SYSTEMS AND METHODS FOR ANNEALING SHEET METAL COILS

Abstract

A facility with an annealing system including one or more (typically a plurality of) autonomous vehicles, e.g., shuttles, cars, etc., which autonomous vehicles each receive sheet metal coils, e.g., one, two, or more sheet metal coils, and move the sheet metal coils about the facility. The sheet metal coils generally include aluminum coils, though other sheet metal coils, such as brass, copper, steel, etc. coils, can be used without departing from the scope of the present disclosure. The annealing system also can include a stationary unit or component, or a plurality of stationary units, configured to dock with the autonomous vehicles to facilitate annealing of the coils on or within the autonomous vehicles.

Description

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims the benefit of U.S. Provisional Patent Application No. 62/932,623, filed Nov. 8, 2019; and U.S. Provisional Patent Application No. 62/951,054, filed Dec. 20, 2019, and the contents of the foregoing applications are incorporated by reference herein in their entirety.

TECHNICAL FIELD

The present disclosure is directed to processing metallic materials, and in particular, facilities, systems, and methods for processing rolled sheet metals, such as aluminum coils. Other aspects also are described.

BACKGROUND

Vehicle manufacturers, such as manufacturers of automobiles and airplanes, generally have been employing more and more aluminum in the production of new vehicles, e.g., to attempt to reduce the weight of vehicles. In turn, demand for aluminum has increased significantly, and also, demand for varied, different sized, or custom orders of aluminum has increased. Existing processing facilities, however, generally are not fit to meet these demands and also experience several additional issues/challenges.

For example, existing facilities typically include large capacity annealing furnaces that are specifically designed to anneal a high number of aluminum coils simultaneously, such as up to 18 or more coils at a time. Due to thermodynamic issues, these large annealing furnaces usually must be filled to, or close to, capacity for efficient annealing of these coils and thus generally cannot effectively anneal small numbers of coils, such as one or two coils at a time. And, because these annealing furnaces typically cannot accommodate efficient annealing of smaller numbers of coils at a time, the entire process usually must wait until an adequate number of coils, such as 10 or more coils, are available. Processing of the coils, and other processes at the facility, therefore can be significantly delayed while waiting for the requisite amount of coils to fill the annealing furnace, thereby creating a significant backlog of coils coming off of a rolling mill and/or other preprocessing stations (especially considering that a typical annealing process can take up to 24 hours or more). Furthermore, existing facilities with such large annealing systems generally do not provide the flexibility for quickly and efficiently fulfilling smaller or on-demand type orders of aluminum.

Some existing facilities have attempted to employ storage and retrieval systems for storing or queueing of coils exiting the rolling mill and waiting for their time in the annealing furnace. However, these storage systems can have several downsides, e.g., requiring large amounts of space further adding to the already significant footprint of these existing facilities. In addition, existing facilities generally move the coils throughout the facility, e.g., between rolling mills, storage areas, the annealing furnace, and/or other processing stations, using ridge cranes or large vehicles, such as large trucks, fork lifts, etc., which can cause further delays due to the required loading and unloading of the coils and also can increase risk of injury to facility workers and other personnel.

It thus can be seen that a need exists for facilities, systems, and methods that significantly reduce production/processing time of sheet metal coils and also allow for additional flexibility to enable the efficient fulfillment of smaller, custom, and/or on-demand orders. The present disclosure addresses the foregoing and other related, and unrelated, issues and/or problems in the relevant art.

SUMMARY

In one aspect, the present disclosure is directed to a facility with an annealing system including one or more (typically a plurality of) autonomous vehicles, e.g., shuttles, cars, etc., which autonomous vehicles each receive sheet metal coils, e.g., one, two, or more sheet metal coils, and move the sheet metal coils about the facility. The sheet metal coils generally include aluminum coils, though other sheet metal coils, such as brass, copper, steel, etc. coils, can be used without departing from the scope of the present disclosure. The annealing system also can include a stationary unit or component, or a plurality of stationary units, configured to interface or dock (the terms being used interchangeably in this disclosure), and to thus, communicate, with the autonomous vehicles to facilitate annealing of the coils on or within the autonomous vehicles. (Docking/interfacing facilitates communication between an autonomous vehicle and a stationary unit by way of a dock, or by docking, which communication can include, for example, one or more of, without limitation, physical connections, signal communications, fluid communications, and electronic communications.)

The autonomous vehicles can receive the sheet metal coils from a rolling mill at the facility. The rolling mill can include mill components as understood by those skilled in the art, including, but not limited to, one or more mandrels, rollers, or other mechanisms for generating and/or processing of the sheet metal coils. In one embodiment, the autonomous vehicles can be configured to dock, and to, thus, communicate, with a dock of the rolling mill to receive the coils from the rolling mill, e.g., without the use of cranes, forklifts, or other lifting mechanisms.

The autonomous vehicles further can move the received sheet metal coils towards and to the stationary unit or to selected ones of the stationary units and dock, and, thus, communicate, with the stationary unit(s) for annealing of the sheet metal coils on the autonomous vehicles. For example, upon a determination that a stationary unit, or a dock thereof, is available, an autonomous vehicle, supporting the received sheet metal coils, can be directed to the available stationary unit and dock with the stationary unit (e.g., for docking, the autonomous vehicle can be received within a chamber of the stationary unit or an external dock of the autonomous vehicle can connect, engage, or otherwise communicate with an external dock of the stationary unit) to facilitate annealing of the received sheet metal coils. With an autonomous vehicle docked with a stationary unit, the annealing processing can be initiated. In one example, the annealing process can include heating the sheet metal coils to a prescribed temperature, holding the heat at the prescribed temperature for a set period of time, and then cooling the sheet metal coils at or to a prescribed temperature and/or at a particular rate.

The sheet metal coils generally can remain on the autonomous vehicles (e.g., supported by or attached to a coil support of the autonomous vehicles) throughout the annealing process. That is, annealing can be completed without removal of the sheet metal coils from the autonomous vehicles. (The phrase—on the/an autonomous vehicle(s)—is meant to encompass the various ways the steel coils are received and/or supported by the vehicle, such as in, on, or within the autonomous vehicle.)

When the annealing process is complete, the respective autonomous vehicle can be released from the respective stationary unit and can move the annealed sheet metal coil(s) to one or more post-processing stations (such as cutting stations, e.g., laser or plasma, shipping stations, etc.).

The autonomous vehicles can dock with the post-processing stations to enable further processing of the annealed sheet metal coils, e.g., while remaining in the autonomous vehicles, and/or to enable unloading of the annealed sheet metal coils from the autonomous vehicles.

According to some embodiments, an autonomous vehicle also can have a propulsion mechanism (e.g., a plurality of wheels, continuous track, etc.) and a drive system (e.g., including a motor, engine, or other driving mechanism) configured to drive or otherwise power the propulsion mechanism for moving the autonomous vehicle about the facility. According to some embodiments, an autonomous vehicle also can have a chassis connected to the propulsion mechanism and drive system. The chassis can be configured to support at least one sheet metal coil. According to some embodiments, an autonomous vehicle also can include a control system for receiving and/or generating one or more control signals for controlling the drive system, e.g., for driving and steering or otherwise directing the autonomous vehicle about the facility. According to some embodiments, an autonomous vehicle further can include a power source, e.g., including one or more batteries or other suitable portable, rechargeable power source, for powering the drive system, control system, and other components of the autonomous vehicle.

In one construction, to dock with the stationary units, the autonomous vehicles can be configured to be received within the stationary units (e.g., within a chamber of the stationary units). That is, the autonomous vehicles can be sized, dimensioned or configured to be received through an opening or port in the stationary units and into a chamber of the stationary unit to facilitate annealing of one or more sheet metal coils in the chamber of the stationary unit. An autonomous vehicle further can include an insulating portion or wall that is supported by the chassis. The insulating portion can be configured to engage or contact a portion of the stationary unit, with the autonomous vehicle received in the chamber, e.g., to at least partially seal the chamber during annealing. An autonomous vehicle further can include a coil support, which can include or comprise, for example and without limitation, a cradle, a cage, a framework, or a plurality of spindles, that is configured to hold at least one sheet metal coil on the autonomous vehicle.

