Patent ID: 12240175

The present invention relates to a docking arrangement10for a manufacturing process such as an additive manufacturing process.

Referring toFIGS.1and2, the docking arrangement10includes a dock11to which a container in the form of hopper12may be coupled. These Figures show the hopper12undocked from and docked to the dock11, respectively. In use, the dock11may correspond to a machine of an additive manufacturing process and the hopper12may contain powder (such as metal powder) to be supplied to that machine.

The hopper12includes a stand22and supporting arms24for supporting a container14of the hopper12on the stand22. In the illustrated embodiment, three supporting arms24are provided. The container14may include powder for the additive manufacturing process. The container comprises an upper cylindrical portion above a frustroconical portion, leading to an outlet.

The hopper12includes an outlet16which may be coupled and secured to an inlet18on the dock11. The coupling between the outlet16of the hopper12and the inlet18includes a locking mechanism100. As is described in detail herein, the locking mechanism100comprises means to lock and secure the outlet16and inlet18to allow material from the container14of the hopper12to be supplied to a further component of the manufacturing process via the dock11. In the illustrated embodiment, the inlet18is provided with a conduit20for supplying the material from the hopper12to the further component of the manufacturing process.

The stand22of the hopper12includes apertures21in a base thereof for receiving corresponding projecting members23on the dock11. As shown, the projecting members23project upwardly from a surface13of the dock11. The coupling of the apertures21with respective projecting members23may act to further secure the hopper12to the dock11, in use.

The hopper12is provided with a valve arrangement26for controlling flow of material out of the container14of the hopper12. In presently preferred embodiments the valve arrangement comprises an outlet valve in the form of a butterfly valve, however, it will be appreciated that the invention is not limited in this sense and the valve arrangement26can comprise any suitable valve type. In the illustrated embodiment, the outlet valve is controlled via an operating handle50. As is described herein, operating handle50may be used to open and/or close the outlet valve of the valve arrangement26through rotation of a lever52of the operating handle50, which may be effected in embodiments via an actuator40operatively coupled with the operating handle50. In the illustrated embodiment, the actuator40forms part of the dock11and is positioned such that, upon docking of the hopper12on the dock11, the operating handle50and actuator40are positioned relative to one another for subsequent actuation of the operating handle50.

The hopper12is additionally provided with a gas inlet32. As described with reference toFIGS.19and20, in use, the gas inlet32may be used to control a pressure level inside the container14of the hopper12. For example, it may be desirable to increase the pressure within the hopper12to aid flow of the material from the outlet16.

As discussed herein, the docking arrangement10includes a dock11which may correspond (or form part of) to a machine of an additive manufacturing process (such as, for example, an additive manufacturing machine or a sieve) and the hopper12may contain powder to be supplied to that machine. However, in some instances it may be desirable for powder/material to be delivered to the hopper12—e.g. to replenish the material therein. Accordingly, the hopper12is provided with an openable hatch30in an upper surface providing access to the interior of the container14of the hopper12. In some instances, material from a further hopper may be deposited into the hopper12. In such cases, the docking arrangement10may be used, where the inlet18(and optionally conduit20) serve as an inlet to hopper12and a separate hopper is docked on the dock11. This may be useful in embodiments where materials in two different hoppers may need to be blended, or simply for replenishing the material in hopper12. In embodiments, material from one hopper or an additive manufacturing machine may be passed through a sieve before being deposited in the hopper12. In such instances, the docking arrangement10may be adapted to receive a sieve.

FIGS.3to7Billustrate an embodiment of the operating handle50and show how the actuator40may be used to actuate the operating handle50to open and/or close the outlet valve of the valve arrangement26.

The operating handle50includes a lever52which may be rotated between a plurality of rotational positions and a rotatable shaft56connected to the lever52. As is described herein, rotation of the lever52causes a corresponding rotation of the shaft56which in turn acts on the outlet valve (not shown) to control flow of the material out of the hopper12.

