein after “control signal(s)”). As used herein, “control signal(s)” are any electronic communication adapted to control an imaging system. In one embodiment, control signal(s) are electronic communication adapted to control a motor. In other embodiments, control signal(s) are electronic communication adapted to control the focus of an imaging device, or adapted to control the field of view of an imaging device, among others. In one embodiment, controller600may be a separate component of the system. In one embodiment, the controller600may comprise the body tracking system500and/or the imaging system100.

As noted above, the controller600is in electronic communication610with the imaging system100. The imaging system100may be adapted to respond to control signals(s) received from the controller600. In one embodiment, the imaging system100comprises the controller. In one embodiment, the motorized device106may be adapted to move the imaging device mount120in response to control signals(s), and thereby move at least the first imaging device102from a first imaging position to a second imaging position. The first imaging position may be associated with a first body position of the operator, and the second imaging position may be associated with a second body position of the operator.

In one embodiment, and as illustrated inFIG. 5, the body part may be the operator's head402. The operator's head402may move from a first head position to a second head position, causing the tracking marker502associated with the operator's hard hat504to move from a first tracking position to a second tracking position. The camera501may detect the first and the second positions of the tracking marker502and communicate body tracking information related to the movement of the operator's head to the controller600. In response to the body tracking information, the controller600may communicate control signal(s) to the imaging system100. The control signal(s) may be adapted to control the motorized device to correspondingly move the imaging device mount120, thereby moving the first imaging device102from a first imaging position to a second imaging position and moving the second imaging device103from third imaging position to a fourth imaging position, wherein the first and third imaging positions are associated with the first head position and the second and forth imaging positions are associated with the second head position. The change in imaging positions of the first and second imaging devices102,103may cause the intersection of the first and second imaging axes104,105to move from a first imaging target8to a second imaging target9. Thus, the stereoscopic display300may first display stereoscopic image(s)310of the first imaging target8and second display stereoscopic image(s)310of the second imaging target9. In another embodiment, the body part may be associated with an appendage of the operator such as arm, hand, finger, leg, or foot of an operator, for example.

The body tracking system500may also/alternatively be used to change the field of view. As used herein, “field of view” is the area from which an imaging device obtains an image. In one embodiment, narrowing the field of view of the imaging device, or “zooming in,” is associated with a corresponding magnification of the image such that the image, as viewed by the operator, retains the same outer dimensions. In another embodiment, broadening the field of view of the imaging device, or “zooming out” is associated with a corresponding reduction of the image such that the image, as viewed by the operator, retains the same outer dimensions. In one embodiment, the field of view may change while the imaging position remains unchanged. In one embodiment, the operator's appendage (e.g., a hand) may move from a first appendage position to a second appendage position. The camera501may detect the first and the second appendage positions and communicate body tracking information related to the movement of the operator's appendage to the controller600. In response to the body tracking information, the controller600may communicate control signal(s) to the imaging system100. The control signal(s) may be adapted to control the field of view of at least one of the first and second imaging devices102,103.

As may be appreciated, any of the above components may be integrated, if appropriate. For example, and referring now toFIGS. 1 and 4, the image processor200may be integral with the imaging system100, or may be a separate component. For example, the image processor200may be integral with one or both of the first and second imaging devices102,103. Likewise, the image processor200may be integral with the display device300. Similarly, the image processor200may be integral with the body tracking device500. Furthermore, the image processor200may be integral with the controller600. In other words, the image processor200may be integral with the imaging system100and/or the display device300and/or the body tracking device500and/or the controller600. Likewise, the display device300may be integral with the image processor200and/or the body tracking device500and/or the controller600. The body tracking device500may be integral with the image processor200and/or the display device300and/or the controller600. The controller600may be integral with the imaging system100and/or the image processor200and/or the display device300and/or the body tracking device500. The imaging system100may be integral with the image processor200and/or the controller600.

While various embodiments of the present disclosure have been described in detail, it is apparent that modifications and adaptations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and adaptations are within the spirit and scope of the present disclosure.