In addition, or in alternative constructions, an autonomous vehicle can include an on-vehicle furnace with a furnace housing or casing including a plurality of insulated walls or portions that at least partially surround and/or define a furnace chamber (or compartment) configured to receive and house sheet metal coils. In one example, the furnace chamber of the autonomous vehicle can be sized to receive a single sheet metal coil; however, in additional or alternative construction, the furnace chamber can be sized to receive two, three, or even four or more sheet metal coils. An autonomous vehicle also can include a coil support positioned within the furnace chamber for supporting the sheet metal coils within the furnace chamber (e.g., to secure the sheet metal coils within the furnace chamber and to reduce or prevent dislocation thereof during movement of the autonomous vehicle). Still further, an autonomous vehicle can have an external docking interface that is configured to interact with a corresponding dock of a stationary unit for interfacing with the stationary units. The docking interface can include a passage or vent (or a plurality of passages or vents) in communication with the furnace chamber of the autonomous vehicle to receive fluid flow, e.g., air flow, from the stationary unit to facilitate annealing of the sheet metal coils within the furnace chamber of the autonomous vehicle. The docking interface also can have one or more sealing features that help to maintain a substantially air or fluid tight seal between the furnace chamber and the stationary unit, e.g., to substantially prevent, reduce, or inhibit the loss of fluid flow and/or heating or cooling within the furnace of the autonomous vehicle or stationary unit.

According to some embodiments, a stationary unit can include a housing including a plurality of walls or portions defining one or more chambers or compartments configured to receive one or more autonomous vehicles and/or to house or support the various components of the stationary unit. In one example construction, the plurality of walls of a stationary unit can be insulated walls and can form a furnace. The plurality of walls can at least partially surround and define a furnace chamber of the stationary unit into which one or more autonomous vehicles can be received for annealing of one or more sheet metal coils supported by the autonomous vehicles.

In an alternative construction, however, a stationary unit can include an external dock that is configured to interface, and to thus communicate, with an external dock of an autonomous vehicle to facilitate annealing of one or more sheet metal coils within a furnace of the autonomous vehicle. The housing of the stationary unit further can include a flow path or flow paths defined through the chamber(s) that allows for fluid flow, e.g., the passage of air, through the housing.

A stationary unit also can include an air mover (e.g., an air blower, etc.) that is configured to draw air through the housing of the stationary unit. The air mover is in communication with the chamber of the stationary unit, for the autonomous vehicle that is received within the furnace chamber of the stationary unit, or in communication with the furnace chamber of the autonomous vehicle, for autonomous vehicles externally docked with the stationary units, to provide fluid flow, e.g., heated or cooled air flow, to the furnace chamber of the stationary unit or furnace chamber of the autonomous vehicle for annealing of the sheet metal coils.

A stationary unit further can include one or more intakes, e.g., including vents or other openings, in communication with the air mover and flow path (or paths) defined though the housing of the stationary unit to allow air to be drawn from the environment or other source of air into the stationary unit by the air mover.

In addition, a stationary unit can include at least one heat source (e.g., fired burners, heating coils, electric heating elements, or other suitable heat sources) provided along the stationary units or along the flow path (or a specific flow path of the plurality of flow paths) in the stationary units and configured to heat air directed into to the furnace chamber of the stationary units (or the furnace chamber of the autonomous vehicles) by the air mover to facilitate heating during the annealing process.

The stationary units additionally can include at least one cooling source (e.g., a network of cooling coils, tubes, or pipes that receive a cooled fluid) provided in or along the stationary unit to provide cooled air to the furnace chamber of the stationary units (or the furnace chamber of the autonomous vehicles) to facilitate cooling during the annealing process.

Still further, a stationary unit can include a nitrogen source, such as nitrogen injection system, that allows for the introduction of nitrogen (e.g., nitrogen gas) into the furnace chamber of the stationary unit (or the furnace chamber of an autonomous vehicle), e.g., to help to prevent or reduce oxidization of the sheet metal coils during annealing.

In other aspects, the present disclosure is directed to a method for processing and/or annealing of sheet metal coils. The method can include docking/interfacing an autonomous vehicle with a rolling mill (e.g., with one or more docks of the rolling mill) for receipt of one or more sheet metal coils onto/into the autonomous vehicle. The method also can include positioning the coil(s) onto a coil support on an autonomous vehicle or within furnace chamber of an autonomous vehicle, e.g., such that the sheet metal coil(s) is supported by the coil support. The method then can include moving or directing the autonomous vehicle with the sheet metal coil(s) to a stationary unit, and interfacing or docking the autonomous vehicle with the stationary unit (e.g., by receiving the autonomous vehicle within a furnace chamber of the stationary unit or connecting an external docking interface of the autonomous vehicle with an external dock of the stationary unit). Upon interfacing or docking, the method can include heating the sheet metal coil(s) to a prescribed temperature within the furnace of the stationary unit or furnace of the autonomous vehicle, such as by directing heated air to the furnace chamber of the stationary unit or the furnace chamber of the autonomous vehicle (e.g., using a heat source and air mover of the stationary unit), and maintaining the prescribed temperature within the furnace chamber of the stationary unit (or autonomous vehicle) for a set time period. After this set time period has expired, the method can include cooling the sheet metal coil(s) within the furnace chamber to a prescribed temperature for a set time period and/or at a particular cooling rate (e.g., using a cooling source and air mover of the stationary unit). Thereafter, e.g., upon completion of the annealing process, the method can include releasing the autonomous vehicle from the stationary unit, and directing the autonomous vehicle, with the annealed coil(s) therein, to one or more post processing stations for further processing and/or unloading of the annealed sheet metal coils.

The facilities, methods, and systems in accordance with the present disclosure include various alternative combinations of one or more autonomous vehicles and one or more stationary units, including example combinations that can utilize within the same facility/method/system multiple autonomous vehicles of the same makeup and features (e.g., same embodiments thereof as discussed herein) and multiple stationary units of the same make-up and features (e.g., same embodiments thereof as discussed herein); as well as example combinations that can utilize within the same facility/method/system collections of autonomous vehicles of different makeups and features (e.g., different embodiments thereof as discussed herein) and collections of stationary units of different makeups and features (e.g., different embodiments thereof as discussed herein).

Example embodiments can include, without limitation, a first plurality of stationary units, each of which includes multiple of external docks, a second plurality of stationary units, each of which includes one or more internal furnace chambers, a third plurality of stationary units, each of which includes both external docks and at least one furnace chamber, a first plurality of autonomous vehicles, each of which includes an on-vehicle furnace chamber, a second plurality of autonomous vehicles, each of which includes an external dock, and a third plurality of autonomous vehicles, each of which includes both an external dock and an on-vehicle furnace chamber, or the facility can include combinations and permutations of the foregoing.

Accordingly, the facilities, systems, and methods provided by the present disclosure can enable quick and efficient fulfillment of smaller and/or on-demand or custom orders of sheet metal coils. Furthermore, the facilities, methods, and systems of the present disclosure may reduce or eliminate the need for constantly loading and unloading of the sheet metal coils (e.g., from ridge cranes, large trucks, fork lifts, etc.), and/or significantly reduce wait times and backlog of the sheet metal coils coming off a rolling mill or other processing stations.

These and other advantages and aspects of the embodiments of the disclosure will become apparent and more readily appreciated from the following detailed description of the embodiments and the claims, taken in conjunction with the accompanying drawings. Moreover, it is to be understood that both the foregoing summary of the disclosure and the following detailed description are exemplary and intended to provide further explanation without limiting the scope of the disclosure as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a further understanding of the embodiments of the present disclosure, are incorporated in and constitute a part of this specification, illustrate embodiments of the invention, and together with the detailed description, serve to explain the principles of the embodiments discussed herein. No attempt is made to show structural details of this disclosure in more detail than may be necessary for a fundamental understanding of the exemplary embodiments discussed herein and the various ways in which they may be practiced.