The lever52is coupled to (e.g. suitably fixed to or integrally formed with) rotatable shaft56of the operating handle50approximately half way along its length via an coupling portion64such that the lever52is pivoted about its centre defining first and second lever arms53a,53beither side of the coupling portion64. In use, the lever52(and hence the rotatable shaft56) is rotatable between two rotational positions corresponding to a fully closed and fully open configuration of the associated valve arrangement26.

In this embodiment, the actuator40takes the form of a dual piston arrangement which includes a first piston42and second piston45. The first and second pistons42,45are moveable between a plurality of positions in order to effect rotation of the lever52. As shown and described herein, the first piston42is configured to act on the first lever arm53a, and the second piston45is configured to act on the second lever arm53bto rotate said lever arms53a,53bas required.

The first piston42includes a first pair of piston arms41a,41band an upper supporting member43to which the piston arms41a,41bare coupled. A first roller49ais mounted to the supporting member43and positioned so as to interact, in use, with the first lever arm53aof the lever52. The piston arms41a,41bare configured, in use, to move in and out of a first piston chamber47, for example, through a hydraulic or pneumatic arrangement introducing or removing fluid from within the piston chamber47. Alternatively, the actuator40may comprise an electrical actuator such as a solenoid or motor configured to move arms41a,41b. In moving in and out of the first piston chamber47, the piston arms41a,41bcause corresponding movement of the supporting member43, and hence the roller49a, to actuate movement (linear and/or rotational) of the lever52through interaction with the first lever arm53a.

Similarly, the second piston45includes a second pair of piston arms44a,44band an upper supporting member46to which the piston arms44a,44bare coupled. A second roller49bis mounted to the supporting member46and positioned so as to interact, in use, with the second lever arm53bof the lever52. The piston arms44a,44bare configured, in use, to move in and out of a second piston chamber48, for example, through a hydraulic or pneumatic arrangement introducing or removing fluid from within the piston chamber48. Alternatively, and as described above, the actuator40may comprise an electrical actuator. In moving in and out of the second piston chamber48, the piston arms44a,44bcause corresponding movement of the supporting member46, and hence the roller49b, to actuate movement (linear and/or rotational) of the lever52through interaction with the second lever arm53b.

The pistons42,45are configured to move linearly between a retracted position, a first position and a second position. In moving from a retracted position to a first position, the pistons42,45may, depending on the rotational position of the lever52, be brought into contact with respective lever arms53a,53b.

Specifically, with the lever52in its first rotational position, moving the first piston42from its retracted position to its first position brings the first roller49ainto contact with the first lever arm53a. As discussed herein, bringing the first roller49ainto contact with the first lever arm53amay cause linear movement of the first lever arm53a. Subsequently moving the first piston42from its first position to its second position acts on the first lever arm53ato rotate the lever52from its first rotational position to its second rotational position. As is described herein, this may act to open the valve arrangement26.

Similarly, with the lever52in its second rotational position, moving the second piston45from its retracted position to its first position brings the second roller49binto contact with the second lever arm53b. As discussed herein, bringing the second roller49binto contact with the second lever arm53bmay cause linear movement of the second lever arm53b. Subsequently moving the second piston45from its first position to its second position acts on the second lever arm53bto rotate the lever52from its second rotational position to its first rotational position. This may act to close the valve arrangement26.

The first and second rollers49a,49bare configured to cause linear movement of the lever52from a first linear position to a second linear position when the first and/or second roller49a,49bis brought into contact with the respective lever arm53a,53b—i.e. upon movement of the respective piston42,45from a retracted position to a first position. This linear movement of the lever52is necessary to disengage a rotation retention mechanism which otherwise prevents rotation of the lever52. As is shown inFIG.6(and discussed in detail below with reference toFIGS.8-11B), the operating handle50includes an outer sheath54within which the rotatable shaft56is received. The sheath54includes a slot60which is configured to receive a projecting portion58associated with the shaft56. The slot60includes a series of notches62a,62b,62cdefining rotational positions of the lever52and hence shaft56of the operating handle50. The projecting portion58is configured to move along the slot60in the outer sheath54upon rotation of the lever52and corresponding rotation of the shaft56. With the lever52in its first linear position, the projecting portion58may be received within one of the notches62a,62b,62cthereby preventing rotation of the shaft56under the operation of the lever52. Accordingly, moving the lever52to its second linear position (e.g. by bringing the roller49aor49binto contact with respective lever arms53a,53bof the lever52) is necessary to cause the projecting portion58to move out of contact with one of the notches62a,62b,62cthereby allowing the shaft56to be rotated under movement of the lever52.

