Ductile cast iron pipeline electric furnace coil 3D modeling assisted replacement method

Abstract

This invention discloses a 3D modeling-assisted replacement method for ductile iron pipe electric furnace coils, belonging to the field of ductile iron pipe electric furnace coils. The method includes the following steps: Step 1: Drawing 3D graphics; Step 2: Establishing a 3D model; Step 3: Simulation testing. This invention solves the problem that existing steel shells have limited internal space, and many components are relatively large and heavy, making coil replacement difficult, time-consuming, labor-intensive, and prone to rework when the coil ages. This invention uses a 3D model to provide workers with a realistic demonstration, explanation of operating steps and precautions, and promotes standardized operations according to the process table and pipeline layout diagram, eliminating various errors, improving work efficiency, ensuring work quality, preventing burns from water pipes being too close to high-temperature objects, and preventing excessive bending of water pipes from affecting flow. It has high accuracy and reliability, greatly improving the efficiency of coil maintenance and replacement.

Description

Technical Field

[0001] This invention relates to the field of electric furnace coil technology for cast iron pipes, specifically a 3D modeling-assisted replacement method for electric furnace coils in ductile iron pipes. Background Technology

[0002] The intermediate frequency electric furnace is a crucial link in the blast furnace and pipe casting processes. It can raise the temperature of the low-temperature molten iron produced from the blast furnace to the high temperature required for pipe casting. Furthermore, by adding auxiliary materials to the electric furnace, it removes excessive levels of harmful elements such as sulfur, magnesium, and carbon present in the blast furnace molten iron. Due to the harsh working environment of the electric furnace, with its constant exposure to high-temperature molten iron, and the fact that the main component of the electric furnace is the furnace body (outer shell of stainless steel, inner core component of the furnace—the coil), the coil is coated with a thick layer of castable refractory material both inside and out, and is covered with numerous water-cooled cables and cooling hoses. To control the magnetic field distribution after the coil is energized, 12 magnetic yokes are evenly distributed close to the outer side of the coil. Each yoke is firmly attached to the coil by multiple push rods evenly distributed along its height. To prevent the yokes from melting under the influence of the magnetic field, each yoke is connected to external hoses that introduce cooling water, which then enters through copper pipes on the yoke for cooling. In addition, to prevent coil displacement during furnace start-up and water pouring, 12 thick, long screws inside the steel shell press the coil down through the top of the cast iron. Cooling water for all yokes and coils is distributed and circulated systematically via a water distributor. Because the required cooling water volume varies for different parts of the yoke and coil, cooling water hoses come in various diameters. No part of these hoses can be close to the heating elements of the furnace to avoid burns, nor can they be twisted or deformed in the slightest. Insufficient cooling in any part could lead to serious consequences such as coil damage, causing significant economic losses, or even furnace explosions and mass casualties. Therefore, it is necessary to replace the coils in the piped electric furnace. Due to the numerous intricately distributed components inside the steel shell, the limited internal space, and the relatively large and heavy size of many components, replacing the coil when it ages is extremely difficult, time-consuming, labor-intensive, and prone to rework, failing to meet current requirements. Therefore, we propose a 3D modeling-assisted replacement method for ductile iron piped electric furnace coils. Summary of the Invention

[0003] The purpose of this invention is to provide a 3D modeling-assisted replacement method for electric arc furnace coils in ductile iron pipelines. The 3D model provides a realistic demonstration for workers, explaining the work steps and precautions. During operation, standardized procedures are implemented according to the process schedule and pipeline layout diagram, eliminating various errors, improving work efficiency, and ensuring work quality. This method facilitates worker operation, prevents burns from pipes being too close to high-temperature objects, and avoids excessive pipe bending affecting flow. It boasts high accuracy and reliability, significantly improving coil maintenance and replacement efficiency and reducing the possibility of errors during operation. Furthermore, it can serve as an excellent training material for maintenance personnel, allowing them to clearly understand the equipment status and quickly master the key points of coil replacement, making it more convenient to use and solving the problems mentioned in the background art.

[0004] To achieve the above objectives, the present invention provides the following technical solution: a method for 3D modeling-assisted replacement of electric furnace coils in ductile iron pipes, comprising the following steps:

[0005] Step 1: Draw 3D graphics. First, use the data acquisition module to accurately measure the actual installation position and size of the steel shell, coil, support wood, tie rod, and magnetic yoke on site. Then, combine the data with the equipment installation drawings. For parts with dimension markings on the drawings, further verify the measurement results. For parts without dimensions on the drawings, use the measurement results as the standard.