FIGS. 1A-1E illustrate various views of a facility for processing sheet metal coils according to principles of the present disclosure.

FIG. 2 illustrates a perspective view of an autonomous vehicle according to one example of the present disclosure.

FIGS. 3A-3F illustrate various views of an annealing system for the facility according to one aspect of the present disclosure.

FIG. 4 illustrates an annealing system for the facility according to a further aspect of the present disclosure.

DETAILED DESCRIPTION

The following description is provided as an enabling teaching of embodiments of this disclosure. Those skilled in the relevant art will recognize that many changes can be made to the embodiments described, while still obtaining the beneficial results. It will also be apparent that some of the desired benefits of the embodiments described can be obtained by selecting some of the features of the embodiments without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the embodiments described are possible and may even be desirable in certain circumstances. Thus, the following description is provided as illustrative of the principles of the embodiments of the present disclosure and not in limitation thereof.

FIGS. 1A-1E show various views of a facility 10 according to principles of the present disclosure. The facility 10 can facilitate the processing of metals, and in one example, the facility 10 can facilitate the generation and/or processing of sheet metal coils 12, such as rolled aluminum coils. These sheet metal coils 12 can be used for manufacturing in automotive and/or aerospace applications, such as manufacturing of automobiles (e.g., body panels, parts, etc.), aerospace vehicles (e.g., panels, parts, components, etc. of airplanes, satellites, or for other suitable aerospace applications), and/or for any other suitable products, processes, etc. as will be understood by those skilled in the art. It will be further understood though in one embodiment the facility 10 generally processes aluminum coils, the present disclosure is not limited to aluminum coils and in additional or alternative embodiments can be used for the generation, processing, etc. of any suitable metal coils, such as copper, brass, steel, titanium, etc. and/or other synthetic materials, composite materials, etc., without departing from the scope of the present disclosure.

As further indicated in FIGS. 1A-1E, the facility 10 generally includes a rolling mill 14, an annealing system 16, and one or more post-processing stations 18. The facility 10 further can include one or more pre-processing stations 13 (FIG. 1E). The annealing system 16 includes a plurality of autonomous vehicles 20, such as shuttles, cars, etc., configured to direct, move, and/or carry sheet metal coils about the facility 10. The annealing system 16 additionally includes one or more stationary units or components 22 that interface or dock with the autonomous vehicles 20 to facilitate annealing of the sheet metal coils on or within the autonomous vehicles 20. The autonomous vehicles 20 can receive one or more sheet metal coils 12 from the rolling mill 14, move the received sheet metal coils 12 to a selected stationary unit 22, dock with the selected stationary unit 22 for annealing of the received sheet metal coils 12 (while remaining on or in the autonomous vehicles 20), and upon completion of annealing, move or deliver the annealed coils to one or more of the post-processing stations 18.

According to embodiments of the present disclosure, the pre-processing station(s) 13 can include systems, mechanisms, etc. for preparing, processing, etc. sheet metals, such as metal blocks or ingots to be rolled into metal sheets and/or the metal sheets, themselves. For example, the pre-processing station(s) 13 can include one or more pre-heating stations, cutting stations, etc. for processing of metal blocks or ingots and/or metal sheets. The metal blocks or metal sheets further can be provided from the preprocessing station(s) 13 to the rolling mill 14 by any suitable mechanisms, such as conveyors, vehicles, etc. The metal blocks or sheets can be delivered from the pre-processing stations 13 to the rolling mill 14 using the autonomous vehicles 20 or other transporters, such as cranes, fork lifts, manually-driven vehicles, etc., without departing from the scope of the present disclosure.

The rolling mill 14 can receive the metal sheets (and/or metal blocks) from the pre-processing stations 13 and can process the sheets (and/or blocks) into sheet metal coils. For example, the rolling mill 14 can include rolling mill components as understood by those skilled in the art, including, but not limited to, one or more mandrels, rollers, and/or other mechanisms that facilitate processing of metal sheets (and/or metal blocks) into sheet metal coils 12. The sheet metal coils 12 can include a sheet metal that is rolled or wrapped about a spindle or support roll that supports the rolled sheet metal; though the metal sheets can be rolled without a spindle or support roll without departing from the scope of the present disclosure. As FIGS. 1A-1B and 1E indicate, the autonomous vehicles 20 can dock with the rolling mill 14 so the sheet metal coils 12 generated at the rolling mill 14 can be loaded into, in, or otherwise received by the autonomous vehicles 20. In one example, FIG. 1E shows that the rolling mill 14 can include one or more docks 24 that are configured to interface with a dock of the autonomous vehicles 20 (e.g., external dock 426) to load the sheet metal coils into the autonomous vehicles 20 (e.g., into a furnace chamber 444 of the autonomous vehicles 20, as generally shown in FIG. 4). The docks 24 of the rolling mill 14 can include one or more mechanisms, e.g., conveyors, rollers, lifting or transfer mechanisms, etc., that facilitate relatively quick and easy loading of the sheet metal coils 12 on or within the autonomous vehicles 20, e.g., without the use of cranes, fork lifts, manually driven vehicles, etc. The sheet metal coils 12 then can be driven or otherwise directed to a selected stationary unit 22 (e.g., upon a determination that a stationary unit 22 is available). It will be understood that even though only one rolling mill 14 is shown in FIGS. 1A, 1B, 1C, and 1E, the facility 10 can include a plurality of rolling mills, such as two, three, four, five or more rolling mills, without departing from the scope the present disclosure.

FIGS. 1A-1E additionally indicate that the one or more stationary units 22 can include a dock 28 that is configured to communicate with the autonomous vehicles 20. That is, the autonomous vehicles 20 can deliver the sheet metal coils 12 to the stationary units 22 from the rolling mill 14 and dock with the stationary units 22 to facilitate annealing of the sheet coils, 12 e.g., without removing the sheet metal coils 12 from the autonomous vehicles 20. For example, as discussed in further detail below with respect to FIGS. 3A-3F and 4, the stationary units 22 can include one or more annealing facilitators, including one, more or all of an air mover 30, a heat source 32, a cooling source 34, and a nitrogen source 36 that are configured to deliver heated and cooled fluid flow, e.g., heated and cooled air flow, to the autonomous vehicles 20 for annealing of the sheet metal coils 12 on or within the autonomous vehicles 20 (e.g., within a furnace chamber of the stationary unit 22 (FIGS. 1A-1D and 3A-3F) or within a furnace chamber of the autonomous vehicles 20 (FIGS. 1E and 4)). The nitrogen source 36 can introduce nitrogen into the stationary units 22 or the autonomous vehicles 20 to prevent, reduce, or inhibit oxidation during or after the annealing process. As determined by selected or specified annealing requirements, one or more of the annealing facilitators are placed in communication with the appropriate chamber (e.g., furnace chamber 368 of a stationary unit 322 or furnace chamber 444 of an autonomous vehicle 20) by the dock configurations, as made more apparent, below. Upon completion of the annealing process, the autonomous vehicles 20 can deliver the annealed sheet metal coils 12 to the post processing station(s) 18.

FIGS. 1A-1E, 3A-3F, and 4 further indicate that the annealing system 16 can include a plurality of stationary units 22, each having a single dock 28. In addition, or in alternative constructions, as indicated in FIG. 1E, at least one of the stationary units 22 can have a plurality of docks 28 to facilitate interfacing and, thus, communication with more than one autonomous vehicle 20 at a time. In one embodiment, as generally indicated in FIG. 1D, the facility 10 can include a plurality of rows or columns, e.g., two or more, of stationary units 22 arranged side by side or otherwise adjacent to one another. For instance, FIG. 1D shows two adjacent rows of stationary units 22, with the stationary units 22 in one row facing away from or in the opposition direction from the stationary units 22 in the other row. Although the figures of the present closure show the annealing system 16 to have a plurality of stationary units 22, a single stationary unit 22 with a plurality of docks 28 (or only a single dock or interface 28) can be employed, without departing from the scope of the present disclosure.