The roller49aand lever52are configured such that upon movement of the first piston42from its first position to its second position, and hence rotating the lever52from its first rotational position to its second rotational position, the first lever arm53amoves out of contact with the roller49a. This allows the lever52to move linearly from its second linear position to its first linear position (e.g. under the operation of a biasing member—see below) to re-engage the rotation retention mechanism to prevent further rotation of the lever52. In this way, the lever52may be retained in its second rotational position following actuation by the first piston42. Specifically, this is achieved by angling the roller49awith respect to the lever52such that, with the first piston42in its first position and the lever in its first rotational position, the roller49ais positioned perpendicular to the longitudinal axis of the first lever arm53a. As the first piston42is moved to its second position, moving the lever52through an angle of 90° to its second rotational position, the roller49ais moved to a position whereby it is positioned parallel longitudinal axis of the first lever arm53a, thus moving the lever arm53aout of contact with the roller49a.

Roller49bis configured in the same way. Specifically, roller49bis configured such that upon movement of the second piston45from its first position to its second position, and hence rotating the lever52from its second rotational position to its first rotational position, the second lever arm53bmoves out of contact with the roller49b. This allows the lever52to move linearly from its second linear position to its first linear position (e.g. under the operation of a biasing member—see below) to re-engage the rotation retention mechanism to prevent further rotation of the lever52. In this way, the lever52may be retained in its first rotational position following actuation by the second piston45. Specifically, this is achieved by angling the roller49bwith respect to the lever52such that, with the second piston45in its first position and the lever52in its second rotational position, the roller49bis positioned perpendicular to the longitudinal axis of the second lever arm53b. As the second piston45is moved to its second position, moving the lever52through an angle of 90° to its first rotational position, the roller49bis moved to a position whereby it is positioned parallel longitudinal axis of the second lever arm53b, thus moving the lever arm53bout of contact with the roller49b.

FIGS.8-11Billustrate a variant of the operating handle50shown in the preceding Figures. Except where explicitly identified below, the operating handle50shown inFIGS.8-11Bis substantially identical in configuration to the operating handle50shown in the preceding Figures. Accordingly, unless otherwise stated, the following description further details the configuration of the operating handle50shown and described above.

As discussed herein, the operating handle50is configured, in use, to control operation of an outlet valve (not shown) of the valve arrangement26for controlling flow of a manufacturing material out of the outlet16of the hopper12. The operating handle50includes a lever52, a rotatable shaft56which includes first and second shaft portions56a,56b, and an outer sheath54in which the rotatable shaft56is located. The first shaft portion56ais connected to the lever52such that rotation of the lever52causes a corresponding rotation of the shaft56which in turn acts on the outlet valve (not shown) to control flow of the material out of the hopper12. In the illustrated arrangement, a bore80is provided in the end of the shaft56which acts as a female coupling for interaction with a corresponding male coupling on the valve arrangement26. When coupled, the rotation of the shaft56acts to effect a corresponding rotation in the male coupling of the valve arrangement26for opening and closing the outlet valve.

The lever52comprises a coupling portion64and is coupled to the first shaft portion56a(e.g. integrally formed with or suitably connected to) the first shaft portion56avia the coupling portion64. The coupling portion64itself is integrally formed with or suitably connected to the remainder of the lever52, as will be appreciated.