[0006] Step 2: Create a 3D model. Draw in 3D graphics software and generate individual part drawings precisely according to the confirmed dimensions. After all parts are completed, generate the overall 3D assembly drawing. Create a 3D model of the electric furnace coil that includes all other components except for the cooling water pipes and cables. Create a digital model that is scaled down to the same size as the real object and has all dimensions exactly the same.

[0007] Step 3: Simulation testing. After the model is built, water-cooled cables and cooling water pipes are generated in the 3D model at physical dimensions and connected through the simulation connection module. Simulation tests are conducted on the removal and installation of tie rods, magnetic yokes, coils, cables and water pipes inside the steel shell. Optimization is carried out based on the test results.

[0008] Preferably, the data acquisition module is used to acquire 3D data of the coil, steel shell, support wood, magnetic yoke, tie rod, and water pipe.

[0009] The simulation connection module is used to simulate the connection of the coil water-cooled cable, the water inlet pipe of the water distributor, the water outlet pipe of the water distributor, the 1-12 magnetic yoke water pipes, the short-circuit ring water pipe, the cooling ring water pipe, the upper coil water pipe and the lower coil water pipe.

[0010] Preferably, the data acquisition includes a coil 3D data acquisition module, a steel shell 3D data acquisition module, a support wood 3D data acquisition module, a magnetic yoke 3D data acquisition module, a tie rod 3D data acquisition module, and a water pipe 3D data acquisition module.

[0011] Preferably, the coil 3D data acquisition module, steel shell 3D data acquisition module, support wood 3D data acquisition module, magnetic yoke 3D data acquisition module, and pull rod 3D data acquisition module are all used to measure the dimensions of the actual object and verify them against the dimensions in the drawings.

[0012] Preferably, the water pipe 3D data acquisition module is used to measure the size of the actual object and to measure the direction of the site.

[0013] Preferably, the coil includes various inlet and outlet water pipes and cable interfaces associated with the coil.

[0014] Preferably, the optimization based on the test results specifically includes:

[0015] Optimize the connection paths and layout between each unit to ultimately obtain the best non-interfering connection paths and operation sequence.

[0016] Through testing and optimization, the best work procedures for personnel were determined, and the most reasonable layout and connection path for water pipes of various sizes was optimized.

[0017] Based on the optimized results, a disassembly and assembly operation procedure table and a pipeline layout diagram are generated.

[0018] Preferably, generating the disassembly and assembly operation procedure table and pipeline layout diagram based on the optimized results specifically includes:

[0019] Optimize the water pipe routing and generate an optimal pipe layout diagram.

[0020] Optimize the installation sequence of water pipes and cables, and generate an optimal process schedule.

[0021] Compared with the prior art, the beneficial effects of the present invention are:

[0022] 1. This invention provides workers with a realistic demonstration of the operation, operation steps, and precautions based on a 3D model before coil replacement, making the process intuitive and clear. During operation, standardized operations are implemented according to the process sheet and pipeline layout diagram, eliminating various errors, improving work efficiency, and ensuring work quality. Through testing and optimization, the optimal process steps for personnel are determined, avoiding mutual interference between various components during operation. The most reasonable layout and connection path of water pipes of various sizes are optimized, which not only facilitates workers' operation but also prevents water pipes from being too close to high-temperature objects and causing burns, or water pipes from being bent excessively, affecting flow rate.

[0023] 2. Based on the optimized results, this invention generates a disassembly and assembly operation procedure table and a pipeline layout diagram. It accurately grasps the external dimensions and precise location distribution of all components such as coils, magnetic yokes, tie rods, water distributors, and various water pipes and cables inside the steel shell. After inputting the data into 3D software, a digital model with dimensions completely consistent with the actual object is established. Then, through software model simulation, the connection paths and layouts between each unit are optimized, ultimately obtaining the best non-interfering connection paths and operation sequences. This method is highly accurate and reliable, greatly improving the efficiency of coil maintenance and replacement, reducing the possibility of errors during operation. It can also serve as an excellent training material for maintenance personnel, allowing them to clearly understand the equipment status as if they were actually there, quickly master the key points of coil replacement, and make the equipment more convenient to use. Attached Figure Description

[0024] Figure 1 This invention describes the workflow of a 3D modeling-assisted replacement method for electric furnace coils in ductile iron pipes.

[0025] Figure 2 This is a schematic diagram of the data acquisition module for a 3D modeling-assisted replacement method for electric furnace coils in ductile iron pipes according to the present invention.

