A bucket sampler and method of manufacture

Abstract

A bucket-type sampler and its manufacturing method are disclosed, comprising a bucket rod, a connecting paper tube, a connecting rod, a sealing cap, a quartz glass inner liner, and a casting cup. The quartz glass inner liner is disposed inside the casting cup, with its upper end extending beyond the top of the casting cup. The sealing cap is U-shaped with its opening facing downwards, covering the quartz glass inner liner. The lower end of the sealing cap presses against the upper end of the casting cup, and a sealing refractory mortar is applied between the outer periphery of the sealing cap and the upper end of the casting cup to form a sealing structure. The connecting rod is vertically arranged, with its lower end connected to the outer periphery of the casting cup and its upper end inserted into the lower end of the connecting paper tube to form a connecting structure. The bucket rod is a multi-segmented, zigzag rod structure, with its lower end inserted into the upper end of the connecting paper tube to form a connecting structure. This invention provides good sampling results, has a simple equipment structure, and, when used with a fully automatic analysis and testing device, solves the problem of obtaining a large number of internal control standard samples required for continuous and rapid steelmaking production and steel grade research.

Description

Technical Field

[0001] This invention relates to the field of sampling equipment, and more particularly to a bucket-type sampler and its manufacturing method. Background Technology

[0002] Existing liquid metal samplers are made of materials such as sand molds, ceramics, metal molds, glass pipettes, or a combination of these materials to form a mold chamber (i.e., a sample cup). The sampler is immersed in molten metal to extract a small conical casting (with varying geometric dimensions), which is then solidified to prepare a sample for liquid metal chemical composition analysis.

[0003] The earliest steel bucket-type sampler used was a cylindrical sample spoon with a handle 2.5 meters long. It was used by a person to directly insert the sample into the ladle to extract the molten steel into a conical casting. After cooling, it was used as a sample for composition analysis. The advantage was that it was relatively direct and accurate. The disadvantages were that the upper end had burrs that needed to be ground before the sample could be pneumatically delivered; the conical shape made it difficult to demold, and it could not be matched with a fully automated robotic inspection line.

[0004] While existing samplers are widely used in various processes of steelmaking, the sampling operation inevitably involves passing through the slag layer on top of the molten steel and the decomposition of the sampler material itself in the molten state, which inevitably leads to sample contamination. For example, when dealing with ultra-low carbon (below 0.002%) steel, the samples generally have increased carbon, nitrogen, and sulfur content. In addition, due to unreasonable structure, the samples may have defects such as porosity, shrinkage cavities, shrinkage porosity, inclusions, and cracks, resulting in defects such as segregation of chemical composition and metallographic structure. At the same time, the accuracy of sampling is also affected by accidental factors such as temperature changes and inconsistencies in the insertion depth, angle, time interval, and point position of the sampler. Summary of the Invention

[0005] (I) Purpose of the Invention

[0006] To address the technical problems existing in the background art, this invention proposes a bucket-type sampler and its manufacturing method, which has good sampling effect, simple equipment structure, and is used in conjunction with a fully automatic analysis and testing device, thus solving the problem of obtaining a large number of internal control standard samples required for continuous and rapid steelmaking production and steel grade research and development.

[0007] (II) Technical Solution

[0008] To address the aforementioned problems, this invention provides a bucket-type sampler and its manufacturing method, comprising a bucket rod, a connecting paper tube, a connecting rod, a sealing cap, a quartz glass inner liner, and a casting cup;

[0009] The quartz glass inner liner is placed inside the mold cup, with its upper end extending beyond the top of the mold cup; the sealing cap is U-shaped with the opening facing downwards, and the sealing cap covers the quartz glass inner liner. The lower end of the sealing cap presses against the upper end of the mold cup, and a sealing structure is formed between the outer periphery of the sealing cap and the upper end of the mold cup by setting sealing refractory putty.

[0010] The connecting rod is set vertically, with its lower end connected to the outer periphery of the mold cup and its upper end inserted into the lower end of the connecting paper tube to form a connecting structure;

[0011] The lifting rod is a multi-segment zigzag rod structure. The lower end of the lifting rod is inserted into the upper end of the connecting paper tube to form a connecting structure.

[0012] Preferably, the inner diameter of the quartz glass inner liner is 35mm, the outer diameter is 40mm, and the height is 73mm.

[0013] Preferably, the inner diameter of the sealing cap is 40.5 mm.