At an end of the outer sheath54, specifically the opposing end of the sheath54to the lever52, the sheath54includes connection points70for connecting and securing the operating handle50to a valve arrangement26on the hopper12of the docking arrangement10. Further, at this end of the sheath54, apertures74a,74bare provided for receiving screws72for securing the second shaft portion56bat the appropriate position within the sheath54. The apertures may comprise a threaded surface for interacting with the screws72. Corresponding (threaded) apertures76a,76bare provided at the end of the second shaft portion56b.

First and second shaft portions56a,56bare operatively coupled via rods66which are configured to be located in corresponding slots67a,67bin first and second shaft portions56a,56b. The rods66provide an interface between the first and second shaft portions56a,56bensuring that the second shaft portion56brotates with the first shaft portion56aupon rotation of the lever52(e.g. through operation of an actuator).

The length of slots67a,67bis sufficiently large enough to allow a corresponding rod66to move within the slots67a,67b, e.g. such that the first shaft portion56amay be moved axially with respect to the second shaft portion56bbetween first and second axial positions along an axis running substantially centrally along the length of the shaft56. In use, the first shaft portion56amoves between first and second axial positions upon linear movement of the lever52, which may be moved manually or under the operation of an actuator (e.g. actuator40) as discussed herein.

Equally, the length of the slots67a,67bis sufficiently small such that at least a portion of a corresponding rod66is received within each opposing slot67a,67bwith the first shaft portion56ain either its first or second axial position such that the first shaft portion56aand second shaft portion56bremains operatively coupled at all times. This ensures that the first and second shaft portions56a,56bcannot rotate independently.

In its first axial position, the first shaft portion56ais separate from the second shaft portion56bwith a gap78therebetween (seeFIGS.10A &10B). In its second axial position, the first shaft portion56ais brought proximal to the second shaft portion56bsubstantially eliminating any gap78therebetween (seeFIGS.11A &11B).

First and second shaft portions56a,56bare additionally operatively coupled via a biasing member in the form of spring68located at either end in respective bores69a,69bin the first and second shaft portions56a,56b. The spring68is configured to provide a biasing force which acts with or against movement of the first shaft portion56abetween its first and second axial positions. In the illustrated embodiment, the biasing force provided by the spring68acts against movement of the first shaft portion56afrom its first axial position to its second axial position. Equally, the biasing force provided by the spring69acts with movement of the first shaft portion56bfrom its second axial position to its first axial position. In this way, the biasing force acts to urge/retain the first shaft portion56ato its first axial position unless acted on—e.g. via interaction of a user or an actuator with the lever52or other component of the operating handle50.

Configuring the shaft56in this manner ensures that both first and second shaft portions56a,56brotate together, but allows for the second shaft portion56bto remain substantially stationary in an axial direction—for example, with respect to the outlet valve (not shown) such that it remains operatively coupled to the outlet valve at all times—and for the first shaft portion56ato move relative to the second shaft portion56bin an axial direction as may be required—for example, to engage/disengage a rotation retention mechanism as discussed herein.

As discussed briefly above, the operating handle50includes a rotation retention mechanism for retaining the lever52and hence shaft56in one of a plurality of rotational positions as may be required. Specifically, the outer sheath54includes a slot60which is configured to receive a projecting portion58associated with the first shaft portion56a. The projecting portion58is configured to move along the slot60in the outer sheath54upon rotation of the lever52and corresponding rotation of the shaft56. In the illustrated embodiment, the projecting portion58takes the form of a dowel suitably located and secured within an opening in the first shaft portion56aand projecting from an exterior surface of the first shaft portion56a.

The slot60includes a number of notches62a,62b,62cfor receiving the projecting portion58. Notches62a,62b,62cact to prevent rotation of the shaft56by retaining the projecting portion58. In effect, the notches62a,62b,62cdefine three angular positions in which the shaft56and lever52can be retained. Notch62acorresponds to the first rotational position of the lever52, notch62ccorresponds to the second rotational position of the lever52, whilst notch52bcorresponds to an intermediate rotational position of the lever52between the first and second rotational positions. Accordingly, the notches62a,62b,62ccorrespond to three operational states of the outlet valve (not shown), e.g. a fully closed, an intermediate and a fully open state for controlling flow of the manufacturing material.

