Simple tool and detection method capable of rapidly measuring erosion states of upper nozzle and seating brick core of steel ladle

Abstract

The invention discloses a simple tool capable of rapidly measuring the erosion state of a steel ladle upper nozzle and a brick cup core and a detection method, and belongs to the technical field of steelmaking tools. The tool comprises a main rod, a triangular head fixed at the front end of the main rod, a first detection rod, a second detection rod and a third detection rod which are sequentially arranged at the front part of the main rod and are gradually increased in length, and a limiting rod vertically arranged on the top surface of the main rod. The fishbone structure formed by the triangular head and the multi-stage detection rod extends into the upper nozzle, so that the expanding erosion grade of the upper nozzle can be quickly and quantitatively judged according to the contact state of the detection rods with different lengths and the inner wall. Meanwhile, the residual thickness of the core of the brick cup can be accurately measured by observing the relative position of the top end of the triangular head and the lowest erosion point of the brick cup through positioning of the limiting rod. According to the method, the problem of high misjudgment rate of traditional manual visual inspection is solved, safe, accurate and efficient online detection is realized, and the refractory material cost and the ladle accident risk are remarkably reduced.

Description

Technical Field

[0001] This invention belongs to the field of steelmaking tool technology, specifically relating to a simple tool and detection method that can quickly measure the erosion state of the ladle nozzle and the core of the seat brick. Background Technology

[0002] In the management and control of steel ladles used in steelmaking production, the industry currently faces the following technical bottlenecks regarding the degree of erosion of the ladle's inlet and the core of the bedding bricks: The inherent limitations of traditional visual inspection: The judgment results are highly subjective and inconsistent, depending on the operator's experience and skill level. Under high-temperature conditions, visual judgment is easily affected by the environment, with a misjudgment rate of over 25%. It is impossible to quantitatively assess the state of erosion, making it difficult to establish a unified replacement standard; Limitations of existing measurement techniques: Although some measuring tools exist (such as CN112935234A), most use graduated probes for point-by-point measurements, which presents the following problems: The measurement process is cumbersome and time-consuming, with a single test taking 30-60 seconds. It requires operators to read and record data, which is inconvenient to operate in high-temperature and harsh environments. The inability to quickly classify and determine the state of erosion affects the efficiency of production decision-making. Technical requirements for optimizing the use of refractory materials: With technological advancements, the diameter of the injection hole at the ladle's water inlet has been increased from Φ50mm to Φ55mm. Under the same operating conditions, traditional methods struggle to accurately assess abnormal corrosion, leading to: Overly conservative replacement: directly increases refractory material costs by approximately 15-20%; Risks of delayed replacement: Increased risk of major safety accidents such as ladle puncture. Production stability was affected: emergency repairs caused production disruptions. Summary of the Invention

[0003] The purpose of this invention is to solve the above-mentioned technical problems and provide a simple tool and detection method that can quickly measure the erosion status of the ladle water inlet and the core of the seat brick.

[0004] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: A simple tool for quickly measuring the erosion state of the ladle nozzle and the core of the seat brick includes a main rod, a guide head set at the front end of the main rod, and multiple sets of detection components spaced apart along the axial direction of the main rod. The length of the multiple sets of detection components increases from the front end to the rear end of the main rod. The main rod is also provided with a limiting component.

[0005] Furthermore, the guide head is a triangular head, which is an isosceles triangle structure with its base fixedly connected to the front end of the main rod.

[0006] Furthermore, the multiple sets of detection components include multiple pairs of detection rods that are perpendicular to the main rod and symmetrically fixed on the left and right sides of the main rod.

[0007] Furthermore, the detection rod includes a first detection rod, a second detection rod, and a third detection rod of different lengths, and the length of the third detection rod is greater than the length of the second detection rod, the length of the first detection rod, and the length of the base of the triangular head.

[0008] Furthermore, the length of the base of the triangular head is less than the diameter of the ladle inlet, the length of the first detection rod is greater than half the diameter of the ladle inlet, and the length of the third detection rod is equal to half the diameter of the ladle inlet when it is at its maximum expansion.

[0009] Furthermore, the limiting component is a limiting rod, which is vertically fixed in the middle of the top surface of the main rod.

[0010] Furthermore, a handle is provided at the rear end of the main rod.

[0011] Furthermore, the first detection rod, the second detection rod, and the third detection rod are all located in the same plane as the triangular head, forming a "fishbone" structure.