[0014] Preferably, the overall height of the molded cup is 75mm, the internal height is 65mm, the outer diameter is 55mm, and the inner diameter is 42mm.

[0015] Preferably, the length of the connecting rod is 500mm and the length of the connecting paper tube 2 is 400mm.

[0016] This invention also proposes a method for manufacturing a bucket-type sampler, comprising the following steps:

[0017] S1: Processing and manufacturing molded cups;

[0018] S2: Processing and manufacturing a quartz glass inner liner; the quartz glass inner liner is placed inside the molded cup, and the upper edge of the quartz glass inner liner is 8mm higher than the upper end of the molded cup;

[0019] S3: Process and manufacture the sealing cap, which is then attached to the cup opening of the quartz glass inner liner; sealing refractory putty is applied between the outer periphery of the sealing cap and the upper end of the molded cup to form a sealed structure;

[0020] S4: Fabricate the bucket lifting rod and connecting rod; weld the lower end of the connecting rod to the mold cup; the connecting rod does not melt within seconds in molten steel;

[0021] S5: Process and manufacture connecting paper tubes; the bucket lifting rod and connecting rod are connected through connecting paper tubes.

[0022] Preferably, the bucket-type sampler includes the following usage steps:

[0023] S1: Hold the bucket lifting lever and vertically immerse the equipment in molten steel for 5 seconds, then vertically remove it;

[0024] S2: Tap out the sample from the quartz glass liner and quickly immerse the sample in 20°C cold water for 1 minute to carry out a rapid cooling process;

[0025] S3: The sample is separated, cooled, cut and ground, and the sample preparation time is controlled within 2 minutes.

[0026] This invention provides excellent sampling results, has a simple equipment structure, and is equipped with a fully automated analysis and testing device, thus solving the problem of obtaining a large number of internal control standard samples required for continuous and rapid steelmaking production and steel grade research and development. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the bucket-type sampler and its manufacturing method proposed in this invention. Detailed Implementation

[0028] To make the objectives, technical solutions, and advantages of the present invention more clearly understood, the present invention will be further described in detail below in conjunction with specific embodiments and with reference to the accompanying drawings. It should be understood that these descriptions are merely exemplary and are not intended to limit the scope of the present invention. In addition, in the following description, descriptions of well-known structures and technologies are omitted to avoid unnecessary confusion of the concepts of the present invention.

[0029] like Figure 1 As shown, the present invention proposes a bucket-type sampler and its manufacturing method, which includes a bucket rod 1, a connecting paper tube 2, a connecting rod 3, a sealing cap 4, a quartz glass inner liner 6, and a casting cup 7;

[0030] The quartz glass inner liner 6 is set inside the mold cup 7, with its upper end extending out of the top of the mold cup 7; the sealing cap 4 is U-shaped with the opening facing downwards, and the sealing cap 4 covers the quartz glass inner liner 6. The lower end of the sealing cap 4 presses against the upper end of the mold cup 7, and a sealing structure is formed between the outer periphery of the sealing cap 4 and the upper end of the mold cup 7 by setting sealing refractory putty 5.

[0031] The connecting rod 3 is set vertically, with its lower end connected to the outer periphery of the mold cup 7, and its upper end inserted into the lower end of the connecting paper tube 2 to form a connecting structure;

[0032] The lifting rod 1 is a multi-segment zigzag rod structure. The lower end of the lifting rod 1 is inserted into the upper end of the connecting paper tube 2 to form a connecting structure.

[0033] In an optional embodiment, the quartz glass inner liner 6 has an inner diameter of 35 mm, an outer diameter of 40 mm, and a height of 73 mm.

[0034] In an optional embodiment, the inner diameter of the sealing cap 4 is 40.5 mm.

[0035] In one optional embodiment, the overall height of the molded cup 7 is 75mm, the internal height is 65mm, the outer diameter is 55mm, and the inner diameter is 42mm.

[0036] In an optional embodiment, the length of the connecting rod 3 is 500 mm, and the length of the connecting paper tube 2 is 400 mm.

[0037] In an optional embodiment, the following usage steps are included:

[0038] S1: Hold the bucket lifting rod 1 and vertically immerse the equipment in the molten steel for 5 seconds, then vertically remove it;

[0039] S2: Tap out the sample from the quartz glass inner liner 6 and quickly immerse the sample in cold water at 20°C for 1 minute to carry out a rapid cooling process;

[0040] S3: The sample is separated, cooled, cut and ground, and the sample preparation time is controlled within 2 minutes.