The first shaft portion56a, and hence the shaft56as a whole, is able to be rotated when the first shaft portion56ais in its second axial position. Similarly, the first shaft portion, and hence the shaft56, is unable to be rotated when the first shaft portion56bis in its first axial position as a result of contact between the projecting portion58and one of the notches62a,62b,62cin the slot60. Providing the spring68ensures that unless the handle50is acted on (by a user or by an actuator) the first shaft portion56ais held in its first axial position with the projecting portion58retained in contact with one of the notches62a,62b,62cpreventing rotation of the shaft56. In order to rotate the shaft56—i.e. to open/close the associated outlet valve—the first shaft portion56amust be moved against the biasing force provided by the spring68to its second axial position (e.g. through linear movement of the lever52), thereby disengaging the projecting portion58from the notch62a,62b,62c. This in turn allows the projecting portion58to be moved along the slot60—i.e. upon rotation of the shaft56. After the shaft56is rotated to its desired angular position (corresponding to an associated operational state of the outlet valve) any external force applied to the first shaft portion56a, e.g. by a user acting on the lever52or via an actuator, may be released, and the spring68acts to urge the first shaft portion56aback to its first axial position with the projecting portion58engaged with a corresponding notch62a,62b,62cin the slot60and the rotational position of the lever52and shaft56retained.

In the variant shown inFIGS.8-11B, the lever52is pivoted about the operating handle50at an end thereof rather than at its centre as is the case with the operating handle50shown in the preceding Figures. Accordingly, the configuration of the actuator40may be unsuitable for use with this variant. Accordingly, in the variant shown inFIGS.8-11B, the coupling portion64of the lever52includes a bore65which acts as a female coupling configured to receive a corresponding male coupling of an associated actuator (not shown). When coupled via the male/female coupling, the actuator may be configured to cause linear movement and/or rotation of the shaft56—i.e. without a user manually acting on the lever52. In this way, the arrangement provides an operating handle which may be controlled either manually or automatically without manual input as the situation may require. However, in this variant the actuator may have to be separately aligned with and coupled to the bore65following positioning of the hopper12with the dock11. It may, however, be desirable to align the actuator with the operating handle upon docking of the hopper, as with the embodiment shown inFIGS.1-7B.

In a further variant (not shown in the Figures), the operating handle may comprise a right angle drive type arrangement whereby a vertically oriented actuator (for example a vertical actuator drive shaft) may be received within a correspondingly oriented coupling on the operating handle upon docking of the hopper12. In such an arrangement, the operating handle may include a gear arrangement, which could include a pair of bevel gears to effect corresponding rotation of a horizontally oriented drive shaft of the valve arrangement26under operation/rotation of the actuator.

In embodiments, the operating handle50may be specific to a type of material contained within the hopper12. For instance, in the variant shown inFIGS.8-11B, the bore65may include a configuration which is specific to the type of material contained within the hopper12. Accordingly, a specifically configured actuator must be used to act on the operating handle50to open and close the associated outlet valve. The actuator may be associated with a certain component of the manufacturing process. In this way, the configuration of the operating handle50may be such that handle50may only be used (and material deposited from the hopper50) for specific components within the manufacturing process. Accordingly, the operating handle50may be configured to prevent the wrong type of material being deposited at the wrong location or to the wrong component.

FIGS.12-15Billustrate an embodiment of a locking mechanism100in accordance with the invention. The locking mechanism100is configured to couple and secure an outlet16of the hopper12to an inlet18of a further component of an additive manufacturing process, such as an additive manufacturing machine. Specifically, the locking arrangement100is provided with the inlet18and is positioned such that it may act on an external surface of the outlet16when the outlet16is received within an open upper end of the inlet18.