[0012] A method for detecting the erosion state of the sprue nozzle of a steel ladle, using the aforementioned simple tool, includes the following steps: Insert the triangular head into the top nozzle of the ladle; The degree of enlargement of the inlet can be determined by observing the contact state between different detection rods and the inner wall of the ladle inlet. When the triangular head can extend but the first detection rod cannot, it is determined that the diameter has not been expanded. When the first detection rod can be inserted and contacts the inner wall, it is determined to be a slight enlargement. When the second detection rod can be inserted and contact the inner wall, it is determined to be a moderate enlargement. When the third detection rod can be inserted and contacts the inner wall, it is determined that the limit of diameter expansion has been reached.

[0013] A method for detecting the residual thickness of the core of a steel ladle seat brick, using the aforementioned simple tool, includes the following steps: Extend the main rod into the seat brick channel so that the limit rod presses against the bottom plate of the ladle mechanism; Observe the relative positional relationship between point A at the top of the triangular head and point O at the lowest point of erosion; If point A does not exceed point O, the base brick can continue to be used. When point A exceeds point O, it is determined that the base brick needs to be replaced.

[0014] 1. This invention achieves quantitative and visual detection of erosion status, improving judgment accuracy: A "fishbone" structure is formed by combining a triangular head with multiple detection rods of different lengths (first, second, and third detection rods). When the tool is inserted into the ladle's inlet, the contact state between each detection rod and the inner wall directly corresponds to different enlargement levels (e.g., no enlargement, slight enlargement, moderate enlargement, and extreme enlargement). This design transforms traditional experience-based qualitative visual inspection into quantitative detection based on physical dimensions, effectively avoiding misjudgments caused by differences in personnel experience, and significantly improving the accuracy and consistency of erosion status judgment. 2. This invention enhances safety and reliability, reducing the risk of ladle accidents: By setting the length of the third detection rod to half the maximum diameter of the upper water inlet, a replacement warning is triggered promptly when the detection rod contacts the inner wall, preventing major accidents such as ladle steel penetration caused by overuse of the upper water inlet or the seat brick. Simultaneously, in measuring the residual thickness of the seat brick, the positional relationship between the apex of the triangular head and the lowest point of erosion is used to clearly define the criteria for continued use or replacement of the seat brick, thereby systematically reducing production safety risks and ensuring the stable and smooth operation of the steelmaking process. 3. This invention optimizes refractory material cost control and avoids unnecessary waste: This invention can accurately identify the erosion state of the water inlet and the seat brick, avoiding premature replacement of refractory materials due to excessive conservatism, thus extending the service life of refractory materials and reducing material costs; at the same time, it can also prevent abnormal erosion from being aggravated due to delayed replacement, reducing emergency repairs and associated losses. 4. This invention is simple and quick to operate, and adaptable to high-temperature and harsh working conditions: The invention has a simple structure, consisting only of a main rod, a triangular head, a detection rod, and a limiting rod. It requires no complex power supply or electronic equipment; operators simply need to hold the handle and insert it for measurement to complete the test. The entire process is quick, making it ideal for use in high-temperature, dusty steelmaking environments, improving testing efficiency and reducing the time personnel are exposed to hazardous environments. 5. This invention offers multiple uses, enhancing the scientific basis of maintenance decisions: This invention integrates the functions of measuring the inlet diameter expansion and the residual thickness of the seat brick. Through the cooperation of the limiting rod and the triangular head, it achieves accurate determination of the residual height of the seat brick. This multi-functional design reduces the number of tools, simplifies the maintenance process, and enables on-site personnel to make maintenance decisions based on unified and objective standards, thereby improving the standardization and scientific level of ladle management. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a schematic diagram of the measurement of erosion at the steel ladle inlet diameter expansion according to the present invention; Figure 3 This is a schematic diagram of the measurement of the erosion residual thickness of the core of the steel ladle seat brick according to the present invention; In the diagram: 1-Main rod; 2-Triangle head; 3-First detection rod; 4-Second detection rod; 5-Third detection rod; 6-Limit rod; 7-Handle; 8-Ladle water inlet. Detailed Implementation Example

[0016] The present invention will be further described below with reference to the embodiments and accompanying drawings.

[0017] A simple tool for quickly measuring the erosion state of the top nozzle and core of the seat brick of a steel ladle includes a main rod 1, a triangular head 2, two first detection rods 3, two second detection rods 4, two third detection rods 5, and a limiting rod 6. The triangular head 2 is an isosceles triangle structure, with its base fixedly connected to the front end of the main rod 1. The rear end of the main rod 1 is provided with a handle 7. The two first detection rods 3, two second detection rods 4, and two third detection rods 5 are all perpendicular to the main rod 1 and are uniformly and symmetrically fixed on the left and right sides of the front part of the main rod 1. The length of the measuring rod 5 is greater than the length of the second measuring rod 4, which is greater than the length of the first measuring rod 3, which is greater than the length of the base of the triangular head 2. The third measuring rod 5, the second measuring rod 4, and the first measuring rod 3 are all located in the same plane as the triangular head 2, forming a "fishbone" structure. The limiting rod 6 is vertically fixed in the middle of the top surface of the main rod 1. The length of the base of the triangular head 2 is less than the diameter of the ladle water inlet. The length of the first measuring rod 3 is greater than half the diameter of the ladle water inlet. The length of the third measuring rod 5 is equal to half the diameter of the ladle water inlet when it is under maximum expansion.