[0041] In this invention, the thick-walled design of the mold cup 7 is for rapid cooling and increased resistance to melting in molten steel; the upper edge of the quartz glass inner liner 6 is 8 mm higher than that of the metal mold cup, which prevents the molten steel from tilting and overflowing during extraction, ensuring a burr-free upper edge for the sample, and providing space when the sampler is lifted over the slag layer, allowing for easy removal of the 3 mm slag after cooling; the quartz glass inner liner 6 is easily demolded and peeled off, and when used in conjunction with a pneumatic sample delivery and robotic automated analysis line (the entire process takes 5 minutes), it improves steelmaking quality control and production efficiency. High production efficiency; the quartz glass inner liner 6 is cast in an open-mouth manner, allowing for direct venting and uniform casting, completely eliminating defects in chemical composition and metallographic structure caused by porosity, shrinkage cavities, inclusions, and cracks; the quartz glass has a load softening temperature of 1800℃, while the molten steel temperature is 1560-1670℃, ensuring clean and accurate sampling without the cup cracking. Furthermore, its reasonable structure avoids the carbon, nitrogen, and sulfur enrichment issues commonly found in other sampling methods, providing the most valuable specimens for accurate and uniform analysis of the chemical composition of molten steel. The connecting paper tube 2 is for single use and easy replacement.

[0042] It should be noted that this equipment provides a device for preparing samples for the entire steelmaking process (especially the precise qualitative analysis of finished products in the refining and continuous casting stages, as well as the analysis of the uniformity and accuracy of the composition in steel grade research and development), and its manufacturing and usage methods. The equipment can also be applied to the smelting and sampling of other liquid metals.

[0043] This invention also proposes a method for manufacturing a bucket-type sampler, comprising the following steps:

[0044] S1: Processing and manufacturing molded cups 7;

[0045] S2: Process and manufacture quartz glass inner liner 6; place quartz glass inner liner 6 inside the mold cup 7, and the upper edge of quartz glass inner liner 6 is 8mm higher than the upper end of the mold cup 7.

[0046] S3: Process and manufacture sealing cap 4, which is then fastened to the cup opening position on the quartz glass inner liner 6; sealing refractory putty 5 is applied between the outer periphery of sealing cap 4 and the upper end of the molded cup 7 to form a sealed structure;

[0047] S4: Process and manufacture the bucket lifting rod 1 and the connecting rod 3; weld the lower end of the connecting rod 3 to the mold cup 7; the connecting rod 3 does not melt within 5 seconds in molten steel;

[0048] S5: Process and manufacture connecting paper tube 2; bucket lifting rod 1 and connecting rod 3 are connected through connecting paper tube 2.

[0049] This invention features a small size, light weight, and simple operation, overcoming the combustion splashes and buoyancy issues associated with paper tube samplers during steel molten material sampling. The assembly process and sampling method are innovative, achieving a 100% success rate. The total time for sampling, cooling, separation, cutting, and grinding is short (2 minutes), fully demonstrating reliability and convenience, and improving production speed. The lifting rod 1 is not disposable, significantly reducing manufacturing costs. The equipment has wide applications, overcoming the limitations of ordinary sample spoons, which are designed as conical samples for easy demolding. The "metal mold + ceramic gate + paper tube wrapping" sampler of ordinary sample spoons increases carbon pollution and has poor practical performance.

[0050] It should be noted that the sample of this invention is a regular cylinder that is compatible with the fully automated inspection line of the robotic arm and does not require grinding; however, if the sample has burrs at the top, it cannot be put into the pneumatic sample delivery box, and if it is a cone, it cannot be put on the automated line.

[0051] As shown in Table 1 (Summary of data on the five main components of carbon, silicon, sulfur, aluminum, and nitrogen in two 3W2031 boilers):

[0052]

[0053] Table 1

[0054] As shown in Table 1, among the four sample types—the bucket-type cylindrical sample, the fiber-coated cone sample, the ordinary cone sample, and the ultra-low carbon disc sample—only the ultra-low carbon disc sample closely matches the data of this bucket-type sampler. Furthermore, the spectral analysis of the sample's uniformity and accuracy fully meets the requirements of the internal control standard. The fiber-coated cone sample and the ordinary cone sample exhibit severe segregation and are unsuitable for refining, continuous casting, and other finished product processes.