The locking mechanism100includes a pair of opposing locking members in the form of rollers102a,102bwhich are moveable in a direction perpendicular to their rotation axis. In the orientation shown in the Figures, this comprises movement in a horizontal direction. Movement of the rollers102a,102bis controlled via respective linear actuators in the form of pistons104a,104b. The rollers102a,102bare mounted to respective pistons104a,104bvia respective clevis-type fasteners106a,106bwhich allow rotational movement of the rollers102a,102babout respective rotation axes. This mounting arrangement is shown inFIG.13. Alternatively, the rollers may include an outer collar which is rotationally mounted, for example by way of needle roller bearings, to the remainder of the roller.

In use, the pistons104a,104bare configured to control movement of the respective rollers102a,102bbetween a first longitudinal position (as shown inFIGS.14A and14B) and a second longitudinal position (as shown inFIGS.15A and15B). In the illustrated embodiment, the first longitudinal position of the rollers102a,102bcorresponds to an “unlocked” state of the locking mechanism100and the second longitudinal position corresponds to a “locked” state of the locking mechanism100.

In alternative embodiments the rollers are mounted on an actuator other than a piston and cylinder device. This may be an electrical actuator, such as a solenoid.

The outlet16of the hopper12is provided with a groove112about an exterior surface thereof, depicted here by opposing groove sections112a,112b. The groove sections112a,112bcorrespond to respective rollers102a,102b. The groove112may be provided about the entire circumference of the outlet16. In such embodiments, this may allow the hopper12to be secured within the docking arrangement10without requiring the hopper12to be positioned with the groove112precisely aligned with respective rollers102a,102b.

In use, the groove sections112a,112bare configured to receive at least part of respective rollers102a,102bto secure the outlet16of the hopper12to the inlet18. Specifically, the process of coupling and securing the outlet16and inlet18begins with the rollers102a,102bprovided in the first longitudinal position. With the rollers102a,102bin the first longitudinal position, the outlet16of the hopper12is able to be brought proximal and preferably into contact with the inlet18. In the illustrated embodiment, the outlet16is positioned within a recess107within the open end of the inlet18as shown inFIGS.14A and14B. With the outlet16in this position, the rollers102a,102bare moved to the second longitudinal position (as shown inFIGS.15A and15B) under the operation of respective pistons104a,104b. When in the second longitudinal position the rollers102a,102bare at least partly received in the groove112, specifically in corresponding groove sections112a,112bin the exterior wall of the outlet16preventing the outlet16from being withdrawn from the recess107in the inlet18. In this way, the locking mechanism100may be used to couple and secure the outlet16to the inlet18.

Pistons104a,104bare controlled pneumatically through the introduction and/or removal of gas from within respective piston chambers108a,108b. The gas is supplied and/or removed from piston chambers108a,108bvia respective supply pipes110a,110b. As will be appreciated, introduction of gas into the piston chambers108a,108bwill cause the pistons to move inwardly (in the configuration shown in the Figures) and hence cause the rollers102a,102bto move to the second longitudinal position. Removal of gas from within the piston chambers108a,108bwill cause the pistons to move outwardly (in the configuration shown in the Figures) and hence cause the rollers102a,102bto move to the first longitudinal position.

Locking and unlocking of the locking mechanism100may preferably be controlled centrally via a control system (not shown). The central control system may also take into account other operational states of components of the docking arrangement10in controlling operation of the locking mechanism100. For example, the central control system may require that the outlet valve of the valve arrangement26be in a closed state before allowing/controlling the locking mechanism100to unlock. Equally, the central control system may be configured to prevent opening of the outlet valve of the valve arrangement26unless the locking mechanism100is locked with the outlet16and inlet18coupled and secured in position.

An alternative locking mechanism100′ is shown inFIGS.16and17.

The locking mechanism100′ includes a pair of locking members in the form of cams102a′,102b′, rotatably mounted at respective primary pivot points109a′,109b′. In use, rotation of the cams102a′,102b′ about the respective primary pivot points109a′,109b′ causes the cams102a′,102b′ to move into and out of the interior of inlet18to between locked and unlocked positions to engage and disengage with the outlet16of the hopper12in a similar fashion to rollers102a,102bshown in the preceding Figures.