[0018] Base length of Triangle Head 2: 60mm Main rod 1 length: 560mm First detection rod 3 length: 65mm Second detection rod 4 length: 70mm Length of third detection rod 5: 75mm Detection rod spacing: 40mm Limit rod 6 length: 50mm Distance between the limit rod and the apex of the triangular head: 230mm Example

[0019] Another size configuration is available for ladle inlets of different specifications: The base length of the triangular head 2 is 50mm; Main rod 1 length: 500mm; Length of the first detection rod 3: 55mm; Length of the second detection rod 4: 60mm; Length of the third detection rod 5: 65mm; Detection rod spacing: 35mm; Limit rod 6 length: 45mm; Example

[0020] To accommodate more precise erosion condition classification, four sets of detection rods are installed: First detection rod length: 60mm Second detection rod length: 65mm Third detection rod length: 70mm Fourth detection rod length: 75mm The other structures are the same as in Example 1.

[0021] In actual operation, the inventors used the tool of this invention to conduct on-site tests on 50 steel ladles used continuously, and compared the results with traditional manual visual inspection methods, obtaining the following experimental results:

[0022] Test conditions: The initial diameter of the ladle inlet is Φ60mm, and the maximum safe threshold for diameter expansion is Φ150mm.

[0023] Detection efficiency: Using the tool of this invention, the average detection time for a single water inlet is about 5-8 seconds, which is much lower than the 30-60 seconds required for traditional visual judgment, and the detection efficiency is improved by about 85%.

[0024] The error rate of traditional visual judgment is as high as 25% (out of 50 water inlets, 12 were replaced prematurely or delayed).

[0025] After using the tool of this invention, the false judgment rate was reduced to 0%, and the expansion status of all water inlets was accurately identified: When the first detection rod (65mm) contacts the inner wall, it is determined to be a slight enlargement (hole diameter ≥ Φ130mm). When the second detection rod (70mm) contacts the inner wall, it is determined to be a moderate enlargement (hole diameter ≥ Φ140mm). When the third detection rod (75mm) contacts the inner wall, it is determined to be a limit expansion (hole diameter ≥ Φ150mm), triggering a replacement warning.

[0026] Cost savings: Premature replacement of the eight inlets was avoided, directly saving approximately 12% of refractory material costs.

[0027] Test conditions: The original height of the seat brick is 300mm, and the lowest point of erosion O is 180mm away from the bottom plate of the steel ladle mechanism.

[0028] Consistency of inspection: Under the operation of different operators, the results of traditional visual judgment vary from person to person and the differences are significant. The results of judging the residual thickness of the same brick using the tool of this invention are completely consistent, eliminating the subjective bias of traditional visual judgment.

[0029] Safety and Reliability: During the test, the tool successfully identified three seat bricks that had reached the erosion limit (point A at the top of the triangular head exceeded point O), and arranged for their replacement in a timely manner, thus avoiding a possible ladle accident.

[0030] In traditional visual inspection, two of these three bricks were mistakenly judged as "still usable," significantly reducing the safety risk.

[0031] Maintenance decision optimization: Based on tool measurement results, the average service life of the base bricks was extended by about 2-3 cycles, while no production interruptions occurred due to insufficient residual thickness.

[0032] Based on the above field tests, the results show that this tool can achieve rapid and quantitative judgment of erosion at the ladle nozzle, improving detection efficiency by more than 85% and reducing the false judgment rate from 25% of traditional visual inspection to 0%. Furthermore, in measuring the residual thickness of the refractory bricks, the tool's consistency and reliability are significantly better than manual judgment, effectively preventing ladle accidents. In summary, this invention demonstrates significant progress in improving detection accuracy, ensuring production safety, and reducing refractory material costs.