The post-processing stations 18 can include any suitable types of post-processing stations, such as trimming/cutting (e.g., including laser, water, or plasma cutting systems), uncoiling, flattening, shipping stations, etc., and/or other post-processing stations as will be understood by those skilled in the art. As FIG. 1E further indicates, the post-processing stations 18 can include one or more docks 38 or other communication mechanisms that are configured to interface with the autonomous vehicles 20, e.g., to facilitate further processing of the annealed sheet metal coils 12 and/or removal of the sheet metal coils 12 from the autonomous vehicles 20. In addition, or in alternative constructions, the post-processing stations 18 and their docks 38 can be configured to allow for post-processing of the sheet metal coils 12, e.g., cutting, scoring, etc. or other post processing as understood by those in the art, while the sheet metal coils 12 remain in the autonomous vehicles 20. The autonomous vehicles 20 can move the sheet metal coils 12 between various post-processing stations 18 (if a plurality of post processing stations are employed), though other movers and transporters capable of of moving the annealed sheet metal coils 12 about/between the post processing stations 18 can be used without departing from the scope of the present disclosure. In embodiments, the post-processing station(s) 18 can include a trimming or cutting station (e.g., including laser, plasma, water cutters/cutting systems or other suitable cutting systems as understood by those skilled in the art) that is configured to cut, score, etc. the annealed sheet metal coils, while the sheet metal coils remain in, or otherwise engaged with, the autonomous vehicles 20. In one example embodiment, the post-processing stations 18 can include a laser or plasma cutting table, as generally shown in FIGS. 1A-1D.

FIG. 2 shows an autonomous vehicle 220 according to one embodiment of the present disclosure. The autonomous vehicle 220 shown in FIG. 2 is configured to be received within a stationary unit 22 (such as stationary units 322, see, e.g., FIG. 3F) for annealing of one or more sheet metal coils 12 supported by the autonomous vehicle 220 within the stationary unit 22. As shown in FIG. 2, the autonomous vehicle 220 includes a coil support cradle 248 that is configured to at least partially receive and support a sheet metal coil 12. The cradle 248 includes a cradle body 250 that includes a generally curved or arcuate upper surface 250A that is complementary or otherwise contoured to correspond to the sheet metal coil 12. The sheet metal coil 12 can engage the upper surface 250A of the cradle body 250 and can be held in place under the weight of the sheet metal coil 12; though the cradle 248 can include or communicate with one or more locking mechanisms or devices (not shown) for securing or attaching the sheet metal coil 12 to the cradle 248. The autonomous vehicle 220 further can include a chassis 252 that supports the cradle 248 and sheet metal coil 12 received by the cradle 248. The chassis 252 also is connected to a propulsion mechanism 254 (e.g., wheels, tracks, etc.) of the autonomous vehicle 220 for driving the autonomous vehicle 220 about the facility 10. The chassis 252 further can include or be connected to an insulating portion 255, which as discussed in detail in relation to FIGS. 3A-3F below, is configured to engage the stationary units 322 when the autonomous vehicle 220 is docked within the stationary unit 322 to generate a seal between the autonomous vehicle 220 and the stationary unit 320, e.g., to prevent, reduce, or inhibit the loss of heat or cooling and/or air/fluids during annealing.

FIG. 4 provides a schematic illustration of an autonomous vehicle 420 according to another embodiment of the present disclosure. As shown in FIG. 4, the autonomous vehicle 420 generally includes a furnace 440 that receives sheet metal coils 12 and facilitates annealing of the received sheet metal coils 12 within the autonomous vehicle 420. The furnace 440 has a furnace chamber or compartment 444 (or a plurality of compartments) that is configured to receive and house the sheet metal coils 12. In one construction, the furnace chamber 444 (or compartments) is generally dimensioned, sized, and/or otherwise configured to receive one sheet metal coil 12; however, in alternative constructions the chamber 444 can be dimensioned, sized, and/or configured to receive more than one sheet metal coil 12, such as two, three, four, or five or more coils 12, without departing from the scope of the present disclosure. The furnace 440 also has a plurality of insulated furnace sections or portions 446 that at least partially surround and/or define the furnace chamber 444 (or various compartments of the furnace).

According to embodiments of the present disclosure, the insulated portion 255 (FIG. 2) and the insulated portions 446 (FIG. 4) can include one or more insulating materials that help to reduce, inhibit, or prevent the escape heat or cooling within the stationary unit 322 or the autonomous vehicle 420 and/or help to maintain a selected/specific temperature within the stationary unit 322 or the autonomous vehicle 420. In one construction, the insulated portions 255 and/or 246 can include a non-RFC (refractory ceramic fiber) insulating blocks. The non-RCF insulating blocks can be connected, e.g., welded or otherwise attached to the chassis 252 (FIG. 2) or to one or more furnace walls, e.g., side walls and ceiling of the furnace 440 (FIG. 4). Other insulating materials, e.g., including RCF blocks, poured or tile castable insulting materials, etc., also can be used without departing from the scope of the present disclosure. For example, an insulating poured or tile castable material or other insulating materials as will be understood in the art that can be used for support, e.g., for supporting the coils, components of the autonomous vehicles, facility personnel, etc., without additional support or precautions. In one embodiment, the insulating materials can be selected such that autonomous vehicles and stationary units can support a maximum temperature of approximately 1000° F. to approximately 1400° F.; however, higher temperatures can be supported, such as approximately 2000° F. to approximately 2300° F. or more without departing from the scope of the present disclosure.

As additionally indicated in FIG. 4, according to some embodiments, the autonomous vehicle 420 can include a coil support assembly 448, within the furnace chamber 444, that is configured to support and/or hold one or more sheet metal coils 12. The coil support assembly 448 (identified in FIG. 4, solely by way of example, as a cradle) can include one or more locking mechanisms, supports, etc., that are configured to be connected to one or more coils 12 and to hold the coils 12 within the furnace chamber 444 such that the coils 12 are not displaced, shifted, etc. when/as the autonomous vehicle 420 is moved about the facility 10. Generally, the coil support assembly 448 can be configured to support and hold up to two sheet metal coils 12 at a time, though the coil support assembly 448 can be configured to support other amounts of sheet metal coils 12, such as only one and/or three, four, or five or more, without departing from the scope of the present disclosure.

As further indicated in FIG. 4, the autonomous vehicle 420 can include an external dock 426 (sometimes also referred to herein as a docking interface 426 or as an external docking interface 426) that is configured to interface, and to thus communicate, with the docks 24, 428, and 38 of the rolling mill 14, stationary units 22 (e.g., stationary units 422), and/or the post processing stations 18 to facilitate docking of the autonomous vehicle 420. The external dock 426 can include one or more attachment or connection mechanisms that facilitate attachment or connection of the dock 426 with the various docks, 24, 428, and 38, and further can include one or more sealing features or other sealing components that facilitate the generation of a substantially fluid tight or air tight seal with an external dock 428 of the stationary units 22, e.g., to substantially reduce, prevent, or inhibit the escape of fluids, e.g., air, from the vehicle's furnace chamber 444 and/or the stationary units 22. The docking interface 426 further can include an inlet 450, e.g., made up of one or more vents, fluid passages, etc., that is in communication with the furnace chamber 444 to allow for the receipt of fluid, e.g., heated or cooled air, from the stationary units 22 during the annealing process.

Additionally, the docking interface 426 can include one or more gates or other movable portions that are configured to close off or at least partially obstruct the inlet 450 to reduce, prevent, or otherwise inhibit the introduction of unwanted particulates or other contaminates into the furnace chamber 444, e.g., during driving movement of the autonomous vehicle 420. It further will be understood that though FIGS. 1E and 4 show that the autonomous vehicle 420 can including a single docking interface 426 that is configured to interface with each of the docks 24, 428, and 38 of the rolling mill 14, stationary unit 22, and post processing station 18, respectively, the autonomous vehicle 420 can include a plurality of docks each specifically designed to interface with one or more of the docks 24, 428, and 38, without departing from the scope of the present disclosure. As FIG. 4 additionally indicates, the autonomous vehicle 420 also can include a chassis 452 that is configured to support the furnace 440. The chassis 452 can be connected to one or more propulsion mechanisms 454 that drive movement of the autonomous vehicles 420 about the facility 10.