[0055] It should be noted that 10,000 samplers were manufactured and assembled in this equipment. They were tested on almost all smelting equipment in Taiyuan Iron & Steel Group's converters, electric furnaces, argon blowing stations, AOD furnaces, LF furnaces, RH furnaces, CD furnaces, and continuous casting plants, and received unanimous praise. They met the requirements for the preparation and processing of internal control standard samples for high-quality carbon structural steel, cold-rolled silicon steel, pure iron, stainless steel, wheel and axle steel, X80 pipeline steel, military, nuclear power, and port bridge steel. To date, 1 million samplers have been successfully used, generating an output value of 22 million yuan, which has greatly reduced the cost per ton of steel.

[0056] The sampler and manufacturing method of this invention, together with a fully automated analysis and testing device, solve the problem of obtaining a large number of internal control standard samples required for continuous and rapid steelmaking production and steel grade research and development, and the accuracy of component analysis meets national and international standards.

[0057] It should be understood that the specific embodiments described above are merely illustrative or explanatory of the principles of the invention and do not constitute a limitation thereof. Therefore, any modifications, equivalent substitutions, improvements, etc., made without departing from the spirit and scope of the invention should be included within the protection scope of the invention. Furthermore, the appended claims are intended to cover all variations and modifications falling within the scope and boundaries of the appended claims, or equivalent forms of such scope and boundaries.

Claims

1. A bucket-type sampler, characterized in that, It includes a lifting rod (1), a connecting paper tube (2), a connecting rod (3), a sealing cap (4), a quartz glass inner liner (6), and a casting cup (7); The quartz glass inner liner (6) is set inside the mold cup (7), and its upper end extends out of the top of the mold cup (7); the sealing cap (4) is U-shaped with the opening facing downwards. The sealing cap (4) covers the quartz glass inner liner (6), and the lower end of the sealing cap (4) presses against the upper end of the mold cup (7). A sealing structure is formed between the outer periphery of the sealing cap (4) and the upper end of the mold cup (7) by setting sealing refractory putty (5); The connecting rod (3) is set vertically, with its lower end connected to the outer periphery of the mold cup (7) and its upper end inserted into the lower end of the connecting paper tube (2) to form a connecting structure; The lifting rod (1) is a multi-segment zigzag rod structure. The lower end of the lifting rod (1) is inserted into the upper end of the connecting paper tube (2) to form a connecting structure. A method for manufacturing a bucket-type sampler includes the following steps: S1: Processing and manufacturing the molded cup (7); S2: Process and manufacture quartz glass inner liner (6); The quartz glass inner liner (6) is placed inside the molded cup (7), and the upper edge of the quartz glass inner liner (6) is 8mm higher than the upper end of the molded cup (7); S3: Process and manufacture a sealing cap (4), which is attached to the cup mouth of the quartz glass inner liner (6); a sealing refractory putty (5) is placed between the outer periphery of the sealing cap (4) and the upper end of the molded cup (7) to form a sealed structure; S4: Process and manufacture the bucket lifting rod (1) and the connecting rod (3); the lower end of the connecting rod (3) is welded to the mold cup (7); the connecting rod (3) does not melt within 5 seconds in molten steel; S5: Process and manufacture the connecting paper tube (2); the bucket lifting rod (1) and the connecting rod (3) are connected through the connecting paper tube (2).

2. The bucket-type sampler according to claim 1, characterized in that, The inner diameter of the quartz glass inner liner (6) is 35mm, the outer diameter is 40mm, and the height is 73mm.

3. The bucket-type sampler according to claim 1, characterized in that, The inner diameter of the sealing cap (4) is 40.5 mm.

4. The bucket-type sampler according to claim 1, characterized in that, The overall height of the molded cup (7) is 75mm, the internal height is 65mm, the outer diameter is 55mm, and the inner diameter is 42mm.

5. The bucket-type sampler according to claim 1, characterized in that, The length of the connecting rod (3) is 500mm, and the length of the connecting paper tube (2) is 400mm.

6. The bucket-type sampler according to any one of claims 1-5, characterized in that, The following usage steps are included: S1: Hold the bucket lifting rod (1), immerse the equipment vertically into the molten steel for 5 seconds, and then remove it vertically. S2: Tap out the sample from the quartz glass inner liner (6) and quickly put the sample into cold water at 20°C for 1 minute to carry out the quenching process. S3: The sample is separated, cooled, cut and ground, and the sample preparation time is controlled within 2 minutes.

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