[0033] During use, the operator holds the rear of the main rod 1 and the handle 7, and inserts the triangular head 2 into the ladle inlet 8. The degree of expansion of the inlet is reflected in real time by the contact status of the first detection rod 3, the second detection rod 4, and the third detection rod 5 with the inner wall of the ladle inlet 8. When the triangular head 2 can be inserted, but the first detection rod 3 cannot be inserted: the inner wall of the ladle water inlet 8 has not yet been enlarged; When the first detection rod 3 can be inserted and contact the inner wall: the inner wall of the ladle water inlet 8 undergoes slight expansion; When the second detection rod 4 extends into and contacts the inner wall: the inner wall of the ladle water inlet 8 undergoes moderate expansion; When the third detection rod 5 can be inserted and contact the inner wall: the inner diameter of the ladle water inlet 8 has reached its limit and must be replaced immediately.

[0034] By observing the contact state between different detection rods and the inner wall through the above operations, the degree of enlargement of the water inlet can be reflected in real time, the enlargement level can be determined, and a visual and quantitative assessment of the degree of erosion can be achieved.

[0035] After the ladle inlet 8 is removed from the seat brick and the seat brick channel is cleaned, the operator holds the rear of the main rod 1 and the handle 7, with the main rod 1 close to one side of the seat brick channel, and inserts it into the channel, so that the limit rod 6 is firmly pressed against the bottom plate of the ladle mechanism. Observe the relative position relationship between the top point A of the triangular head 2 and the lowest point O of erosion. When point A does not exceed point O, it indicates that the seat brick can still be used online; when point A exceeds point O, it indicates that the seat brick must be maintained offline or replaced.

[0036] This tool allows for precise determination of whether the remaining height of the base bricks meets the maintenance or removal standards, replacing traditional visual judgment and improving the scientific nature of maintenance decisions.

Claims

1. A simple tool for quickly measuring the erosion state of the ladle nozzle and the core of the seat brick, characterized in that: The utility model relates to a ladle nozzle diameter detection device, including main rod (1), the guide head of setting in the front end of main rod and the detection component of the interval setting of multiple groups along the axial direction of main rod, the length of multiple groups detection component is increasing along the front end of main rod to rear end direction, still be equipped with the limiting component (6) on main rod.

2. The simple tool according to claim 1, characterized in that: The guide head is triangular head (2), and the triangular head is isosceles triangle structure, and the middle of bottom is fixedly connected with the front end of main rod (1).

3. The simple tool according to claim 2, characterized in that: The multiple detection components include multiple pairs of detection rods perpendicularly to the main rod and symmetrically fixed to the left and right side surfaces of the main rod.

4. The simple tool according to claim 3, characterized in that: The detection rods include first detection rods (3), second detection rods (4) and third detection rods (5) with different lengths, and the length of the third detection rods (5) is greater than that of the second detection rods (4), which is greater than that of the first detection rods (3), which is greater than the length of the base of the triangular head (2).

5. The simple tool according to claim 4, characterized in that: The length of the base of the triangular head (2) is less than the aperture of the ladle nozzle, the length of the first detection rods (3) is greater than half of the aperture of the ladle nozzle, and the length of the third detection rods (5) is equal to half of the aperture of the ladle nozzle (8) when the aperture is expanded to the limit.

6. The simple tool of claim 1, wherein: The limiting component is a limiting rod (6) vertically fixed to the middle of the top surface of the main rod (1).

7. The simple tool of claim 1, wherein: The rear end of the main rod (1) is provided with a handle (7).

8. The simple tool according to claim 4, characterized in that: The first detection rods (3), the second detection rods (4) and the third detection rods (5) are located in the same plane as the triangular head (2), forming a "fishbone" structure.

9. A method for detecting the erosion state of a ladle shroud, using the simple tool according to any one of claims 4 to 8, characterized in that, The steps include: The triangular head (2) is inserted into the ladle nozzle (8); By observing the contact state of different detection rods with the inner wall of the ladle nozzle (8), the expansion degree of the nozzle is determined; When the triangular head (2) can be stretched and the first detection rods (3) cannot be inserted, it is determined that the nozzle has not been expanded; When the first detection rods (3) can be inserted and contact with the inner wall, it is determined that the nozzle has been expanded slightly; When the second detection rods (4) can be inserted and contact with the inner wall, it is determined that the nozzle has been expanded moderately; When the third detection rods (5) can be inserted and contact with the inner wall, it is determined that the nozzle has reached the limit of expansion.

10. A method for detecting the residual thickness of a core portion of a ladle brick using the simple tool according to any one of claims 6 to 8, characterized by The steps include: The main rod (1) is inserted into the seat brick channel, and the limiting rod (6) is pressed against the bottom plate of the ladle mechanism; Observe the relative position relationship between the top point A of the triangular head (2) and the lowest point O of the erosion; When the point A does not exceed the point O, it is determined that the seat brick can continue to be used; When the point A exceeds the point O, it is determined that the seat brick needs to be replaced.

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