The autonomous vehicles 220 (FIGS. 2) and 420 (FIG. 4) further can be configured to charge or recharge while docked with the stationary units 22. For example, the dock 28 can include one or more power or charging mechanisms that facilitate charging or other power consumption by the autonomous vehicles 220 or 420 when docked with the stationary units 22. That is, the autonomous vehicles 20 (e.g., power source 60 discussed below) can be charged when the autonomous vehicles 20 dock with the stationary units 22 during the annealing process (which can take up to 24 hours to complete). Furthermore, the autonomous vehicles 20 also can be charged while waiting for the coils, e.g., at the rolling mill 14, post processing stations 18, etc.

According to embodiments of the present disclosure, the propulsion mechanisms 254 and 454 can include a plurality of wheels 256 and 456 (e.g., connected to the chassis 252/452 by one or more axles, bearings, ball joints, etc.); however, in alternative constructions, the propulsion mechanism(s) 254/454 can include continuous track assemblies or other suitable propulsion mechanisms or systems without departing from the scope of the present disclosure. The autonomous vehicles 220 and 420 further can include a drive mechanism or system 58 including one or more electric motors or other suitable drive mechanism, e.g., engines, for driving/powering the propulsion mechanisms 254/454 (FIG. 4). The autonomous vehicles 220/420 also generally includes a power source 60, such as one or more batteries or other suitable portable power source or power storage, for powering the drive system 58 and/or other components of the autonomous vehicles (FIG. 4).

The autonomous vehicles 220 and 420 additionally can include a control system 62 including one or more controllers, processors, etc. for controlling the operations and functions of the autonomous vehicles 220 and 420 (FIG. 4). The control system 62 further can include one or more memories (e.g., RAM, ROM, and other non-volatile memories) for storing instructions, workflows, programs, etc. that can be accessed and executed by the one or more controllers/processors to facilitate operation of the autonomous vehicles 220 and 420. In addition, or in alternative constructions, the control system 62 can include one or more transmitters/receivers that enable the communication of control signals to and from the autonomous vehicles 220/420 to facilitate the control of the operations and functions thereof. The control system 62 also can include or communicate with one or more sensors, e.g., a safety sensors and/or camera systems (such as, motion stop sensors, kick stops, Safety Laser scanners, etc.), and/or a AGV collision avoidance system to facilitate moving or directing the autonomous vehicles 220/420 about the facility 10.

FIGS. 3A-3F and 4 additionally show example stationary units 322 and 422 according to embodiments of the present disclosure. As FIGS. 3A-3F and 4 indicate, the stationary units 322 and 422 include a housing or casing 364 and 464 having a plurality of sections or portions 366 and 466 that at least partially surround and/or define one or more chambers or compartments 368 and 468 that receive the autonomous vehicles 220 (FIGS. 3A-3F) and/or various components of the stationary unit 322/422 (FIGS. 3A-3F and 4). The plurality of sections 366 and 466 can include or be connected to an insulated material to help to maintain a selected temperature within the housing 364/464, e.g., to prevent, reduce, or inhibit the dissipation, or the increase of, heat therein or otherwise control or maintain a temperature within the stationary units 322/422.

In one example construction, as shown in FIGS. 3A-3F, the sections 366 (or 466) can include an outer layer 366A of metallic material, such as steel or other suitable metal. In addition, the sections 366 (or 466) can include an inner layer 366B of insulating material, such as non-RCF insulating blocks connected, e.g., welded or otherwise attached, to the metallic layer 366A (FIGS. 3D and 3F); though other insulating blocks or materials, e.g., including RCF blocks, poured or tile castable insulting materials, etc., also can be used without departing from the scope of the present disclosure.

In some embodiments, the insulating materials can be selected such that the stationary units 322 (or 422) can support a maximum temperature of approximately 1000° F. to approximately 1400° F.; however, the stationary units 322 (or 422) can support higher temperatures, such as approximately 2000° F. to approximately 2300° F. or more. As further shown in FIGS. 3A-3F, the sections 366 (or 466) can include a plurality of vertical and longitudinal supports 377 (e.g., including metal, such as steel, beams, channels, etc.) connected to and reinforcing the outer metallic layer 366A. The stationary units 322 (or 422) further can include a frame 372 made up of a plurality of columns or supports 374 that support the housing 364 (or 464) on a floor 376 (FIG. 3F) of the facility 10 and raises the housing 364 (or 464) to a prescribed height above the floor 376 (e.g., to correspond to a height of the autonomous vehicles 220), as generally indicated in FIGS. 3A-3D and 3F.

The stationary unit 322 shown in FIGS. 3A-3F defines a furnace 300 that is configured to receive one or more of the autonomous vehicles 222 to facilitate annealing of sheet metal coils 12 carried by the autonomous vehicles 320 within the stationary unit 322. In particular, the dock 28 of the stationary units 322 can include an opening or port 382 that allows for receipt of one or more autonomous vehicles 320 into the chamber 368 (which is a furnace chamber) of the stationary unit 322 (FIG. 3F). FIG. 3F shows that the furnace chamber 368 generally is sized or dimensioned to receive/house one autonomous vehicle 220 at a time; however, the furnace chamber 368 can be sized to receive more than one autonomous vehicle 220, such as two, three, four, or more autonomous vehicles 220 at a time, to increase the number of sheet metal coils 12 that can be annealed simultaneously.

As further shown in FIG. 3F, stationary units 322 include a bottom portion 383 of the plurality of portions 366 of the housing 364. The bottom portion 383 has an opening or slot 384 that is configured to at least partially receive one or more autonomous vehicles 220. The opening 384 in the bottom portion 383 is sized, dimensioned, or configured such that the one or more autonomous vehicles 220 are engaged against the bottom portion 383, when the one or more autonomous vehicles 220 are docked within the stationary unit 322. That is, for docking of an autonomous vehicle(s) 220 with the stationary unit 322, the autonomous vehicle 220 can be moved into the furnace chamber 368 through the port 382, such that the insulated portion 255 of the autonomous vehicles 220 at least partially engages or contacts the bottom portion 383 of the housing 364. For example, the insulated portion 255 of the autonomous vehicle 220 can at least partially seal the opening 384, e.g., to prevent, reduce, or inhibit the escape or release of heat or cooling during annealing or to otherwise control or maintain a temperature within the furnace chamber 368. As also indicated in FIG. 3F, the insulating layer 366B extends into the opening 384, and the insulating layer 366B at least partially contacts or engages the insulated portion 255 of the autonomous vehicle(s) 220, when the autonomous vehicle 220 is docked with the stationary unit 322, e.g., to facilitate sealing of the chamber 368.

FIGS. 3A-3F further indicate that the stationary units 322 include a door or gate 390 configured to close off or seal the port 382 during annealing. The gate 390 can be moveable between an open position that allows autonomous vehicles 220 to enter or otherwise be received within the chamber 368, and a closed position that substantially seals the chamber 368 during annealing, e.g., to prevent, inhibit, or reduce or release of heat or cooling during annealing. The stationary units 322 further can include one or more drive mechanisms 392 (e.g., a hydraulic or pneumatic cylinder or other suitable drive mechanism, such as a motor, engine, etc.) for driving movement of the gate 390 between its open and closed positions. The drive mechanism 392 can be connected to the gate 390 by a linkage assembly 394, e.g., including one or more linkages, such as chains, wires, etc., that allow for driving of the gate 390 by the drive mechanism 392. The stationary units 322 further can include a riser support assembly 396, e.g., with one or more bodies, supports, etc., and the drive mechanism 392 can be positioned on, e.g., along a top portion 396A of, the riser support assembly 396. In this regard, the drive mechanism 392 can raise the gate 390 above the port 382 to the open position and lower the gate 390 to close or seal off the port 382 in the closed position. The gate 390 can be engaged by tracks 397 provided on opposing sides of the port 382 to guide movement of the gate 390 between its open and closed positions (FIG. 3A). Furthermore, the insulated layer 366B can extend into the port 382 and can at least partially contact or engage the gate 390 in the closed position, e.g., to insulate and/or seal the chamber 368 against the release or escape of heat or cooling during annealing.