[0026] Figure 3 This is a schematic diagram of the simulation connection module of a 3D modeling-assisted replacement method for electric furnace coils in ductile iron pipes according to the present invention. Detailed Implementation

[0027] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0028] To address the problem of existing steel housings containing numerous intricately distributed components within limited internal space, many of which are relatively large and heavy, making coil replacement extremely difficult, time-consuming, labor-intensive, and prone to rework when the coil ages, please refer to [the relevant documentation / reference needed]. Figure 1 This embodiment provides the following technical solution:

[0029] A method for replacing ductile iron pipe electric furnace coils using 3D modeling includes the following steps:

[0030] Step 1: Creating 3D graphics. First, the actual installation positions and dimensions of the steel shell, coils, supporting timbers, tie rods, and magnetic yokes are accurately measured on-site using the data acquisition module. This includes the coils and their associated inlet and outlet water pipes and cable interfaces. Then, the measurements are combined with the equipment installation drawings. For components with dimensions marked on the drawings, the measurements are further verified. For components without dimensions on the drawings, the measurements are used as the standard. By combining the research of equipment technical data with on-site measurements, the exact dimensions and connection point distribution of all components inside the steel shell, such as coils, magnetic yokes, tie rods, water distributors, and various water pipes and cables, are accurately determined. This allows for accurate 3D modeling, ensuring the accuracy of the drawings and thus improving the effectiveness of the simulated connection results.

[0031] Step Two: Create a 3D model. Draw in 3D graphics software, accurately generate individual part drawings according to the confirmed dimensions, and generate the overall 3D assembly drawing after completion. Create a 3D model of the electric furnace coil that includes all components except cooling water pipes and cables. Create a digital model that is proportionally scaled down to the actual object and has all dimensions that are completely consistent with the actual object. It is effective, highly accurate, and reliable. It can also serve as an excellent training material for maintenance personnel, allowing them to clearly understand the equipment status as if they were there, and quickly master the key points of coil replacement.

[0032] Step 3: Simulation Testing. After the model is established, water-cooled cables and cooling water pipes are generated in the 3D model at physical dimensions and connected through a simulation connection module. The simulation connection module is used to simulate the connection of the coil water-cooled cables, water distributor inlet pipe, water distributor outlet pipe, 1-12 magnetic yoke water pipes, short-circuit ring water pipe, cooling ring water pipe, upper coil water pipe, and lower coil water pipe. Simulation tests are conducted on the disassembly and installation of tie rods, magnetic yokes, coils, cables, and water pipes inside the steel shell. Optimization is performed based on the test results to determine the optimal procedure for personnel operation, avoiding interference between components during operation. The most reasonable layout and connection path for water pipes of various sizes are optimized, which facilitates worker operation and prevents water pipes from being too close to high-temperature objects and from being excessively bent, affecting flow rate. Based on the optimization results, a disassembly and assembly operation procedure table and pipeline layout diagram are generated, greatly improving the efficiency of coil maintenance and replacement and reducing the possibility of errors during operation.

[0033] The data acquisition module is used to collect 3D data of the coil, steel shell, supporting wood, magnetic yoke, tie rod, and water pipe. The coil, steel shell, supporting wood, magnetic yoke, tie rod, and water pipe data acquisition modules are used to measure the dimensions of the actual objects and verify them against the dimensions on the drawings. The water pipe data acquisition module measures the dimensions of the actual objects and maps them according to the site layout. This ensures the accuracy of the data acquisition results, allowing for more precise dimensions during 3D modeling and guaranteeing the simulation effect.

[0034] Optimizations were made based on the test results, specifically including:

[0035] Optimize the connection paths and layout between each unit to ultimately obtain the best non-interfering connection paths and operation sequence.

[0036] Through testing and optimization, the best work procedures for personnel were determined, and the most reasonable layout and connection path for water pipes of various sizes was optimized.

[0037] Based on the optimized results, a disassembly and assembly operation procedure table and a pipeline layout diagram are generated, specifically including:

[0038] Optimize the water pipe routing and generate an optimal pipe layout diagram.

[0039] Optimize the installation sequence of water pipes and cables, and generate an optimal process schedule.