The cams102a′,102b′ are additionally rotatably mounted at ends thereof to respective linear actuators in the form of pistons104a′,104b′ via secondary pivot points107a′,107b′. In use, movement of the cams102a′,102b′ is controlled via the pistons104a′,104b′ as described herein. Specifically, the pistons104a′,104b′ are configured to control movement of the respective cams102a′,102b′ between a first rotational position corresponding to an “unlocked” state of the locking mechanism100′ and a second rotational position corresponding to a “locked” state of the locking mechanism100′. In the unlocked state, the cams102a′,102b′ are positioned substantially out of the interior of the inlet18(as shown inFIG.17). In the locked state, the cams102a′,102b′ project into the interior of the inlet18to engage an exterior surface (e.g. a groove112) of a corresponding outlet16of a hopper12as discussed above.

As will be appreciated, pistons104a′,104b′ may be controlled pneumatically through the introduction and/or removal of gas from within respective piston chambers108a′,108′b. The gas is supplied and/or removed from piston chambers108a′,108b′ via respective supply pipes110a′,110b′.

Introduction of gas into the piston chambers108a′,108b′ causes the pistons to move upwardly (in the configuration shown in the Figures) and hence cause the cams102a′,102b′ to rotate about respective primary pivot points109a′,109b′ from a first rotational position to a second rotational position. Conversely, removal of gas from within the piston chambers108a′,108b′ will cause the pistons108a′,108b′ to move downwardly (in the configuration shown in the Figures) and hence cause the cams102a′,102b′ to rotate about respective primary pivot points109a′,109b′ in the opposite sense from a second rotational position to a first rotational position.

In the illustrated embodiment, cams102a′,102b′ are “over-centre” cams. Rotation of the cams102a′,102b′ about respective primary pivot points109a′,109b′ past the horizontal—i.e. past where the primary pivot points109a′,109b′ are horizontally aligned with respective secondary pivot points107a′,107b′—effectively locks the cams102a′,102b′ in place when in respective second rotational positions unless otherwise acted on by respective pistons104a′,104b′. Specifically, this prevents any internal force/pressure on the cams102a′,102b′, e.g. by the outlet16of the hopper12from unintentionally “unlocking” the locking mechanism100′, in use.

As with locking mechanism100, locking and unlocking of the locking mechanism100′ may preferably be controlled centrally via a control system (not shown). Again, the central control system may also take into account other operational states of components of the docking arrangement10in controlling operation of the locking mechanism100′.

An example control strategy200of a central control system is shown in the flowchart ofFIGS.18A and18B. Where applicable,FIGS.18A and18Binclude representations showing the operational state of the locking mechanism100and operating handle50/actuator40arrangement at each step of the control strategy200.

FIG.18Aillustrates a first part of the control strategy200which includes securing the hopper12on the dock11and subsequently opening the valve arrangement26to allow material within the hopper12to be delivered to the associated further component of the manufacturing process.

Specifically, at202, the locking mechanism100is provided in an open configuration. That is, the rollers102a,102bare retained in respective first longitudinal positions allowing an outlet16of the hopper12to be brought into position with respect to the inlet18of the dock11as described herein. At this step, the first and second pistons42,45of the actuator40are retained in a retracted position with rollers49a,49bout of contact with respective lever arms53a,53b. The lever52is provided in its first rotational position, as shown, which corresponds to a closed configuration of the associated valve arrangement26.

At204, a check is performed to confirm that the outlet16of the hopper12is positioned within the inlet18of the dock11. If not, the locking mechanism100remains in the open configuration.

Once the outlet16of the hopper12is in position within the inlet18, the locking mechanism100may be closed at step206. As discussed herein, closing the locking mechanism100includes powering pistons104a,104bto move respective rollers102a,102bto second longitudinal positions and specifically into contact with respective groove sections112a,112bwithin the exterior surface of the outlet16. During this step, the first and second pistons42,45are retained in respective retracted positions.