A feature of the stationary unit dock 28, according to some embodiments of the stationary unit 322 that utilizes the internal furnace chamber 368 of the stationary unit, is that selected annealing facilitators, and related vents, passages, ducts, conduits, etc. that allow for fluid flow into the stationary unit furnace chamber 368, are within or in communication (for example, without limitation, fluid communication) with the furnace chamber and, thus in communication with the coil support of the autonomous vehicle and any coil supported thereon, while the autonomous vehicle 20 is docked within the furnace chamber 368 of the stationary unit 322.

In the embodiment shown in FIG. 4, the dock 28 of the stationary units 422 include an external dock 428 that is configured to interface to and to, thus, communicate with the external docking interface 426 of the autonomous vehicles 420 to enable docking of the autonomous vehicles 420 with the stationary unit 422. The external dock 428 of the stationary unit 422 can include one or more vents, passages, etc., that allow for the passing of fluid flow, e.g., air flow, between one or more docked autonomous vehicles 420 (e.g., to the furnace chamber 444 of the autonomous vehicles 420) and the stationary unit 422, and further can include one or more connection mechanisms and/or sealing features that are configured to interact with corresponding connections mechanisms and sealing features of the autonomous vehicle dock 426, e.g., to facilitate connection of the stationary unit dock 428 and the dock 426 and/or the generation of a substantially fluid tight or air tight seal therewith, e.g., to substantially reduce, prevent, or inhibit the escape of fluids, e.g., air, from the furnace chamber 444 and/or housing 464 of the stationary unit 422. The dock 428 can have a power source to provide power to the autonomous vehicles 420 when the autonomous vehicles 420 are docked with the stationary units 422. FIG. 4 further shows that the stationary unit 422 also can have a flow path or flow passage 470 (or a plurality of flow paths or passages) defined through the housing 464 that allows for the passage of fluid flow, e.g., air flow, at least partially through the stationary unit 422. The flow path or paths 470 can include one or more ducts, conduits, etc. and/or other suitable airflow passages.

As further shown in FIGS. 3A, 3C-3F, and 4, the stationary units 322/422 further can have an air mover 30, such as an air fan, blower, pneumatic air mover, etc. In the embodiment shown in FIGS. 3A and 3C-3F, the air mover 30 is positioned within the furnace chamber 368 of the stationary unit 322 and can be connected to a top or upper portion 398 of the plurality of portions 366. In the embodiment shown in FIG. 4, the air mover 30 is positioned within the stationary units 422 along and/or otherwise in communication with the flow path 470. The air mover 30 is configured to pull air into and/or through the housing 364/464 to direct air to the furnace chamber 368 of the stationary unit 322 or the furnace chamber 444 of one or more docked autonomous vehicles 420. The stationary units 322/422 further can have one or more intakes or exhausts 74, e.g., including one or more vents and/or other suitable openings, defined within/along at least one wall 366/466 of the housing 364/464 and configured to allow ambient air, or air external to the stationary units 322/422, to be pulled into (and through) the housing 364/464 by the air mover 30 or to allow air in the stationary units 322/422 to be released. The stationary unit 422 further can have one or more outlets 476 that are in communication with, or a part of, the external dock 428 of the stationary unit 422 to allow the fluid/air pulled through the housing 464 to be directed and/or provided to the autonomous vehicle 420, i.e., to the furnace chamber 444 of the autonomous vehicle 420. As such, fluid, e.g., heated or cooled air, can be provided to the furnace chamber 368 of the stationary units 322, or from the stationary units 422 to the furnace chambers 444 of the autonomous vehicles 420 for annealing of the one or more coils supported by the autonomous vehicles 220/420 when the autonomous vehicles 220/420 are docked with the stationary units 322/422.

As also indicated in FIGS. 3A, 3C, 3F and 4, the stationary units 322/422 have a heat source or heating system 32 configured to generate heat, e.g., heating the fluid (e.g., air) moving into the stationary units 322/422 to facilitate heating during annealing of the one or more coils 12 on (or within) the autonomous vehicles 220 (or 420). The heat source 32 can include a gas fired burner or burners. The burner(s) can indirect fired burners, e.g., including a burner or radiant tube(s), though the burner(s) also can include direct fired, i.e., open flame, burners, or other suitable burners as will be understood by those skilled in the art. The gas can include natural gas, propane gas, etc. However, other heat sources or heaters, such as other heated coils or electric heaters or heating elements, as will be understood by those skilled in the art can be used without departing from the scope of the present disclosure. In the embodiment shown in FIGS. 3A, 3C-3D, and 3F, the heat source 32 can include a plurality of heat sources 32 connected to the top portion 398 of the stationary unit housing 364. In the embodiment shown in FIG. 4, the heat source 32 can be positioned along or otherwise in communication with the flow path 470 (or the dedicated/specific flow path) such that air moved along the flow path 470 by the air mover 30 can be heated to a selected or prescribed temperature before it is directed to the furnace chamber 444 of the autonomous vehicles 420. In constructions with a plurality of flow paths, the heat source 32 can be provided along or otherwise be in communication with a specific flow path of the plurality of flow paths that is dedicated or otherwise corresponds to the heat source 32.

FIGS. 3D, 3F, and 4 further show that the stationary units 322/422 further include a cooling source or cooling system 34 generally configured facilitate cooling during annealing of the one or more coils 12 in the autonomous vehicles 220/420. In the embodiment shown in FIGS. 3D and 3F, the cooling source 34 is provided within the furnace chamber 368, e.g., to cool air or fluid provided to the furnace chamber 368 by the air mover 30. In one example construction, the cooling source 34 can be integrated with the air mover 30. In the embodiment shown in FIG. 4, the cooling source can be provided along the flow path 470, e.g., to cool air or fluid moving along the flow path 470 by the air mover 30. In the construction having a plurality of flow paths, the cooling source 34 can be provided along or otherwise be in communication with a specific flow path of the plurality of flow paths that is dedicated or otherwise corresponds to the cooling source 34. The cooling source 34 can include one or more coils or a network of coils 34A that are positioned about or otherwise integrated with the air mover 30 that receive a cooling fluid such that air moved by the air mover 30 is cooled to a selected or prescribed temperature and directed into the furnace chamber 368 of the stationary unit 322 (FIGS. 3D and 3F) or the furnace chamber 444 of the autonomous vehicle 420 (FIG. 4).

Still further, the stationary units 322/422 include a nitrogen source 36 for introducing nitrogen into the autonomous vehicles 420 and/or stationary units 322. The nitrogen source 36 can include one or more injectors, nozzles, or other suitable mechanisms that are configured to direct a nitrogen fluid, e.g., nitrogen gas, into the furnace chamber 368 of the stationary units 322 or the furnace chamber 444 of the autonomous vehicles 420 during, before, and/or after annealing of the one or more coils 12, e.g., to help to substantially reduce, inhibit, or prevent oxidization of/on the one or more coils 12 during (or after) annealing. In one example construction, the nitrogen source 36 can be positioned substantially near, adjacent, etc., the air mover 30 to disperse or mix nitrogen into the furnace chamber 368 of the stationary units 322 or the furnace chamber 444 of the autonomous vehicles 420; however, the nitrogen source 36 can be otherwise positioned or configured to directly or indirectly disperse or mix nitrogen into the autonomous vehicles and/or the stationary units.