[0040] In summary, the 3D modeling-assisted replacement method for ductile iron pipeline electric furnace coils of the present invention provides workers with a clear and intuitive understanding of the process by demonstrating the operation steps and precautions using a 3D model before the coil replacement operation. During the operation, standardized procedures are implemented according to the process schedule and pipeline layout diagram, eliminating various errors, improving work efficiency, and ensuring work quality. Through testing and optimization, the optimal process steps for personnel are determined, avoiding interference between components during operation. The most reasonable layout and connection path for water pipes of various sizes are optimized, facilitating worker operation while preventing burns from pipes being too close to high-temperature objects and preventing excessive pipe bending from affecting flow rate. Based on the optimized results, a disassembly and assembly process schedule and pipeline layout are generated. The diagram accurately captures the external dimensions and precise location distribution of all components within the steel shell, including coils, yokes, tie rods, water distributors, and various water pipes and cables. After inputting this data into 3D software, a digital model is created that perfectly matches the dimensions of the actual components, scaled down proportionally. Through software simulation, the connection paths and layouts between units are optimized, ultimately achieving the best non-interfering connection paths and operational sequences. This method boasts high accuracy and reliability, significantly improving the efficiency of coil maintenance and replacement, reducing the possibility of errors during operation. It can also serve as an excellent training material for maintenance personnel, allowing them to gain a clear understanding of the equipment's condition and quickly master the key points of coil replacement, making it more convenient to use.

[0041] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0042] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for replacing ductile iron pipe electric furnace coils using 3D modeling, characterized in that: Includes the following steps: Step 1: Draw 3D graphics. First, use the data acquisition module to accurately measure the actual installation position and size of the steel shell, coil, support wood, tie rod, and magnetic yoke on site. Then, combine the data with the equipment installation drawings. For parts with dimension markings on the drawings, further verify the measurement results. For parts without dimensions on the drawings, the measurement results shall prevail. Step 2: Create a 3D model, draw in 3D graphics software, accurately generate individual part drawings according to the confirmed dimensions, and generate the overall 3D assembly drawing after all are completed. Create a 3D model of the electric furnace coil that includes all other components except for the cooling water pipes and cables, and create a digital model that is scaled down to the same size as the real object. Step 3: Simulation testing. After the model is built, water-cooled cables and cooling water pipes are generated in the 3D model at physical dimensions and connected through the simulation connection module. Simulation tests are conducted on the removal and installation of tie rods, magnetic yokes, coils, cables and water pipes inside the steel shell. Optimization is carried out based on the test results.

2. The method for 3D modeling-assisted replacement of ductile iron pipe electric furnace coils according to claim 1, characterized in that: The data acquisition module is used to acquire 3D data of coils, steel shells, supporting wood, magnetic yokes, tie rods, and water pipes. The simulation connection module is used to simulate the connection of the coil water-cooled cable, the water inlet pipe of the water distributor, the water outlet pipe of the water distributor, the 1-12 magnetic yoke water pipes, the short-circuit ring water pipe, the cooling ring water pipe, the upper coil water pipe and the lower coil water pipe.

3. The method for 3D modeling-assisted replacement of ductile iron pipe electric furnace coils according to claim 2, characterized in that: The data acquisition includes a coil 3D data acquisition module, a steel shell 3D data acquisition module, a support wood 3D data acquisition module, a magnetic yoke 3D data acquisition module, a tie rod 3D data acquisition module, and a water pipe 3D data acquisition module.

4. The method for 3D modeling-assisted replacement of ductile iron pipe electric furnace coils according to claim 3, characterized in that: The coil 3D data acquisition module, steel shell 3D data acquisition module, support wood 3D data acquisition module, magnetic yoke 3D data acquisition module, and pull rod 3D data acquisition module are all used to measure the dimensions of the actual object and verify them against the dimensions in the drawings.

5. The method for 3D modeling-assisted replacement of ductile iron pipe electric furnace coils according to claim 3, characterized in that: The water pipe 3D data acquisition module is used to measure the dimensions of the actual object and to measure the direction of the site.

6. The method for 3D modeling-assisted replacement of ductile iron pipe electric furnace coils according to claim 1, characterized in that: The coil includes various inlet and outlet water pipes and cable interfaces attached to the coil.

7. The method for 3D modeling-assisted replacement of ductile iron pipe electric furnace coils according to claim 1, characterized in that: The optimization based on the test results specifically includes: Optimize the connection paths and layout between each unit to ultimately obtain the best non-interfering connection paths and operation sequence; Through testing, the optimal work process steps for personnel were determined, and the most reasonable layout and connection path for water pipes of various sizes were optimized. Based on the optimized results, a disassembly and assembly operation procedure table and a pipeline layout diagram are generated.

8. The method for 3D modeling-assisted replacement of ductile iron pipe electric furnace coils according to claim 7, characterized in that: The process of generating the disassembly and assembly operation schedule and pipeline layout diagram based on the optimized results specifically includes: Optimize the water pipe routing and generate an optimal pipe layout diagram; Optimize the installation sequence of water pipes and cables, and generate an optimal process schedule.

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