At steps208&210a pressure check is performed to confirm that a sealed connection has been formed between the outlet16and inlet18. If not, the process returns to step202where the locking mechanism100may be opened to repeat the locking process of steps202to206.

Once a sealed connection is confirmed, pistons42,45are powered to respective first positions at step212. Specifically, roller49aassociated with piston42is brought into contact with the first lever arm53aof the lever52thereby depressing the lever52to disengage the rotation retention mechanism.

At step214, piston42is powered to its second position thereby rotating the lever52and hence shaft56of the operating handle50through an angle of 90° to its second rotational position, as shown. The second rotational position of the lever52corresponds to an open configuration of the valve arrangement26, thereby allowing material from the hopper12to exit through the outlet16into the further component of the manufacturing process via inlet18.

Once a desired amount of material has been removed from the hopper12, a reverse process may be performed to close the valve arrangement26and unlock the locking mechanism100thereby allowing the hopper12to be removed from the dock11. This is shown inFIG.18B.

At step216, the second piston45is powered to its second position causing the roller49bto act on the second lever arm53bof the lever52thereby causing the lever52to rotate through an angle of 90° back to its first rotational position. In doing so, the valve arrangement26may be closed preventing any more material from leaving the hopper12.

At step218, both the first and second pistons42,45are moved back to retracted positions whereby the rollers49a,49bare brought out of contact with respective lever arms53a,53b. In doing so, the lever52is free to move under the bias provided by spring68to engage the rotation retention mechanism to secure the lever52in its first rotational position (with the valve arrangement26closed).

At step220, a check is performed to confirm that the valve arrangement26has been closed. If not, the process returns to step216to repeat the steps216and218to close the valve arrangement26.

Once the valve arrangement26is confirmed to have been closed, the process continues to step222where the locking mechanism100may be opened. Specifically, pistons104a,104bare powered to move respective rollers102a,102bto first longitudinal positions and specifically out of contact with respective groove sections112a,112bwithin the exterior surface of the outlet16. This releases the hopper12from the dock11allowing it to be removed.

FIGS.19and20illustrate a further feature of the docking arrangement10. Specifically, these figures illustrate the operational use of the gas inlet32. As shown, a gas supply unit34is coupled to the gas inlet32and is connected via a gas supply line33to a gas supply35associated with the dock11. To effect this coupling, supply pipes36a,36bof the supply line are coupled via couplers38a,38bto respective couplers37a,37bon the dock11.

The gas provided by the gas supply may in some instances comprise air, but may equally comprise a specific type of gas as required by the material contained within the hopper12. As discussed herein, some materials may oxidise in air so must be kept under a controlled atmosphere. Accordingly, the gas supply35may comprise an inert gas (e.g. argon, nitrogen, etc.) which may suitably inhibit oxidation or other deterioration of the material within the hopper12.

In a further use case, the gas supply35provides a source of gas to the hopper12for controlling a pressure level within the hopper12to assist in the flow of material from the outlet16of the hopper12. The hopper12can additionally include a gas outlet (not shown) which may act as a bleed valve to ensure the pressure level inside the container14remains at a desired level, or below an acceptable maximum pressure level, for example. This enables gas to be bled from the hopper12enabling the gas supply35to be used to purge the hopper12of gas it contains, replacing it with gas from the gas supply35.

The gas supply unit34can include one or more pressure sensors for monitoring the pressure within the hopper12, and control the supply of gas to the hopper12based on the monitored pressure level. Operation of the gas supply unit34can be controlled by a control system (not shown).

In further embodiments, the gas supply35can be coupled to a gas inlet (not shown) at an interface between the outlet16of the hopper12and the inlet18on the dock11. In such embodiments, the gas supply35can be used to purge the interface between the hopper12and the component of the manufacturing process to prevent deterioration of the material when it is being transferred to the component.

The one or more embodiments are described above by way of example only. Many variations are possible without departing from the scope of protection afforded by the appended claims.