Accordingly, in operation, the air mover 30 can be activated to direct air to the furnace chamber 368 of the stationary unit 322 or the furnace chamber 444 of the autonomous vehicles 420 (e.g., upon a determination that an autonomous vehicle 220/420 is properly docked or connected to the stationary unit 322/422). The heat source 32 also can be activated to heat the furnace chamber 368 or 444 to a selected/prescribed temperature. In one embodiment, the prescribe temperature can be up to about 1000° F.; though in other additional or alternative embodiments, higher temperatures can be employed, such as 2000° F. or more. The autonomous vehicles 220/420 and/or stationary units 322/422 can include one or more sensors configured to capture information related to the temperature of the air in the furnace chamber 368 or 444.

When the temperature of the air directed to or within the furnace chamber 368 or 444 reaches the selected/prescribed heated temperature (e.g., as determined based on information captured by the one or more sensors), the selected/prescribed heated temperature can be held/maintained in the furnace chamber 368 or 444 for a set time period. Thereafter, e.g., upon expiration of the set time period, the heating source 32 can be deactivated and the cooling source 34 can be activated to cool the air directed to the furnace chamber 368 or 444 by the air mover 30. For example, cooled air can be directed to the furnace chamber 368 or 444 until the temperature of the air directed to or within the furnace chamber 368 or 444 reaches a selected or prescribed cooled temperature (e.g., as determined based on information captured by the one or more sensors). The cooled air can be provided for a prescribed time period and/or to cool the one or more coils 12 at a particular rate. The nitrogen source 36 can be activated before, during, and/or after the heating and cooling of the one or more coils 12, e.g., to prevent, reduce, or inhibit oxidization.

The stationary units 322/422 further can include a control system 80 (FIG. 4) including one or more controllers, processors, etc. for controlling the operations and functions of the stationary unit 322/422 (and/or the autonomous vehicles 220/420). The control system 80 can include one or more memories (e.g., RAM, ROM, and other non-volatile memories) for storing instructions, workflows, programs, etc. that can be accessed and executed by the one or more controllers/processors to facilitate operation of the stationary units 322/422 (and/or the autonomous vehicles 220/420). In addition, or in alternative constructions, the control system 80 can include one or more transmitters/receivers that enable the communication of control signals to and from the stationary unit 322/422 to facilitate the control of the operations and functions of the stationary unit 322/422.

The annealing system 16 (or the facility 10) also can include one or more additional controllers or control systems 100 for controlling the functions, operations, etc. of the autonomous vehicles 220/420, stationary units 322/422, etc. (FIG. 1E). The control system 100 can include one or more processors, computing devices, etc. and one or more memories (e.g., RAM, ROM, and other non-volatile memories) for storing instructions, workflows, programs, etc. that can be accessed and executed by the one or more controllers/processors to facilitate operation of the annealing system 16 (or other systems, stations, etc. at the facility 10). The control system 100 also can include one or more transmitters/receivers that enable the communication of control signals to and from the stationary units 322/422 and/or the autonomous vehicles 220/420 to facilitate the control of the operations and functions of the stationary units 322/422 or autonomous vehicles 220/420. The control system 100 can communicate with the control systems 62 and 80 of the autonomous vehicles and stationary units via a network 102. The control systems 100, 62, and 80 can be separate control systems that communicate to control the various operations of the autonomous vehicles 220/420, stationary units 322/422, and/or components of the pre-processing station(s) 13, rolling mill 14, and post processing station(s) 18 or the control systems 100, 62, and 80 can be part of the same control system. Components of the control systems can be provided throughout the facility 10; though the components of the control systems can be housed entirely within the autonomous vehicles 220/420 and/or the stationary units 322/422.

A process for operation of the facility according to one embodiment of the present disclosure is described below. For example, e.g., when it is determined that one or more sheet metal coils are ready to be received from the rolling mill 14, one or more of the autonomous vehicles 20 can be directed to and docked with one or more docks 24 of the rolling mill 14 for receipt of one or more sheet metal coils. The sheet metal coils can be positioned on or within the autonomous vehicles 20 such that the sheet metal coils 12 are supported by the coil support 248/448. Further, one or more locking mechanisms of the coil support 248/448 can be activated or engaged to secure the received sheet metal coils 12.

Thereafter, the autonomous vehicle(s) 20 with the one or more sheet metal coil(s) 12 can be directed and moved to a stationary unit 22, e.g., upon a determination that a stationary unit 22 or a dock of a stationary unit 28 is available for docking with an autonomous vehicle 20. The autonomous vehicle(s) 20 can be interfaced with the dock 28 of the open/available stationary unit 22 (e.g., by receiving the autonomous vehicle within the stationary unit 22 or externally docking with the stationary unit 22).

After the autonomous vehicle 20 is docked, the annealing process can be initiated. For example, as discussed, the one or more sheet metal coils can be heated to a prescribed temperature by heating the stationary unit 22 or the autonomous vehicle 20 (e.g., using the heat source 32 and air mover 30 of the stationary unit 22). The prescribed temperature within the stationary unit 22 or autonomous vehicle 20 can be held or maintained for a set time period. Then, after this set time period has passed, the one or more sheet metal coils 12 can be cooled to a prescribed temperature or at a particular rate by directing cooled air to the stationary unit 22 or the autonomous vehicle 20 (e.g., using the cooling source 34 and air mover 30 of the stationary unit 22).

Thereafter, e.g., upon completion of the annealing process, the autonomous vehicle 20 can be released from the stationary units 22 (e.g., the autonomous vehicle 20 can be moved out of the stationary unit 22 or the external dock can be disconnected or disengaged), and directed, with the annealed coil(s) 12 therein, to the one or more post processing stations 18.

The autonomous vehicles 20 can be docked with the post-processing station(s) 18 (e.g., the dock 426 can be connected to or engaged with the dock 38). At the post-processing stations 18, the annealed coil(s) 12 can be unloaded for further processing thereof (e.g., cutting, shipping, etc.); however, the autonomous vehicles 20 can be configured to allow for further processing of (e.g., cutting) the annealed coil(s) 12 on or within the autonomous vehicles 20.

The foregoing description generally illustrates and describes various embodiments of the present invention. It will, however, be understood by those skilled in the art that various changes and modifications can be made to the above-discussed construction of the present invention without departing from the spirit and scope of the invention as disclosed herein, and that it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as being illustrative, and not to be taken in a limiting sense. Furthermore, the scope of the present disclosure shall be construed to cover various modifications, combinations, additions, alterations, etc., above and to the above-described embodiments, which shall be considered to be within the scope of the present invention. Accordingly, various features and characteristics of the present invention as discussed herein may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the invention, and numerous variations, modifications, and additions further can be made thereto without departing from the spirit and scope of the present invention as set forth in the appended claims.

Claims

1. A facility for processing sheet metal coils, comprising:

a rolling mill configured to generate one or more sheet metal coils;

an annealing system for annealing of the one or more sheet metal coils, including: an autonomous vehicle that is configured to receive the one or more sheet metal coils from the rolling mill and to move the one or more coils about the facility, the autonomous vehicle including a coil support that receives and supports the one or more sheet metal coils on or within the autonomous vehicle; and at least one stationary unit configured to dock with the autonomous vehicle to facilitate annealing of the one or more sheet metal coils on the autonomous vehicle; and

one or more post processing stations, the autonomous vehicle moving the one or more sheet metal coils to the one or more post processing stations after annealing.

2. The facility of claim 1,

wherein the at least one stationary unit comprises a stationary unit furnace chamber, the stationary unit furnace chamber being sized to receive within the stationary unit furnace chamber at least a portion of the autonomous vehicle that contains the coil support, and

wherein the at least one stationary unit is configured to dock with the autonomous vehicle to facilitate annealing of the one or more sheet metal coils within the stationary unit furnace chamber while the one or more sheet metal coils remain on the autonomous vehicle.

3. The facility of claim 2,

wherein the at least one stationary unit further comprises one or more annealing facilitators selected from the group consisting of an air mover, a heat source, a cooling source, and a nitrogen source, and

wherein the at least one stationary unit is configured to place the one or more annealing facilitators in communication with the stationary unit furnace chamber during annealing of the one or more sheet metal coils within the stationary unit furnace chamber.

4. The facility of claim 1,

wherein the autonomous vehicle comprises an autonomous vehicle furnace chamber, in which the coil support is located; and

wherein the at least one stationary unit is configured to dock with the autonomous vehicle to facilitate annealing of the one or more sheet metal coils within the autonomous vehicle furnace chamber.

5. The facility of claim 4,

wherein the at least one stationary unit comprises one or more annealing facilitators selected from the group consisting of an air mover, a heat source, a cooling source, and a nitrogen source, and

wherein the at least one stationary unit and the autonomous vehicle are cooperatively configured to place the one or more annealing facilitators in communication with the autonomous vehicle furnace chamber during annealing of the one or more sheet metal coils within the autonomous vehicle furnace chamber.

6. A facility for processing sheet metal coils, comprising:

an annealing system for annealing of one or more sheet metal coils, comprising: an autonomous vehicle movable about the facility, the autonomous vehicle including a coil support; and at least one stationary unit including one or more annealing facilitators selected from the group consisting of an air mover, a heat source, a cooling source, and a nitrogen source, and including a stationary unit dock; the autonomous vehicle being selectively and releasably dockable to the stationary unit dock, thereby defining a docked condition and an undocked condition; wherein the one or more annealing facilitators of the at least one stationary unit are placed in communication with the coil support of the autonomous vehicle when the autonomous vehicle is the docked condition, such that annealing of a coil on the autonomous vehicle is facilitated when the autonomous vehicle is in the docked condition and while the coil remains on the coil support.

7. The facility of claim 6, wherein the one or more annealing facilitators include three or more facilitators selected from the group consisting of an air mover, a heat source, a cooling source, and a hydrogen source.

8. The facility of claim 6,

wherein the at least one stationary unit comprises a stationary unit furnace chamber in communication with the one or more annealing facilitators, the stationary unit furnace chamber being sized to receive within the stationary unit furnace chamber at least a portion of the autonomous vehicle that contains the coil support;

wherein the stationary unit dock includes an entry port to the stationary unit furnace chamber, the entry port being sized to accept through the entry port and into the stationary unit furnace chamber at least a portion of the autonomous vehicle that contains the coil support; and

wherein the one or more annealing facilitators are placed in communication with the stationary unit furnace chamber and thus with the coil support of the autonomous vehicle when the coil support is in a docked condition in the stationary unit furnace chamber.

9. The facility of claim 6,

wherein the autonomous vehicle comprises an autonomous vehicle furnace chamber, in which the coil support is located, and an autonomous vehicle dock including an inlet port in communication with the autonomous vehicle furnace chamber configured to interface with the stationary unit dock;

wherein the stationary unit dock comprises an outlet port in communication with the one or more annealing facilitators, the outlet port of the stationary unit dock and the inlet port of the autonomous vehicle dock being configured to interconnect and pass fluid flow from the outlet port to the inlet port when the autonomous vehicle is in the docked condition; and

wherein the one or more annealing facilitators of the at least one stationary unit are placed in communication with the autonomous vehicle furnace chamber and with the coil support therein when the autonomous vehicle is the docked condition, such that annealing of a coil on the autonomous vehicle is facilitated when the autonomous vehicle is in the docked condition and while the coil remains on the coil support.

10. The facility of claim 6,

wherein the autonomous vehicle is a first autonomous vehicle and the facility comprises a plurality of autonomous vehicles independently movable about the facility, each including a coil support, and

wherein the at least one stationary unit comprises a plurality of stationary units,

each stationary unit of the plurality of stationary units including one or more annealing facilitators selected from the group consisting of an air mover, a heat source, a cooling source, and a nitrogen source, and

each stationary unit of the plurality of stationary units including one or more stationary unit docks,

each autonomous vehicle of the plurality of autonomous vehicles being selectively and releasably dockable to each stationary unit dock of each stationary unit of the plurality of stationary units, and

wherein the one or more annealing facilitators of each respective stationary unit are placed in communication with the coil support of each autonomous vehicle when the respective autonomous vehicle is in the docked condition, such that annealing of a coil on the autonomous vehicle is facilitated when the autonomous vehicle is in the docked condition and while the coil remains on the coil support.

11. The facility of claim 6, further comprising a controller configured to control functions and operations of the autonomous vehicle and the at least one stationary unit, including identification of stationary units available for docking, movement of autonomous vehicles about the facility, and operation of docking communications.

12. The facility of claim 6, wherein:

the autonomous vehicle comprises an autonomous vehicle dock through which the autonomous vehicle communicates with external systems; and

the facility further comprises a rolling mill configured to generate one or more sheet metal coils, the rolling mill including a rolling mill dock configured to communicate with the autonomous vehicle dock to facilitate delivery of one or more sheet metal coils to the autonomous vehicle; and one or more post processing stations, each post processing station including a station dock configured to communicate with the autonomous vehicle dock to facilitate post processing of coils annealed while on the autonomous vehicle.

13. A method for operating a facility for processing sheet metal coils, the method comprising:

receiving one or more sheet metal coils on an autonomous vehicle;

moving the autonomous vehicle about a facility to a stationary unit within the facility;

docking the autonomous vehicle with the stationary unit, while the one or more sheet metal coils remain on the autonomous vehicle; and

annealing the one or more sheet metal coils while the one or more sheet metal coils are still on the autonomous vehicle,

wherein the stationary unit provides during annealing, one or more of air flow, heated air flow, cooled air flow, and nitrogen introduction.

14. The method of claim 13, wherein moving the autonomous vehicle comprises:

identifying via a control system the stationary unit as an available stationary unit, from among a plurality of stationary units within the facility, that is available for docking; and

directing via the control system a coil laden autonomous vehicle to the identified, available stationary unit.

15. The method of claim 13, wherein moving the autonomous vehicle comprises:

identifying via a control system an available stationary unit dock of an available stationary unit, from among a plurality of stationary units within the facility, that is available for docking; and

directing via the control system a coil laden autonomous vehicle to the identified, available stationary unit dock.

16. The method of claim 13, wherein moving the autonomous vehicle comprises:

identifying via a control system a stationary unit dock, from among a plurality of docks of a single stationary unit within the facility, that is available for docking; and

directing via the control system a coil laden autonomous vehicle to the identified, available stationary unit dock.

17. The method of claim 13, further comprising generating one or more sheet metal coils at a rolling mill; and wherein the receiving one or more sheet metal coils on an autonomous vehicle includes receiving the sheet metal coils on the autonomous vehicle while at the rolling mill.

18. The method of claim 13, further comprising moving the one or more sheet metal coils to one or more post processing stations after annealing and while still on the autonomous vehicle.

19. The method of claim 13,

wherein docking the autonomous vehicle with the stationary unit comprises placing the one or more sheet metal coils into a furnace chamber defined within the stationary unit, while the one or more sheet metal coils remain on the autonomous vehicle; and

wherein annealing the one or more sheet metal coils further comprises providing one or more of air flow, heated air flow, cooled air flow, and nitrogen introduction to the furnace chamber of the stationary unit, while the one or more sheet metal coils are simultaneously on the autonomous vehicle and in the furnace chamber.

20. The method of claim 13,

wherein receiving one or more sheet metal coils on an autonomous vehicle comprises receiving the one or more sheet metal coils into a furnace chamber defined on the autonomous vehicle; and

wherein annealing the one or more sheet metal coils further comprises providing one or more of air flow, heated air flow, cooled air flow, and nitrogen introduction from the stationary unit to the furnace chamber of the autonomous vehicle, while the one or more sheet metal coils remain on the autonomous vehicle.

21. The method of claim 13,

wherein docking the autonomous vehicle with the stationary unit comprises a docking step selected from the group consisting of (i) the autonomous vehicle being received within a chamber of the stationary unit and (ii) an external dock of the autonomous vehicle communicating with an external dock of the stationary unit, and

wherein annealing the sheet metal coils while the sheet metal coils are still on the autonomous vehicle comprises heating the sheet metal coils to a prescribed temperature, holding heating of the sheet metal coils at the prescribed temperature for a set period of time, and then cooling the sheet metal coils.